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AG4 Scanner Product Manual

1. Banner AG4 Series User Manual P N 144924 rev A 02 2010 19 Banner AG4 Series Safety Laser Scanner 2 1 3 Replacement Parts Window with seal for AG4 Laser Scanner AG4 CPD15 Straight Config plug connector 15 pin for AG4 auto configuration AG4 PCD9 Straight plug connector and dust plug 9 pin AG4 for X2 interface AG4A SW A Configuration and diagnostics software AG4soft Windows 95 98 2000 NT XP 2 2 Specifications 24V de 20 30 Power supply in acc with IEC 742 with safe supply isolation and compensation with voltage dips of up to 20 ms in acc with EN 61496 1 Over current protection Via 1 6 A fuse melting fuse in the cabinet see below Over voltage protection Over voltage protection with safe limit stop Protective earth conductor Connection not permitted Supply Current Approx 420 mA exclusive of load use 2 5 A power supply Fuse Power Supply 1 6A normal blow medium time lag fuse user supplied Supply Voltage UB Response Time Min 80 milliseconds 2 scans Max 640 milliseconds 16 scans see Section 4 9 for more information Wavelength Model AG4 4E Model AG4 6E 150 mm resolution 200 mm to 4 0 m 150 mm resolution 200 mm to 6 25 m 70 mm resolution 200 mm to 4 0 m 70 mm resolution 200 mm to 6 25 m 50 mm resolution 200 mm to 2 8 m 50 mm resolution 200 mm to 2 8 m 40 mm resolution 200 mm to 2 2 m 40 mm resolution 200 mm to 2 2 m 30 mm resolution 200 mm to 1 6 m 30 mm
2. For a given Protective Field height the corresponding maximum detection capability resolution d can be calculated using the following formula d H 15 50 mm or d H 15 2 Figure 3 9 If the field is close to the floor 50 mm resolution is Figure 3 10 A field with 70 mm resolution is mounted no lower required than 300 mm above the floor Banner AG4 Series User Manual P N 144924 rev A 02 2010 33 Banner AG4 Series Safety Laser Scanner A WARNING PROTECTIVE FIELD HEIGHT STATIONARY HORIZONTAL FIELDS Where the height of a horizontal Protective Field is H gt 300 mm there is a risk that a person can go undetected beneath the field If it is possible for an individual to crawl undetected under the Protective Field and access the hazard install supplemental guarding to prevent this access 3 3 4 Minimum Safety Separation Distance Stationary Applications US Standards Response Time Considerations The Scanner s mirror rotates every 40 ms 25 scans revolutions per second The safety outputs will switch off only after an object is detected in the Protective Field for at least two consecutive scans The Scanner s minimum response time is therefore 80 ms 2x 40ms To increase the Scanner s reliability in an adverse environments e g with fine airborne particles increase the number of scans required before the scanners safety outputs turn off With each additional scan the response time Tr increases
3. 5 1 2 LED Status Displays Table 9 LED status displays e Boot process configuration process e Safety outputs or switching function are switched off e Boot process configuration process Safety outputs or switching function are switched off e Data comparison with ConfigPlug e Object detected in the active Protective Field e Safety outputs or switching function are switched off e Object detected in the active Warning Field The sensor function is active the active Protective Field is free e Safety outputs or switching function are switched off e Start restart interlock is active The sensor function is active the active Protective Field is free The active Warning Field is free e Safety outputs or switching function are switched on The sensor function is active the active Protective Field is free e Object detected in the active Warning Field e Safety outputs or switching function are switched on 0 LED OFF 1 LED flashes at 4 Hz 1 LED ON LED not relevant 1 LED flashes at 2 Hz 2 x LED flashes twice 4 P N 144924 rev A 02 2010 Banner AG4 Series Safety Laser Scanner Object is in the Warning Field and the Protective Field Check the Warning Field and Protective Field definition if required Actuate the start restart switch Object is in the Warning Field Check the Warning Field definition if required AG4 Safety Laser Scanner User Manual Banne
4. where d the Scanner s Detection Capability Resolution For Detection Capability Resolution d gt 64 mm 2 5 Dpf is 900 mm 36 A WARNING DETERMINE CORRECT STOP TIME Stop time T must include the response time of all devices or controls that react to stop the machine If all devices are not included the calculated Safety distance S will be too short This can lead to serious bodily injury or death Be sure to include the stop time of all relevant devices and controls in the calculations A WARNING PROPER SAFETY DISTANCE The Protective Field must be located far enough from the nearest hazard such that an individual cannot reach the hazard before cessation of hazardous motion or situation Failure to establish and maintain the minimum safety distance could result in serious bodily injury or death Table 4 Vertical Protective Field Applications Normal Approach Detection Capability Resolution pp d 30 mm 1 2 78 mm 3 1 40 mm 1 6 112 mm 4 5 50 mm 2 146 mm 5 9 70 mm 2 75 900 mm 36 150 mm 5 9 900 mm 36 Horizontal Protective Field Applications parallel approach Dpf 1200 mm 48 Note See Section 3 3 3 for information on allowable Protective Field height versus resolution Scanner Specific Additional Distance Factors Two Scanner specific factors must be considered when calculating the Minimum Safety distance Zsm Zrer Zsm Measurement Tolerance Factor Zsm s th
5. Con signs pan o i m pommia O a m prommen s Re pat oommnaton oee O a e tacoma recse Plug X2 as RS 422 port a 000 0 000 Oo oo NSN oh ene OOo INESIS e KN Figure 2 5 Plug X2 interface assignment as RS 422 port EN GND shield Ground shield Banner AG4 Series User Manual P N 144924 rev A 02 2010 25 Banner AG4 Series Safety Laser Scanner 3 Installation Before installing the Scanner read Sections 1 and 3 of this manual in their entirety The System s ability to perform its safety guarding function depends upon the appropriateness of the application and upon its proper mechanical and electrical installation and interfacing to the guarded machine A risk assessment must determine if the application of the Scanner is appropriate which includes the AG4 software configuration and the Protective and Warning Field coverage If all mounting installation interfacing and checkout procedures are not followed properly the System cannot provide the protection for which it was designed Installation must be performed by a Qualified Person as defined in Section 4 1 See Warning below A WARNING READ THIS SECTION CAREFULLY BEFORE INSTALLING THE SYSTEM The user is responsible for satisfying all local state and national codes and regulations relating to the installation and use of this control system in any particular application Take extreme care to meet all legal requirements and follow all technical installatio
6. The list of standards below is included as a convenience for users of this Banner product Inclusion of the standards below does not imply that the product complies specifically with any standard other than those specified in the Specifications section of this manual U S Application Standards SOURCES OSHA Documents Superintendent of Documents Government Printing Office P O Box 371954 Pittsburgh PA 15250 7954 Tel 202 512 1800 http Awww osha gov ANS Accredited Standards American National Standards Institute ANSI 11 West 42nd Street New York NY 10036 Tel 212 642 4900 http Awww ansi org B11 Documents Safety Director The Association for Manufacturing Technology AMT 7901 Westpark Drive McLean VA 22102 Tel 703 893 2900 http www m gtech org RIA Documents Robotics Industries Association RIA 900 Victors Way P O Box 3724 Ann Arbor MI 48106 Tel 734 994 6088 http Awww robotics org NFPA Documents National Fire Protection Association 1 Batterymarch Park P O Box 9101 Quincy MA 02269 9101 Tel 800 344 3555 http www nipa org Alternate sources for these plus ISO IEC EN DIN and BS Standards Global Engineering Documents 15 Inverness Way East Englewood CO 80112 5704 Tel 800 854 7179 http fwww global ihs com National Standards Systems Network NSSN 25 West 43rd Street New York NY 10036 Tel 212 642 4980 http www nssn com Document Center Inc
7. Dada Wet with cloth soaked in AG4 cleanser articles stickin Wipe free in one swipe with cleaning cloth Vacuum without touching Particles statically charged Wipe free in one swipe with cleaning cloth soaked with AG4 cleanser Banner AG4 Series User Manual P N 144924 rev A 02 2010 83 Banner AG4 Series Safety Laser Scanner Wet with cloth soaked in AG4 cleanser Particles drops smearing Wipe free in one swipe with cleaning cloth Water drops Wipe free in one swipe with cleaning cloth Wet with cloth soaked in AG4 cleanser Oil drops l l l l Wipe free in one swipe with cleaning cloth Wet with cloth soaked in AG4 cleanser Fingerprints l l l i Wipe free in one swipe with cleaning cloth If the cleaning takes longer than four seconds removing fingerprints for example the Scanner displays a front screen monitoring fault If this occurs reset the Scanner using the Start restart switch E ud Soak cloth with cleanser Wipe front screen free in one swipe Figure 5 3 Front screen cleaning procedure 5 4 3 Cleaning the Scatter Screens Soak cloth with cleanser Wipe scatter screen free in one swipe Figure 5 4 Scatter screen cleaning procedure 84 P N 144924 rev A 02 2010 AG4 Safety Laser Scanner User Manual Banner AG4 Series Safety Laser Scanner 5 4 4 Changing the Front Screen Window If the front screen is scratched replace it Only a Qualified Person may change the front screen It is
8. Default Start Restart Interlock enabled Manual AGV Automated guided vehicle Horizontal Protective Field mobile Resolution 70 mm Maximum Protective Field range AG4 4E 4 m 13 2 AG4 6E 6 25 m 20 6 Start Restart Interlock selectable Manual or Auto reset Default Automatic Start and Restart enabled Auto Access Perimeter Guarding Vertical Protective Field stationary Passage Control access guarding Resolution 150 mm Maximum Protective Field range AG4 4E 4 m 13 2 AG4 6E 6 25 m 20 6 Start Restart Interlock selectable Manual or Auto reset Default Start Restart Interlock enabled Manual Vertical Guarding Arm Detection Vertical Protective Field stationary Arm protection point of operation Resolution 40 mm Maximum Protective Field range 2 2 m 7 26 Start Restart Interlock selectable Manual or Auto reset Default Start Restart Interlock enabled Manual Vertical Guarding Hand Detection Vertical Protective Field stationary Hand protection point of operation Resolution 30 mm Maximum Protective Field range 1 6 m 5 28 Start Restart Interlock selectable Manual or Auto reset Default Start Restart Interlock enabled Manual Vertical Guarding Body Detection Vertical Protective Field stationary Body protection danger zone guarding Resolution 150 mm Maximum Protective Field range AG4 4E 4 m 13 2 AG4 6E 6 25 m 20 6 Start Restart Interlock sel
9. See Section 5 1 1 and 5 1 2 for diagnostic information and resolution of error fault conditions See Section 5 2 for communication errors and loss of communication Recovery Procedures To recover from a Lockout condition all errors must be corrected and a reset routine must be performed as described below or power must be cycled power the Scanner down wait a second or two then power it up NOTE See Section 4 5 for power up and Run mode behavior Reset Routine To reset the Scanner close the reset switch for Y to 5 seconds and then open it Closing the reset switch too long will cause the sensor to ignore the reset request the switch must be closed from 1 4 second to 5 seconds but no longer per Section 4 5 5 1 1 Scanner LED Status Display 72 P N 144924 rev A 02 2010 AG4 Safety Laser Scanner User Manual Banner AG4 Series Safety Laser Scanner Five LEDs on the housing front show the Scanner s operating status LED OR Key Flashes Fault on the Field Pair control 2 Hz inputs Active Warning Field is interrupted Flashes Front screen is dirty Flashes ConfigPlug configuration is not 4 Hz compatible with the Scanner Safety outputs or switching function OSSD 1 and 2 are switched off Safety outputs or switching function OSSD 1 and 2 are switched on Start restart interlock is active Front screen is dirty Figure 5 1 Status LEDs Banner AG4 Series User Manual P N 144924 rev A 02 2010 73
10. s path and can protect the mobile vehicle and its load from collisions Only use the Scanner on vehicles with electrical drives e g servo or electrically controlled drive and braking The Protective Field must be configured so that the mobile vehicle can come to a complete stop before a collision can occur If it is not possible to completely safeguard the vehicle including trailers protruding or overhanging loads etc during the full length of travel including curves additional safeguarding such as additional Scanners or bumper edge switches must be used see 3 2 3 The following instructions are general in nature and are intended to provide guidance to safely install the Scanner on mobile vehicles It is not possible to give exact recommendations for all mobile applications the designer user must also comply with the vehicle manufacturers recommendations and all applicable regulations and standards See also the warning and the basic installation guidelines in Section 3 Safety standards covering mobile vehicles or automated automatic guided vehicles AGV include BS DIN EN 1525 Bbwerless Industrial Trucks and Their Systems ISO 3691 4 Driverless Industrial Trucks and Their Systems ANSI ITSDF ASME B56 5 Sfety Standard for Guided Industrial Vehicles IEC 61496 3 Bquirements for Active Opto Electronic Protective Devices Responsive to Diffuse Reflection AOPDDR The user must also regularly check the safeguardin
11. to more than 2540 mm s 100 s they are not conclusive determinations Consider all factors including the physical ability of the operator when determining the value of K to be used 2 Ts is usually measured by a stop time measuring device If the machine manufacturer s specified stop time is used add at least 20 to allow for possible clutch brake system deterioration This measurement must take into account the slower of the two MPCE channels and the response time of all devices or controls that react to stop the machine e g UM FA 9A safety module See Notice Regarding MPCEs If all devices are not included the calculated safety distance Ds will be too short and serious injury could result 3 Consideration for Adjacent Scanners When adjacent Scanner share the same detection plane and have an unobstructed view of each other an additional 40 ms time must be added to the response times of both scanners If the adjacent scanners detection planes are shielded so that there is no clear line of sight between sensors or there is at least a 4 100 mm detection plane offset then the 40 ms addition is not required 34 P N 144924 rev A 02 2010 AG4 Safety Laser Scanner User Manual Banner AG4 Series Safety Laser Scanner Dpf Considerations Vertical Protective Field Applications Normal Approach For Detection Capability Resolution where d lt 64 mm 2 5 the formula for Dpf is Dpf 3 4 x d 7 mm or Dpf 3 4 x d 0 275
12. 5 for diagnostic indications and codes 4 8 Normal Operation Four configurations affect the AG4 behavior at power up and during Run mode Banner AG4 Series User Manual P N 144924 rev A 02 2010 69 Banner AG4 Series Safety Laser Scanner e Restart Interlock with Start Interlock Manual Reset e Automatic Restart Interlock with Start Interlock Automatic Reset with manual power up e Automatic Restart Interlock with Automatic Start Automatic Reset e Automatic Restart Interlock with Start Test Automatic Reset with test at power up In any case the clearing of the Protected Field PF or the reset of a start restart interlock condition MUST NOT initiate dangerous machine motion Machine control circuitry must be designed so that one or more initiation devices must be engaged i e a conscious act to start the machine in addition to the Scanner turning ON its safety outputs OSSD1 and OSSD2 See Section 1 12 1 4 8 1 System Power Up The Scanner will power up in one of three ways depending on the Start Restart reset Interlock configuration 1 12 1 and whether the Start Test is enabled 1 12 2 These options will be limited by the selected application see Section 3 When power is applied the Scanner conducts self tests to detect critical internal faults determine configuration settings and prepare for operation which can take up to 30 seconds typical e Start Interlock Manual Power up If no faults are detected during
13. Figure 3 14 Diagram to determine the additional distance Zr with lack of floor clearance Hr Za Application Specific Additions Za is the additional distance needed to account for factors that can otherwise affect the safe application of the Scanner Examples include e Approach speed of an individual who is unaware of the vehicle s movement ISO 13855 Bsitioning of Safeguard with Respect to Approach Speed defines walking speed as 1600 mm s 63 s thus Za 1600 mm s x Ts Tr e Additional clearance to avoid crushing Za 500 mm 20 per ISO 13854 EN349 e The effect of turning with long vehicles or trailers resulting in large lateral travel Multiple factors may or may not result in a cumulative effect Za Zar Zaz Zan Evaluate each factor to determine its impact on all Additional Distance Factors Z Additional Side Distance Z Protective Field Width The width of the Protective Field is determined by the width of the mobile vehicle and the Additional Distance Factors Z as described above also see Figure 3 13 Zerr and Zricnt The distance Z may be different for the two sides and the leading edge The width of the Protective Field must be greater than the width of the mobile vehicle Z Zsm t Zrett ZF Za It is important that the factor Za include the effect of turning with long vehicles or trailers resulting in large lateral travel Banner AG4 Series User Manual P N 144924 rev A 02 2010 45 Banner AG4 Series
14. Manual Banner AG4 Series Safety Laser Scanner 3 3 7 Reset Start Restart Switch Location The reset switch must be mounted at a location that complies with the warning below If any hazardous areas are not in view from the switch location additional means of safeguarding must be provided The switch should be protected from accidental or unintended actuation e g through the use of rings or guards A key actuated reset switch provides some operator or supervisory control as the key can be removed from the switch and taken into the guarded area However this does not prevent unauthorized or inadvertent resets due to spare keys in the possession of others or additional personnel entering the guarded area unnoticed Resetting a safeguard must not initiate hazardous motion Safe work procedures require a start up procedure to be followed and the individual performing the reset to verify that the entire hazardous area is clear of all personnel before each reset of the safeguard is performed If any area cannot be observed from the reset switch location additional supplemental safeguarding must be used at a minimum visual and audible warnings of machine start up A WARNING RESET SWITCH LOCATION All reset switches must be e Outside the guarded area e Located to allow the switch operator full unobstructed view of the entire guarded area while the reset is performed e Out of reach from within the guarded area and e Protected
15. P N 144924 rev A 02 2010 49 Banner AG4 Series Safety Laser Scanner 3 In RUN mode observe the Scanner s status indicators to determine status see Table 8 and Section 5 If a status indicator begins to flash at any time the Scanner has entered an error or lockout condition See Section 5 1 for further information 4 Ensure that the Scanner is in RUN mode the Protective and Warning Fields are clear of intrusions and the AG4 LEDs indicate as shown in Figure prFields clear OSSDs are ON or figure Fields clear AG4 waiting for reset above Then go to Section 3 6 3 Trip Test for Protective and Warning Field verification 3 6 3 Trip Test Protective and Warning Field Verification NOTE The PC Interface can assist in monitoring the position of objects and the status of the Protective and Warning Fields but when possible use the LED indicators to determine whether a field has been interrupted 1 Ensure that the Scanner is in Run mode the Protective and Warning Fields are clear of intrusions and the LED indicators show JE Se A 6483 EE 00000 00 1 2 1 2 3 4 5 Fields clear AG4 waiting for reset OR Fields clear OSSDs are ON 2 Ifa Warning Field is used with the guarded machine at rest using the appropriate test piece that matches the configured expected resolution interrupt the Warning Field perimeter and verify LED 2 Yellow turns ON as expected Remove the test piece and verify that LED 2 turns OFF Rep
16. PC that can fail in such a manner that there is the loss of the safety stop command OR in such a manner that the safety function can be suspended overridden or defeated unless accomplished with the same or greater degree of safety A WARNING OSSD INTERFACING To ensure proper operation the Scanner OSSD output parameters and machine input parameters must be considered when interfacing the Scanner solid state OSSD outputs to machine inputs Machine control circuitry must be designed so that the maximum load resistance value is not exceeded and that the maximum specified OSSD OFF state voltage does not result in an ON condition Failure to properly interface the OSSD outputs to the guarded machine could result in serious bodily injury or death 3 7 2 FSD Interfacing Connections Final switching devices FSDs can take many forms although the most common are forced guided mechanically linked relays or an interface module The mechanical linkage between the contacts allows the device to be monitored by the external device monitoring circuit for certain failures Depending on the application the use of FSDs can facilitate controlling voltage and current that differs from the OSSD outputs of the Scanner FSDs can also be used to control an additional number of hazards by creating multiple safety stop circuits Safety Stop Protective Stop Circuits A safety stop allows for an orderly cessation of motion for safeguarding purposes wh
17. PC Interface connector Do not exceed 10 meters 30 of cable length or communication errors may occur When using a USB to serial adaptor keep total cable length to a minimum Do not use the AG4 PCD9USB 1 with the 10 meter AG4 PCD9 10 cordset Do not exceed 5 m USB cable length if an USB extension cable is used with a USB to serial adaptor See http en us support belkin com app for further information on the AG4 PCD9USB 1 BELKIN p n F5U257 and miscellaneous PC drivers 5 2 1 AG4Soft Pop up Error Messages Examples of pop up error messages that indicate communication problems or a lockout include Db No Scanner connected l x Message No Z000 No Scanner connected The selected action cannot be executed D Get configuration data from the Scanner X Message Ho 0301 An eror occured while getting the configuration data The configuration data was not loaded from the Scanner MM Scanner status information x 1 An error occurred while ascertaining the Scanner system data RS ti ES The diagnostics data cannot be displayed 82 P N 144924 rev A 02 2010 AG4 Safety Laser Scanner User Manual Banner AG4 Series Safety Laser Scanner 5 3 Electrical and Optical Noise The Scanner is designed and manufactured to be highly resistant to electrical and optical noise and to operate reliably in industrial settings However serious electrical and or optical noise may cause a random OFF state of the OSSDs In ver
18. Qualified Person who configures installs and or maintains it must be aware of the power up behavior of the Scanner and instruct the machine operator on the operation of the Scanner At a minimum the machine manufacturer must provide information to the user to inform the operator of the requirements for the safe operation of the machine and the Scanner This also includes providing the necessary instructions needed by the Designated Person or operator to ensure the safe use of the Scanner e g checkout procedures The machine operational instruction materials may never describe a situation that could expose an operator to a hazard 1 8 Laser The Scanner has a Class 1 laser Under normal conditions no special precautions are necessary when working with or handling a Class 1 laser Observe the applicable legal and local regulations for operating laser equipment Laser Klasse 1 Laser Class 1 Laser de Classe 1 Figure 1 6 Laser Safety label and its location 1 9 High Voltage A WARNING HIGH VOLTAGE EXISTS INSIDE THE AG4 Do not open the AG4 with power applied In connection with fault diagnosis or repair such as screen replacement the unit should only be opened by a Qualified Person Otherwise return the Scanner to the factory for repair or replacement Failure to observe this warning could result in serious injury or death Figure 1 7 High Voltage Safety label and its location Banner AG4 Series User Manual P N 1449
19. Safety Laser Scanner 3 4 4 Mobile Side Guarding on AGVs Vertical Protective Fields If the Additional Side Distance Z cannot be complied with or if additional safeguarding is otherwise required additional AG4 vertical Protective Fields can be used see Application Guide p n 147900 The Protective Field must be configured so that the mobile vehicle can come to a complete stop before a collision can occur In the case of vertical Protective Fields on mobile vehicles the Scanner is typically mounted facing down at a slight tilt such that the lower edge of the Protective Field extends a distance of Z as described above if possible To determine the dimension to the edge of the side of the Protective Field use the Minimum Distance D formula described above The Scanner should be configured with a resolution of at least 150 mm to detect the torso of an individual i e Body protection danger zone guarding The risk assessment should determine if a smaller resolution is necessary Table 7 Vertical Guarding Application Application Configuration Description Vertical Guarding Body Detection Vertical Protective Field stationary Body protection danger zone guarding Resolution 150 mm Maximum Protective Field range AG4 4E 4 m 13 2 AG4 6E 6 25 m 20 6 Start Restart Interlock selectable Manual or Auto reset Default Start Restart Interlock enabled Manual Note Reference contour surface monitoring function is ma
20. User Manual AG4soft Change authorization level sjwjolr xj Authorization Operator Op Banner Safety Laser Scanner A Warnin Banner AG4 Series Safety Laser Scanner NOTE A dialog box may appear that says that there is a problem in identifying a serial port If so see Section 4 3 1 Establishing Communications Between the PC and the Scanner A dialog box should appear and ask if you would like to edit the configuration with the wizard if so click OK If not prompted the wizard can also be accessed by clicking on the Gonfiguration operating mode tab and then selecting in the menu bar path Gonfiguration gt Wizard Since no configuration is loaded in the AG4Soft program an error message will be displayed Click YES to load a configuration file A dialog box asks you to select the appropriate Safety Laser Scanner Choose AG4 4E or AG4 6E and click EXIT Select Safety Laser Scanner sjw o R xj S5jwjojri Xx A ele xy a Configuration wizard forthe access level Authorized Customer AS a Select the device that you want to configure This preselection sets device dependent parameters and protective field definitions Cancel Safety Laser Scanner features Number of field pairs Maximum protective field size 4000 mm E Supported usage options Danger zone guarding Leg detection danger zone guarding AGY Automatic guided vehicles Passage control access guarding Arm protection point of op
21. adaptor Apply power to the Scanner Status information can now be uploaded and the configuration can be downloaded to the Scanner See Section 4 3 6 2 Initial Optical Field Verification Table 8 Typical LED indications shown below assumed Warning Field controls Alarm 1 a Protective and Warning Fields clear x A A Cal 2 _ ES CJ OSSD and Alarm 1 Auxiliary outputs ON 2 se o v 1 2 3 4 5 b Protective Field clear Warning Field interrupted r 1 w m OSSD outputs ON E AN Ey Set si Alarm 1 Auxiliary OFF SS O0 boo 1 2 3 4 5 c Protective and Warning Fields interrupted a 7 OSSD and Alarm 1 Auxiliary outputs OFF io A F Be 7 L e 0 0 1 2 3 a 5 d Protective Field clear Warning Field interrupted Sy OSSD outputs held OFF Qu A e Els Alarm 1 Auxiliary OFF gt e n 1 2 3 4 5 e Protective and Warning Fields clear T OSSD outputs OFF and waiting for start restart reset A fa ra Alarm 1 Auxiliary output ON m mn ses 1 2 4 5 1 Inspect nearby areas for retro reflective surfaces If found attempt to remove cover or otherwise prevent the surface from being located in the Scanner s detection plane If unable to do this then ensure that 100 mm 4 has been added to the separation distance See Zret Retro reflector Factor in Sections 3 3 4 and 3 3 5 2 Inspect installation for unmonitored areas and adjacent Scanners see Section 3 3 1 and 3 3 2 Banner AG4 Series User Manual
22. addition to OSHA regulations several other organizations provide information about the use of safeguarding devices Refer to the American National Standards Institute ANSI the Robotics Industries Association RIA the Association for Manufacturing Technology AMT and others Banner Engineering Corp makes no claim regarding a specific recommendation of any organization the accuracy or effectiveness of any information provided or the appropriateness of the provided information for a specific application The user has the responsibility to ensure that all local state and national laws rules codes and regulations relating to the use of this safeguarding system in any particular application are satisfied Extreme care is urged to ensure that all legal requirements are met and that all installation and maintenance instructions contained in this manual are followed Safety Standards Applicable to Use of this Product See inside back cover for information pertaining to applicable U S and International standards and where to acquire copies Certificate of Adequacy This instruction manual P N 144924 satisfies the requirements of Machinery Directive 2006 42 EC Section 1 7 4 Instructions 2 P N 144924 rev A 02 2010 AG4 Safety Laser Scanner User Manual Banner AG4 Series Safety Laser Scanner About this Document The information for applying and configuring the Banner AG4 Safety Laser Scanner the Scanner is covered in several doc
23. an area scan through any window or transparent materials Doing so can result in false detection that will cause nuisance machine stoppages 1 12 Basic Operation Functions The configuration of the following AG4 functions must be accomplished by a Qualified Person in order to ensure that personnel who are exposed to potentially dangerous situations are adequately protected 12 P N 144924 rev A 02 2010 AG4 Safety Laser Scanner User Manual Banner AG4 Series Safety Laser Scanner 1 12 1 Start Restart Reset Interlock A WARNING MANUAL and AUTOMATIC START RESTART RESET Application of power to the Scanner components the clearing of the Protected Field PF or the reset of a start restart interlock condition MUST NOT initiate dangerous machine motion Machine control circuitry must be designed so that one or more initiation devices must be engaged i e a conscious act to start the machine in addition to the Scanner turning ON its safety outputs OSSD1 and OSSD2 Failure to do so could cause a machine to operate in an unexpected way resulting in serious bodily injury or death A Warning START RESTART RESET SWITCH LOCATION The system Start Restart Reset switch must be accessible only from outside and in full view of the hazardous area Reset switches must also be out of reach from within the safeguarded space and must be protected against unauthorized or inadvertent operation via rings guards key or other means If
24. and deliberate manipulation of the Scanner If the Protective Field contains a reference contour surface the Scanner monitors both the Protective Field for intrusions and the reference surface for field position If the distance between the sensor and the reference surfaces changes from the original configuration greater than the measurement tolerance factor Zsm the Scanner will detect the change and switch the OSSDs to OFF The reference contour monitoring function can also prevent an inappropriate Field Pair from becoming active The design of the installation and the risk assessment must identify the need and use of the reference contour surface monitoring function In horizontal applications this function ensures that the safeguarded area does not change due to the Scanner moving or changing position because an of impact vibration or poor maintenance practices e g rotational movement In a vertical application the position of the Protective Field has a critical impact on the separation safety distance If there is an angular movement of the Scanner that causes the Protective Field to be positioned closer to the hazard an individual could access the hazard before the machine can stop i e the safety distance is too short With a vertical Protective Field angle of approach greater than 30 it is required that at least two sides areas or surfaces of the Protective Field must be defined as reference contour These two surface
25. configuration and be included with the machine documentation see the AG4soft Software Instruction Manual for more information on configuration documentation For stationary application it is recommended to mark the perimeter of the Protective Field s on the floor as an awareness means for individuals in the area For mobile applications it is recommended that the diagram be readily available for review If required install means to protect the Scanner from physical damage sources of optical interference e g other Scanners or prevent the Scanner from being used as a climbing aid Ensure that these means do not impair the field of view NOTE See AG4 Series Safety Laser Scanner Application Guide P N 147900 for application check list items and application examples 3 2 Protective Field and Warning Field Considerations 28 Ensure the dimension size and coverage of the Protective Field can detect an intrusion and allow the Scanner s OSSDs to stop the dangerous movement before personnel can access the hazard See safety distance Section 3 3 4 3 3 5 and stopping distance Section 3 4 Ensure that access to all hazards is not possible for all Field Pair switchover applications see Section 1 12 4 Protective Fields with a range of less than 200 mm are not permitted Ensure that safety distance and stopping distance calculations incorporate all factors that can effect response time including The additive effect of all device re
26. d lt 2 8 C 850 mm 34 For resolutions greater than 70 mm 2 8 other standards may require C 1200 mm 48 or more NOTE C can never be less than 0 zero Table 5 Vertical Protective Field Applications Normal Approach Detection Capability Resolution d C 30 mm 1 2 128 mm 5 sli 34 70 mm 2 75 850 mm 34 150 mm 5 9 1200 mm 48 Horizontal Protective Field Applications Parallel Approach C 1200 mm 0 4 x H or C 48 0 4 x H where H is the distance of the Protective Field above the floor or walking surface 1000 mm max see Section 3 1 3 for more information C can never be less that 850 mm 34 Banner AG4 Series User Manual P N 144924 rev A 02 2010 37 Banner AG4 Series Safety Laser Scanner Additional Scanner Specific Distance Factors Two Scanner specific factors must be considered when calculating the Minimum Safety distance Zsm amp Zrefi Zsm Measurement Tolerance Factor Zsm is the additional distance needed to account for distance measurement error The value for Zsm is a function of the distance from the Scanner rotary mirror s center point to the furthest point of the Protective Field measured along the radial RG For Vertical Protective Fields normal approach Zsm O For Horizontal Protective Fields parallel approach Zsm 83 mm 3 3 for Protective Fields RG lt 3500 mm 138 Zsm 100 mm 4 for Protective Fields RG 2 3500 mm 138 Zrer
27. dimensions Banner AG4 Series User Manual P N 144924 rev A 02 2010 23 Banner AG4 Series Safety Laser Scanner 2 4 Connector Plug Assignments X1 plug interface assignment Figure 2 3 X1 plug interface assignment 24 PIN Colorcode Signal Description 2 Input start restart reset switch connection 24V dc Supply voltage 4 FP 1 Input for activating Field Pair 1 Semiconductor output PNP with turn OFF with e Warning Field interruption white with black Alarm 1 Aux Front screen dirty stripe e Internal fault e None output held OFF See Section 1 12 6 gt black OSSD 1 Semiconductor Safety output channel 1 turn OFF with Protective Field interruption 12 white OSSD 2 Semiconductor safety output channel 2 turn OFF with Protective Field interruption 13 NN Not connected 14 A Not connected Semiconductor output with switch off with Aux Front screen dirty FP 2 FP 3 P4 w lt D o 10 1 1 gt v 3 N white with e Internal fault See Section 1 12 6 brown stripe RO gt al P N 144924 rev A 02 2010 AG4 Safety Laser Scanner User Manual Banner AG4 Series Safety Laser Scanner Interface assignment plug X2 Plug X2 as RS 232 port Signal Deseription O ME ea OOOO E amp 4 M O EN GND shield Ground shield oo 6 Oo o 000 0 wo tn a cono Figure 2 4 Plug X2 interface assignment as RS 232 port
28. ooooooonccicooccccccooconononcononononconanononnanononos 51 SL Permanent HOOKUP orilla 51 3 12 OSSD OUTPULCONNMECHONS A e e hn 51 3 1 2 FSD Interfacing Connections ai 52 3 7 3 Machine Primary Control Elements and External Device Monitoring 53 NOTICE Fegarding MIP CES woes cee ias 54 3 7 4 Alarm Auxiliary Output ococonocccocccccoocncconcnccnncncnnncncnnncnnnnncnnnnnrnnnnnrnnnnnrnnnnnrnnrnnrnrrnnrnnnnneos 54 3 0 Preparing tor System OA da 54 4 System Operation and Configuration occoccccicninnccnannannonconconcrnarnarnannannancncanons 58 Sr A A eaclticeueen et 58 4 2 System Configuration SettingsS oooccccocononococnonecononnoconononoanononononnonanononnanononos 58 4 2 1 Using the Configuration WizZard oocccooncccocccococococonocononacoconocononnrnnonnrnnonnrnnonncncnnncnnss 58 4 2 2 Configuration Wizard Changing Protective and Warning FieldS oooooooomo 64 4 2 3 Configuration Wizard Saving the Configuration ccconcccconcncconcnnonncnnnoncnonnncnnnoncnnnnnnnnos 66 4 3 Connecting the PC to the Scanner sesa o E A 66 4 3 1 Establishing Communications Between the PC and the Scanner occocccccccccccnccncnccnnccns 67 4 4 Opening a Configuration File rs files ooooooccooniccconncccooonononononnonononnonanonnnnarononos 68 4 5 Downloading a Configuration to the ScaMMer ococoonicicoccnncocononononnnnonononconanononnanononos 69 4 6 Start Restart Int
29. outputs turn OFF With each additional scan the response time t1 increases by 40 ms With K 1600 mm s the separation safety distance increases by 64 mm 40 ms x 1600 mm s per additional scan A WARNING AG4 RESPONSE TIME ADJUSTMENTS Do not increase the Scanner s 80 ms response time for vertically positioned Protective Fields such as work cell access Entry Exit or perimeter guarding applications where a person could move quickly through the Protective Field without being detected Failure to follow this recommendation could result in serious bodily injury or death A WARNING DETERMINE CORRECT STOP TIME Stop time T must include the response time of all devices or controls that react to stop the machine If all devices are not included the calculated Safety distance S will be too short This can lead to serious bodily injury or death Be sure to include the stop time of all relevant devices and controls in the calculations A WARNING PROPER SAFETY DISTANCE The Protective Field must be located far enough from the nearest hazard such that an individual cannot reach the hazard before cessation of hazardous motion or situation Failure to establish and maintain the minimum safety distance could result in serious bodily injury or death Minimum Safety Separation Distance Formula When all factors that influence the Safety distance are considered the formula is S K x T C Zsm Zreni where S the minimum dis
30. over or through the guarded area and into the hazard without being detected Mechanical barriers e g hard guarding or supplemental safeguarding may be required to comply with this requirement and is described by ANSI B11 safety requirements or other appropriate standards Banner AG4 Series User Manual P N 144924 rev A 02 2010 39 Banner AG4 Series Safety Laser Scanner e AG4 Safety Hard Guarding Laser Scanner protective field 1 Opening q 8 he Conveyor e AG4 Safety Laser Scanner od Area protective field 2 em Guarding uring EZ SCREEN EZ SCREEN Reset Switch Figure 3 11 An example of supplemental safeguarding Figure 3 11 shows an example of supplemental safeguarding inside a robotic work cell The EZ SCREEN LP safety light screen in conjunction with the hard guarding is the primary safeguard Supplemental safeguarding such as Scanners used as area guards is required in areas that cannot be viewed from the reset switch i e behind the robot and the conveyor Additional supplemental safeguarding may be required to prevent clearance or trapping hazards e g the safety mat as an area guard between the robot the turntable and the conveyor 3 4 Additional Installation Considerations for Mobile Applications The Scanner can protect individuals entering an area with a variable or moving hazard protect individuals and objects located within a mobile vehicle
31. planned eophosbon ed see ol uw Gren a name tor the Soto Laser Srann erd e deeooion of its noid of thin Safety Laser Scanner ol uaa e ordes ta bo ahja to eland idant Enf Laaer E canpera ger Lore guaina si cankurabion ee with Galeton of the requested resolution Manum 20 charactors Resolution Ther plesvincton Balsas hia EA E anil spoh iiia hold blica Eiescnpieon Shar bohesor ee nic on the Lasar Scanner fui H Caution E ith Aiinmaie ele eelectian e shel enreda lophraliecousics TAA bo prendo for gr ou midi parents hee Goan tem setae desc wen the Stet riolo unginn Serdan Config Oimn Mavani TOO charas Restan behar PR i Sally Later Scanear veel beheia Cc i ahy miraus ole protect boki PP duna tunning opornica y im fa 3 im The next few dialog boxes affect safety relevant parameters The first allows the choice of application options and start restart or reset behavior dependent on the application see Section 3 Basic Installation Guidelines Banner AG4 Series User Manual P N 144924 rev A 02 2010 59 Banner AG4 Series Safety Laser Scanner Select Freely Selectable Presettings for the purposes of this walk through While the resolution is fixed at 70 mm this option allows the most flexibility in learning the wizard Configuration wizard Configuration miz ard Ealah Pacari paroles aia alenar PARATENE Application Solectron of feo phsnned sopicsbon erd aga gi a Application Salei ol thee panne
32. restart auto reset is chosen the Start Behavior drop down menu becomes available allowing the choice of Automatic start Start Interlock and Start test see Section 1 12 1 These options determine the operation of the Scanner at power up Restart delay i e ON delay can be set from 160 ms to 10160 ms default is 2000 ms Click NEXT when complete The next dialog box allows setting of the Protective Field and Warning Field response times individually Care must be taken because all fields are affected by these settings After clicking NEXT the dialog box allows activating default or deactivating the dust suppression algorithm It is recommended to keep the algorithm activated Click NEXT Longa ation mirana Configuration izand Eater rales pararaicsa Emah ralen paramaicra FF repose trit Rigo ney Geo of the Satety Lesir Scanner until the palo tlstod Our uppriti Tht Ga suppr rian Parco ierant Far availabe of Bre Saht mwiiching quiputs se ich of 06509114 and 51 13 wath proocinan Aid Lasos Sceanprwboo small perticioen eer in they eir fied ma hale menpian Actrvidird ag matane chips ar ineei Ontedeccheaje the duel ivppriisan luncion ehen in eddfon lo Dracs peopla fo Solo Larm Scanner must alas detect tarme en and amali objects in your application WF response ime Pruepanso nme of the Sainty Lara Scanner until alarn output AE A A matches of 1 9 wrih waneng tied mer p icn achimvad by ioenamg the Goson
33. stop circuits and the MPCEs are mounted within the same control panel adjacent to each other and are directly connected to each other or where the possibility of such a failure can be excluded If this cannot be achieved then dual channel control should be used Methods to exclude the possibility of these failures include but are not limited to e Physically separating interconnecting control wires from each other and from secondary sources of power e Routing interconnecting control wires in separate conduit runs or channels e Locating all elements modules switches and devices under control within one control panel adjacent to each other and directly connected with short wires e Properly installing multi conductor cabling and multiple wires through strain relief fittings Over tightening of a strain relief can cause short circuits at that point e Using positive opening or direct drive components installed and mounted in a positive mode 3 7 3 Machine Primary Control Elements and External Device Monitoring A machine primary control element MPCE is an ectrically powered element that directly controls the normal operation of a machine in such a way that it is the last element in time to function when machine operation is to be initiated or arrested per IEC61496 1 Examples include motor contactors clutch brakes valves and solenoids Depending on the level of risk of harm it may be required to provide redundant MP
34. the direction of movement is sufficiently distant from the vehicle and its load This dimension length of the Protective Field is described as the Minimum Distance D The Side Distance Z or the width of the Protective Field is used to ensure that the sides of the vehicle or a protruding load do not create a hazard It is highly recommended that an oversized Warning Field in comparison to the Protective Field be used The Warning Field and its associated output signal the approach of the mobile vehicle e g by sounding a horn or illuminating lights beacons and reduce the speed of the mobile vehicle This can reduce the need or the amount of braking and wear on the drive mechanisms The Protective Field configuration must take into account trapping crushing hazards that could be created by physical objects near the path of the mobile vehicle An example would be an elevated conveyor that the sensing field of the Side Distance Z passes under but does not provide enough clearance This situation can occur if the distance between the end of the conveyor and the side of the mobile vehicle is less than 500 mm 20 per ISO 13854 EN349 IMimum Gaps to Avoid Crushing The following items apply to the calculation for determining the Minimum Distance D Protective Field length e Maximum speed of the AGV Do not rely on the speed reduction initiated by the Warning Field e The Scanner response time e The response time of the mobile vehicle
35. the risks after receiving the output signal from the protective equipment t2 is influenced by temperature switching time of valves ageing of components and other factors t2 is usually measured by a stop time measuring device If the machine manufacturer s specified stop time is used add at least 20 to allow for possible clutch brake system deterioration This measurement must take into account the slower of the two MPCE channels and the response time of all devices or controls that react to stop the machine e g UM FA 9A safety module See Notice Regarding MPCEs in Section 3 4 3 If all devices are not included the calculated safety distance Ds will be too short and serious injury could result Consideration for Adjacent Scanners When adjacent Scanners share the same detection plane and have an unobstructed view of each other an additional 40 ms must be added to the response times of both Scanners If the adjacent scanners detection planes are shielded therefore no clear line of sight between sensors or there is at least a 100 mm 4 detection plane offset then the 40 ms addition is not required Distance Adjustment C Based on the Possible Field Intrusion Vertical Protective Field Applications Normal Approach For Resolutions d lt 40 mm 1 6 the formula for C is C 8 x d 14 mm or C 8 x d 0 55 where d the Scanner s Detection Capability Resolution For resolutions 40 mm lt d lt 70 mm 1 6 lt
36. the self test the Scanner enters Run mode and evaluates the Protective and Warning Fields If no obstructions are detected the Yellow Start Restart Reset indicator LED 5 in Figure 1 3 to indicate the Scanner is waiting for a manual reset to turn ON the OSSD outputs e Automatic Start Automatic Reset If no faults are detected during the self test the Scanner enters Run mode and evaluates the Protective and Warning Fields If no obstructions are detected the OSSDs turn ON after the restart delay time 160 ms to 10160 ms in 40 ms increments and the two Green indicators LEDs 1 and 3 in Figure 1 3 turn ON No manual reset operation is required e Start Test Test at Power up If no faults are detected during the self test the Scanner waits for the Protective Field to be interrupted by an object equal to or greater than the configured resolution e g a test piece Then after the field is clear the OSSD outputs turn ON The Protective Field must be clear before the test is performed or all obstructions must be removed and then the test can be performed No manual reset operation is required 4 8 2 During Run Mode The Scanner can be configured for two output configurations e Restart Interlock Manual Reset When the Protective Field becomes interrupted by an object larger than the configured resolution the OSSD outputs turn OFF within the configured response time see 4 6 If the Protective Field then becomes clear the LED 1 indi
37. then clear the Protective Field with a test rod after the Scanner is powered up Only then will the Scanner outputs turn ON so the machine can be started The function is available only when Auto Reset is selected When the start test is combined with the automatic restart function the start test serves as a start restart signal 1 12 3 Dust Suppression The dust suppression function increases the reliability of the Scanner when small particles are in the air e g material chips or insects Deactivate the dust suppression function when the Scanner must detect extremely fast or small objects in the application 1 12 4 Field Pairs Independently Activated Protective and Warning Fields Through the use of the Field Pair FP inputs external logic e g a PLC is capable of selecting one of eight configured Field Pairs stored in the Scanner at any given time A Field Pair is defined as the combination of a configured Protective Field PF and a Warning Field WF When active see Table 1 a specific Field Pair is in sole control of the safety outputs OSSD1 and OSSD2 and the ALARM 1 auxiliary output This function is useful to change the safeguarded area in an application in which a hazard is not continually present or in mobile applications in which direction speed and stopping distance varies After the Scanner is configured switching over or etivating an individual Field Pair is controlled by the four P inputs on the Machine Inter
38. this document or below Banner Engineering Corp Application Engineering Group 9714 Tenth Avenue North Minneapolis MN 55441 Phone 763 544 3164 or Toll Free US only 888 373 6767 email sensors bannerengineering com They will attempt to troubleshoot the system from your description of the problem If they conclude that a component is defective they will issue an RMA Return Merchandise Authorization number for your paperwork and give you the proper shipping address 2 Pack the component s carefully Damage which occurs during return shipping is not covered by warranty Banner AG4 Series User Manual P N 144924 rev A 02 2010 87 Banner AG4 Series Safety Laser Scanner 6 Safety System Testing Study each procedure in its entirety to understand each step thoroughly before beginning Refer all questions to a Banner applications engineer at the address or numbers listed on the back cover of this manual Checkouts must be performed as detailed in Section 6 1 below and results must be recorded and kept in the appropriate place e g near the machine and or in a technical file This must include a printout of the Scanner s configuration and the shape of all Protective Fields Additional factors and checks may be required that are dependent on the application machine or local regulations and laws A user risk assessment will determine what these additional factors and checks will be and should be incorporated with the checkouts be
39. 111 Industrial Road Suite 9 Belmont CA 94002 Tel 650 591 7600 http www document center com ANSI B11 General Requirements ANSI B11 1 Mechanical Power Presses ANSI B11 2 Hydraulic Power Presses ANSI B11 3 Power Press Brakes ANSI B11 4 Shears ANSI B11 5 Iron Workers ANSI B11 6 Lathes ANSI B11 7 Cold Headers and Cold Formers ANSI B11 8 Drilling Milling and Boring ANSI B11 9 Grinding Machines ANSI B11 10 Metal Sawing Machines ANSI B11 11 Gear Cutting Machines ANSI B11 12 Roll Forming and Roll Bending Machines ANSI B11 13 Single and Multiple Spindle Automatic Bar and Chucking Machines ANSI B11 14 Coil Slitting Machines ANSI B11 15 Pipe Tube and Shape Bending Machines ANSI B11 16 Metal Powder Compacting Presses ANSI B11 17 Horizontal Extrusion Presses ANSI B11 18 Machinery and Machine Systems for the Processing of Coiled Strip Sheet and Plate ANSI B11 19 Performance Criteria for Safeguarding ANSI B11 20 Manufacturing Systems ANSI B11 21 Machine Tools Using Lasers ANSI B11 22 Numerically Controlled Turning Machines ANSI B11 23 Machining Centers ANSI B11 24 Transfer Machines ANSI B11 TR3 Risk Assessment ANSI RIA R15 06 Safety Requirements for Industrial Robots and Robot Systems NFPA 79 Electrical Standard for Industrial Machinery OSHA Regulations OSHA Documents listed are part of Code of Federal Regulations Title 29 Parts 1900 to 1910 OSHA 29 CFR 1910 212 General Require ments for Gu
40. 24 rev A 02 2010 11 Banner AG4 Series Safety Laser Scanner 1 10 Handling the Scanner Observe the permissible environmental conditions for storage and operation Front Screen and Scatter Screens The Scanner s front screen and scatter screens must be clean free of damage and properly installed e Avoid touching the front screen e Clean dirty screens immediately see Maintenance and Repairs Section 5 4 e Replace damaged screens immediately see Maintenance and Repairs Section 5 4 The Scanner s IP protection is guaranteed only when properly screwed on plugs or plug cover caps are used Only operate transport and store the Scanner with screwed on control cable X1 and PC cable X2 or dummy plug X2 installed 1 11 Scanner Limitations Environmental limitations The Scanner is not suitable for use outdoors or under conditions with significant temperature fluctuations Humidity condensation and other weather influences can impair the safety function e Use the Scanner only in environmentally controlled areas e Observe all technical data and ambient conditions For industrial use only The Scanner can cause radio interference and is not suitable for use in residential areas Only use the Scanner in industrial environments Not for use on vehicles with combustion engines The Scanner is not suitable for use on vehicles with combustion engines because alternators or ignition systems can cause EMC disturbances Make no
41. 3 Mechanical Installation Considerations Many factors influence the layout of the Scanner s mechanical installation For stationary applications these include separation safety distance supplemental safeguarding hard guarding unmonitored areas shadows or areas behind the Scanner adjacent Scanners and the height of the Protective Field in horizontal applications In addition mobile applications must take into account the stopping performance and distance of the mobile vehicle which the Scanner is controlling A WARNING POSITION COMPONENTS CAREFULLY The Scanner must be positioned such that the hazard cannot be accessed by reaching over under around or through the sensing field Additional guarding may be required see Safety distance Section 3 3 4 5 Pass Through Hazards Section 3 3 6 and Supplemental Safeguarding Section 3 3 8 3 3 1 Unmonitored Areas A WARNING UNMONITORED AREAS The area behind the Scanner and near it on either side shown in the following figure is not monitored Unmonitored areas can create an access route to the hazard or a blind zone where a person cannot be detected Make sure that this unmonitored area is minimized so that no one can access this area undetected by recessing the Scanner into the machine using supplemental safeguarding or using mechanical barriers to prevent access Failure to do so could result in serious bodily injury or death Behind and To the Sides of the Scann
42. 4 Fax 91 20 66405623 www bannerengineering co in india bannerengineering com Banner Engineering Asia Taiwan Neihu Technology Park 5F 1 No 51 Lane 35 Jihu Rd Taipei 114 TAIWAN Tel 886 2 8751 9966 Fax 886 2 8751 2966 www bannerengineering com tw info bannerengineering com tw WARRANTY Banner Engineering Corp warrants its products to be free from defects for one year Banner Engineering Corp will repair or replace free of charge any product of its manufacture found to be defective at the time it is returned to the factory during the warranty period This warranty does not cover damage or liability for the improper application of Banner products This warranty is in lieu of any other warranty either expressed or implied
43. BANNER more sensors more solutions AG4 Series Safety Laser Scanner User Manual Original Instructions 02 2010 P N 144924 rev A Banner AG4 Series Safety Laser Scanner Important read this page before proceeding In the United States the functions that the Banner AG4 Series Safety Laser Scanner is intended to perform are regulated by the Occupational Safety and Health Administration OSHA Outside of the United States these functions are regulated by other agencies organizations and governments Whether or not any particular Safety Laser Scanner installation meets all applicable requirements depends upon factors that are beyond the control of Banner Engineering Corp These factors include the way in which the Safety Laser Scanner is applied installed wired operated and maintained It is the responsibility of the purchaser and user to apply this Safety Laser Scanner in full compliance with all relevant applicable regulations and standards The Banner AG4 Series Safety Laser Scanner can guard against accidents only when it is properly installed and integrated into the machine properly operated and properly maintained Banner Engineering Corp has attempted to provide complete application installation operation and maintenance instructions In addition please direct any questions regarding application or use of the scanner to the factory applications department at the telephone number or addresses shown on the back cover In
44. CEs or other control devices that are capable of immediately stopping the dangerous machine motion irrespective of the state of the other These two machine control channels need not be identical they could also be diverse redundant but the stop time performance of the machine Ts used to calculate the safety distance see Sections 3 3 4 and 3 3 5 must take into account the slower of the two channels Refer to Figure 3 20 or consult the machine manufacturer for additional information To ensure that an accumulation of failures does not compromise the redundant control scheme i e cause a failure to danger a method to verify the normal functioning of MPCEs or other control devices is required The Scanner provides this function only when configured for manual start restart reset with MPCE monitoring contacts wired in series with the reset start restart switch as shown in Figure 3 19 see also 3 3 7 Reset Switch Location When the Scanner is configured for Automatic Start Restart Reset to properly monitor the MPCEs an External Device Monitoring EDM function must be provided by an external means from the Scanner One example using the UM FA 9A 11A safety Module is shown in Figure 3 20 The UM FA 9A 11A can be configured for both manual or automatic reset and provide the required EDM function For external device monitoring to function properly each device must include a normally closed N C forced guided mechanically linked contact
45. ED Diagnostic Key LED Meg ON Sensor function is active the active Protective Field is clear 1 green Flashes Fault on the Field Pair control 2 Hz inputs O Flashes Front screen is dirty Flashes ConfigPlug configuration is not 4 Hz compatible with the Scanner y Safety outputs OSSD 1 and 2 afety outputs an pk AI JAN are switched ON Active Warning Field is interrupted 2 yellow irty Safety outputs OSSD 1 and 2 are switched OFF N N N Start restart interlock is active reset required O 5 yellow Flashes Front screen is dirty 2 Hz Flashes Figure 1 3 Status LEDs 1 2 Mounting System Optional The AG4 MBK1 mounting system simplifies Scanner installation and alignment The mounting system is available as an accessory see Section 2 Figure 1 4 AG4 Scanner with AG4 MBK1 mounting system in place 1 3 Machine Interface X1 ConfigPlug The ConfigPlug included as part of the machine interface cables is used to store the Scanner configuration and transfer it to another Scanner This simplifies the exchanging of a faulting or damaged Scanner The plug saves the configuration 8 P N 144924 rev A 02 2010 AG4 Safety Laser Scanner User Manual Banner AG4 Series Safety Laser Scanner when the PC transfers the operational parameters to the Scanner When the original Scanner is replaced and a new Scanner is connected to power with the ConfigPlug the plug automatically transfers the confi
46. Field Pair activated Input Signal definition High logical 1 16 30V Low logical 0 lt 3V Laser Protection Class Class 1 IEC 60825 1 8 Field Pairs in combination of Protective Field and Warning Field can be switched over by external inputs Field Pair 8 is Configurations not user configurable see Section 1 12 ww eS Operating Conditions Temperature 0 to 50 C Humidity Max 95 Indicators Five LEDs on front show Safety Sensor Status Shock and Vibration 10 to 150 Hz frequency 5 G max 50 m s approx in X Y and Z directions for twenty times each Max Cordset Length 15 pin plug 50 m 9 pin plug 10 m RS 232C 50 m RS 422 Design Standards IEC 61496 1 3 Type 3 ISO 13849 1 Category 3 PL d IEC 61508 1 to 7 SIL 2 and IEC 62061 SIL CL2 Certifications Banner AG4 Series User Manual P N 144924 rev A 02 2010 21 2 3 Dimensions 122 3 77 8 Cable bending radius measurement is cable dependent AG4 CPD15 minimum bend radius 25 mm 1 static 89 mm 3 5 flexible Rotary mirror axis Figure 2 1 AG4 dimensions 22 Banner AG4 Series Safety Laser Scanner ca 195 b Beam level All dimensions in mm A Interface X1 for connection with control system B Interface X2 for connection with PC or laptop P N 144924 rev A 02 2010 AG4 Safety Laser Scanner User Manual Banner AG4 Series Safety Laser Scanner Ea Y e All dimensions in mm Figure 2 2 AG4 MBK 1 Mounting system optional accessory
47. G4 front screen window by press the RW button on the BT 1 and moving across the full length of the window with the BT 1 lenses facing away from the AG4 If the BT 1 s indicator lights check for light from other sources e g other safety laser scanners by racking down the emitted light using the BT 1 5 4 Servicing and Maintenance 5 4 1 Removing the Scanner from the Machine If the Scanner is to be removed from the machine and stored for a period of time it is recommended to restore the Scanner to the default configuration settings see AG4soft Software Instruction Manual 5 4 2 Cleaning the Front Screen Window and Scatter Screens Clean the Scanner s front and scatter screens regularly at a frequency depending on the surrounding environmental conditions and using the recommended materials Use only the AG4 CLN cleaning kit specified in Section 2 consisting of approved cleanser and cleaning cloths Do not use scouring pads or cloths that can cause scratching e g paper towels Never use solvents that can damage the plastic materials The cleaning procedure depends on the type and degree of contamination see Table 12 Table 12 Cleaning the Scanner front screen Vacuum without touching or blow away softly oil free Particles loose scouring oe Wipe free in one swipe with cleaning cloth Vacuum without touching or blow away softly Particles loose non scouring l l ee Wipe free in one swipe with cleaning cloth
48. Pairs must be analyzed in respect of failure modes to ensure that an unintended switchover does not occur In higher risk applications it is highly recommended to use redundant sensors or switches to initiate or enable a Field Pair change Diverse technology can minimize the possibility of common cause or common mode failures e Ensure that selecting deselecting Field Pairs does not expose any individual to a hazard Supplemental safeguarding may be required Field Pair 8 Field pair 8 is pre configured and is not user adjustable lts Protective Field and Warning Field are deactivated and its OSSD safety outputs and ALARM 1 auxiliary output remain ON unless a lockout occurs This Field Pair must only be used when there is no exposure to any hazard Supplemental safeguarding may be required during the selection of Field Pair 8 It is not possible to power up start when Field Pair 8 is selected Field pairs 1 through 7 typically the Field Pair with the largest Protective Field must be selected at power up and then a switchover to Field Pair 8 can be accomplished according to the conditions stated above It is allowed to switch over from Field Pair 8 to any configured Field Pair A WARNING FIELD PAIR 8 FUNCTION Field Pair 8 deactivates the entire Protective Field and Warning Field monitoring function of the Scanner This creates a condition where the Scanner OSSD safety outputs are always ON even if an individual enters the potentially ha
49. Reset LED 1 Green LED 3 Red and LED 5 Yellow are ON 9 An interrupted Protective Field PF condition indicates that one or more objects are being detected within the active protected Field To correct this situation identify the interruption via the AG4Soft Measured contour display operating mode or by observing the area covered by the Protective Field and then remove all objects or realign the Scanner per Section 3 If the system is in a Start Restart Interlock waiting for Reset condition perform a manual reset 10 Once the two Green LED indicators are ON perform the trip test described in Section 3 4 3 on each of the configured Protective Fields to verify proper system operation and to detect possible unmonitored areas Verify that if the Protective Field boundary is identified i e marked on the floor that it matches the corresponding Protective Field Do not continue until the Scanner System passes the trip test Do not expose any individual to any hazard during the following checks A WARNING BEFORE APPLYING POWER TO THE MACHINE Verify that the guarded area is clear of personnel and unwanted materials such as tools before applying power to the guarded machine Failure to do so could result in serious bodily injury or death A WARNING IF TRIP TEST INDICATES A PROBLEM If the Scanner does not respond properly to the trip test do not attempt to use the system If this occurs the Scanner cannot be relied o
50. Retro Reflector Factor Zrer iS the additional distance needed to account for error due to reflections from retro reflective or shiny surfaces that are present in the scanning plane No Retro reflectors Zref O Retro reflectors located within the scanning plane of the Protective Field Zref 100 mm 4 3 3 6 Pass Through Hazards A ass through hazard is associated with applications where personnel may pass through a safeguard which issues a stop command to remove the hazard and then continues into the guarded area such as in perimeter guarding Subsequently their presence is no longer detected and the related danger becomes the unexpected start or restart of the machine while personnel are within the guarded area A pass through hazard typically results from large safety distances calculated from long stopping times large minimum object sensitivities reach over reach through or other installation considerations A pass through hazard can be generated with as little as 75 mm 3 between the defined area and the machine frame or hard guarding Reducing or Eliminating Pass Through Hazards Eliminate or reduce pass through hazards whenever possible While it is recommended to eliminate the pass through hazard altogether this may not be possible due to machine layout machine capabilities or other application considerations One solution is to ensure that personnel are continually sensed while within the hazardous area This c
51. ab click on Settings gt Control Panel gt System System Properties gt Hardware gt Device Manager gt Ports COM amp LPT AG4 PCD9USB 1 USB to Serial Adaptor If using the model AG4 PCD9USB 1 select Belkin USB to Serial Adaptor and note the COM port to which the device has been assigned The Baud rate bits per second must match the Baud rate of the AG4 default is 57600 Click on Pr Settings to verify both these settings If PC Hardware Installation Wizard appears follow its instructions to install the device drivers When using the model AG4 PC9USB 1 USB to serial adaptor keep total cable length to a minimum Do not use the AG4 PCD9USB 1 with the 10 meter AG4 PCD9 10 cordset Do not exceed 5 m USB cable length if a USB extension cable is used with the AG4 PCD9USB 1 See hitp en us support belkin com app for further information on the AG4 PCD9USB 1 BELKIN p n F5U257 and miscellaneous PC drivers 4 4 Opening a Configuration File rs files Click on highlight the Gonfiguration Operating Mode tab and then click on e Load configuration data from a file and transfer to scanner 9 Operating Mode Icon to directly download a saved configuration or e oad Configuration data from file 6 Operating Mode Icon to open a saved configuration to review or manipulate the configuration and then e Click on fransfer configuration data from PC to scanner icon 11 Operating Mode Icon Note If followi
52. against unauthorized or inadvertent operation such as through the use of rings or guards If any areas within the guarded area are not visible from the reset switch additional safeguarding must be provided as described by the ANSI B11 series or other appropriate standards Failure to do so could result in serious injury or death 3 3 8 Supplemental Safeguarding As described in Sections 3 3 4 and 3 3 5 the Scanner components must be properly positioned such that an individual cannot reach through the defined area and access the hazard point before the machine has stopped Additionally the hazard cannot be accessible by reaching around under or over the defined area To accomplish this supplemental guarding mechanical barriers such as screens or bars as described by ANSI B11 safety requirements or other appropriate standards must be installed Access will then be possible only through the defined area of the Scanner or through other safeguarding that prevents access to the hazard see Figure 3 11 The mechanical barriers used for this purpose are typically called trd guarding there must be no gaps between the hard guarding and the defined area Any openings in the hard guarding must comply with the safe opening requirements of ANSI B11 or other appropriate standard A WARNING THE HAZARD MUST BE ACCESSIBLE ONLY THROUGH THE GUARDED AREA The installation of the Scanner must prevent any individual from reaching around under
53. an be accomplished by using supplemental safeguarding such as described by the ANSI B11 series of safety requirements or other appropriate standards see Section 3 3 8 An alternate method is to ensure that once the safeguarding device is tripped it will latch and will require a deliberate manual action to reset This method of safeguarding relies upon the location of the reset switch as well as safe work practices and procedures to prevent an unexpected start or restart of the guarded machine see Section 3 3 7 A WARNING USE OF SCANNER FOR PERIMETER GUARDING If a Scanner is installed in an application that results in a pass through hazard e g perimeter guarding either the Scanner or the Machine Primary Control Elements MPCEs of the guarded machine must cause a Latched response following an interruption of the defined area The reset of this Latched condition may only be achieved by actuating a reset switch that is separate from the normal means of machine cycle initiation The switch must be positioned as described in Section 3 3 7 Lockout Tagout procedures per ANSI Z244 1 may be required or additional safeguarding as described by ANSI B11 safety requirements or other appropriate standards must be used if a pass through hazard cannot be eliminated or reduced to an acceptable level of risk Failure to observe this warning could result in serious bodily injury or death 38 P N 144924 rev A 02 2010 AG4 Safety Laser Scanner User
54. any areas are not visible from the reset switch additional means of safeguarding must be provided Failure to do so could result in serious bodily injury or death The start restart reset interlock has two functions 1 Start interlock 2 Restart interlock This interlock function is used to enable the machine s normal start command Actuating cycling this input must not cause hazardous motion or a hazardous situation After clearing the AG4 start restart interlock a second deliberate action by the operator e g actuating the machine cycle start switch is required to begin or resume the machine s operation Using Start Restart Reset Interlock e Install an appropriate start restart switch see Specifications which causes the Scanner outputs to turn ON when the switch is actuated e Position the start restart switch outside the hazardous area so that it cannot be activated from within the hazardous areas The operator must be able to see all hazardous areas from this position e Label the start restart switch with the safeguarding device e g Scanner to be reset so that the safeguarded area is easy to identify e Ensure that no personnel are in the hazardous area before actuating the start restart switch Start Interlock The start interlock function prevents the AG4 outputs OSSD1 and OSSD2 from automatically turning ON when power is initially applied to the AG4 either initially or after an interruption of power a
55. arding of All Machines OSHA 29 CFR 1910 147 The Control of Hazardous Energy lockout tagout OSHA 29 CFR 1910 217 Guarding of Mechanical Power Presses International European Standards ISO 12100 1 amp 2 EN 292 1 amp 2 Safety of Machinery Basic Concepts General Principles for Design ISO 13857 Safety Distances Upper and Lower Limbs ISO 13850 EN 418 Emergency Stop Devices Functional Aspects Principles for Design ISO 13851 EN 574 Two Hand Control Devices Functional Aspects Principles for Design ISO 62061 Functional Safety of Safety Related Electrical Electronic and Programmable Control Systems ISO 13849 1 EN 954 1 Safety Related Parts of Control Systems ISO 13855 EN 999 The Positioning of Protective Equipment in Respect to Approach speeds of Parts of the Human Body ISO 14121 EN 1050 Principles of Risk Assessment ISO 14119 EN 1088 Interlocking Devices Associated with Guards Principles for Design and Selection IEC 60204 1 Electrical Equipment of Machines Part 1 General Requirements IEC 61496 Electro sensitive Protection Equipment IEC 60529 Degrees of Protection Provided by Enclosures IEC 60947 1 Low Voltage Switchgear General Rules IEC 60947 5 1 Low Voltage Switchgear Electromechanical Control Circuit Devices IEC 60947 5 5 Low Voltage Switchgear Electrical Emergency Stop Device with Mechanical Latching Function Safety standards covering mob
56. atic Start and Restart enabled Auto Start Restart Reset Interlock The default configuration is automatic start and restart automatic reset with a 2 second delay after the Protective Field becomes clear The 2 second OSSD ON delay is required by BS DIN EN1525 and is meant to allow an individual to fully clear the area protected by the Scanner In the AGV application option the user has the choice of Atomatic start St Interlock manual reset at power up or Std test This option affects all Field Pairs and is not dependent on Field Pair switchover parameters See Section 1 12 1 and 1 12 4 for complete information Scanner Response Time The AG Automated Guided Vehicle application option automatically sets the Scanner response time to the 160 ms default The user may enter values from 80 ms to 640 ms in 40 ms increments Vehicle Speed The vehicle s expected maximum speed should be identified in the configuration This allows the AG4 algorithm to maximize the interference dust immunity The options are up to 1500 mm s up to 2500 mm s up to 4000 mm s and over 4000 mm s default Field Pair Switchover In applications that incorporate Field Pair switchover Minimum Distance D and Side Distance Z must be calculated individually for all Protective Field pairs 3 4 3 Protective Field Area Length and Width The horizontal Protective Field will prevent a collision only if the edge of the field in
57. ationary Applications US Standards 34 3 3 5 Minimum Safety Distance Stationary Applications European Standards 36 37050 PASS FMrOUGh Mazatlan 38 3 3 7 Reset Start Restart Switch Locati0nN ccooocccooocococococonococonococonacononacononacnnnnncnconaros 39 3 3 8 Supplemental SafeQuarding cccccesceceececceseeceeeeecseeeesseseesseeeesseseesseeeesssseesseeeessagees 39 3 4 Additional Installation Considerations for Mobile Applications oooooooocoo 40 2 Ic OUIIUII Cla Sosa O O E aethaube ewes A 41 3 4 2 Configuration Considerations ccoconcccconcncconcnccnncnnonncnnonncnononcnnnnncnnnnnrnnnnnrnnonnrnrnnnrnennneos 41 3 4 3 Protective Field Area Length and Width ooocccoccccoccconcnconcncnnnconcnconcnnnnconnnncnncnnns 42 3 4 4 Mobile Side Guarding on AGVs Vertical Protective FieldS ccoooocccconcncooocnnonnoo 46 3 5 Electrical Connections coi ileus cnnenadien id deuavnasinatienbideeiveiaanndunb leveenitie 47 DI FROURING CADES O E ETA A 47 3 5 2 Initial Electrical COMETAS ada 48 3 0 Scanner Inilial ONeckdUl ii e N 48 3 6 1 Initial Power Up and Configuration of the Scanner occcconcncconcnccnncnccnncnnnnncncnnncnnnnncnnnnnoos 49 3 6 2 Inittal Optical Field Vertice da nth AAA 49 3 6 3 Trip Test Protective and Warning Field Verificati0n oooocccconcncconnnnconnnnonannnnonons 50 3 7 Electrical Interface to the Guarded Machine
58. atter Screens occcoccccccnccccnconcnccnnnnononos 83 5 4 3 Cleaning the Scatter Screens cccconcccocococonococonacononaconnnncnnonnrnnonnrnnnnnrnnonncnnnnnrnnnnncncnnnens 84 5 4 4 Changing the Front Screen WindOw oocccconcnccoccncccncncnnncnnnoncnononcnnnnncnnnnnrnnnoncnonnnoos 85 5 4 5 Calibrating the Front Screen WiNdOW cccccccccseeeeeeeeeeeseeeeeseueeeseueesseueesseeesseneesaaeees 86 5 4 6 Scanner Replacement Procedure cooocccccccccccccocnconcnconnnnonnnonononnnnnonnnonnnonnnnnnnnnnnnnnnncnnos 87 5 5 Repairs and Warranty Service ooooococonicccocooconononononoonononononnonanonnnnarononnnnnonanenennarinonos 87 Ox Safety System SN eo 88 6 7 Schedule of CHECKOUUS orrena re E E esaide pain AEEA 88 6 2 COMMISSIONING CHECKOUE na e a a A A A 89 6 3 SONU DANY CHECK Utd ai ads 91 6 4 Semi Annual Six Month Check0Ut cooococccoccccnccocononoocononononnonanonnonaronononrononanennnnanons 91 Te Co ty see a rs aE ee Sree a rR eae 92 Tet LISU OL ADDIOVIQUONS A aa 92 MAISON a at a doit 92 EC Declaration of Conformity acusada 94 P N 144924 rev A 02 2010 AG4 Safety Laser Scanner User Manual Banner AG4 Series Safety Laser Scanner 1 Overview The Banner AG4 Safety Laser Scanner the Scanner is an optical two dimensional measuring Safety Laser Scanner The Scanner emits periodic light pulses via a rotating deflection mirror The light pulses reflect back from objects in the sensing field and are then detect
59. by 40 ms With K 1600 mm s the separation safety distance increases by 64 mm 40 ms x 1600 mm s per additional scan A WARNING SCANNER RESPONSE TIME ADJUSTMENTS Do not increase the Scanner s 80 ms response time for vertically positioned Protective Fields such as work cell access Entry Exit or perimeter guarding applications where a person could move quickly through the Protective Field without being detected Failure to follow this recommendation could result in serious bodily injury or death Minimum Safety Separation Distance Formula When all factors that influence the Safety Distance are considered the formula is Ds K x Ts Tr Dpf Zsm Zrefi where Ds the safety distance in mm inches K 1600 mm per second 63 inches per second see note 1 below Ts maximum stopping time sec of the machine see note 2 below Tr maximum response time sec of the Scanner see note 3 below Dpf Depth penetration factor The additional distance required by U S standards such as ANSI B11 19 to prevent a person from encroaching towards the hazard without being detected Zsm the additional distance needed to account for distance measurement error Zref the additional distance needed to account for error due to reflections from retro reflective surfaces Notes 1 The OSHA recommended hand speed constant K has been determined by various studies and although these studies indicate speeds of 1600 mm s 63 s
60. cator will be GREEN and the YELLOW Start Restart Reset indicator LED 5 on Figure 1 3 will indicate the Scanner is waiting for a manual reset to turn ON the OSSD outputs The OSSD outputs come back ON only when the Protective Field is clear and after a manual reset This is also known as Latch Output mode e Automatic Restart Interlock Automatic Reset When the Protective Field becomes interrupted by an object larger than the configured resolution the OSSD outputs turn OFF within the configured response time see 4 6 If the Protective Field then becomes clear OSSD outputs come back ON No resets of any kind are needed This is also known as Trip Output mode Internal Faults Lockouts If a critical fault s is detected the Scanner enters a lockout condition the OSSD outputs remain OFF and diagnostic information is displayed on the LED display LED 5 flashes at a 4Hz rate and is available via the AG4Soft program To access diagnostic information highlight the System Data Operating tab and click on menu bar path System Data gt Display the Scanner s diagnostics list See Section 5 for resolution of error fault conditions 4 9 Determining Response Time The Scanner s response time is the time needed to switch OFF its OSSD outputs after an object is detected Two response time options are provided in the AG4Soft program and must be noted to determine the Safety Distance Minimum Distance Either of the two response times can be confi
61. changed in two steps 1 Change the front screen 2 Calibrate the front screen When replacing the Scanner front screen due to contamination or similar e Perform all work in a dust free environment if possible e Do not touch any of the parts inside the device e Clean new front screen especially fingerprints before re using the Scanner 1 Remove the Scanner from the machine 2 Place the Scanner on an even base 3 Loosen the four Allen screws on the rear of the housing and carefully pull the two housing parts apart 4 Loosen the screws of the fixing plates 5 Remove the fixing plates 6 Push the old front screen backwards out of the housing 7 Hold the new front screen on the sides and carefully place it in the correct position 8 Ensure that the rubber seal sits correctly in the slot provided for this in the housing and is not damaged Banner AG4 Series User Manual P N 144924 rev A 02 2010 85 Banner AG4 Series Safety Laser Scanner 9 Check that there is no gap of light between the front screen and the housing Fix the front screen with the fixing plates 10 Support while screwing the fixing plates with a little pressure on the furthest outside edge of the front screen 11 Check the Scanner components e g mirror optics or housing parts for dust and blow the Scanner down as required with a light oil free stream of compressed air 12 Carefully put the two housing parts back to
62. d SSD to the ON state from a lockout condition Also refers to the act of using the switch to Reset the System Latch Condition The response of the OSSD outputs they turn OFF when an object blocks interrupts a light beam of the System operating in Latch mode A manual Reset must be performed after all objects are removed beam s clear to Reset the output latch and allow the outputs to turn ON Lockout Condition A condition of the System that is automatically attained when it detects internal or certain external errors A lockout condition causes all of the System OSSD outputs to turn or remain OFF sending a stop signal to the guarded machine To restore the System to Run mode all errors must be corrected and a manual Reset must be performed Machine Primary Control Element MPCE An electrically powered element external to the System which directly controls the machine s normal operating motion in such a way that it is last in time to operate when motion is either initiated or arrested Machine Response Time The time between the interruption by the System OSSDs and the instant when the dangerous parts of the machine reach a safe state by being brought to rest Separation Safety Distance That distance along the direction of approach between the outermost position at which the appropriate test piece is just detected and the nearest dangerous machine part s Also called Safety distance Start restart interlock When applied
63. d eophosbon emd see ol uw gt ofthe Saber Laser Scena altho Sniry Laser Scenn anger fore guarding Zz Fneety selectable gresefings Dernge tone quending wih d fesion ol the requested resolution with delos of the requested resolution Lea deteci n Jangar tons guarding Pesoton AGY Anoma paded vetician They pressulescnan lss und eaan pri t They A AA fee Passage conital ACCBES guarding 3po h polea old blind 3po he hilac Meda lira Arm prolteci n por cl operaban guerding gt Hand protection pointolopere on guaira Sman oh o ici on the Lasi Scania Tan buhawi Sman behear miar maithi on the Lasar Scanner Mode protechoo danger One gumin Caution Caitir With Aurineiniic elare eelection n aiin winny Sian imartock ith Anrinintic siat eeleictian e gi wani fuptcalfscourc Anhnar sl fapbealfecuurics min Ge Proved co or pou it paramolts het Greim sioh Stet intarkrck miii bo pirated co gr pou miht parami lis hel darea y sigh dpon ven the Sted interlocks funca dipon ven thes Sten mierak functian Rusa behemi we Pati Sahiy Laver Scans dien beter Phaolaet interlock Salley Lever Scans diar bebe Foes 1 Aho mitans ol tay protectin field PF dune running oporelion EE Amine Rest se or mlman ol the protec inki PP during running opomin i ey Lalo Fret delos bre ahar PF release i feun me Brck hos oe Genai lt Binch hie gt pE pena The restart behavior default option is Restart Interlock Manual Reset If Automatic
64. desrad siider This is ensured by spproprainiy spph rg a contol wake cn Her xI ping Tiran rl t Back Hoot Dr Genad E Ce ot penai 60 P N 144924 rev A 02 2010 AG4 Safety Laser Scanner User Manual Banner AG4 Series Safety Laser Scanner The final dialog boxes in the wizard are considered Administrative Parameters and allow configuration of the functionality of Alarm Output 1 see Section 1 12 6 the amount of measurement data that is communicated see Section 1 12 5 and the baud rate of the X2 PC serial interface Banner AG4 Series User Manual P N 144924 rev A 02 2010 61 Banner AG4 Series Safety Laser Scanner After these parameters have been configured use defaults for the walk through click OK to return to the main Configuration screen which is indicated by the yellow highlighted tab on the top toolbar i e Operating Mode Tabs Note The Scanner manuals can be accessed by clicking on Help on the Menu Bar Note The display can be manipulated via the menu bar path Settings gt PC configuration gt Change diagram color or gt Rotate contour display by 180 FM Ver Setting Configuration Pretective warng ad System data Lecurky Hilo Menu Bar a Operating Mode Tabs active mode 750 highlighted yellow 70m s0 Operating Mode 500 Work Space Icons Ra 5 000 150 Position cursor 1o small blue ring 2500 3m 220 2000 1500 1000 a500 0000 2500 do
65. dily injury or death Minimum Distance D Protective Field Length The following calculations do not specifically take into account the speed of an individual since it can be assumed that an individual will recognize and will avoid the hazard or at a minimum stop their movement If this cannot be reasonably expected such as if the Warning Field is not used to signal the approach of the vehicle the factor Za should incorporate the expected speed of an individual see below When all factors that influence a mobile vehicle stopping performance are considered the formula is D Dsp Zsm Zrer ZF Za where D Minimum distance from the vehicle surface to the edge of the Protective Field in mm Dsp Stopping distance in mm Zsm the additional distance needed to account for distance measurement error Zref the additional distance needed to account for error due to reflections from retro reflective surfaces Zr the additional distance needed to account for AGV ground clearance Za application specific additions Note In the following figure ZLEap Zsm Zrer Zf Za Protective Field Figure 3 13 Calculating minimum distance in a mobile vehicle application Banner AG4 Series User Manual P N 144924 rev A 02 2010 43 Banner AG4 Series Safety Laser Scanner Dsp Vmax X Ts Tr Dg where Dsp Stopping distance in mm Vmax the maximum velocity as stated by the manufacturer of the mobile vehicle T
66. drive logic including the response time of any interfacing devices such as UM FA A safety module 25 ms The braking distance of the AGV including environmental conditions such as wet or slippery flooring Absence or lack of clearance in front or to the sides of the AGV The speed of movement of an individual The reduced efficiency of the braking system due to wear A WARNING AG4 RESPONSE TIME ADJUSTMENTS Do not increase the Scanner s 80 ms response time for vertically positioned Protective Fields such as work cell access Entry Exit or perimeter guarding applications where a person could move quickly through the Protective Field without being detected Failure to follow this recommendation could result in serious bodily injury or death 42 P N 144924 rev A 02 2010 AG4 Safety Laser Scanner User Manual Banner AG4 Series Safety Laser Scanner A WARNING DETERMINE CORRECT STOP TIME Stop time Ts must include the response time of all relevant devices or controls that react to stop the mobile vehicle If all devices are not included the calculated Minimum Distance D will be too short This can lead to serious bodily injury or death A WARNING PROPER SEPARATION DISTANCE The Protective Field must be located far enough from the nearest hazard such that an individual cannot reach the hazard before cessation of hazardous motion or situation Failure to establish and maintain the Minimum Distance D could result in serious bo
67. e additional distance needed to account for distance measurement error The value for Zsm is a function of the distance from the Scanner the rotary mirror s center point to the furthest point of the Protective Field measured along the radial RG For Vertical Protective Fields normal approach Zsm O For Horizontal Protective Fields parallel approach Zsm 83 mm 3 3 for Protective Fields RG lt 3500 mm 138 Zsm 100 mm 4 for Protective Fields RG 2 3500 mm 138 Zrer Retro Reflector Factor Banner AG4 Series User Manual P N 144924 rev A 02 2010 35 Banner AG4 Series Safety Laser Scanner Zrer IS the additional distance needed to account for error due to reflections from retro reflective or shiny surfaces that are present in the scanning plane No Retro reflectors Zref O Retro reflectors located within the scanning plane of the Protective Field Zret 100 mm 4 3 3 5 Minimum Safety Distance Stationary Applications European Standards Response Time Considerations The Scanner s mirror rotates every 40 ms 25 scans or revolutions per second The safety outputs will switch OFF only after an object is detected in the Protective Field for at least two consecutive scans The Scanner s minimum response time is therefore 80 ms 2 x 40 ms To increase the Scanner s reliability in an adverse environments e g with fine airborne particles increase the number of scans required before the Scanner s safety
68. e place until the Scanner has been checked out This may require lockout tagout procedures refer to OSHA1910 147 ANSI 2244 1 or the appropriate standard for controlling hazardous energy These connections will be made after the initial checkout procedure has been successfully completed 48 P N 144924 rev A 02 2010 AG4 Safety Laser Scanner User Manual Banner AG4 Series Safety Laser Scanner 3 6 1 Initial Power Up and Configuration of the Scanner Verify that e Power has been removed from or is not available to the guarded machine its controls or actuators e The machine control circuit or the safety module is not connected to the OSSD outputs at this time permanent connections will be made later e The slide switch in the Machine Interface X1 plug housing is set to the 1 left default position if previously not accomplished see Section 3 5 1 and e The PC Interface cable AG4 PCD9 xx is connected to the X2 connector on the Scanner if not previously accomplished but is not connected to the PC serial port If used install the AG4 PC9USB 1 Serial to USB adaptor to a version 2 0 USB port on the PC but not to the PC Interface cable AG4 PCD9 xx Open the AG4soft program and log in as an Authorized Customer If not previously accomplished configure the Scanner as described in Section 4 2 or the AG4Soft manual Connect the PC via the PC Interface cable AG4 PCD9 xx to a serial port or to the AG4 PCD9USB 1 Serial to USB
69. e s rs poro time imiltacen In liso Fs Ihis ana Ss painais Bairi rth lina platina in inl deecions nus be creara by A4 min per 40 mo mapane lone Mosa Pobla Moa elke enter all imer an maliplas of ha acen pma ol Allens PEA Ays Aang e parents led cia A Fe TH Pe Puede 0 gu se a ral Beck Hui m conc Bock Near w a The fifth page of the wizard determines which Field Pairs the Scanner is allowed to start up power up when multiple Field Pairs are used The sixth page determines which Field Pairs can switch to other Field Pairs during Field Pair switchover see Section 1 12 4 After clicking on the appropriate boxes use defaults for the walk through click NEXT to complete Configuration wizard Emerald pararaiesn Esteheraleupst parma Configuration miz ard Mala cstachon ci the held pers MF per the Sinner siar Pemutihan hedd parir erichoa ra fe la a mep 5 ou may stan enh FFI Swrichowar la other held paira ie mot pamedted Serichower bo other field pira in rot pamini Smchorwer bo olor add pain ie mol pete Sanichovar lo lhes fede perras pol parmiied Srevlicherwar bo ather fede pira te motparten Serichornr to athe field paira is ank pamirsa STC Cre lo Gh Dak jar 15 a parna Fali paire ine ha troi o apasiar wart Prald poireaichovers ana edo red wih Of the Scanner we raleased wih a 4 Acro og must be tresen gri ma corp PORN pin al mug l The tam Fold per 0 Geld pai sequenta conurpondle weh Mo
70. eases Additional Distance Factors Z Specific for Mobile Applications For mobile applications two additional factors must be considered Zsm and Zrefi Zsm Measurement Tolerance Factor Zsm is the additional distance needed to account for distance measurement error The value for Zsm is a function of the distance from the Scanner rotary mirror s center point to the furthest point of the Protective Field measured along the radial RG For Horizontal Protective Fields parallel approach Zsm 83 mm 3 3 for Protective Fields RG lt 3500 mm 138 Zsm 100 mm 4 for Protective Fields RG 2 3500 mm 138 Zrefi Retro Reflector Factor Zrer IS the additional distance needed to account for error due to reflections from retro reflective or shiny surfaces that are present in the scanning plane No retro reflectors Zrefl O Retro reflectors located within the scanning plane of the Protective Field Zren 100 mm 4 Zr Mobile Vehicle AGV Ground Clearance The additional distance Zr is required if the mobile vehicle does not have sufficient ground clearance HF such that there is no space under the vehicle or Scanner for the tips of feet If the wheels are mounted near the side wall always add an additional distance Zr 2 150 mm otherwise Zr is determined according to Figure 3 14 44 P N 144924 rev A 02 2010 AG4 Safety Laser Scanner User Manual Banner AG4 Series Safety Laser Scanner F 20 40 60 80 100 120 140 160
71. eat this along the entire Warning Field perimeter as shown in Figure 3 16 Pay special attention at needle and cone shaped areas see Section 3 3 1 3 With the appropriate test piece that matches the configured expected resolution interrupt the perimeter of the Protected Field and verify LED 1 Green turns OFF Remove the test piece and verify that LED 1 turns ON Repeat this along the entire Protective Field perimeter see Figure 3 16 below and verify that the configured field e Responds to the intrusion of the test piece e Has no unmonitored areas as described in Section 3 3 1 e Complies with the separation safety distance calculated in Section 3 3 4 or 3 3 5 Note Pay special attention at needle and cone shaped areas see Section 3 3 1 Note For stationary applications verify that the marking of the perimeter of the Protective Field on the floor corresponds to LED 1 If the floor has not been marked do so now with the aid of the response of LED 1 4 Verify that the height of the Protective Field at the perimeter is at the expected level e g 150 mm for mobile applications e Protective Fields 90 to 190 In at least three locations approx 90 apart from each other e Protective Fields 90 or less In at least two locations 90 apart from each other 50 P N 144924 rev A 02 2010 AG4 Safety Laser Scanner User Manual Banner AG4 Series Safety Laser Scanner Figure 3 17 Scanner trip tests ho
72. eckout procedures are also found on Banner document p n 147899 contained on the installation CD 88 P N 144924 rev A 02 2010 AG4 Safety Laser Scanner User Manual Banner AG4 Series Safety Laser Scanner 6 2 Commissioning Checkout Perform this checkout procedure as part of the Scanner installation after it has been interfaced to the guarded machine as described in Sections 3 5 and 3 7 or whenever changes are made to the system either a new configuration of the Scanner or changes to the machine Record checkout results and store on or near the guarded machine as required by applicable standards Requirements e The AG4 has been configured with the configuration software e Interface X1 of the Scanner is connected to the control system or safety switching device e Protective housing cap is attached to interface X2 PC connection optional A WARNING UNPREDICTABLE MACHINE STARTUP There is a risk of unpredictable machine behavior at the initial start up of the machine The Qualified Person must take precautions to ensure that no one is in or near the hazardous area during these safety system tests Tester Qualified Person as defined in Section 4 1 To prepare the System for this checkout 1 Examine the guarded machine to verify that it is of a type and design compatible with the Scanner See Section 1 11 for information on the proper use and intended purpose including misapplications 2 Verify that the Scanner is confi
73. ectable Manual or Auto reset Default Start Restart Interlock enabled Manual Note Reference contour surface monitoring function is manually configured Determine the area to be safeguarded and the AG4 s installation location Determine whether to install the Scanner with or without the AG4 MBK1 mounting system 4 Determine the size and coverage of the Protective Field and Warning Field if used depending on physical location of the AG4 installation and the minimum safety distance Section 3 3 4 5 or the stopping distance of the mobile vehicle Section 3 4 Determine the start restart operating mode manual or automatic reset Section 1 12 1 If the start restart interlock manual reset is used determine the position for the reset switch Section 3 3 7 Determine if Field Pair switchover is required and identify the conditions for use Section 1 12 4 Cs to 2 Configure the Scanner with the configuration software see the AG4soft Software Instruction Manual p n 144923 for complete instructions See Section 3 2 Important Many safety relevant parameters are preset in the configuration and diagnostics software Use these preset values wherever possible Banner AG4 Series User Manual P N 144924 rev A 02 2010 27 10 11 Banner AG4 Series Safety Laser Scanner Record the Scanner configuration and Protective Warning Fields dimensioning This document should identify and be signed by the individual s responsible for the
74. ected to the PC and the AG4Soft program is open If not previously accomplished in Section 3 6 1 connect the PC Interface cable AG4 PCD9 xx to the X2 connector on the Scanner and to the PC serial port A USB to serial adaptor is available AG4 PCD9USB 1 if the PC does not provide a serial port see below If used connect the AG4 PCD9USB 1 Serial to USB adaptor to a version 2 0 USB port and then to the PC Interface cable AG4 PCD9 xx The X1 Machine Interface connection should have been previously made see Section 3 5 Depending on the situation it may be required that the machine be disabled with no power available to the machine actuators Lockout Tagout regulations may apply see Sections 3 5 and 3 7 Apply power to the Scanner After the Scanner has passed internal testing communication is established AG4 Connection is displayed on the Status line after approximately 30 seconds The current configuration automatically loads from the Scanner the Ghange authorization level dialog box appears it is recommended to be logged in as an Authorized customer default password bannera and the status information is ascertained from the Scanner Review this information and click on Exit At this time the measured area yellow outline the Warning Field and the Protective Field are displayed The uploaded configuration can be reviewed or manipulated or a saved configuration can be opened and downloaded to the Scanner as d
75. ed by the Scanner receiver The Scanner calculates the precise position of an obstruction from the light travel time and the pulse s emitted angle If the obstruction is within the user defined Protective Field PF the Scanner switches the safety outputs OFF Only when the Protective Field is free of obstructions does the Scanner turn its safety outputs back ON either automatically or following a manual restart reset signal depending on the operating mode Configured Warning Field WF User defines shapes and ranges Configured Protective Field PF Use defines shapes and ranges a person in the Protective AA Maximum Monitored Area 50 meters Configurable Protective Field and Warning Field field of view 5 extension Configurable Protective Field and Warning Field field of view 5 extension Maximum Protective Field AG4 4E 4 meters range AG4 6E 6 25 meters Maximum Warning Field range 15 meters Figure 1 1 Scanner detection ranges 1 2 1 1 O 1 X1 interface for controlling the machine with Protective cap 2 X2 interfaces for PC laptop with Protective cap 3 Status display js i i G E A Scatter screens 5 Front screen aN ir QUIN ae HA pio gt al Figure 1 2 Scanner features 1 1 Status Display Five LEDs on the housing front show the Scanner s operating status Banner AG4 Series User Manual P N 144924 rev A 02 2010 7 Banner AG4 Series Safety Laser Scanner L
76. edure Semi annually the Scanner and its interface to the guarded machine should be thoroughly checked out this checkout must be performed by a Qualified Person see Section 6 4 and the Semi Annual Checkout Card for the procedure A copy of these test results should be posted on or near the machine Whenever changes are made to the System either a new configuration of the Scanner or changes to the machine the Commissioning Checkout should be performed see Section 6 2 A WARNING VERIFY PROPER OPERATION It is the user s responsibility to verify proper operation on a regular basis as instructed in Section 6 Failure to do so can result in undetected problems which if not corrected can result in serious bodily injury or death Banner AG4 Series User Manual P N 144924 rev A 02 2010 71 Banner AG4 Series Safety Laser Scanner 5 Troubleshooting and Maintenance A WARNING SHUT DOWN MACHINERY BEFORE SERVICING The machinery to which the Scanner is connected must not be operating at any time during major service or maintenance This may require lockout tagout procedures refer to OSHA1910 147 ANSI 2244 1 or the appropriate standard for controlling hazardous energy Servicing the Scanner while the hazardous machinery is operational could result in serious bodily injury or death The Scanner uses three diagnostics levels to quickly resolve errors Proceed in steps to resolve an error 1 Determine the Scanner s status si
77. eference Contour Monitoring be used for all stationary applications that have surfaces that can be monitored Failure to follow these recommendations can potentially create a dangerous situation that may lead to serious injury or death 1 12 6 Alarm Auxiliary Outputs Two auxiliary output functions provide current sourcing PNP solid state output 100 mA max and are used for non safety control functions a typical use is to signal the state of the OSSDs to a programmable logic controller PLC The Alarm outputs can have a different response time from the Protective Field response time The response time can Banner AG4 Series User Manual P N 144924 rev A 02 2010 17 Banner AG4 Series Safety Laser Scanner be configured for a minimum of 80 ms to a maximum of 640 milliseconds default 160 ms See Section 4 or the AG4Soft manual for more information Alarm 1 Auxiliary 1 output X1 5 is configurable to provide status of the following output turns OFF when None output is held OFF Device Warning lockout condition or dirty window indication i e LED 5 is flashing Warning Field interrupted automatic reset only default Device Warning or Warning Field interrupted Alarm 2 Auxiliary 2 output X1 15 provides the Device Warning function which signals a lockout condition or dirty window indication i e LED 5 is flashing by turning OFF the output See Figures 3 18 3 19 and 3 20 for hookup wiring information Imp
78. eference measurement failed glare from another eave light source 905 nm or rotation speed error 41 42 Scanner performs reset Invalid diagnostics command received software not a compatible with firmware Use a newer version of the configuration and diagnostics software Invalid diagnostics value requested software not ENA compatible with firmware Use a newer version of the configuration and diagnostics software 2800 2 2 Field Pair control inputs activated longer than 1 s Check the switchover times of the control inputs FP FP4 Banner AG4 Series User Manual P N 144924 rev A 02 2010 79 Banner AG4 Series Safety Laser Scanner The Protective Field switchover performed does not 2800 3 comply with the specifications programmed in the Check the activation of the Protective Fields in the program wizard Scanner 2800 meee ae Be et nee AS Check the activation of the control inputs FP1 FP4 Operation 2800 E nuSanig EAS CONO VONAGE sor ner sIOlecive Check the activation of the control inputs FP1 FP4 Field activation No Protective Field activated Can occur during If detected during running operation check the activation of the control 2800 ee Operation and switching off the device inputs FP1 FP4 Error while testing the inputs for the Protective Field 2801 p intemal defect Contact the customer service The Protective Field activation performed does not 2802 3 comply with the specifications programmed in
79. er The area behind and on either side the Scanner is not monitored see Figure 3 1 3 It must not be possible to walk in unmonitored areas or otherwise access them This can be accomplished by recessing the Scanner into the machine using supplemental safeguarding or using mechanical barriers to prevent access If there is a possibility that the Scanner could be used as a climbing aid or standing surface use a physical cover set at an angle over the Scanner see Figure 3 2 3 Special attention to these areas must be addressed in vertical Protective Field applications so that the resolution at the edges of the Protective Field does not increase If an increased resolution cannot be prevented then the worst case resolution must be used to determine the Dpf U S formula or the C factor European formula in the safety distance calculation see Sections 3 3 4 and 3 3 5 x 1 Scanner 2 PF 3 Unmonitored area Figure 3 1 Protective Field Unmonitored Areas Banner AG4 Series User Manual P N 144924 rev A 02 2010 29 Banner AG4 Series Safety Laser Scanner Recessing into the machine surface PF Physical cover Scanner Machine Figure 3 2 Recessing into the Machine Contour Shadowing Within the Protective Field A WARNING SHADOWING WITHIN THE PROTECTIVE FIELD Permanent and moveable objects in the Protective Field can create a shadow that results in an unprotected zone that may provide an access route to the haza
80. er than the diameter of the specified test piece enters the Protective Field In a trip condition FSD 1 and FSD 2 simultaneously de energize and open their contacts A trip condition clears automatically when the object is removed from the Protective Field User An entity that utilizes a machine or related equipment The user is typically regarded as the entity that employs the operator of the machine and or supervises the operation of the machine including production and maintenance Banner AG4 Series User Manual P N 144924 rev A 02 2010 93 Banner AG4 Series Safety Laser Scanner EC Declaration of Conformity Banner Engineering Corp 9714 Tenth Avenue North Minneapolis MN 55441 5019 USA We herewith declare that the Banner AG4 Series Safety Laser Scanner for industrial control is in conformity with the provisions of the Machinery Directive Directive 98 37 EC Machinery Directive valid until 29 December 2009 and 2006 42 EC Machinery Directive and all essential Health and Safety Requirements have been met EY Sy 3 17 2010 3 17 2010 R Eagle Engineering Manager Date Peter Mertens Managing Director Date Banner Engineering Corp Banner Engineering Europe 9714 Tenth Avenue North Park Lane Culliganlaan 2F Minneapolis MN 55441 5019 USA 1831 Diegem Belgium Download the complete EC Declaration of Conformity as a PDF file at www bannerengineering com AreaScanner 94 P N 144924 rev A 02 2010 AG4 Safety Laser Scanner User Manual
81. eration guarding Hand protection point of operation guarding Body protection danger zone guarding y Yes No Exit Do you wantto edit configuration data with the wizard E Configuration data invalid 2 Message No 1100 4 Scanner configuration must be loaded before a configuration data and detection warning Field data change Do you want to load a configuration from a file For the purpose of this walk through select standard rs file double click from the list of configuration files provided in the Select a file to open box After the file is successfully loaded click OK The Configuration Wizard opens with a dialog box that allows naming of the Scanner and a note or description of the location of the Scanner that the configuration will eventually be loaded into No entry is required for the purposes of the walk through Click on NEXT Note Navigation can move forward or backward through the wizard using the NEXT or BACK buttons Clicking on OK will end the wizard and open the AG4Soft Configuration window with the changes that had been made Clicking on CANCEL will end the wizard without retaining the changes To re enter the wizard click on Gonfiguration operating mode tab and select in the menu bar path Gonfiguration gt Wizard Conas ation miai Configuration wizard p Administrare pasarela Sadek ralevnnl pararralera Set Laver cmd nen Apphcation Faleti of theo
82. erious injury or death 1 6 1 Designated Person A Designated Person is identified and designated in writing by the employer as being appropriately trained to perform the specified checkout procedures on the Scanner A machine operator so designated may be a Designated Person The Designated Person is empowered to e Perform manual resets and hold possession of the reset key e Perform the daily Scanner checkout procedure 1 6 2 Qualified Person A Qualified Person by possession of a recognized degree or certificate of professional training or by extensive knowledge training and experience has successfully demonstrated the ability to solve problems relating to the installation of the Scanner and its integration with the guarded machine In addition to everything for which the Designated Person is empowered the Qualified Person is empowered to e Install the Scanner e Perform all Scanner checkout procedures e Control the password to access the Scanner s configuration program e Access and change the Scanner s configuration settings e Reset the system following a lockout condition e Perform maintenance and repairs as described in Section 5 1 7 Responsibility for Safety The responsibility for the proper use of the Scanner and compliance with the regulations and directives that apply in the country of use lies with the machine s manufacturer and operator At a minimum the machine manufacturer is responsible for 10 P N 144924 re
83. erlock Reset Procedures oooococoonccccooccccccononononcononononnonarononnanononos 69 Banner AG4 Series User Manual P N 144924 rev A 02 2010 Banner AG4 Series Safety Laser Scanner 4 6 1 Resetting the SysSteM ooocccconcccocccococococonacoconncnconncnconncnnnnncnnnnnrnnnnnrnnnnrnnnnnrnrnnrnnnonenes 69 TS SUS INOICALONS ii ico a a 69 4 8 Normal OPE MOM dis AS A AE A AS AE 69 HO o Ys tem Power UD 70 4 02 DUNG RUN Modest ada 70 4 9 Determining Response THMC c ccccscccccsecscnsescnsnscnsuescnsusensusensusssusasensusensusensuasaneass 70 4 10 Periodic Checkout RequireMents ooccccoccnoconnccccnncononoconnonononnonononnnnonannonanonenznninans 71 5 Troubleshooting and Maintenance sssssssssssssssnsnunnsnsnnnnnnnnnnnnnnnnnunnnnnnnnnnnnnnnnnnae 72 5 1 Troubleshooting Lockout CONdI IONS ccoooonccccoonononononnononononnanononononnonanononnaninonos 12 dl Scanner LED Status Dis play ou AR 72 Diet LED Status DISPIYS Sal 74 5 1 3 LED Warning and Error Displays 2200 aii ta Ra 15 9 1 2 SCaninen EMO COC S vr cescu sa natetesestns A t n 76 5 2 Communication Errors and Loss Of COMMUNICATION cooocccconnccconncconinconnnccnnnnnos 82 5 2 AG4ISo Pop up Error Messages E 82 5 3 Elecincal and Optical NOISE A ee a ii 83 5 4 Servicing and MAN A iS 83 5 4 1 Removing the Scanner from the Machine ccoonccccoccncccncnccnncnccnncncnnncnononcnnnnncncnoncnonnnons 83 5 4 2 Cleaning the Front Screen Window and Sc
84. escribed in Section 4 4 If communications are not established see Section 4 3 1 66 P N 144924 rev A 02 2010 AG4 Safety Laser Scanner User Manual Banner AG4 Series Safety Laser Scanner Manipulating the Uploaded Configuration The configuration can be changed via the wizard Configuration Operating Mode tab highlighted Configuration gt Wizard or by manually changing settings and fields via the Cofiguration and the Rrtective Warning Fields definition Operating Mode tabs See Section 4 2 2 or the AG4Soft manual for information on changing the configuration See Section 4 4 for information on downloading a configuration to the Scanner Opening a Saved Configuration Click on highlight the Gonfiguration Operating Mode tab and then click on Load Configuration data from file 6 Operating Mode Icon to open a saved configuration to review or manipulate the configuration e g the file saved in Section 4 2 3 during the walk through See Section 4 4 for information on downloading a configuration to the Scanner 4 3 1 Establishing Communications Between the PC and the Scanner Ensure that e The AG4Soft program is open then e The PC Interface cable AG4 PCD9 xx is connected to the X2 connector and the PC and e Power is applied to the Scanner If communications are not established a serial communications port may need to be selected Highlight the Configuration Operating Mode tab then on the Menu Bar click o
85. ev A 02 2010 AG4 Safety Laser Scanner User Manual Banner AG4 Series Safety Laser Scanner Note Due to the timing requirements it is recommended that the selection of Field Pairs 5 6 7 or 8 be made via PC PES or PLC logic Additional switches or sensors can be used to enable allow Field Pair switchover e For switching between Field Pairs 1 2 3 and 4 the new Field Pair s is active before the original Field Pair is deactivated Field Pairs uerlap during the one second switchover time limit See timing diagram Figure 1 9 e Ifno Field Pairs are selected active after the switchover time a lockout will occur i e all FP inputs are OV dc or an open connection e Selecting an invalid Field Pair s or not completing the selection within the switchover time will result in a lockout e Selecting Field Pairs that are not configured will result in a lockout e Switching between Field Pairs that are not allowed per the rmitted Field Pair switchover table will result in a lockout See the AG4Soft Software Manual e The Scanner is allowed to power up see Section 1 12 1 Start Restart Reset Interlock with Field Pair 1 through 7 selected as configured in the Field Pair Sanner start table See the AG4Soft Software Manual and leld Pair 8 below for more information In addition factors dependent on the risk assessment that may affect the safety circuit integrity level include e The means of selecting Field
86. face X1 plug see Table 1 and Figures 3 18 3 19 and 3 20 A WARNING PROTECTIVE FIELD PAIR SWITCHING Field Pair Switching is used to temporarily suspend or change the area of safeguarding Changing the Protective Warning Field Pair from one pair to another must not expose any individual to a hazard or hazardous situation Supplemental safeguarding may be required In higher risk applications use redundant sensors or switches to initiate or enable a Field Pair change The conditions for switching Field Pairs must be in accordance with a risk assessment Machine stopping braking distances Scanner system response time including interfacing devices machine stop time and other factors that influence the Safety Distance Minimum Distance and Stopping Distance calculations must be considered in order to safely use the Field Pair Switchover function Conditions to Allow Switching Field Pairs e Only one Field Pair can be active after the switchover time See Field Pair Input Logic table 1 e Field Pair switchover is allowed even if there is an intrusion into the active Protective Field i e OSSDs are OFF e The switchover must be made within one second except when Field Pairs 5 6 7 or 8 are configured at which time the switchover must occur within 40 ms In this case the original Field Pair is active during the switchover the new Field Pair becomes active after a maximum of 80 ms See timing diagram Figure 1 9 14 P N 144924 r
87. g function of the AG4 and the speed and braking functions of the mobile vehicle See the checkout procedures in Section 6 A CAUTION TRAINING 40 P N 144924 rev A 02 2010 AG4 Safety Laser Scanner User Manual Banner AG4 Series Safety Laser Scanner The user must instruct all individuals that may interact with the mobile vehicle at a minimum e not to approach the vehicle directly or from the sides while moving e familiarize with warning signals or lights beacon e familiarize with the size of the Warning and Protective Fields 3 4 1 Mounting The mounting of the Scanner should take into account e the surface contour of the path of the vehicle including holes bumps inclines ramps and other variations in the surface e deflection of springs or other vibration dampeners that could cause the plain of the Protective Field to vary e unmonitored areas created by the installation of the AG4 see below and Section 3 3 1 The point of mounting is typically in the center of the leading edge of the vehicle and is aligned horizontally to achieve a consistent scanning height over the entire Protective Field Mounting Height The Scanner should be mounted as low as possible in order to prevent people from passing beneath the sensing field by lying on the floor BS DIN EN 1525 and IEC 61496 3 recommend that the Protective Field with a resolution of 70 mm be as near as possible to the floor but no greater than 200 mm 7 9 above the f
88. g the location of the points and the size of the fields Please refer to Section 3 3 1 Needle and Cone Shaped Fields for important information The fields can be limited to 180 i e the 0 000 meter mark on the vertical axis if the area behind the Scanner is otherwise guarded see Section 3 3 1 This setting is found in menu bar path Settings gt PC Configuration gt 190 Protective Warning Fields option default is checked enabled Unchecking this option results in a 180 field and is effective after the field shape has been changed Zoom in or out of an area by using minus 1 and plus 2 icons and the directional arrows on the Navigation Tool Bar or by drawing a box around the area of interest left click hold to draw box release To resize and center the fields click on the center circle button on the Navigation Tool Bar If a field definition icon is clicked on by mistake use the ESC key to deselect the icon There is no ado function please refer to the AG4Soft manual for further information on changing and adjusting the Protective and Warning Fields In most stationary applications a rerence boundary must be defined Icons 28 and 29 are used to create and modify this function that prevents the miss adjustment or misalignment of the Scanner For the purpose of the walk through a reference boundary will not be programmed refer to the AG4Soft manual for further information Moves blue circle cursor up or lef
89. gether The two retaining bolts must slide into the rubber sleeves provided for this 13 Carefully tighten the Allen screws 1 Retaining bolts on the housing rear by alternating 2 between them Rubber sleeves 14 Remove any fingerprints on the front screen Figure 5 5 Scanner front screen replacement procedure 5 4 5 Calibrating the Front Screen Window Requirements e The new front screen is correctly mounted e Front screen is clean and scratch free e Ambient temperature 20 C to 25 C A CAUTION ENSURE FRONT SCREEN IS CLEAN Faulty calibration may be caused by a dirty or scratched front screen Only calibrate front screens that are clean and free of scratches and marring 1 Connect interface X1 with the control system 86 P N 144924 rev A 02 2010 AG4 Safety Laser Scanner User Manual Banner AG4 Series Safety Laser Scanner 2 Connect interface X2 with the PC 3 Calibrate the front screen using the software see AG4soft Software Instruction Manual 5 4 6 Scanner Replacement Procedure The replacement scanner must be the same model and be installed in the same position and alignment as the original Scanner to be replaced A typical replacement procedure 1 Remove all power from the Scanner and the machine see warning at the beginning of Section 5 2 Remove the original Scanner 3 Mount the replacement Scanner using the existing mounting bracket or holes 4 Ensure that the alignment e g til
90. gnaled via LEDs and remove the errors with the specified measures listed in the diagnostic Key 2 Read the diagnostics list with the configuration and diagnostics software and remove the errors with the aid of the solution provided 3 Create a service file with the configuration and diagnostics software and send this service file for remote diagnostics to Banner see AG4soft Software Instruction Manual for more information Refer to Figure 5 1 for LED names and locations 5 1 Troubleshooting Lockout Conditions A WARNING LOCKOUTS AND POWER FAILURES Power failures and Lockout conditions are indication of a problem and must be investigated immediately by a Qualified Person Attempts to continue to operate machinery by bypassing the Scanner or other safeguards is dangerous and could result in serious bodily injury or death A Lockout condition causes all of the Scanner OSSD outputs to turn or remain OFF sending a stop signal to the guarded machine Diagnostic error codes are available to assist in the identification of the cause s of lockouts The Scanner provides easy methods for determining operating problems A Lockout condition is indicated by LED 5 YELLOW on the LED display flashing at a 4Hz rate and diagnostic information is available via the AG4Soft program To access diagnostic information highlight the Sstem Data Operating tab and click on menu bar path Sstem Data gt Display the Scanner s diagnostics list
91. guration into the new Scamner 1 4 Product Labels 1 4 1 Product Identification Plate The product identification plate is located on the side of the Scanner and details information as shown below ra CE AG44E Made in Germany art no 82137 supply voltage 24v 0c 30 max power 28 W perm ambient temp 0 50 C CSA C222 enclosure rating IP 65 response time adjustable min 80ms uL 50s8 61010 C SE US fabricated in 2099 OSSD 1 2 max 250mA 24V DC safety category DION s IEC N 6149 3 Type 3 resolution adjustable EN 61508 62061 SIL2 30 1 40 150170 1 150mm ISO 13849 1 PL d Kats 99998888 R Banner Eng Corp 9714 Tenth AVE N Minneapolis MN 55441 USA Figure 1 4 Product identification plate 1 4 2 Safety Notice A Safety notice is located next to the interface connectors on the Scanner as shown Achtung Ym gas Endringen von Stavo zu verhindern m ssen beide Steckerhauben immer fest montert sein Der Scheibenwechsel daf nur von qualifiziertem Personal unter Beachtung der Mentageanleitung f r die Frontscheibe durchgefuhrt werden ing 1 prevent penetration by dust both piug caps must always be Warning firmly in place The optical window shall be changed only by qualified personnel The mountng instructions for the optical window shalt be consuited Attention Les deux capots doivent toujours tre fixes sur les connecteurs pour emp cher la poussi re de penetrer int rieur La vitre dor te remplac e excl
92. gured for a time between 80 ms 640 ms in 40 ms increments 70 P N 144924 rev A 02 2010 AG4 Safety Laser Scanner User Manual Banner AG4 Series Safety Laser Scanner e Protective Field PF response time Time until the Scanner switches off the OSSD 1 and OSSD 2 safety outputs or switching function Default 80 ms e Warning Field WF response time Time until the Scanner switches off the Alarm output Default 80 ms To determine the configured response times establish communications with the Scanner at which time the status information should automatically upload from the Scanner The Protective Field response time and the Warning Field response time will be listed in the Sanner status information dialog box A text file can be created or the information can be sent to a printer If the 6anner status information dialog box does not appear or otherwise needs to be accessed click on highlight the System data Operating Mode tab and then on the Menu Bar click on System data gt Transfer information from Scanner to PC to access the information 4 10 Periodic Checkout Requirements To ensure continued reliable operation the System must be checked out periodically See Section 6 for more information At every shift change power up and machine setup change the Daily checkout should be performed this checkout may be performed by a Designated or Qualified Person see Section 6 3 and the Daily Checkout Card for the proc
93. gured for the intended application see Section 4 2 and 4 4 and all mounting hardware is secured 3 Verify that the minimum safety separation distance from the closest hazard of the guarded machine to the Protective Field s is not less than the calculated distance per Section 3 3 4 U S stationary applications 3 3 5 European stationary applications or 3 4 3 mobile applications of this manual 4 Verify that e Access to any dangerous parts of the guarded machine is not possible from any direction not protected by the Scanner hard guarding or supplemental safeguarding and e It is not possible for a person to stand between or climb over under the protected Field s and the dangerous parts of the machine or stand on top of the Scanner see Section 3 or e Supplemental safeguarding and hard guarding as described by the appropriate safety standards are in place and functioning properly in any space between the Protective Field s and any hazard which is large enough to allow a person to be undetected by the Scanner see Sections 3 3 1 and 3 3 3 5 Verify that all reset switches are mounted outside and in full view of the guarded area out of reach of anyone inside the guarded area and that means of preventing inadvertent use is in place See Section 3 3 7 6 Examine the electrical wiring connections between the Scanner OSSD outputs and the guarded machine s control elements to verify that the wiring meets the requirements s
94. hicle moved at Motion Monitor speed very much exceeded Check the activation of the Protective Fields in the speed matrix and the Exceeding cannot be corrected speed the vehicle moved at Motion Monitor maximum speed exceeded or wrong Check the activation of the Protective Fields in the speed matrix and the Field Pair activation Cannot be corrected speed the vehicle moved at Motion Monitor activated Field Pair was not released Check the activation of the Protective Fields in the speed matrix and the in the configuration Motion Monitor error on the Field Pair control inputs Activated Protective Field not defined Motion Monitor further travel blocking cannot switch off the safety outputs or switching function OSSDs Banner AG4 Series User Manual program wizard Check the activation of the creep and further travel blocking functions Check the connection wiring of the OSSDs P N 144924 rev A 02 2010 81 Banner AG4 Series Safety Laser Scanner 5 2 Communication Errors and Loss of Communication See Section 4 3 Conecting to the Scanner and Section 4 3 1 Establishing Communications Between the PC and the Scanner for general information concern such items as Cofiguring the PC Serial Port oss of Communications and USB to serial adaptors including the AG4 PCD9USB 1 Only use AG4 PCD29 cordsets or standard RS232 extension cordsets with SUB D9 connectors to connect to the AG4 X2
95. ich results in the stopping of motion and removal of power from the MPCEs assuming this does not create additional hazards A safety stop circuit typically comprises a minimum of two normally open N O contacts from forced guided mechanically linked relays which are monitored via external device monitoring to detect certain failures in order to prevent the loss of the safety function Such a circuit can be described as a afe switching point Typically safety stop circuits are either single channel which is a series connection of at least two N O contacts or dual channel which is a separate connection of two N O contacts In either method the safety function relies on the use of redundant contacts to control a single hazard if one contact fails ON the second contact will arrest the hazard and prevent the next cycle from occurring See Figure 3 19 The interfacing of the safety stop circuits must be accomplished so that the safety function cannot be suspended overridden or defeated unless accomplished in a manner at the same or greater degree of safety as the machine s safety related control system that includes the Scanner The normally open safety outputs from a safety module provide a series connection of redundant contacts that form safety stop circuits for use in either single channel or dual channel control See Figure 3 20 Dual Channel Control Dual channel control provides the ability to electrically extend the safe
96. ies User Manual P N 144924 rev A 02 2010 63 Banner AG4 Series Safety Laser Scanner 4 2 2 Configuration Wizard Changing Protective and Warning Fields To modify or create the shape of the Protective and Warning Fields click on Priective Warning Fields definition tab on the Operating Mode Tabs Notice that the selection of the Operating Mode icons has changed See AG4Soft Software Manual for complete descriptions 15 16 17 18 19 ARA Aaa EA al eal 15 Displayed Field Pairs selection 16 Load Protective Warning Field from a file loads field only see icon 6 17 Save Protective Warning Field as a file loads field only see icon 7 18 Print Protective Warning Field 19 Select Protective Warning Field 20 Enter Protective Warning Field numerically 21 Define elliptical Protective Warning Field 22 Define rectangular Protective Warning Field 23 Define polygonal Protective Warning Field 24 Change Protective Warning Field segment 25 Change Protective Warning Field segment on all fields 26 Reduce Protective Warning Field limits 27 Blank out Protective Warning Field segment 28 Define Protective Field segment as reference contour 29 Reset reference contour definition for Protective Field segment 30 Delete Protective Warning Field resets to Default Field 31 Transfer changed Protective Warning Fields from PC to Scanner Select a field to be changed by clicking on the menu arrow of the Select P
97. igure 3 3 A shadow within the Protective Field 30 P N 144924 rev A 02 2010 AG4 Safety Laser Scanner User Manual Banner AG4 Series Safety Laser Scanner 3 3 2 Needle and Cone Shaped Protective Field Contours A CAUTION NEEDLE AND CONE SHAPED PROTECTIVE FIELD CONTOURS Any safety distance calculations must consider and resolve the effects of needle or cone shaped Protective Fields Boundaries or contours that rely on too few measurement points e g one or two may not reliably turn OFF the OSSDs when an object is present Needle and cone shaped Protective Field boundaries are not recommended because they may not reliably detect and respond to objects i e turn OFF the OSSDs compared with smooth field boundaries made up of multiple measurement points Two effects are to be considered 1 Not identifying the proper size of the detected object outward cone shapes and 2 An increase in resolution inward cone shapes Outward Needle and Cone Shaped Field Contours An object equal to or greater than the stated resolution e g 70 mm will be detected at point A Object 1 in Figure 3 4 because enough sensing points are present at that location to detect the full 70 mm size of the object Objects 2 or 3 may not be identified as being larger than the resolution because at that distance the angle is too narrow and has too few sensing points to detect the full 70 mm resolution size Inward Needle and Cone Shaped Field Co
98. ile vehicles or automated automatic guided vehicles AGV include BS DIN EN 1525 Dnveness Industrial Trucks and Their Systems ISO 3691 4 Driverless Industrial Trucks and Their Systems ANSI ITSDF ASME B56 5 Safety Standard for Guided Industrial Vehicles IEC 61496 3 Requirements for Active Opto Electronic Protective Devices Responsive to Diffuse Reflection AOPDDR more sensors more solutions Banner Engineering Corp 9714 Tenth Ave North Mpls MN 55441 Tel 763 544 3164 www bannerengineering com sensors bannerengineering com Contact Banner Engineering Corp US or e mail Banner Engineering Europe Park Lane Culliganlaan 2F Mexico Diegem B 1831 BELGIUM mexico bannerengineering com Tel 32 2 456 07 80 Brazil Fax 32 2 456 07 89 www bannereurope com mail bannereurope com brasil bannerengineering com Banner Engineering China Shanghai Rep Office Rm G H I 28th Flr Cross Region Plaza No 899 Lingling Road Shanghai 200030 CHINA Tel 86 21 54894500 Fax 86 21 54894511 www bannerengineering com cn sensors bannerengineering com cn Banner Engineering Japan Cent Urban Building 305 3 23 15 Nishi Nakajima Yodogawa Ku Osaka 532 0011 JAPAN Tel 81 6 6309 0411 Fax 81 6 6309 0416 www bannerengineering co jp mail bannerengineering co jp Banner Engineering India Pune Head Quarters Office No 1001 Sai Capital Opp ICC Senapati Bapat Road Pune 411016 INDIA Tel 91 20 6640562
99. ile icon 16 review or manipulate the field as necessary e Click on Transfer changed Protective Warning Fields from PC to Scanner icon 31 Note The same options are accessible from the top Menu Bar Follow the prompts review and accept the configuration and then perform the appropriate checkout procedure as described in Section 6 or return to Section 3 6 2 Initial Optical Field Verification 4 5 Downloading a Configuration to the Scanner Note Communications must be established with the AG4 at this time see 4 3 and the Authorization Level selected must be Authorized Customer With a configuration open and following the walk through click on highlight the Gonfiguration Operating Mode tab and then click on Fransfer configuration data from PC to Scanner 11 Operating Mode Icon Review the configuration and the fields as they are displayed and if correct click on Accept After the transfer of the configuration data has been confirmed click OK If the fields are clear the Scanner either should be awaiting a reset or should have automatically reset with the OSSD output ON Note This finishes the wizard walk through demonstration Perform the appropriate checkout procedure as described in Section 6 or return to Section 3 6 2 Initial Optical Field Verification 4 6 Start Restart Interlock Reset Procedures 4 6 1 Resetting the System System resets are typically performed using an external reset switch This swi
100. iliary 2 See Section 1 12 4 for further information on Field Pair Switchover See Section 3 7 5 for further information on the non safety Alarm Auxiliary outputs Arc suppressors EP1 FP4 See PLC Switching see WARNING device hookup below PLC Switching Device Hookup UM Module Auto Reset 24V de PLC Switching Device to No Connection MSC Monitor Contacts or Jumper for No 633 Monitoring MSC1 MSC2 MSC3 Select Required Field Pair Note OV dc must be common with the AG4 see WARNING 633 Figure 3 19 Hookup using UM module 56 P N 144924 rev A 02 2010 AG4 Safety Laser Scanner User Manual Banner AG4 Series Safety Laser Scanner 24V dc G Scanner OV dc Restart 2 Reset 24V dc FP1 Alarm 1 Auxiliary 1 FP2 FP3 FP4 Alarm 2 e Auxiliary 2 See Section 1 12 4 for further information on Field Pair Switchover See Section 3 7 5 for further information on the non safety Alarm Auxiliary outputs The Manual Reset function can be accomplished by the SC22 3 or other safety rated logic device In this case the Scanner is configured for automatic start restart Reset Figure 3 20 Hookup to the SC22 3 Safety Controller Banner AG4 Series User Manual P N 144924 rev A 02 2010 Safety Controller OV dc 24V dc OVdc PLC Switching Device to Select Required Field Pair SC22 3 A1 A1 A2 A2 57 Banner AG4 Se
101. line of sight to another Scanner and that share the same detection plane with it must be adjusted or shielded so that their light pulses are not detected by the adjacent Scanners or 40 ms must be added to the response time of all adjacent Scanners The Scanner design minimizes the possibility of optical interference from adjacent Scanners Light from adjacent scanners including those of other manufacturers can cause the response time to increase by 40 ms if the fields overlap in the same plane see Figure 3 5 below To eliminate the possibility of optical interference and increasing the response time e Install mechanical shielding barriers in stationary applications both horizontal and vertical Protective Fields e Forscanners mounted side by side this shielding must be at least at the height of the front screen window and flush with the front of the housing see Figure 3 5 Ensure that the means of shielding does not create any unmonitored areas see Section 3 3 1 Install scanners at an off set height of at least 100 mm see Figure 3 6 e Install scanners with Protective Fields with a crossed alignment see Figures 3 7 and 3 8 3 1 Hazard 2 Scanner 3 Machine with recessing for sensor installation 4 PFs 5 Shielding 2 100 mm 2 100 mm Figure 3 6 Height offset mounting and parallel alignment Figure 3 7 Adjacent mounting without height offset and with crossed alignment 2 100 mm Figure 3 8 Adjacent moun
102. loor see Figure 3 12 In general a height of 150 mm 5 9 has been recognized by industry to be the most advantageous height above the floor Figure 3 12 Determining mounting height Unmonitored Areas Mounting the Scanner on the mobile vehicle must not create unmonitored areas between the Protective Field and the vehicle such that the Scanner cannot respond to an object with a cross section of 70 mm or more see below and Section 3 3 1 Unmonitored areas on a mobile vehicle can be prevented by Design contour of the mobile vehicle Position of the Scanner Mounting the Scanner recessed within the vehicle Mounting the Scanner under a physical guard or overhanging parts of frame Using supplemental safeguarding such as bumper or edge switches Using mechanical barriers to prevent access 3 4 2 Configuration Considerations For mobile vehicle applications the application option AG Automated Guided Vehicle is typically chosen however the risk assessment should determine the appropriate option see Section 3 1 Table 6 AGV Application Application Configuration Description AGV Automated guided vehicle Horizontal Protective Field mobile Resolution 70 mm Banner AG4 Series User Manual P N 144924 rev A 02 2010 41 Banner AG4 Series Safety Laser Scanner Maximum Protective Field range AG4 4E 4 m 13 2 AG4 6E 6 25 m 20 6 Start Restart Interlock selectable Manual or Auto reset Default Autom
103. low For easy reference print out the procedures and post them near the machine application A WARNING PERIODIC CHECKOUTS The commissioning periodic and daily safety system checks must be performed by appropriate personnel at the appropriate times in order to ensure that the safety system is operating as intended Failure to perform these checks may create a potentially dangerous situation which could lead to serious injury or death 6 1 Schedule of Checkouts Trip Test The procedure for Scanner trip test is described in Section 3 4 3 This procedure must be performed at installation and at any time the Scanner the guarded machine or any part of the application is installed or altered The procedure must be performed by a Qualified Person Commissioning Checkout Perform the procedure described in Section 6 2 at installation or whenever changes are made to the Scanner configuration or to the machine being guarded The procedure must be performed by a Qualified Person Shift Daily Checkout Perform the Daily Checkout procedure described in Section 6 3 at each shift change or machine setup change whenever the System is powered up at least daily The procedure may be performed by a Designated Person or a Qualified Person Semi Annual Checkout Perform this procedure described in Section 6 4 every six months following installation The procedure must be performed by a Qualified Person NOTE The Shift Daily and Semi Annual Ch
104. low and in Figures 3 18 3 19 and 3 20 Final connection of the OSSD and Alarm Auxiliary outputs will occur after configuration and the initial checkout The user must refer to the installation instructions of any interfacing device e g UM FM 9A 11A for proper hookup and checkout If used connect the external reset switch to the reset wire violet on the Machine Interface cordset and to 24V dc see Figures 3 18 and 3 20 See warning in Section 3 3 3 about the physical location of the reset switch The reset switch must be a normally open switch that is held closed for approximately 1 4 second but no longer than 5 seconds and then re opened to accomplish the reset The switch must be capable of switching 10 to 30V dc at 30 mA 3 6 Scanner Initial Checkout The initial checkout procedure must be performed by a Qualified Person see Section 4 1 It must be performed only after configuring the System and after connections are made per Section 3 5 Initial checkout is performed on two occasions 1 To ensure proper installation when the System is first installed and 2 To ensure proper System function whenever any maintenance or modification is performed on the System or on the machinery being guarded by the System See Section 6 1 for a schedule of required checkouts For the initial checkout the Scanner must be checked without power being available to the guarded machine Final interface connections to the guarded machine cannot tak
105. meters and start the transfer again message overwritten Interface X2 time specifications not complied with send data not acknowledged Check the interface parameters and start the transfer again Previous message not completely issued interface X2 ty Nae Check the interface parameters and start the transfer again time specifications not complied with Error memory cannot be read internal defect If reset is not successful contact customer service Error memory cannot be transferred transfer error on neraca X9 Check the interface parameters and start the transfer again Motor does not reach the nominal speed after start If reset is not successful contact customer service internal defect Motor speed not constant after start internal defect _ If reset is not successful contact customer service Motor does not reach the nominal speed after start If reset is not successful contact customer service internal defect Motor speed not constant after start internal defect If reset is not successful contact customer service Motor speed not constant after start time exceeded If reset is not successful contact customer service 76 P N 144924 rev A 02 2010 AG4 Safety Laser Scanner User Manual Banner AG4 Series Safety Laser Scanner Activity Safety outputs or switching function OSSDs cannot 1110 be switched short circuit with 0 V DC or 24 V DC Check the connection wiring of the OSSDs Safety o
106. modifications to the Scanner The Scanner may not be modified or the Protective function of the Scanner can no longer be guaranteed Where changes are made to the Scanner all guarantee claims against the manufacturer of the Scanner shall no longer apply Service life Tm in accordance with DIN ISO 13849 The Scanner s PL and PFHa specifications refer to the Tm service life of 20 years Repairs or replacement of wear and tear parts do not extend the service life Protective function limits The Scanner does not protect against including but not limited to e Parts that are ejected from a machine e Splashing spraying liquids e Gases and vapors e Radiation Vapors smoke dust particles Vapors smoke dust and all particles visible in the air can cause the machine to switch OFF unintentionally Do not use the Scanner in environments in which heavy vapors smoke dust or other visible particles are present Stray light limitations Light sources including infrared fluorescent and strobe lights can impair reliability Ensure that no interfering light sources are present within the Scanner detection plane e Prevent reflective surfaces at beam level e Where applicable take additional separation safety distances into account e Ensure that there are no other photoelectric sources within the Scanner detection plane that can impair performance Monitoring through a window restriction Do not use the Scanner to monitor
107. n and maintenance instructions contained in this manual The user has the sole responsibility to ensure that the Scanner is installed and interfaced to the guarded machine by Qualified Persons in accordance with this manual and with applicable safety regulations Read Section 1 and all of Section 3 of this manual carefully before installing the System Failure to follow these instructions could result in serious bodily injury or death Y O 26 P N 144924 rev A 02 2010 AG4 Safety Laser Scanner User Manual Banner AG4 Series Safety Laser Scanner 3 1 Basic Installation Procedure Note A horizontal Protective Field is considered to be 30 or less from a level floor or walking surface 1 Identify the appropriate application from the choices in the Configuration Wizard see table below Note A selectable configuration option is also available in the wizard Table 2 Pre Determined Applications Contained within the Configuration Wizard Application Configuration Description Area Guarding Horizontal Protective Field stationary Danger zone guarding Resolution 70 mm Maximum Protective Field range AG4 4E 4 m 13 2 AG4 6E 6 25 m 20 6 Start Restart Interlock enabled Manual Reset Area Guarding Leg detection Horizontal Protective Field stationary Leg detection danger zone guarding Resolution 50 mm Maximum Protective Field range 2 8 m 9 24 Start Restart Interlock selectable Manual or Auto reset
108. n Settings gt PC configuration gt Interface and baud rate to access the P onfiguration window Ensure that e The Serial Interface is set to the same port as that assigned to the Scanner interface by the PC Device Manager gt Ports COM amp LPT e g C I 18 the actual port will vary and e The Baud Rate matches the PC Baud rate e g 57600 If this information needs to be identified or if configuring the PC serial port is required see below PC Configuration x Options Serial interface Baud rate R5232 57600 Baud C R5422 OK Cancel The communication status displayed on the Situs Line should change from AG4ynchron to AG4 Connection Sychron means the PC is waiting for Scanner to synchronize Comection means the PC is in communication with the AG4 Once the connection is made several dialog boxes may appear follow instructions and the Sanner status information window may also appear click on EXIT after reviewing Highlighting the lRasure contour display Operating Mode tab should display the measured area yellow outline the Warning Field and the Protective Field Loss of Communication If a loss of communication occurs attempt a manual reset or cycle power then 1 Disconnect the AG4 PCD9 xx serial cordset at the AG4 PC9USB 1 or at the Scanner s X2 connector 2 Close the AG4Soft program 3 Connect USB cable at the PC if
109. n to stop dangerous machine motion when a person or object enters the Protective Field Serious bodily injury or death could result 11 Apply power to the guarded machine and verify that the machine does not start up Interrupt the Protective Field with the appropriate test piece whose size matches the configured resolution and verify that it is not possible for the guarded machine to be put into motion while the Protective Field is interrupted Repeat for each configured Protective Field 12 Initiate the machine cycle or motion of the guarded machine or mobile vehicle While it is moving use the appropriate test piece to interrupt the Protective Field Do not attempt to insert the test piece into the dangerous parts of the machine or directly in the path of the moving vehicle Upon interrupting the Protective Field at any point verify that e For stationary applications The dangerous parts of the machine come to a stop with no apparent delay Remove the test piece from the Protective Field verify that the machine does not automatically restart and that the initiation device s must be engaged to restart the machine e For mobile applications The vehicle stops within the identified predetermined distance Remove the test piece from the Protective Field verify that the vehicle does not unintentionally restart and if required that the initiation device s must be engaged to restart the mobile vehicle This must be accomplished at numero
110. nd its return The Scanner outputs will turn ON only after the Protective Field PF is clear and the start restart switch is actuated Restart Interlock Manual Restart Manual Reset when the Protective Field PF is Clear The restart interlock prevents the AG4 outputs OSSD1 and OSSD2 from automatically turning ON as soon as the Protective Field is clear The restart interlock function always includes the start interlock function Scanner outputs turn ON only when the Protective Field is clear and the start restart reset switch is actuated Automatic Start Restart Auto Reset when the Protective Field PF is Clear The automatic start restart function enables the Scanner s safety outputs to turn ON after power is applied if and when the Protective Field is clear and after the Rstart Delay Time has expired The automatic start restart function may be used only under the following conditions Banner AG4 Series User Manual P N 144924 rev A 02 2010 13 Banner AG4 Series Safety Laser Scanner e Machine control circuitry is designed so that one or more initiation devices must be engaged i e a conscious act is required to start the machine in addition to the Scanner turning ON its safety outputs OSSD1 and OSSD2 or e Itis not otherwise possible to access the hazard area except while being continually detected by the Protective Field 1 12 2 Start Test The start test function requires the operator to interrupt and
111. ner with the guarded machine must be verified before the combined Scanner and machine may be put into service To do this a Qualified Person must perform the Commissioning Checkout Procedure described in Section 6 2 54 P N 144924 rev A 02 2010 AG4 Safety Laser Scanner User Manual Banner AG4 Series Safety Laser Scanner 24V dc ve Scanner j Fuse 1 64 OV de Blue nn nea ea l ied Orange FP1 Alarm 1 i Wht BIk Shield 1 7 Alarm 219 Auxiliary 2 Single Channel 4 Th ad Safety Stop ee Figure shows Field Pair 1 Circuit s x ti a peace selected See Section 1 12 4 for i further information on Field Pair EA E hy Switchover Dual Channel lt See Section 3 7 5 for furth Sane Or n 3 7 5 for r na See Sectio or furthe Circuit a information on the non safety Alarm Auxiliary outputs NOTE Do not exceed OSSD maximum load capacitance specification Warning Monitoring FSDs FSDs must be monitored for proper operation 1 channel EDM can only be used when the Scanner is configured for manual reset See Section 3 7 2 Figure 3 18 Hookup with FSD inputs Banner AG4 Series User Manual P N 144924 rev A 02 2010 Auxiliary 1 O FP2 FP3 FP4 O 11 O 12 OV dc 59 Banner AG4 Series Safety Laser Scanner OV de Reset 24V de FP1 Alarm 1 Auxiliary 1 UM FA 9A FP2 FP3 see datasheet pin 141249 FP4 Alarm 215 Aux
112. nfiguration data as a file 7 A Scanner s configuration file includes the following data e Administrative data file name application description e Safety relevant data e g startup process e Protective Field or Warning Field configuration data contours and limits The AG4Soft program will ask if you want to save a configuration if the ltlasured contour display or Sstem data tabs are selected and the configuration has not been previously saved Note For the purposes of the walk through save the configuration file as described above and proceed to Section 4 3 Saving Only a Protective or Warning Field sf file format In case a mistake is made and an original starting point is needed or otherwise a record of each field is required it can be useful to individually save the Protective and Warning Field shapes as they are created At an appropriate time such as before modifying the shapes of the Protective and Warning Fields the field that is displayed in the Select Protective Warning Field window 19 can be saved by clicking on File gt Save Protective Warning Field as a file or by clicking on the Save Protective Warning Field as a file 17 icon The Protective Warning Fields definition operating mode tab must be highlighted yellow to access this save function 4 3 Connecting the PC to the Scanner Note Ensure power is removed from the Scanner at this point the AG4 PCD9 xx cordset is not conn
113. ng a Protective Field length does not Check all parameters in the wizard calculate the Protective Fields again apie match the predefined braking distance of the vehicle and start the transfer again 45 Motion Monitoring the left side of a Protective Field Check all parameters in the wizard calculate the Protective Fields again does not match the predefined vehicle width and start the transfer again 2018 46 MotionMonitoring the left side of a Protective Field Check all parameters in the wizard calculate the Protective Fields again Avie does not match the predefined vehicle width and start the transfer again 50 Number of measurements in the scan is too small because of motor rotation speed error or internal fuse If reset is not successful contact customer service is defect 1 Error occurred while Scanner was starting Sequential error Reference measurement failed dust in the device as the plug housing or dummy cap not screwed 2201 9 2302 2401 ow Screw the plugs of interfaces X1 and X2 Reference measurement failed glare from another on light source 905 nm or rotation speed error Scanner performs reset Reference measurement failed glare from another a light source 905 nm or rotation speed error oN Dh Dh Dh Scanner performs reset Reference measurement failed glare from another PN light source 905 nm or rotation speed error 0 Scanner performs reset R
114. ng field Once configuration is complete remove the PC Interface cable and replace it with the supplied X2 Dust Plug AG4 PCD9 to maintain the IP rating The Scanner is designed and manufactured to be highly resistant to electrical noise and to operate reliably in industrial settings However extreme electrical noise may cause a random Trip or Latch condition in extreme cases a Lockout is possible Scanner wiring is low voltage routing the cables alongside power wires motor servo wires or other high voltage wiring may inject noise into the Scanner It is good wiring practice and may be required by code to isolate Scanner cables from high voltage wires avoid routing cables close to oisy wiring and provide a good earth ground connection to the cordset shield Banner AG4 Series User Manual P N 144924 rev A 02 2010 47 Banner AG4 Series Safety Laser Scanner 1 X1 Machine Interface 15 pin sub D 2 X2PC Interface 9 pin sub D 3 X2PC Interface cable 4 X2 Dust protective cap Figure 3 16 Scanner Interconnections 3 5 2 Initial Electrical Connections Ensure that electrical power is not applied to the Scanner until told to do so Do not connect any wires to the machine control circuits i e OSSD outputs at this time For the initial power up and checkout only the power connections X1 3 and X1 1 the start restart X1 2 if used and the Field Pair inputs X1 4 X1 6 X1 7 and X1 8 should be connected as described be
115. ng the wizard walk through simply click on Fransfer configuration data from PC to Scanner 11 Operating Mode Icon The same options are accessible from the top Menu Bar click on Configuration gt Load configuration data from a file and transfer to Scanner or click on File gt Load configuration data from file and select an rsfile to open and then Configuration gt Transfer from PC to Scanner Follow the prompts review and accept the configuration and then perform the appropriate checkout procedure as described in Section 6 or return to Section 3 6 2 Initial Optical Field Verification From the Protective Warning Fields Definition Operating Mode Both configuration s files and individual field sf files are accessible when the Rrtective Warning Fields definition Operating Mode tab is highlighted 68 P N 144924 rev A 02 2010 AG4 Safety Laser Scanner User Manual Banner AG4 Series Safety Laser Scanner Configuration s files are accessible from the top Menu Bar click on File gt Load configuration data from file and select an g file to open then click on Protective Warning Fields gt Transfer changed Protective Warning Fields from PC to Scanner Individual fields sf files that have been saved can be accessed and downloaded to the Scanner by the following methods e Click on highlight the Protective Warning Fields definition Operating Mode tab e Click on Load Protective Warning Field from f
116. ntours The effect of an inward cone shape is to increase the effective resolution immediately adjacent to the shape For the Scanner to identify that an object is equal to or greater than the stated resolution e g 70 mm the entire object must be within the Protective Field to turn OFF the OSSDs e g Object 4 When an object enters the unmonitored cone shaped area the start restart inhibit function will enable a reset as soon as the object portion within the Protective Field is smaller than the stated resolution Objects 5 and 6 This will turn ON the OSSDs if the configuration is set to atomatic start restart auto reset or if the reset switch is actuated To prevent a safety distance that is too short at that point the increased effective resolution must be used to determine the Dpf or C factor in the respective safety distance formulas see Sections 3 3 4 and 3 3 5 If a cone shaped field must be used and the safety distance cannot be complied with additional supplemental safeguarding must be used Refer also to the previous section Shadowing Within the Protective Field for more information To verify Protective Field effectiveness perform a trip test see Section 3 6 3 Figure 3 4 Example of inward and outward cone shaped fields Banner AG4 Series User Manual P N 144924 rev A 02 2010 31 Banner AG4 Series Safety Laser Scanner 3 3 3 Adjacent Scanners A WARNING ADJACENT SCANNERS Scanners that have a clear
117. nually configured If it is not possible to completely safeguard the vehicle including trailers protruding or overhanging loads etc during the full length of travel including curves then additional safeguarding e g additional Scanners or bumper edge switches must be used 46 P N 144924 rev A 02 2010 AG4 Safety Laser Scanner User Manual Banner AG4 Series Safety Laser Scanner 3 5 Electrical Connections A WARNING PROPER ELECTRICAL HOOKUP Electrical hookup must be made by Qualified Personnel and must comply with NEC National Electrical Code and local standards Make no more connections to the Scanner than are described in Sections 3 5 through 3 8 of this manual Connection of other wiring or equipment to the Scanner could result in serious bodily injury or death Lockout tagout procedures may be required refer to OSHA 29CFR1910 147 ANSI Z244 1 or the appropriate standard for controlling hazardous energy Following relevant electrical standards and wiring codes such as the NEC NFPA79 or IEC60204 1 always connect earth ground green yellow wire see Figures 3 18 3 19 and 3 20 Do not operate the Scanner without an earth ground connection See the warning above Make the electrical connections in the order described in this section Do not remove cover no internal connections are to be made All connections are made via the X1 and X2 connectors When the X2 connection is no longer required ensure that the X2 Dus
118. o zwo Sdo doo Protective Field 4000 20i 2000 30 do Sao swa 700 ado Cuepor portion in relation Lo the lanet tcanne Center paint Y Ang Rod 0 000 Urte m meters Field Demi acire in the scorrer Information Area feki paer 1 Data puce Sroreet he AGA Syectvon FCS AGA Conia siden Status Line Position of the Scanner Navigation Tool Bar 62 P N 144924 rev A 02 2010 AG4 Safety Laser Scanner User Manual Banner AG4 Series Safety Laser Scanner It should be noted that the proper Oprating Mode tab must be highlighted yellow for the appropriate options within the Menu Bar to be active These options are generally duplicated via the Operating Mode Icons some listed below Some options are found only on the Menu Bar see AG4Soft manual for a complete description of all options Configuration Tool Bar See AG4Soft Software Manual for complete descriptions 1 Zoom out 2 Zoom in 3 Show all full 70 meter x 70 meter display 4 Change authorization level 5 Exit configuration program 6 Load configuration data from file 7 Save configuration data as a file 8 Print configuration data 9 Load configuration data from a file and transfer to Scanner 10 Retrieve configuration data from Scanner 11 Transfer configuration data from PC to Scanner 12 Change configuration data with the wizard 13 Change configuration data 14 Set default configuration values in the Scanner Banner AG4 Ser
119. onfiguration software is used to establish the Scanner operating parameters for complete information see the AG4Soft Software Manual AG4Soft is included on the CD that was included with the Scanner and is also available on line at http www bannerengineering com en US support software The Scanner is configured at the factory with the maximum Protective Field and activated start restart interlock manual reset The Scanner must be configured by the user according to the application 4 2 1 Using the Configuration Wizard During configuration either for the purposes of an initial walk through or the final configuration the Scanner should either not be connected to the PC or if connected the Scanner s power must be removed before the AG4soft program is opened After the AG4soft program is running the Scanner can be connected and power applied see Section 4 3 Changes can be saved for downloading to the Scanner at a later time see Section 4 4 The remainder of this section is designed to be a wk through demonstration of the wizard After installing the AG4Soft configuration software open the program by double clicking ak on the shortcut icon After reading and understanding the warning click OK After a few moments a Ghange Authorization Level dialog box will appear Select Authorized Customer and enter the default password bannera OK i Cancel 58 l g P N 144924 rev A 02 2010 AGA Safety Laser Scanner
120. onse time and stopping performance Banner AG4 Series User Manual P N 144924 rev A 02 2010 9 Banner AG4 Series Safety Laser Scanner A WARNING PROPER USE The AG4 Scanner is for use only on machinery that can be stopped immediately after a stop signal is issued at any point in the machine s stroke or cycle Under no circumstances may the Scanner be used on full revolution clutched machinery or in unsuitable applications as those listed in Section 1 11 Allow only Qualified Persons to install and maintain the Scanner see Section 1 6 Shift Daily checkout procedure must be performed at every power up shift change and machine setup Refer to the instruction manuals and other reference materials located in the Help menu for all installation details wiring diagrams operating instructions shift daily periodic checkout procedures and warnings If there is any doubt about whether or not your machinery is compatible with the Scanner contact Banner s Application Engineers at the factory Failure to follow all instructions and warnings could lead to serious bodily injury or death 1 6 Security Protocol and Checkout Procedures A WARNING CHECKOUTS The commissioning periodic and daily safety system checks must be performed by appropriate personnel at the appropriate times in order to ensure that the safety system is operating as intended Failure to perform these checks may create a potentially dangerous situation which could lead to s
121. ortant Note The alarm auxiliary outputs are not safety rated and should be used only for non safety related diagnostic or system monitoring purposes 18 P N 144924 rev A 02 2010 AG4 Safety Laser Scanner User Manual Banner AG4 Series Safety Laser Scanner 2 Models and Specifications 2 1 Models Accessories and Replacement Parts hora Laser Scanner includes a 9 pin X2 plug and a software CD that includes both hardware and software manuals cordsets and bracket not included Requires AG4 CPD15 machine pore interface cordset and AG4 PCD9 PC connection cordset 6 25 m max range 2 1 1 Cordsets and Connections AG4 CPD15 5 AG4 CPD15 10 Machine interface cordset w ConfigPlug straight cut to length control cordset X1 AG4 CPD15 25 AG4 CPD15 50 AG4 PCD9 3 AG4 PCD9 5 RS232 cordset AG4 to PC PC connection cordset X2 AG4 PCD9 10 AG4 PCD9USB 1 DB9 Serial to USB converter cordset NOTE Do not use with 10 meter AG4 PCD9 10 2 1 2 Accessories AG4 CLN1 AGA cleaning kit includes 150 ml fluid 25 cloths AG4 CLN2 approved fluid for cleaning plastic soft lint free cleaning cloths 1000 ml fluid 100 cloths AG4 MBK1 Mounting system swivel bracket Test box to test the Scanner for proper output behavior prior to connecting to the machine It simulates the machine for the purpose of testing the output reaction of the individual Field Pairs 24 V power supply is not included banana jack 150 mm dia 150 mm resolution
122. possibility of various failures and justify it through the risk assessment process to meet the required level of safety performance such as the requirements of Category 2 3 or 4 See ISO 13849 1 2 for further information Notice Regarding MPCEs Each of the machine primary control elements MPCE1 and MPCE2 must be capable of immediately stopping the dangerous machine motion regardless of the state of the other The two machine control channels need not be identical but the machine s stop time performance Ts used to calculate separation distance must be based on the slower of the two channels A WARNING EDM MONITORING If system is configured for No Monitoring it is the user s responsibility to ensure that this does not create a hazardous situation 3 7 4 Alarm Auxiliary Output The Scanner has two alarm auxiliary status outputs that provide a PNP current sourcing output 100 mA max that switches OFF to indicate the following conditions e Alarm 1 X1 5 If the Warning Field has been interrupted default if the AG4 has locked out or both conditions configurable via the software e Alarm 2 X1 15 If the AG4 has locked out 3 8 Preparing for System Operation After the initial trip test has been accomplished Section 3 4 and the OSSD safety output connections have been made to the machine to be controlled the Scanner is ready for testing in combination with the guarded machine The operation of the Scan
123. ppropriate place e g near or on the machine in the machine s technical file Tester Designated Person or Qualified Person as described in Section 4 1 Refer to the procedure contained on the Daily Checkout card Banner p n 147899 contained on the software disc included with the Scanner If the checkout card is missing contact Banner Engineering or download at www bannerengineering com Print out the instructions to be posted near the installation guarded machine for easy reference 6 4 Semi Annual Six Month Checkout Perform the Semi Annual Checkout procedure every six months following system installation or whenever changes are made to the Scanner configuration or to the machine A copy of checkout results should be recorded and kept in the appropriate place e g near or on the machine in the machine s technical file Tester Qualified Person as described in Section 4 1 Refer to the procedure contained on the Semi Annual Checkout card Banner p n 147899 contained on the software disc included with the Scanner If the checkout card is missing contact Banner Engineering or download at www bannerengineering com Print out the instructions to be posted near the installation guarded machine for easy reference Banner AG4 Series User Manual P N 144924 rev A 02 2010 91 Banner AG4 Series Safety Laser Scanner 7 Glossary 7 1 List of Abbreviations CE European Conformity mark DZ Danger Zone EDM External Device Monito
124. r AG4 Series Safety Laser Scanner 5 1 3 LED Warning and Error Displays Table 10 LED diagnostic codes see signal key at bottom LED signals RAE APA alee Auvana Vall Avan Vall 0 LED OFF 1 LEDON 1 LED flashes at 2 Hz Banner AG4 Series User Manual The sensor function is active the active Protective Field is free The active Warning Field is free Safety outputs or switching function are switched on Front screen is dirty Device fault Safety outputs or switching function are switched off Front screen is dirty Device fault Safety outputs or switching function are switched off ConfigPlug configuration is not compatible with the Scanner the configuration cannot be transferred Device fault Safety outputs or switching function are switched off Errors on the Field Pair control inputs Device fault Safety outputs or switching function are switched off Motion Monitoring has detected a fault Vehicle movement does not agree with the active Field Pair Device fault e Safety outputs or switching function are switched off 1 LED flashes at 4 Hz LED not relevant 2x LED flashes twice Activity Clean the front screen as soon as possible Device still works Clean the front screen Start the Scanner again Replace the Scanner The Scanner type must correspond with the ConfigPlug s configuration Check the Field Pair switchover switchover sequences and switcho
125. rd Eliminate any unprotected access routes by repositioning the Scanner installing additional Scanners or by adding supplemental safeguarding Failure to eliminate access routes caused by the shadowing effect could create a potentially dangerous condition that may lead to serious injury or death Objects that are located within the Protective Field create an unmonitored area directly behind the object This area is best described as a sadow since the light emitted by the Scanner cannot bend around or penetrate through solid objects The shadow effect can be caused by both opaque and transparent objects Any unmonitored areas resulting from the shadow effect must not allow unprotected access routes to the hazard This can be prevented by repositioning the Scanner installing additional Scanners or by adding supplemental safeguarding If the object is moveable such as a scrap bin do one or more of the following e Locate the unmonitored area at a greater distance from the hazard than the calculated safety distance see Sections 3 3 4 3 3 5 e Identify the object as a reference contour see Section 1 12 5 e Enable an alternate Field Pair when the object is relocated or e The moveable object must be interlocked in order to stop and prevent the safeguarded hazard if the object is moved i 2 Scanner 5 PF 4 Unmonitored area Obstruction e g a building column a Y N Unmonitored area due to shadow effect F
126. resolution 200 mm to 1 6 m Sensing object reflectance Minimum 1 8 Sensing object reflectance Minimum 1 8 Protection Field Radius Sensing Range Warning Field Resolution 150 mm at 15 m Sensing range radius 200 mm to 15 m Sensing object reflectance Minimum 20 Scanning Angle max 190 PNP open collector transistor 2 outputs short circuit proofed Rated operating voltage supply voltage UB 3 2 V Max source current 250 mA OSSD1 OSSD 2 Residual voltage 3 2 V or less Operation mode No object in protective field ON Object inside protective field OFF Response Time Min 80 ms 2 scans to max 640 milliseconds 16 scans switching method Output Signal Switching Devices 20 P N 144924 rev A 02 2010 AG4 Safety Laser Scanner User Manual Banner AG4 Series Safety Laser Scanner Alarm Auxiliary Outputs 1 amp 2 PNP open collector transistor Rated operating voltage supply voltage UB 4 V Max source current 100 mA Residual voltage 4 V or less Operation mode Switching method of operation mode set below Scanner at normal operation ON Abnormal operation OFF No object inside Warning Field ON Object inside Warning Field OFF Response Time Min 80 ms 2 scans to max 640 milliseconds 16 scans switching method Start restart 24V opto uncoupled dynamically monitored Field pair switchover Selection of 4 or 8 Field Pairs via 4 control lines 24V opto uncoupled dynamically monitored logically 1
127. rical standards and wiring codes such as the NEC NFPA79 or IEC 60204 1 See the warning in Section 3 5 The connections for supply power and the external reset switch should already be connected The Scanner must also have been configured mounted and passed the initial checkout as described in Section 3 6 The final connections to be made are e OSSD outputs e FSD interfacing e MPCE EDM connections e Alarm Auxiliary Outputs 3 7 2 OSSD Output Connections Both the output signal switching device OSSD outputs must be connected to the machine control so that the machine s safety related control system interrupts the circuit or power to the machine primary control element s MPCE resulting in a non hazardous condition Banner AG4 Series User Manual P N 144924 rev A 02 2010 51 Banner AG4 Series Safety Laser Scanner Final switching devices FSDs typically accomplish this when the OSSDs go to an OFF state See Figure 3 19 Refer to the output specifications in Section 2 2 and the warnings below before making OSSD output connections and interfacing the Scanner to the machine A WARNING INTERFACING OF BOTH OSSDS Both of the OSSD Output Signal Switching Device outputs must be connected to the machine control so that the machine s safety related control system interrupts the circuit to the machine primary control element s resulting in a non hazardous condition Never wire an intermediate device s e g PLC PES or
128. ries Safety Laser Scanner 4 System Operation and Configuration 4 1 Security Protocol Certain procedures for installing maintaining and operating the Scanner must be performed by either Designated Persons or Qualified Persons A Designated Person is identified and designated in writing by the employer as being appropriately trained to perform the specified checkout procedures on the Scanner A machine operator so designated may be a Designated Person The Designated Person is empowered to e Perform manual resets and hold possession of the reset key e Perform the daily Scanner checkout procedure A Qualified Person by possession of a recognized degree or certificate of professional training or by extensive knowledge training and experience has successfully demonstrated the ability to solve problems relating to the installation of the Scanner and its integration with the guarded machine In addition to everything for which the Designated Person is empowered the Qualified Person is empowered to e Install the Scanner e Perform all Scanner checkout procedures e Control the password to access the Scanner s configuration program e Access and change the Scanner s configuration settings e Reset the system following a lockout condition e Perform maintenance and repairs as described in Section 5 See the AG4Soft Software Manual for information on changing and resetting the passwords 4 2 System Configuration Settings The AG4Soft c
129. ring FSD Final Switching Device IEC International Electrotechnical Commission IP Ingress Protection ISO International Organization for Standardization LED Light Emitting Diode OSSD Output Signal Switching Device MPCE Machine Primary Control Element PF Protective Field PLC Programmable Logic Controller VDC Voltage Direct Current WF Warning Field 7 2 List of Terms The following terms are used frequently in this manual Where possible this manual uses definitions from the international product performance standards that govern the design of the AG4 For more definitions visit http www bannerengineering com training glossary php CE European Conformity The CE mark on a product or machine establishes its compliance with all relevant European Union EU Directives and the associated safety standards Danger Zone Defined as the danger area for equipment in operation where there is a serious risk of injury or death to personnel Designated Person A person or persons identified and designated in writing by the employer as being appropriately trained and qualified to perform a specified checkout procedure External Device Monitoring This feature allows the System to monitor the status of external devices such as MPCEs Fixed Guarding Screens bars or other mechanical barriers that prevent a person from entering or remaining in the danger zone undetected Key Reset A key operated switch used to restore the FSDs an
130. rizontal field perimeter and vertical off the floor 5 Repeat steps 1 through 4 for each of the Field Pairs that have been configured if Field Pair Switchover is used Ensure that all fields correspond to the expected fields as determined by the risk assessment If not do not continue until the situation is corrected 6 After all corrections and changes to the configuration and the Warning and Protective Fields have been verified proceed to Section 3 7 A WARNING IF TRIP TEST INDICATES A PROBLEM If the Scanner does not respond properly to the trip test do not attempt to use the system If this occurs the Scanner cannot be relied on to stop dangerous machine motion when a person or object enters the Protective Field Serious bodily injury or death could result 3 7 Electrical Interface to the Guarded Machine A WARNING SHOCK HAZARD Always disconnect all power from the Scanner and the guarded machine before making any connections or replacing any component Use extreme caution to avoid electrical shock at all times 3 7 1 Permanent Hookup Verify that power has been removed from the Scanner and the machine vehicle to which it will connect Make the electrical connections as described in Sections 3 7 1 to 3 7 5 as required by each individual application Lockout tagout procedures may be required refer to OSHA CFR 1910 147 ANSI Z244 1 or the appropriate standard for controlling hazardous energy Follow relevant elect
131. rotective Warning Field 19 For the purpose of the walk through click on Protective Field 1 ESF als Protective field 1 v GSINADS NAAA a ia xi E Y Protective field 1 Waning field 1 Protective field 2 64 Warning field 2 Protective field 3 Warning field 3 Protective field 4 Warning field 4 Protective field 5 Warning field 5 Dratartia tala E AG4 Safety Laser Scanner User Manual Banner AG4 Series Safety Laser Scanner 20 21 22 23 Field definition icons 20 through 23 are typically used to create general field shapes Enter Protective Warning Field numerically 20 creates a rectangular field by entering a distance in millimeters to the front edge and to both sides Define elliptical Protective Warning Field 21 creates a semi circular shape centered at the Scanner by left click hold and then release Click on the icon each time the field is to be changed Define rectangular Protective Warning Field 22 creates a rectangular square shape with on edge centered on the Scanner by left click hold and then release Click on the icon each time the field is to be changed Define polygonal Protective Warning Field 23 allows a point to point creation of an irregular shape by left click to plot each point from left to right A right click completes the field Navigation Tool Bar The values on the Working Space grid and in the Navigation Tool Bar see below can assist in plottin
132. s maximum stop time in seconds of the mobile vehicle see note 1 below Tr maximum response time in seconds of the Scanner see note 2 below Dg Braking Distance at full load and speed as stated by the manufacturer of the mobile vehicle and other environmental factors see note 3 below Notes 1 Ts for the mobile vehicle should be supplied by its manufacturer Ts must include the response time of all devices or controls that react to stop the vehicle e g UM FA 9A Safety Module which are added to determine the total time to cause braking stopping If all devices are not included the calculated distance Dsp will be too short and serious injury could result 2 Consideration for Adjacent Scanners When adjacent Scanners share the same detection plane and have an unobstructed view of each other an additional 40 ms time must be added to the response times of both Scanners If the adjacent detection planes are shielded so that there is no clear line of sight between Scanners or the detection planes are offset by at least 100 mm 4 then the 40 ms addition is not required 3 Braking Distance Dg should incorporate factors such as brake deterioration and environmental factors that can impact braking such as loose dirt gravel wet moisture icing etc which can add 10 or more to the manufacturer s stated distance It should be noted that braking distance is not a linear function it increases by a square function as velocity incr
133. s Independently Activated Protective and Warning Fields 14 1 12 5 Reference Contour Surface Monitoring ccccoocccconcncccncncconcnononcnnnnncnnonncnnonncnnnnanonos 17 1 126 Alarm AS cea 17 2 Models ANG Specification 19 2 1 Models Accessories and Replacement ParlS ocooncccccicccnccononononocncoononanonorncnnnonanos 19 2 11 Cordsets and CG ONMECUONS attend tr a caida 19 ZN ACCES A sande scuinnc Weva cane weccioss E E oan ee ehons eens asada eae eee EES 19 SNS O lA E A O Neue outa ak bee acc mencn ame denies 20 2 2 SP CCIICAUONS saan Waar ee ne ces ess ate De aaa aa a 20 LS DIMENSIONS E A A a aa 22 24 Connector PIUG ASSIQNIMNCIUS e E o ees 24 4 P N 144924 rev A 02 2010 AG4 Safety Laser Scanner User Manual Banner AG4 Series Safety Laser Scanner 9 INStallati N raro 26 3 1 BASICNSTANAUON PIOCO GUNG a ios 27 3 2 Protective Field and Warning Field Considerations ooooccccconccccconcncononononnanononos 28 3 3 Mechanical Installation ConsideratiONS ooooccccconcnccconononoonononononnonanonnonanononnnnononos 29 dl UNMORtoO Sd ATEN A it 29 3 3 2 Needle and Cone Shaped Protective Field Contours ooccocccocncocncocncorncorncnnocanonannnns 31 39 93 Adjacent Scanners oora dues saad A nessa nds cad cakd badesha deh esead E eat aie 32 3 3 3 Positioning Horizontal Protective Fields for Stationary Applications ooocoooo 33 3 3 4 Minimum Safety Separation Distance St
134. s Safety Laser Scanner Table of Contents Safety Standards Applicable to Use of this Product c ccoccoccccccccccncanoconannnooos 2 ETICA Ol AU e ca do 2 ADOSADO CU Nilo and 3 T OVEINVIEW auaa aA E T SAM E E A en en ea 7 1 2 Mounting System OptiONAJ o cocococnccocononococnonocononnonanononnanonocanonnonanononnanonenanos 8 1 3 Machine Interface XT ConfigPlUg s a 8 LARIOS a oe dina id 9 1 41 Product Identification Plate A ene es assed E ees 9 MAR MN ia 9 1 5 Proper Use and Intended PuUrpOS ccoccccoccccocncccnccoconocococnononononononnonononaronornnnnnonanonons 9 1 6 Security Protocol and Checkout Procedures occccoccccconicconnncccnncocnnononnnnononcnnnnonons 10 te Or Destanatea Personas A A AS amc a tii adea lta 10 1 62 QUaIMeEG PETSOM aisr aan T E O O ci 10 1 7 Responsibility for Safety oococccoononoconnonocononocoononoconnnnonononnonanononnnnononaronncnanononos 10 MST PAS SWOEO S aid tao 11 1 4 2 Providing Information tor USE r eta ead See eas ee N AN 11 A ne PE TE AP nae RP es A E E E ee ee T A eee er 11 IAN VOTO a A iaa 11 1 10 Handling the Scanner cion a iii 12 TITS CANO RENO ION S e da ca 12 1 12 Ba i Op ration FUNCIONS ossosa E E ete ea 12 1 12 1 Start Restart Reset Interlock cocooocococonocococococococonococonarononacononarononaroconanonos 13 AS A AEN EE EE seinen ted SE TE E A E S E 14 1123 DUSU SUD ES Orana ees este eet aes ee eens S 14 1 12 4 Field Pair
135. s should be at differing angles to each other e g two legs of a right angle corner A surface in the Warning Field cannot be assigned as a reference contour When one of the following is selected in the configuration software the software will automatically define the boundary of the Protective Field as the reference contour shown as blue segments This can be manually adjusted in the configuration software e Passage Control access guarding Access Perimeter Guarding e Arm Protection point of operation Vertical Guarding Arm Detection e Hand Protection point of operation Vertical Guarding Hand Detection For more information on how to create a Protective Field and use a reference surface see the AG4soft Software Manual 1 Physical frame for reference surface Eh 0 2 Reference surface must form at least two sides of the PF 5 3 Scanner 4 Distance e between the reference contour frame and machine opening recommended e gt 150 mm 4 5 Machine opening contour Figure 1 10 Vertical Protective Field and reference surface for hazard point guarding A WARNING REFERENCE CONTOURS The design of the installation and the risk assessment must identify the need and use of the reference contour surface monitoring function A change in the position or mounting of the Scanner can result in gaps unmonitored areas or an incorrect too small safety distance minimum distance It is recommended that R
136. sponse times such as the Scanner UM FA safety module and all control elements FSDs and or MPCEs Add the appropriate response time values to account for any reasonably foreseeable machine stop time degradation such as due to brake pad wear Ensure that the Protective Field adequately covers all access routes that may lead to the safeguarded hazard or supplemental guarding may be required see Unmonitored Areas Section 3 3 1 Determine if a reference contour surface monitoring function is required especially in vertical Protective Field applications This function prevents unintentional misalignment and deliberate manipulation of the Scanner See Section 1 12 5 Ensure that the safeguarded hazard s cannot be accessed because of the effect of shadowing within the Protective Field by adding supplemental safeguarding such as additional Scanners See Section 3 1 1 Observe the lateral tolerance when dimensioning the Protective Fields e g do not use needle or cone shaped boundaries to define the separation safety distance cone shaped boundaries rely on less accurate angular resolution measurements See Section 3 3 2 Consider and resolve any other application factors that might require an increase in the separation safety distance or stopping distance These factors should be identified via the risk assessment process P N 144924 rev A 02 2010 AG4 Safety Laser Scanner User Manual Banner AG4 Series Safety Laser Scanner 3
137. switching point beyond the FSD contacts With proper monitoring i e EDM this method of interfacing is capable of detecting certain failures in the control wiring between the safety stop circuit and the MPCEs These failures include a short circuit of one channel to a secondary source of energy or voltage or the loss of the switching ability of one of the FSD outputs Such failures could lead to the loss of redundancy or to a complete loss of safety if not detected and corrected The possibility of a failure to the wiring increases as the physical distance between the FSD safety stop circuits and the MPCEs increases as the length or the routing of the interconnecting wires increases or if the FSD safety stop circuits 52 P N 144924 rev A 02 2010 AG4 Safety Laser Scanner User Manual Banner AG4 Series Safety Laser Scanner and the MPCEs are located in different enclosures For this reason dual channel control with EDM monitoring should be used in any installation where the FSDs are located remotely from the MPCEs Single Channel Control Single channel control uses a series connection of FSD contacts to form a safe switching point After this point in the machine s safety related control system failures can occur that would result in the loss of the safety function such as a short circuit to a secondary source of energy or voltage For this reason single channel control interfacing should be used only in installations where FSD safety
138. t Navigation Tool Bar fields move down or right Cursor position in relation to the laser scanner center point A Position E A Angle Radius k End position ES i Angle Radius F Center circle maximizes field display j Moves blue circle cursor down or right fields move up or left In the x axis and y axis the cursor can be used to determine approximate field measurements Banner AG4 Series User Manual P N 144924 rev A 02 2010 65 Banner AG4 Series Safety Laser Scanner The cursor can also be used to click and drag to create a zoom box in which the values of opposite corners are displayed as the Paition and Ed position Left click to set a point Position Right click to mfish End position X and Y values can be used to determine distance between two points by using the formula V Xp Xep Yp Yep 4 2 3 Configuration Wizard Saving the Configuration Saving the Entire Configuration Including the Protective and Warning Fields rs file format When logged in as an Athorized Customer as noted on the status line tool bar there are two primary methods to save the configuration which include the Protective and Warning Fields e Using the Menu Bar with either the Cofiguration or the Prtective Warning Fields definition tabs highlighted yellow click on File gt Save configuration data as a file or e Using the Onfiguration Operating Mode Icon Sve co
139. t Plug AG4 PCD9 is re installed to maintain the IP65 environmental rating 3 5 1 Routing Cables Before connecting the Machine Interface X1 cordset to the Scanner ensure that the slide switch in the plug housing is set to the 1 left default position see Figure 3 15 The X1 cordset has an integrated memory in which the configuration will be stored and automatically re configure the Scanner at power up The Scanner signals the successful transfer by briefly flashing yellow LEDs 2 and 5 X position Memory reads configuration from AG4 1 default position Memory sends configuration to AG4 A Figure 3 15 Machine Interface X1 cordset memory settings Attach the required cordsets to the Scanner Machine Interface X1 and PC Interface X2 and route the Machine Interface cable to the junction box electrical panel or other enclosure in which the safety module the redundant mechanically linked interposing relays FSDs MPCEs or other safety related parts of the control system are located This must be done per local wiring code for low voltage dc control cables and may require installation of electrical conduit See Sections 2 1 1 and 2 4 for information about Banner supplied cables Do the same with the PC interface cable if it is to be permanently installed if this connection is only to be used during configuration or troubleshooting route the cable to the PC such that it does not interrupt the scanni
140. t and rotation matches that of the original Scanner 5a Ensure the X1 plug slide switch is in position 1 default and reconnect the Machine Interface X1 cordset NOTE In position 1 the ConfigPlug automatically downloads the original Scanner configuration at power up LEDs 2 and 5 flash briefly to confirm the successful transfer of the configuration See Figure 5 1 5b If also replacing the Machine Interface X1 cordset or the configuration within the ConfigPlug is corrupted use the PC interface X2 connection to transfer the appropriate configuration from a saved file or create a new configuration see Section 4 or the AG4Soft Software Instruction Manual 6 Apply power to only the Scanner not the machine and perform the Commissioning Checkout Section 6 2 Switch Transfer direction setting The ConfigPlug overwntes the Scanner configuration The Scanner overwrites the configuration previously saved in the ConfigPlug Figure 5 6 ConfigPlug configuration 5 5 Repairs and Warranty Service Scanner components are designed for reliability Do not attempt any repairs to the Scanner other than replacement of the front screen window as described in Section 5 4 2 The Scanner contains no other field replaceable components If repair is necessary do not attempt to repair yourself return the unit to the factory as follows 1 Contact a Banner Factory Application Engineer at the address or numbers listed on the back cover of
141. tance between the hazard and the Protective Field S is never less than 100 mm 4 K approach speed see note 1 below 2000 mm per second 79 per second for S lt 500 mm 20 1600 mm per second 63 per second for S gt 500 mm 20 T overall system stopping performance in seconds see note 2 below C an additional distance in millimeters inches based on intrusion towards the hazard prior to actuation of the Scanner This value is never less than zero Zsm the additional distance needed to account for distance measurement error Zref the additional distance needed to account for error due to reflections from retro reflective surfaces 36 P N 144924 rev A 02 2010 AG4 Safety Laser Scanner User Manual Banner AG4 Series Safety Laser Scanner Notes The above formula is derived from ISO 13855 2002 1 If S is greater than 500 mm then K 1600 mm sec can be used instead of the 2000 mm sec speed however if the 1600 mm sec value is used then S can never be less than 500 mm T is the time from the actuation of the sensing function to the machine s assuming a safe condition comprising a minimum of two phases T t1 t2 Where t1 is the maximum time between the actuation of the sensing function and the output signal switching devices OSSDs being in the OFF state This is the response time of the Scanner t2 is the maximum response time of the machine i e the time required to stop the machine or remove
142. tated in Sections 3 5 and 3 7 7 Remove all obstructions from the Protective Field s Apply power to the Scanner system Verify that power to the guarded machine is OFF e If the Scanner is configured for Start Interlock Manual Power Up the Yellow Start Restart Reset indicator LED 5 will be ON Perform a manual reset close the reset switch for 1 4 to 5 seconds then open the switch to turn ON the OSSD outputs e If the Scanner is configured for Start Test Test at power up the Yellow Start Restart Reset indicator LED 5 will be ON Perform the test by inserting an object equal to or greater than the configured resolution e g test piece momentarily into the Protective Field and then remove Then once the field is clear the OSSD outputs will turn ON e If the Scanner is configured for Automatic Start Automatic Reset the two GREEN indicators LED 1 and LED 3 on Figure 3 and the OSSD outputs turn ON after the restart delay time Banner AG4 Series User Manual P N 144924 rev A 02 2010 89 Banner AG4 Series Safety Laser Scanner 8 Observe the Status indicators and the Diagnostic Display e Lockout LED 5 flashes at a 4Hz rate other LEDs may also be ON or flashing depending on the fault see Section 5 and Table 10 e Protective Field interrupted LED 2 Yellow and LED 3 Red are ON e Protective Field Clear and OSSDs ON LED 1 Green and LED 4 Green are ON e Start Restart Interlock OSSDs OFF waiting for
143. tch must be located as discussed in Section 3 3 7 If supervisory control of the reset switch is required a key switch may be used with the key kept in the possession of a Designated or Qualified Person Using a key switch will also provide some level of personal control since the key may be removed from the switch This will hinder a reset while the key is under the control of an individual but must not be relied upon solely to guard against accidental or unauthorized reset Spare keys in the possession of others or additional personnel entering the safeguarded area unnoticed may create a hazardous situation The Restart Reset input pin 2 Violet wire provides for a manual reset input signal The Scanner requires a manual reset to clear a Start Restart Interlock condition and resume operation following a stop command Internal Lockout conditions also require a manual reset to return to Run mode after the failure has been corrected See Section 1 12 1 for more information Reset Routine To reset the Scanner close the reset switch for 14 to 5 seconds and then open it Closing the reset switch too long will cause the sensor to ignore the reset request the switch must be closed from Y second to 5 seconds but no longer 4 7 Status Indicators A variety of status indicators are clearly visible on the face of the Scanner See Section 1 1 for information on the Status Display Section 3 6 2 for indications during the Trip test and Section
144. that can accurately reflect the status of the device This ensures that the normally open contacts used for controlling hazardous motion have a positive relationship with the normally closed monitoring contacts and can detect a failure to danger e g contacts that welded closed or stuck ON It is strongly recommended that a normally closed forced guided monitoring contact of each FSD and MPCE be connected to EDM inputs see Figures 3 19 and 3 20 If this is done proper operation will be verified Monitoring FSD and MPCE contacts is one method of maintaining control reliability OQSHA ANSI and Category 3 and 4 IS013849 1 If monitoring contacts are not available or do not meet the design requirement of being forced guided mechanically linked it is recommended to e Replace the devices so that they are capable of being monitored or e Incorporate the EDM function into the circuit as close to the MPCE as possible e g monitor the FSDs and e Employ use of well tried tested and robust components and generally accepted safety principles including fault exclusion into the design and installation to either eliminate or reduce to an acceptable minimal level of risk the possibility of undetected faults or failures that can result in the loss of the safety function Banner AG4 Series User Manual P N 144924 rev A 02 2010 53 Banner AG4 Series Safety Laser Scanner The principle of fault exclusion allows the designer to design out the
145. the Check the activation of the Protective Fields in the program wizard Scanner More than 2 Protective Fields selected when starting l l 2802 e Scanner Only activate one of the control inputs FP1 FP4 2802 URAN UICN cono voltage or ME oleae Check the activation of the control inputs FP1 FP4 Field activation 2802 a No Protective Field activated during the Scanner start Activate one of the control inputs FP1 FP4 The Protective Field activation performed does not 2804 3 comply with the specifications programmed in the Check the activation of the Protective Fields in the program wizard Scanner 2804 No Protective Field clearly selected Check the activation of the control inputs FP1 FP4 2804 eee or defective contro voltage for the Protective Check the switchover times of the control inputs FP1 FP4 Field activation 3016 Confirmed single password entered wrong Repeat the password entry 3203 a Scanner has optical glare caused by another device Switch off the supply voltage and start the Scanner again 80 P N 144924 rev A 02 2010 AG4 Safety Laser Scanner User Manual Banner AG4 Series Safety Laser Scanner Activity Scanner has optical glare caused by another device Switch off the supply voltage and start the Scanner again Motion Monitor Field Pair activated wrong several Check the activation of the Protective Fields in the speed matrix and the times Speed exceeding can no longer be corrected speed the ve
146. ting without height offset and with crossed alignment 32 P N 144924 rev A 02 2010 AG4 Safety Laser Scanner User Manual Banner AG4 Series Safety Laser Scanner 3 3 3 Positioning Horizontal Protective Fields for Stationary Applications Height of the Protective Field Above the Floor or Walking Surface The Protective Field should not be located more than 1000 mm above the floor H Where H gt 300 mm there is a risk that a person can go undetected In this case supplemental guarding may be required see warning below The minimum allowable height of the Protective Field H is a function of the scanner s detection capability resolution and is calculated using the following formula H 15 x d 50 mm or H 15 x d 2 in where d the Scanner s Detection Capability Resolution H the distance of the Protective Field above the walking surface Table 3 Examples of Allowable Mounting Height Detection Capability Resolution a d A lt 50 mm 2 70 mm 2 8 300 mm 12 90 mm 3 5 600 mm 24 117 mm 4 6 1000 mm 39 H should not be greater than 1000 mm This ensures detection of a given body part e g thigh leg ankle for a given resolution For example a Protective Field with 70 mm resolution may not reliably detect an ankle which requires a 50 mm resolution Thus the 70 mm resolution Protective Field is intended to reliably detect a leg and should be mounted 300 mm or more above the walking surface
147. to the function of a safety or safeguarding device this term refers to the ability of the device to prevent or allow the machine operating cycle to begin or resume by normal actuating means after the cause of a stop has been removed Also called reset NOTE The reset clearing of the Start Restart interlock of the device must not cause hazardous motion or a hazardous situation but only enable the normal start command 92 P N 144924 rev A 02 2010 AG4 Safety Laser Scanner User Manual Banner AG4 Series Safety Laser Scanner Protective Field The Scanner effective Separation safety distance Safety distance that is required to stop the machine before a person who enters the Protective Field reaches the machine and is specified in ISO 13855 and associated standards Response Time The time between the interruption by the System OSSDs and the instant when the dangerous parts of the machine reach a safe state by being brought to rest Qualified Person A person or persons who by possession of a recognized degree or certificate of professional training or who by extensive knowledge training and experience has successfully demonstrated the ability to solve problems relating to the subject matter and work Response Time The time between the physical initiation of the safety device and the machine coming to a stop or the risk being removed Trip Condition In trip output models the response of the FSD relays when an object equal to or great
148. uments to simplify access to information The documents and configuration program for the Scanner are on the CD that comes with the product The current software version and all PDF documents can also be downloaded from the Banner website http www bannerengineering com Print out the relevant instructions to simplify reading and handling the documents AG4 Series Safety Laser Scanner Quick Reference User Guide AG4soft Program Configuration and diagnostic software AG4soft included with the product on CD ROM AG4 Series Safety Laser AG4 operation capabilities functions and Scanner User Manual applications for the machine designer P N 144924 included with the product on CD ROM this document installer and end user General product information and diagnostic P N 145034 included with the product in print and on AG4 Software Manual How to configure operational settings access diagnostic information and manage P N 144923 included with the product on CD ROM configuration files AG4 Series Safety Laser Application examples intended to give Scanner Applications Guide additional guidance in applying the Scanner pans al Ses Meee woe Sano AG4 Series Safety Laser Instructions for daily and semi annual P N 147899 included with the product on CD ROM to Scanner Checkout Cards checkouts of Scanner installation print as needed and post near the guarded equipment Banner AG4 Series User Manual P N 144924 rev A 02 2010 3 Banner AG4 Serie
149. us points along the entire route i e testing each of the Field Pairs in the configuration 13 Remove electrical power to the Scanner Verify that both OSSD outputs immediately turn OFF and the machine is not capable of starting until power is re applied to the Scanner 14 Test the machine stopping response time using an instrument designed for that purpose to verify that it is the same or less than the overall system response time specified by the machine manufacturer A Banner Applications Engineer can recommend a suitable instrument 90 P N 144924 rev A 02 2010 AG4 Safety Laser Scanner User Manual Banner AG4 Series Safety Laser Scanner 15 Ifthe PC Interface X2 cordset is to be removed ensure that the supplied X2 connector dust plug AG4 PCD9 is re installed Do not continue operation until the entire checkout procedure is complete and all problems are corrected A WARNING DO NOT USE MACHINE UNTIL SYSTEM IS WORKING PROPERLY If all of these checks cannot be verified do not attempt to use or operate the machine until the defect or problem has been corrected Attempts to use the guarded machine under such conditions could result in serious bodily injury or death 6 3 Shift Daily Checkout Perform the Daily Checkout procedure at every shift change power up and machine set up change and at intervals not to exceed 24 hours during continuous machine run periods Record a copy of the checkout results and store in the a
150. used Banner AG4 Series User Manual P N 144924 rev A 02 2010 67 Banner AG4 Series Safety Laser Scanner 4 Open AG4Soft program 5 Connect the AG4 PCD9 xx serial cordset to the AG4 PC9USB 1 or at the X2 connector on the AG4 Note If repeated communication loss occurs check for secure connections ensure AG4 PCD9 xx cordset with RS232 communication are used and or shorten the overall cable length Configuring the PC Serial Port If necessary with the AG4 connected from the Windows Girt tab click on Settings gt Control Panel gt System System Properties gt Hardware gt Device Manager gt Ports COM amp LPT Click on an available COM port note the COM port number select the appropriate Baud rate bits per second which should match the Baud rate of the AG4 default is 57600 Click on Port Settings to verify both of these settings USB to Serial Adaptors If using a USB to serial adaptor do not connect the adaptor to the Scanner until after the PC has identified the new piece of hardware If the Scanner is ON and connected to the USB to serial adaptor when the USB connection is made to the PC the PC can misinterpret the data as a PC mouse causing the mouse cursor to move rapidly around the PC monitor If this occurs disconnect the Scanner from the adaptor and follow the instructions for 46ss of Communication above To identify the port the adaptor is connected to from the Windows Girt t
151. usivement par du personnel qualifi en se r ferant a la documentation du scanner Figure 1 5 Safety notice location 1 5 Proper Use and Intended Purpose Carefully read understand and follow the Instruction Manuals before using or installing this Scanner The literature is contained within the software Help menu or can be downloaded at www bannerengineering com e The Scanner is intended for safeguarding machine hazards and collision avoidance on mobile vehicles e The user is responsible for satisfying all local state and national laws rules codes or regulations relating to the installation and use of this control system in any particular application Take extreme care to meet all legal requirements and follow all installation and maintenance instructions contained in this manual e The user has the sole responsibility to ensure that the Scanner is appropriate for the application and is installed and interfaced by Qualified Persons in accordance with this manual and applicable safety regulations e The Scanner must be integrated into the machine s control system in such a way that an activation of the safety function safely stops or interrupts the dangerous process before a person can be endangered e The Scanner may NOT be used with any machine that cannot be stopped immediately after a stop signal is issued such as single stroke or full revolution clutched machinery or any machine with inadequate or inconsistent machine resp
152. utputs or switching function OSSDs cannot be switched short circuit between OSSD1 and Check the connection wiring of the OSSDs OSSD2 1110 Safety outputs or switching function OSSDs cannot HG be switched short circuit with O V DC or 24 V DC Check the connection wiring of the OSSDs Short circuit between safety outputs or switching 1111 function OSSD1 and OSSD2 Check the connection wiring of the OSSDs Short circuit of one safety output or switching function a OSSD with 0 V DC Check the connection wiring of the OSSDs Short circuit of one safety output or switching function EME OSSD with 24 V DC Check the connection wiring of the OSSDs Angle error detected poss rotation of the sensor 1606 housing switch off and reset followed If reset is not successful contact customer service Angle error detected poss rotation of the sensor housing switch off and reset followed 1607 If reset is not successful contact customer service Motor speed not constant during operation poss 1608 rotation of the sensor housing If reset is not successful contact customer service Motor speed not constant during operation poss 1608 rotation of the sensor housing If reset is not successful contact customer service Motor speed not constant during operation poss 1608 rotation of the sensor housing Oo If reset is not successful contact customer service Signal of a light beam safety de
153. v A 02 2010 AG4 Safety Laser Scanner User Manual Banner AG4 Series Safety Laser Scanner e The safe design and construction of the machine e The safe implementation of the Scanner e Providing all relevant information to the user e g all documentation provided with the AG4 e Compliance with all regulations and directives that allow the user to safely put the machine into operation At a minimum the machine user is responsible for e Instructing and supervising the Qualified Person the Designated Person and the operator e Maintaining the safe operation of the machine e Compliance with all occupational health and safety at work regulations and directives 1 7 1 Passwords Improperly set parameters on the Scanner can cause serious accidents The configuration of the Scanner is therefore protected by passwords Ensure that the passwords are secured by the Qualified Person The default password is bannera call the numbers on the back cover for assistance in the event of a lost password The people responsible for the machine s safety must ensure that the appropriately Qualified Person can properly perform the tests and work on the machine and the Scanner in accordance with their intended use 1 7 2 Providing Information for Use A WARNING SCANNER OPERATION ON POWER UP It is the responsibility of the user of the Scanner to assess what safeguarding devices and methods are appropriate for any given machine or application The
154. ver times At least one Field Pair must always be active For the precise error cause read the diagnostics list with the software Check the vehicle s speed and travel direction Check the control system s Field Pair switchover Wait 5 seconds The Scanner performs a reboot If the reboot is not successful read the diagnostics list with the software P N 144924 rev A 02 2010 Banner AG4 Series Safety Laser Scanner 5 1 2 Scanner Error Codes A diagnostics list can be created with the AG4Soft software The incidents that occurred during the Scanner operation are listed in this diagnostics list Each incident is given with place and number The meaning of the incidents is shown in the following table To access diagnostic information highlight the Sstem Data Operating tab and click on menu bar path Sstem Data gt Display the Scanner s diagnostics list Table 11 Diagnostics codes al Activity Data transfer error on interface X2 Check the interface parameters and start the transfer again Data transfer error on interface X2 Check the interface parameters and start the transfer again Data transfer error on interface X2 Check the interface parameters and start the transfer again Function access command not allowed with currently a Change the authorization level and start the transfer again selected authorization level Interface X2 time specifications not complied with last Check the interface para
155. vice of the window monitoring below the bottom limit dirty front screen Clean the front screen 1705 Signal of a light beam safety device of the window monitoring below the bottom limit oil grease on the Clean the front screen front screen 1705 Safety outputs or switching function OSSDs cannot Check the connection wiring of the OSSDs If reset is not successful 1906 be switched internal or external short circuit contact customer service Banner AG4 Series User Manual P N 144924 rev A 02 2010 1906 1906 1906 1907 1907 2002 2007 2017 2017 2017 2017 2018 2018 2018 NSO Co N N DO o gt gt ow D gt NS gt oO Dh md Dh gt Banner AG4 Series Safety Laser Scanner Activity Safety outputs or switching function OSSDs cannot Check the connection wiring of the OSSDs If reset is not successful be switched internal or external short circuit contact customer service Read back error on the safety outputs or switching Check the connection wiring of the OSSDs If reset is not successful function OSSDs internal or external short circuit contact customer service Error on the laser s switch off path switch off because If reset is not successful contact customer service of eye safety internal defect Angle error detected poss rotation of the sensor EOS If reset is not successful contact customer service housing switch off and reset follo
156. wed Angle error detected poss rotation of the sensor ae If reset is not successful contact customer service housing switch off and reset followed The configuration data displayed for the check was not acknowledged for too long Start the transfer again Date of the Protective Field currently being transferred is older than the date saved in the Scanner Update the PC s date and time setting Data transfer error with ConfigPlug Replace the ConfigPlug or the complete cable with plug The connected Scanner does not support the configuration file in the ConfigPlug Change the Scanner observe the device type The connected Scanner does not support the configuration file in the ConfigPlug Change the Scanner observe the device type Date of the configuration currently being transferred is older than the date saved in the Scanner Update the PC s date and time setting Motion Monitoring error with the speed matrix transfer Start the configuration transfer again Motion Monitoring error with the speed matrix transfer Start the configuration transfer again Motion Monitoring the right side of a Protective Field Check all parameters in the wizard calculate the Protective Fields again does not match the predefined vehicle width and start the transfer again P N 144924 rev A 02 2010 AG4 Safety Laser Scanner User Manual Banner AG4 Series Safety Laser Scanner Place Number Meaning Activity Motion Monitori
157. y extreme electrical noise cases a Lockout is possible If random nuisance noise problems occur check the following e Poor connection between the Machine Interface X1 cable shield and earth ground e Optical interference from adjacent safety laser scanners or other photoelectrics or e Scanner input or output wires routed too close to uisy wiring Note Do not directly ground the Scanner housing Make only those connections as described in Section 3 All Scanner wiring is low voltage running these wires alongside power wires motor servo wires or other high voltage wiring can inject noise into the Scanner It is good wiring practice and may be required by code to isolate Scanner wires from high voltage wires The Banner model BT 1 Beam Tracker see Banner catalog or website is a very good tool for detecting electrical noise It can be used to detect electrical transient spikes and surges Checking for sources of electrical noise Turn off the Scanner and cover the lens of the BT 1 with electrical tape to block optical light from getting into the receiver lens Press the RW button on the BT 1 and position the Beam Tracker on the wires going to the Scanner or any other nearby wires Noise caused by the switching of inductive loads should be addressed by installing proper transient suppression across the load Checking for sources of optical noise Turn off the Scanner Then use a Banner BT 1 Beam Tracker to check for light at the A
158. zardous area Enable select Field Pair 8 only when personnel are not exposed to a hazard Failure to follow these recommendations can potentially create a dangerous situation that may lead to serious injury or death Banner AG4 Series User Manual P N 144924 rev A 02 2010 15 Table 1 Input Logic for Field Pair Control Control Input Wire Field Pair Banner AG4 Series Safety Laser Scanner CAICOS Description ANO O CI PET pene PRT eee PET ene All fields are deactivated A WARNING Scanner outputs remain ON Logic 1 30V dc max 16V min Logic 0 lt 3V de Key Switchover from Field Pair 1 to Field Pair 3 Control Input One second Field Pair _ gt Field Pair 1 Active A O 3 Active 1 0 0 0 1 Field Pair 1 and 1 0 0 1 0 Field Pair 3 active 1 0 1 0 overlap Figure 1 9 Example Field Pair Switchover timing diagrams 6 P N 144924 rev A 02 2010 Switchover from Field Pair 1 to Field Pair 8 FP4 Control Input Field Pair i E y l 1 Active l 8 Active 1 0 0 0 Field Pair 40mstime 40ms 01 1 1 begins at first internal change of testing state All FP inputs must change within this time AG4 Safety Laser Scanner User Manual Banner AG4 Series Safety Laser Scanner 1 12 5 Reference Contour Surface Monitoring The reference contour surface monitoring function prevents unintentional misalignment

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