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ROTOSCAN RS4-4 Laser Scanner for Personnel Protection and

1. Reserved for testing purposes no wiring Please refer to the inside front cover of this technical descrip tion to see the pin assignments Leuze RS4 4 177 178 11 11 1 Start up Communication with the PC or laptop needs to be established so that the ROTOSCAN RS4 4 can be configured and the detection zones and warning fields can be programmed This is also necessary for displaying the measurement contours and for the system check The program RS4soft which is included with delivery makes this easy and convenient to do Refer to the software user manual to find additional important information and helpful explanations In addition we recommend that you consider the following points Hardware and Software Requirements The following components are required for the initial startup e ROTOSCAN RS4 4 e RS232 interface cable 1 1 without cross connection or RS422 interface cable e Shielded control cable for the power supply and for activating a field pair Power supply that meets the requirements specified in Chapter 10 1 e PC or laptop color monitor RS4soft program The PC should fulfill the following requirements Intel processor Pentium class or higher or compatible models such as AMD or Cyrix Atleast 16 MB RAM e 31 2 disk drive or CD ROM drive e Hard drive with at least 8 MB of free memory more if detection zone data and or configuration data are goin
2. aterial Error Codes and Causes Leuze About This Technical Description The technical description of the ROTOSCAN RS4 4 contains all information regarding proper use of the scanner as well as its engineering mechanical and electrical installation and startup Additional information can be found in the operating instructions for the RS4soft software package Both of these sets of documentation as well as the RS4soft software are supplied with every delivered system and are intended for use by the planners operators and maintenance personnel of systems that are safeguarded by the ROTOSCAN RS4 4 It is imperative that all information provided by both the technical description and the operating instructions in particular the safety precautions be strictly observed The technical description and the operating instructions must be kept in a safe place They must also be easily accessible at all times during the entire service life of the scanner Safety precautions and warnings are designated by the symbol Information on the safety of laser devices is designated by the symbol A Leuze lumiflex GmbH Co is not liable for damage resulting from improper use of its equipment Familiarity with this manual constitutes part of the knowledge required for proper use Version of the contents V1 01 No reprints or duplications in full or in part without the express permission of Leuze lumiflex Gm
3. Hu ax Maximum height of the scanning plane from the reference plane in mm d Resolution of the scanner 70 mm throughout the detection zone in mm RS4 4 Leuze 6 4 8 1 Additions and minimum depth of the detection zone The sum of the system specific and application specific detection zone additions see Chapter 6 3 5 is calculated according to the following formula Zaes Zsm ZReEFL Zau ZGES Sum of the system specific and application specific detection zone additions in mm ZsM Measurement error of the scanner in mm Zrer Addition for considering reflectors in mm ZAU Addition for application specific undercut in mm The depth of the detection zone with reference to the direct distance between the danger zone and the detection point or line is calculated according to the following formula St K x Tscan TmascH TNACHLAUF X LNAcHLAUF Zges St Depth of the detection zone distance from the danger zone to the point or line of detection including the system and application specific additions in mm K Approach speed of a person or one of their body parts 1600 mm s in mm s Tscan Response time of the scanner in s Tuasch Response time of the machine or system in s TnachLaur Lag time of the entire system in s LyachLaur Factor for increases in lag time Safety related constant in mm Leuze RS4 4 141 142 6 4 8 2 Maximum range of the detection zone Suax Sr
4. RS4 4 193 15 9 Software User software Communication and parameter setting software for Windows 95 98 2000 NT with safe protocol for programming 15 10 Interfaces RS 232 RS 422 For setting device parameters and defining detection zones and warning fields 15 11 Optics Angle range max 190 Angle resolution 0 36 Lateral tolerance without mounting sys tem with mounting system 0 18 with respect to the back wall of the housing 0 22 with respect to the mounting surface Scanning rate 25 scans s or 40 ms scan Laser protection class Class 1 safe for the eyes in accordance with DIN EN 60825 1 Wavelength 905 nm Beam divergence 2 mrad Time basis 100 s 194 RS4 4 Leuze Leuze 15 12 Environment and Material Enclosure rating IP 65 in accordance with IEC 60529 Shock protection Protection class 2 Operating tempera 0 50 C ture Storage temperature 20 C 60 C Humidity DIN 40040 Table 10 Identification letter E moderately dry Dimensions 140 x 155 x 135 W x Hx D in mm Distance from the middle of the scanning plane to the bottom edge of the housing 48 75 mm Distance from back edge of the housing to the axis of the rotating mirror 68 mm Connection 2 connectors plugged in from above solder connection Control cable length x1 Max 50
5. Sgorr Sppirr Gppirr S Z Smax Maximum range of the detection zone considering the diagonals in mm St Depth of the detection zone in mm Sgp Largest width of the detection zone between the axis of the rotating mirror and the outer edge of the detection zone in mm Gpp rr Largest width of the danger zone between the axis of the rotating mirror and the boundary of the danger zone in mm S Safety distance minimum distance from the danger zone to the point of detection to the plane of detection or to the detection zone in mm Z Required detection zone additions in mm RS4 4 Leuze Leuze St Zz ZUMIN gt ee le l S Ls l i d 1 a A 1 Sp W l Gepirr i i SgpiFF i b A 2 E yoy a aan Smax S Zay Tu a ROTOSCAN RS4 4 b Dangerous machine danger zone c Safety fence to prevent stepping behind d Axis of the rotating mirror e Detection zone Gppifr Largest width of the danger zone 5 Safety distance Sg Entire width of the detection zone Sgp FF Largest width of the detection zone MAX Geometrical maximum distance t Depth of the detection zone Zay Detection zone addition application specific Detection zone additions Zumin Undercut Fig 14 Considering the maximum measurement distance when safeguarding an area RS4 4 143 144 6 4 8 3 Example for calculating the depth of a detection zone This example is
6. 5 1 Stationary Safeguarding of Danger Zones The ROTOSCAN RS4 4 is used to safeguard dangerous working areas at machines and systems where both constant and variable demands are placed on the geometrical shape of the detection zone The aim is to prevent people from entering the danger zone or reaching the danger point with their upper and or lower extremities at the same time without impeding the production process The ROTOSCAN RS4 4 can be mounted directly at the machine table or on the side or in front of the machine Detection zone 1 activated Detection zone 2 deactivated Warning field 1 activated Warning field 2 deactivated Emergency stop and triggering of restart interlock ROTOSCAN RS4 4 XXX N 2 Fig 3 Stationary danger zone monitoring of a robot with two alternating work areas example An example for calculating the dimensions of the detection zone can be found in Chapter 6 4 8 RS4 4 Leuze 5 2 Mobile Safeguarding of Automatic Guided Vehicles For this application the ROTOSCAN RS4 4 is installed on automatic guided vehicles in order to monitor the vehicle path The aim is to detect people or objects in the path of the vehicle and to automatically bring the vehicle to a halt Safety systems available up to now such as bumpers or safety bars have allowed only very low driving speeds to be maintained In contrast using the ROTOSCAN RS4 4 as a non contact advance bumper results in the
7. Tel Int 45 0 44 34 14 54 Fax Int 45 0 44 99 14 54 http www leuze de Spain Leuze electronic S A C Joan G ell 32 E 08028 Barcelona Tel Int 93 0 409 79 00 Fax Int 93 0 490 35 15 E mail leuze chi es http www leuze de 3 France Leuze electronic sarl Z l Nord Torcy B P 62 BAT 3 F 77202 Marne la Vall e Cedex 1 Tel Int 33 0 160 05 12 20 Fax Int 33 0 160 05 03 65 E mail infos leuze electronic fr http www leuze electronic fr Finland SKS tekniikka Oy P O Box 122 FIN 01721 Vantaa Tel Int 358 0 9 85 26 61 Fax Int 358 0 9 852 68 20 E mail sks tekniikka sks fi http www sks fi Great Britain Leuze Mayser electronic Ltd Generation Business Park Barford Rd GB St Neots Cambs PE19 6YQ Tel Int 44 0 1480 40 85 00 Fax Int 44 0 1480 40 38 08 E mail mail leuzemayser co uk http www leuzemayser co uk Greece UTECO A B E E 5 Mavrogenous Str GR 18542 Piraeus Tel Int 30 0 1 421 00 50 Fax Int 30 0 1 421 20 33 E mail uteco uteco gr http www leuze de Hungary Kvalix Automatika Kft Pf 83 H 1327 Budapest Tel Int 36 0 1 399 06 15 Fax Int 36 0 1 369 84 88 E mail info kvalix hu http www kvalix hu Hong Kong Sensortech Company No 43 18th Street Hong Lok Yuen Tai Po N T Hongkong Tel Int 852 26 51 01 88 Fax Int 852 26 51 03 88 E mail sensortech attglobal net FI Ital
8. example Warning field programmed in the ROTOSCAN RS4 4 example Configurable detection zone and warning field expansion 5 Configurable detection d zone and warning field expansion 5 j b SF gt Object in the detection Ua gt l zone a gt Fig 1 The 190 angle range of the ROTOSCAN RS4 4 is divided into 0 36 angle segments RS4 4 Leuze Leuze A laser diode coupled with transmitter optics produces focused light pulses These pulses are projected across the monitored surface by a rotating mirror in such a way that a light pulse is triggered in each of the angle segments within 40 ms scanning rate 25 scans s gules ale O y t H t oo _ L gt tit t Fig 2 Functional principle of the ROTOSCAN RS4 4 The ROTOSCAN RS4 4 can detect people up to a distance of 4 0 m corresponds to the detection zone even if they are wearing very dark clothing or exhibit a low degree of reflectance Dangerous movements are brought to a stand still by two failsafe semiconductor outputs Objects min 150 x 150 mm are detected up to a distance of 15 m corresponds to the warning field and signaled by way of a non safety related semiconductor output Four programmable field pairs each of which consists of one detection zone and one warning field enable the scanner to be optimally adapted to the needs of each particular application The ROTOSCAN RS4 4 can be imp
9. 422 RS 422 interface FP Field pair contains 1 x detection zone and 1 x warning field WF Warning field Leuze RS4 4 109 110 2 4 Guidelines and Standards The following guidelines and standards are of critical impor tance for the implementation of laser scanners Guidelines providing particularly relevant information for users of such systems are marked with an asterisk Guideline Standard Name European Guidelines 98 37 EG Machine guideline 73 23 EWG Low voltage guideline 89 336 EWG EMC guideline A Standards DIN EN 292 1 und 2 Safety of machinery basic concepts DIN EN 1050 Principles of risk assessment B1 Standards DIN EN 294 Safety distances x DIN EN 954 1 Safety related parts of controls DIN EN 999 Approach speeds of body parts B2 Standards DIN EN 60204 1 Electrical equipment of machines DIN EN 60825 1 Safety of machines with laser components DIN EN 61496 1 Electro sensitive protecting x equipment IEC 61496 3 AOPDs responsive to diffuse x reflection AOPDDR RS4 4 Leuze Leuze Guideline Standard Name C Standards DIN EN 775 Industrial robots safety DIN EN 1525 Automatic guided vehicles AGV and their systems DIN EN 12895 Automatic guided vehicles electromagnetic compatibility National Standards DIN 15185 2 Warehousing systems using K rail guided aisle conveyance vehicles This list does not claim to be complete In cer
10. Data overflow ceive protocol message overwritten by new message 302 Processing of the Timeout while waiting transmit protocol for verification of transmitted message 306 Output of measure Previous message not ment values yet completely output 801 Error processing Error memory cannot be read 805 Processing of the Error memory cannot commands to the be transferred error memory 1002 Motor control during Motor does not initialization achieve rated speed 1002 Motor control during Engine revolutions not initialization constant 1110 Test ofthe switch out State of switch puts outputs inconsistent with that shown by the internal memory RS4 4 197 198 Lo Description N Description cat 0 ion 1110 Test of the switch 5 Switch output cannot outputs be switched off 1110 Test of the switch 6 Switch output cannot outputs be switched on 1111 Shortcircuittest ofthe 7 Short circuit of a switch outputs switch output with ground 1111 Shortcircuittest ofthe 8 Short circuit of a switch outputs switch output with Vcc 1606 Motor speed monitor 4 Motor speed error ing zero pulse not detected properly 1607 Monitoring the 5 Motor speed error duration of a scan motor not at rated speed 1705 Processing of field 1 Signal of a field monitoring light barrier monitoring light barrier data below lower limit 1705 Processing
11. Leuze 10 4 Points to Consider When Preparing and Laying the Cables The cross section of cable X1 must be at least 0 5 mm The outer diameter ofthe cable must be between 6 5 mm and 10 mm The maximum cable length for X1 is 50 m The maximum cable length for X2 is 10 m for RS232 The maximum cable length for X2 is 50 m for RS422 twisted pair Use shielded cables Connect the cable shielding with PE to the electronics cabinet only The cables may not be laid loose Scanner control cables may not be laid in a stand parallel to power supply cables for machines This minimizes the effects of inductive interference factors from motors carrying high current In addition the cables should be laid so that they cannot be damaged e g by being crushed or pinched Cabling prepared for connection to the scanner is available as an optional accessory in various lengths and for both inter faces For further information see Chapter 14 Leuze RS4 4 175 10 5 Interface Pin Assignments Pin Assignments for Connector X1 Pin Signal Description 1 GND Ground for the supply voltage 2 Restart Input scanner reset and connecting the restart button UB Supply voltage 24 VDC 4 FP 1 Changeover to field pair 1 5 Alarm Semiconductor output that switches off when the warning field is violated as well as for warning messages such as window slightly dirty error mess
12. ROTOSCAN RS4 4 to a Safety Sequential Circuit with Manual Restart Interlock and Relay Monitoring and without Field Pair Changeover uuesesesenensenennnennennnnnnenenennnnnnnn 169 Connecting the ROTOSCAN RS4 4 to a PLC with Corresponding Safety Level Cat 3 or higher EN 954 and Field Pair Changeover 171 Electrical Connection uuususssnsnannnnnennnnnnnnnnnnnnnunnnnnnnnannnn 173 Electrical Power Supply Connecting the PC and Control Cables to the Scanner Connector Assembly uuensesessanesnnnnnnnssnnnsnnnnunnannnnnnnnnnnnnn Points to Consider When Preparing and Laying the Cables Interface Pin Assignments 176 Hardware and Software Requirements Installing RS4soft and Starting Up the ROTOSCAN RS4 4 ROTOSCAN RS4 4 Status Indicator Status information for the ROTOSCAN RS4 4 Maintenance and Testing List of Test Points Service Disposal 13 14 14 1 15 15 1 15 2 15 3 15 4 15 5 15 6 15 7 15 8 15 9 15 10 15 11 15 12 16 Delivery Package 2uu2u22n22nn0nnunnunnunsannunnunnunnunnunnunnunnennunnenne 186 Accessories Coding of the Control Cable X1 Technical Specifications zusrsnsnnsnnnnnnnnunnnnnnnnnnnnnnnnnnnnnn 190 Test Pieces Detection Zone Detection Zone Additions Warning Field Contour Measurement Electrical Power Supply Inputs Outputs Software Interfaces Optics Environment an
13. X1 Set 50035735 RS4 4 connector complete 9 pin interface X2 RS4 MG X2 Set 50035768 RS4 4 control cable prepared for connection to the scanner 5 m RS4 CB X1 5 50035736 RS4 4 control cable prepared for connection to the scanner 10 m RS4 CB X1 10 50035737 RS4 4 control cable prepared for connection to the scanner 20 m RS4 CB X1 20 50035849 RS4 control cable prepared for connection to the scanner 35 m RS4 CB X1 35 50035850 RS4 control cable prepared for connection to the scanner 50 m RS4 CB X1 50 50035851 RS4 PC cable prepared for connection to the scanner 3m RS4 CB X2 3 50035863 RS4 4 187 Description Abbreviation Order No RS4 PC cable prepared RS4 CB X2 5 50035865 for connection to the scanner 5m RS4 PC cable prepared RS4 CB X2 10 50035867 for connection to the scanner 10 m User program RS4soft RS4 SWD 970070 on diskette and RS4soft MSW DE Set manual German English User program RS4soft RS4 SWD 970078 on diskette and RS4soft MSW F Set manual French ROTOSCAN RS4 4 user RS4 MHW DE 50034330 manual German English ROTOSCAN RS4 4 user RS4 MHW F 50037316 manual French Test piece cylinder 500 RS4 TB 70 500 50036433 mm in length 70 mm in diameter reflectance factor approx 1 8 Test piece cylinder RS4 TB 200 50036434 1000 mm
14. about password levels can be found in the RS4soft user manual Using the scanner to control the passage of people through an area vertical detection zone in accordance with IEC 61496 3 is not admissible Restrictions for Use Glass highly reflective materials such as mirrors reflectance gt 10 000 or objects that do not reflect any light back to the sensor can falsify the measurement result For further information refer to Chapter 6 3 5 Do not expose the ROTOSCAN RS4 4 to flying sparks e g welding flash Do not expose the ROTOSCAN RS4 4 to fog rain or snow Do not expose the ROTOSCAN RS4 4 to vapors smoke or dust Avoid extreme variations in temperature Make sure that the following types of light sources are not present on the scanning plane Laser light from other scanners or sensors Infrared light Fluorescent light Stroboscopic light Please see Chapter 6 2 for more information RS4 4 117 The scanner may not be installed on vehicles with internal combustion engines The ROTOSCAN RS4 4 is conceived for use inside enclosed spaces and with the operating parameters listed in the technical specifications temperature humidity shock vibration etc Please refer to the list of para meters in Chapter 15 Avoid having reflective surfaces such as glass mirrors retro reflectors etc at fixed contours in the scanning plane If this is not possible a detection zone addition must be pr
15. based on the following application data see Fig 14 Largest width between Ggp rr 700 mm the axis of the rotating mirror and the bound ary of the danger zone Access speed K 1600 mm s constant Response time of the Tgcan 0 08 s RS4 4 adjustable Response time of the Tyasch 0 185 machine or system Stopping time or lag Tnacutaur 9 5 s time for braking time of the machine or the dangerous move system ment until standstill Factor for increase in LyachLaur 1 1 fixed addition to lag time account for increased lag time Addition for system ZsM 81 mm when dust specific measurement algorithm is switched error off Addition caused by the Zay 125 mm distance mounting position between the front edge of the undercut to the beam axis of the scanner Height of the sensor H 300 mm scanning plane Safety related C 1200 mm 0 4 Height constant H 1080 mm RS4 4 Leuze Leuze The formula S KX Tscan TmascH TNACHLAUF X LNaCHLAUF results in the safety distance S 1600 mm s 0 08 s 0 1 s 0 5 s 1 1 1080 mm 2248 mm The formula S7 S Zoy Zau results in the detection zone depth St 2248 mm 81 mm 125 mm 2454 mm 6 4 8 4 Example for calculating maximum detection zone range The formula 2 2 MAX ST Sgpier Sppirr Gppirr S Zsm including the width of the danger zone results in the maximum distance to be monit
16. creation of a substantially larger safety zone The vehicles can move faster and down times are reduced to the necessary minimum SF1 Detection zone 1 for low speed SF2 Detection zone 2 for high speed SF3 Detection zone 3 for a route curving to the left SF4 Detection zone 4 for a route curving to the right Traveling straight ahead Fig 4 Safeguarding an automatic guided vehicle example An example for calculating the dimensions of the detection zone can be found in Chapter 8 Leuze lumiflex RS4 4 123 SF1 SF2 124 5 3 Protecting Transporter Trolleys against Collisions Transporter trolleys are generally guided along a system of rails or grooves in the floor Hence the vehicle paths are usually just slightly wider than the trolleys themselves This represents an increased hazard for people since it is impos sible to get out of the way of the trolley For this reason trans porter trolley are used in enclosed areas equipped with suitable access safeguarding Detection zone 1 for slow speed Detection zone 2 for high speed Emergency stop and triggering of restart interlock Direction of travel Undercut C5 SEIN RR x A ER X ER gt rats ER N lt gt RE ER SON ee a NN IN RL ER SER RR N EEE RER 2 ze AAY N 3 BB Ber N BE N BE IN Q Fig 5 Safeguarding a transporter trolley example In these cases the ROTOSCAN RS4 4 is used to detect people or objects in the vehicle pat
17. of a ROTOSCAN RS4 4 mounted on an AGV does not cover the entire front of the vehicle you can prevent the creation of unmonitored zones by changing the installation depth of the scanner or by adjusting the angle range from 180 to 190 If this is not possible due to constructional limitations additional safety measures such as mechanical cover panels switch strips or bumpers must be implemented Please refer to the safety precautions in Chapter 4 6 RS4 4 149 ROTOSCAN RS4 4 mounted on the front of a vehicle ROTOSCAN RS4 4 recessed into the front of a vehicle ROTOSCAN RS4 4 mounted ona protruding vehicle attachment 150 ROTOSCAN RS4 4 Automatic guided vehicle The distance from the back wall of the scanner to the axis of the rotating mirror is 68 mm The 190 detection zone enables an expanded monitored range The detection zone is limited by the scanner recess at the front of the vehicle 180 The protruding attachment results in the creation of unmonitored zones Lateral safety distance between the edge of the roadway and the boundary of the detection zone Sum of the system and application specific additions in the direction of travel Sum of the system and application specific additions to the side Three possibilities for mounting the ROTOSCAN RS4 4 onto an AGV RS4 4 Leuze Leuze 6 5 5 Additi
18. programmed with the largest possible detection zone and with activated restart interlock For this reason LED 5 is constantly lit up when the scanner is switched on When starting up your ROTOSCAN RS4 4 please modify the parameters to meet the specific needs of your application Leuze RS4 4 183 184 12 Maintenance and Testing The faultless function of the scanner must be tested by trained personnel after longer periods of standstill after repairs have been made and in any case at least once per year If there is any doubt as to the proper function of the system or if parameters relevant to the detection zones have changed it is not allowed to use stopgap measures or quick fixes Following each definition of and change to the detection zones the configuration must be checked to see whether the possibility of people standing in the danger zone as well as any barriers provided have been considered by an appropri ate layout of the detection zone s The scanner window and the six diffusing screens above it should be cleaned at regular intervals depending on the application Do not use any cleaning substances that contain caustic solvents or scouring particles Doing so can result in the plastic being clouded We recommend cleaning the scanner window with a soft cloth dampened with water and a small amount of dishwashing liquid drying the window with an absorbent lint free soft cloth If the window monitoring
19. 2 12 1 12 2 12 3 Safeguarding Mobile Machines Purpose of safeguarding Mounting position 147 MOUNTING Height lt cc c cceestacsscscusiettecoeschateratdectenssuchniceastnetsates geeaeeetinsaie 147 Recommendations for mounting in order to prevent unmonitored zones Additions System availability Restart Calculating the dimensions of the detection zone for an AGV Application EN Bee LR Es NER 153 Direction related minimum depth of the detection zone and additions 153 Maximum range of the detection zone Example for calculating the depth of a detection zone Example for calculating the maximum range of a detection ZONE kis fiesta cae ee eee eevee nes 157 149 151 152 153 154 Information on Detection Zone and Warning Field ChangeoverS uunsanansannnsannnnanannunnnnannnnununnunnnnunnnnannnnannnnunnununnn 158 Sequence of a Field Pair Changeover from FP 2 to FP 4 Example Practical AGV Application Example Functions of the ROTOSCAN RSA 4 uauusanusnnunnnunnnunnnnunenn 163 Restart Channels for Field Pair Changeovers FP 1 to FP 4 Alarm X1 5 asandeinsesaertanszansesnengdandasinnsunse 164 OSSD 1 X1 12 and OSSD 2 X1 11 Data Communication Integrating the ROTOSCAN RS4 4 into Machine 67 1 L ge 25 E E E A E ceeusiocnsene 167 Integrating the ROTOSCAN RS4 4 with External Wiring with Relays and Quadruple Field Pair Changeover sses 167 Connecting the
20. 234567 8 9101112131415 A x1 a An 14 K2 Kt K2 K3 ROTOSCAN RS4 4 K3 a Fuse 1 25 A semi time lag d SF2 WF2 b Restart button e SF3 WF3 c SF 1 WF 1 f SF4 WF4 Fig 22 Wiring the ROTOSCAN RS4 4 with evaluation of the OSSDs field pair changeover and restart inter lock example The relays K1 and K2 must have positively guided contacts They are operated directly at the two failsafe semiconductor outputs OSSD 1 X1 12 and OSSD 2 X1 11 The relay K3 is drop out delayed A suitable arc suppressor is required Please note that this results in an increase of the switching times According to DIN EN 954 1 channels x and y must be integrated for Categories 3 and 4 A single channel integra tion comprising z is only admissible for a single channel control and under consideration of the results of a risk analysis Serial machine controls are admissible only insofar the valid regulations allow RS4 4 Leuze Leuze 9 2 Connecting the ROTOSCAN RS4 4 to a Safety Sequential Circuit with Manual Restart Interlock and Relay Monitoring and without Field Pair Changeover eee 24 V t t T GND T PE a cc d on i b N Db 4 y K5 K4 K5 4 ia gt m 1234567 8 9101112131415 83583483181214 24 S21S22 1323 A2 Al sa al ROTOSCAN RS4 4 MSI SR2 F x y z a F
21. 4 The ROTOSCAN RS4 4 is equipped with the interfaces X1 and X2 which provide the following functions 8 1 Restart Depending on the operating state the restart input X1 2 has several functions Enables the restart interlock following the interruption of a detection zone Enables the start interlock following a system start e Restarts after a device error has been eliminated e Recognizes a defined enable signal after a device error after a detection zone interruption for enabling the restart interlock To activate the functions apply 24 V to input X1 2 In the meantime the safety outputs OSSD 1 and OSSD 2 are switched off the indicator at the scanner LED 3 is lit up red The duration of the signal must be between 2 s and 4s The restart input X1 2 must be connected with an external permanently installed button It may not be connected with the remaining controls in order to prevent an unintended release Please see Chapters 6 Information for Planning and Mounting and 10 1 Electrical Power Supply Leuze RS4 4 163 164 8 2 8 3 Channels for Field Pair Changeovers FP 1 to FP 4 To activate the field pairs apply 24 V see Chapter 10 1 to the following inputs X1 4 FP1 X1 6 FP2 X1 7 FP3 X1 8 FP4 When changing over the field pairs please note that the new field pair must be switched on before the previous pair is switched off This procedure is allowed to last a maximum of 1
22. NHALT 1900 mm Factor for wear and 1 1 fixed addition to tear on the brakes LaAnHaLT account for wear and tear on the brakes Measurement error Zgm 81 mm Distance between 90 mm results in an AGV and floor Zaruss addition of 50 mm according to Fig 18 for calculating the ad dition for inadequate floor clearance The formula S Vuaxete X Tscan TetTF Sanjar X LANHALT results in a safety distance of S 1800 mm s 0 08 s 0 1 s 1900 mm 1 1 2414 mm The formula St S Zgyu ZrerL Zaruss Zau results in the following required depth of the detection zone in the direction of travel Sr 2414 mm 81 mm 0 mm 50 mm 0 mm 2545 mm RS4 4 Leuze 6 5 8 4 Example for calculating the maximum range of a detection zone The formula 2 2 max ST Sppier SgpiFF Gepirr Zs under consideration of the width of the danger zone results in the maximum distance to be monitored Suax 2545mm 1481mm Sgpicr 1400 mm 81 mm 1481 mm SMAX 2945 mm Leuze RS4 4 157 158 Information on Detection Zone and Warning Field Changeovers In the course of using machines to their optimum capacity alternating cycles of material insertion and processing often necessitate the creation of variable danger zones Due to their very nature AGV applications also necessarily comprise various danger zones If it is possible for a person to gain access to th
23. SSD outputs are switched off e g during booting LED 1 LED 4 The sensor function is active measurement operation without a viola tion of the activated field pair The OSSDs are switched active high LED 1 LED 2 LED 4 The sensor function is active measurement operation without a viola tion of the activated de tection zone Violation of the activated warning field The OSSDs are switched active high LED 2 LED 3 Violation of the warning field Violation ofthe detection zone The OSSDs are switched off LED 1 LED 4 LED 5 The sensor function is active measurement operation without a viola tion of the activated de tection zone The OSSDs are switched active high Warning message signaled by slow flashing at approx 0 25 Hz e g RS4 4 Leuze 0 0 1 0 1 LED3 LED 5 The OSSDs are switched off Error message signaled by fast flashing at approx 4 Hz e g for a defect or a safety relevant fault 1 0 1 0 1 LED 1 LED 3 LED 5 The sensor function is active measurement operation without an in terruption of the activated field pair The OSSDs are switched off Restart interlock is active O 1 1 0 1 LED 3 LED 5 Interruption of the field pair The OSSDs are switched off Restart interlock is active 1 LED is lit up 0 LED is dark undefined Upon delivery the ROTOSCAN RS4 4 is
24. ages such as window very dirty and for internal errors the functions can also be selected in combination 6 FP2 Changeover to field pair 2 7 FP3 Changeover to field pair 3 8 FP 4 Changeover to field pair 4 9 NC Not connected 10 NC Not connected 11 OSSD Semiconductor output switches off when 1 the detection zone is violated Channel 1 12 OSSD Semiconductor output switches off when 2 the detection zone is violated Channel 2 13 INC Not connected 14 INC Not connected 15 Re Reserved for testing purposes no wiring served 176 RS4 4 Leuze Pin Assignments for Connector X2 used as an RS 232 Port Pin Signal Description 1 md Not connected TxD Data communication transmit RxD Data communication receive Not connected oo wy N GND shield Ground shield RS 232 Not connected NC Not connected NC Not connected oO OC N O Re served Reserved for testing purposes no wiring Pin Assignments for Connector X2 used as an RS 422 Port Description Data communication receive Data communication receive Data communication transmit Data communication transmit Ground shield Select RS422 interface by connect ing a bridge to pin 5 Not connected Not connected Pin Signal 1 TxD 2 TxD 3 RxD 4 RxD 5 GND shield 6 RS 422 7 NC 8 NC 9 Re served
25. ating laser systems must be complied with Operating Conditions and Proper Use The relevant regulations for machine safety apply for the use of the ROTOSCAN RS4 4 The responsible authorities e g trade associations OSHA are available to answer technical questions related to safety issues In general the following conditions for use must be complied with Ifthe scanner is enclosed in a protective housing addi tional window material such as plastic or glass must not be used as it may impair the detection Avoid touching the scanner window and the six diffusing light screens The ROTOSCAN RS4 4 is not suitable for use as a protective device ifitis possible that dangerous fluids will be spewed out or objects will be ejected for machines with long braking times max depth of the detection zone 4 m RS4 4 115 116 For these cases Leuze lumiflex offers suitable safety interlocking devices safety switches with and without guard locking The ROTOSCAN RS4 4 corresponds to safety category 3 in accordance with EN 954 1 In order to maintain this level of safety all elements in the safety chain up to and including the stopping of the dangerous movement must be selected and set up accordingly Only electrical specialists are allowed to work on electrical systems The 24 V DC power supply 20 30 must be pro vided by way of a safety transformer in accordance with IEC 742 The same requirements a
26. bH Co Ehrenbreitsteiner Str 44 D 80993 Munich Germany RS4 4 105 2 1 2 2 Approvals and Certificates Manufacturer Certification Approval and Declaration of EC Conformity EC prototype testing in accordance with DIN EN 61496 1 and IEC 61496 3 BIA Berufsgenossenschaftliches Institut f r Arbeitssicherheit Trade Association Institute for Occupational Safety 53757 Sankt Augustin Germany Wan CE RS4 4 Leuze BIA Pril und Zoning le a im BG PAUFZERT kan tr European non bod i Idantificatiar embar G11 Haagrreectend lar gaeerticten Tamga Kera org amery ri for heime ri che Doreen insimran Here dad eee a Ben tere Fuer Berulegerumsers ieee EC Type Test Certificate m ui peices Lauer lernt JaW amp Ca Ehia Sar 44 GG Binctean Laure werte inah amp Cu bn chet Brio 8 277 Omen Ten Fat pi Ta ur ee Gacy Drs si bee Mioa ga 106 Prog SOLIH SOON Feier freee Ciam semine mieche marp eri Tyan F Larrean Acie teri popes ee ine Hep Im ATs niem POY FOTOS Addl dip pr ol Maney and ride ran fr werner erster IO am ana Temting breme mr Herman DF BY 1400 1 On ae EE 1408 2 02 01 DW WOE NOT C10 DR OE DT A 1 1 Dei Aca Pag I 10 88 DN ae Par J HE Cra deers Anfgrderergpeilame comi ia DP WE EIT aag in metgar ibia fi catagory Jf HH CH EH im imran mi abet For Murfren m ma on le eee ne e baha me eine BA mr b erbia aapa pone Goby pirla ho open in ann
27. ccording to EN 954 1 Type 3 according to DIN EN 61496 1 IEC 61496 3 Start The startup testing and the start inter lock can be set separately Restart Adjustable from 160 ms to 10 s or manual RS4 4 Leuze 15 3 Detection Zone Additions Addition for 81mm deactivated dust suppression Addition for 81 mm for a detection zone size activated dust lt 3 5 m suppression 98 mm for a detection zone size gt 3 5m Addition if retro reflectors or very shiny surfaces such as certain metals or ceramics are present in the scanning plane 0 mm more than 1 2 m behind the detection zone line 110 mm in the detection zone or up to 1 2 m behind detection zone line 15 4 Warning Field Detection range 0 15m Reflectance factor min 20 Object size 150 x 150 mm Response time Double evaluation 80 ms corre sponds to 2 scans up to 16 scans can be selected 640 ms Number of warning fields 4 selectable via switch inputs Output PNP transistor output max 100 mA RS4 4 191 192 15 5 Contour Measurement Measurement 0 50 m for RS4 4 range Reflectance factor min 20 Object size Output Serial interface RS 232 10 m RS 422 50 m Radial resolution 5mm Lateral resolution 0 36 15 6 Electrical Power Supply Supply voltage 24 VDC 20 30 supply according to IEC 742 with saf
28. cles According to IEC 61496 3 the following formulas apply for calculating the safety distance S Vmax X T SanHALT Vuaxetr Maximum speed of the AGV in mm s Response time of the scanner and the AGV ins SANHALT Braking distance of the AGV until standstill in mm Direction related minimum depth of the detection zone and additions The depth of the detection zone in the direction of travel with respect to the distance between the edge of the roadway and the boundary of the detection zone is calculated according to the following formula RS4 4 153 154 St Vmaxrtr X Tscan Tete Sannar X Lannact Zces ST Depth of the detection zone in the direction of travel in mm VMAXFTF Maximum speed of the AGV in mm s Tscan Response time of the scanner in s TFTF Response time ofthe AGV ins LaNHALT Factor for wear and tear on the brakes ZGES Sum of the system specific and application specific additions in mm Zces Zsm ZREFL Zaruss Zau Zsm Measurement error of the scanner in mm Zp er Addition for considering reflectors in mm Z russ Addition for inadequate floor clearance by the AGV in mm Zau Application specific addition in mm 6 5 8 2 Maximum range of the detection zone 2 2 MAX ST SpgpiFF Spoirr Geoirr Zs SMAX Maximum range of the detection zone in mm St Depth of the detection zone in the direction of travel in mm Sepirr Largest width of
29. ction High speed FP2 2 m before the FP1 Low speed curve FP3 Beginning of the FP2 Steering lock curve curve FP1 Straight section FP3 Steering lock straight FP 1 x detection zone 1 x warning field If the AGV is controlled by a PLC for instance which corre sponds to Cat 3 or higher according to DIN EN 954 1 the previous field pair FP can be deactivated immediately after the next field pair has been activated with no time delay This results in a faster switching sequence The applicable safety guidelines and standards as well as the operating instructions for the systems must be strictly com plied with RS4 4 Leuze Leuze a AGV at high speed AGV at low speed c AGV curving to the left at low speed d AGV at high speed o Il Fig 20 Example of a field pair changeover for an AGV on a curved route RS4 4 161 I a AGV driving fast b AGV driving slowly c AGV maneuvering Q Q d Loading ramp Fig 21 Example of a field pair changeover an AGV reduc ing its speed 162 RS4 4 Leuze 8 Functions of the ROTOSCAN RS4
30. e Allows lateral tilting of up to approx 9 to either side from the midpoint setting infinitely adjustable within this range Enables quick replacement of the scanner without requir ing realignment Please refer to the inside back cover to find out which parts and dimensions are required for mounting 6 2 Mounting Adjacent Sensors In order to prevent erroneous switch offs caused by mutual influence between adjacent sensors the following points must be taken into consideration 6 2 1 Direct irradiation To prevent the direct irradiation of outside light by a second sensor of the same type laser light wavelength 905 nm a shield plate must be installed in the scanning plane It is sufficient to place this shield at the height of the scanner window and flush with the front edge of the housing Leuze RS4 4 127 128 6 2 2 ROTOSCAN RS4 4 Machine view from above Detection zones Shield plate flush with the housing Qa0co0m Fig 6 Shielding to prevent direct irradiation Indirect irradiation If multiple laser supported systems are in use the mutual influence of beams reflected by objects in the area cannot be completely excluded This effect can easily be prevented by staggering the levels at which the laser devices are mounted A height differential of 100 mm based on a distance of 4 m between objects is sufficient 100 mm Fig 7 Staggered mounti
31. e Balluff Asia Pte Ltd Blk 1004 Toa Payoh Industrial Parc Lorong 8 03 1489 Singapore 319076 Tel Int 65 252 43 84 Fax Int 65 252 90 60 E mail balluff balluff com sg Slovak Republic SCHMACHTL SK s r o Bardosova 2 A SK 83309 Bratislava Tel Int 421 0 7 54 77 74 84 Fax Int 421 0 7 54 77 74 91 E mail office schmachtl sk http www schmachtl sk Slovenia Tipteh d o o Cesta v Gorice 40 SLO 1111 Ljubljana Tel Int 386 0 61 200 51 50 Fax Int 386 0 61 200 51 51 E mail info tipteh si http www Tipteh si J Thailand Industrial Electrical Co Ltd 85 2 85 3 Soi Sot Phin San Rang Nam Road Rajthevee T 10400 Bangkok Thailand Tel Int 66 0 2 642 67 00 Fax Int 66 0 2 642 42 50 Turkey MEGA Teknik elek San ve Tic Ltd Perpa Ticaret Is Merkezi A Blok Kat 2 No 9 0026 80270 TR 80270 Okmeydani Istanbul Tel Int 90 0 212 320 04 11 Fax Int 90 0 212 320 04 16 E mail mega netone com tr http www leuze de United States Canada Mexico Leuze Lumiflex Inc 300 Roundhill Drive Unit 4 USA Rockaway NJ 07866 Tel Int 1 0 973 586 0100 Fax Int 1 0 973 586 3230 E mail info leuze lumiflex com http www leuze lumiflex com x Leuze Ma bilder des ROTOSCAN RS4 Dimensional Drawings of the ROTOSCAN RS4 Seitenansicht Side view ca 202 2 Vord
32. e writ Fenis majeri The ram ei erh we ee me bed does or the eria LTEC Putter pararon mp bed jeen oe Sp ame ai Phorm ja desiris mai De ni Curae eT Faa cee ce Foe Bag EG TI Pag B37 hi Jarir iaren Abm heeii 111 Pim O Ea aa EN Leuze lumiflex ENE Get Sore ih Be En RS4 4 107 108 EC Declaration of Conformity according to EC Machinery Directive 98 37 EU Annex II C We herewith declare Leuze lumiflex GmbH Co Ehrenbreitsteiner StraBe 44 D 80993 M nchen that the following described safety components in our delivered version complies with the appropriate basic safety and health requirements of the EC Machinery Directive 98 37 EU based on its design and type as brought into circulation by us In case of alteration of the safety components not agreed upon by us this declaration will lose its validity Description of the safety component Laserscanner for safety at work and measurement Safety component Type ROTOSCAN RS4 4 Serial number see type plate Safety category AOPDDR type 3 Safety function electronic sensitive protective device Applicable directives and standards EC machinery directive 98 37 EU EMC directive 89 336 EWG DIN EN 60204 1 06 93 DIN EN 61496 1 06 98 IEC 61496 3 02 01 DIN EN 954 1 03 97 DIN V VDE 0801 01 90 and modification A1 10 94 EN 50082 2 02 96 EN 50081 2 03 94 DIN 40839 Teil 1 10 92 DIN 40839 Teil 2 12 91 draft Notified body according to annex VII Berufsgenossenschaft
33. ed in order to safeguard access from the side and directly in front of the vehicle If is it not possible to completely safeguard the contour of the vehicle including its trailer and the dimensions of its load while making curves additional protective devices such as switch strips must be attached to the side of the vehicle A minimum safety distance Sag of 500 mm to the side of the vehicle must be present on both sides A one sided minimum safety distance is admissible in certain excep tional cases The specifications of DIN EN 1525 must be complied with The basic value of the detection zone width for an AGV corresponds to the maximum vehicle width including the trailer and the dimensions of the load plus the detection zone additions Zs Furthermore the greatest possible lateral shift of the AGV while making curves must be con sidered when defining detection zones If the ROTOSCAN RS4 4 is mounted on vehicles the mounting especially the angle of inclination the vehi cles braking power and if applicable play in the vehicle guidance the difference between the optimum and actual line of guidance must be regularly checked in order to guarantee the reliability of detection RS4 4 121 SF1 SF2 WF1 WF2 122 5 Applications for the ROTOSCAN RS4 4 Due to its continuous coverage of the area its wide range and the ability to select among four field pairs the ROTOSCAN RS4 4 is able to handle even difficult applications
34. els mounting niches and other machine elements may not in any way impair the field of view of the scanner If there are areas of shadow caused by fixed obstacles that were defined as part of the detection zone boundary these must be safeguarded e g by safety grids in order to prevent people standing in them from being able to suddenly enter the detection zone This point must be taken into account in the hazard analysis of the machine or system Be sure that there are no retro reflectors or highly reflec tive surfaces made of metal or ceramic in the area of the detection zone and at the height of the scanning plane Such objects can cause measurement errors In order to ensure a consistent detection height at every point of the detection zone the scanner and hence the scanning plane must be placed in a horizontal position If the function restart interlock is available the restart button must be placed outside of the detection zone ata position from which the entire danger zone can be viewed RS4 4 Leuze 6 1 Attachment and Dimensions For attaching the ROTOSCAN RS4 4 four drill holes are located at the back of the unit The mounting set RS4 MS is available as an accessory It offers the following benefits to the user Speeds up the mounting process by providing screws that are accessible from the front Allows vertical inclinations of up to 9 either up or down infinitely adjustable within this rang
35. eransicht Front view R Kleinster Biegeradius 50 mm Lumiflex Zubeh r Smallest bending radius 50 mm Lumiflex accessory a Drehspiegelachse Axis of the rotating mirror b Scanebene Scanning plane Alle MaBangaben in mm All measurements given in mm Leuze lumiflex Ma bilder des Montagesystems Dimensional Drawings of the Mounting System Seitenansicht Side view Scannermontage fl che Scanner mounting surface Teile bersicht Overview of parts Alle Ma angaben in mm All measurements given in mm Leuze lumiflex Leuze lumiflex GmbH Co Ehrenbreitsteiner Str 44 D 80993 M nchen Tel 49 0 89 1 43 65 0 Fax 49 0 89 1 43 65 190 e mail lumiflex leuze de http www leuze de
36. es the up time of the AGV since it prevents the surrounding contour from being detected as relevant for generating a switch off signal due to a measurement error Furthermore the dust algorithm of the RS4 4 can be implemented if floating particles may be present in the area This algorithm can be activated in the user program RS4soft and prevents the AGV from being switched off unintentionally Please refer to Chapter 6 3 5 RS4 4 Leuze Leuze 6 5 7 6 5 8 6 5 8 1 If the danger zone analysis allows a multiple evaluation detection errors caused by floating particles can be decreased The number of evaluations that is decisive for the response time of the scanner Tscan and thus also requires a larger detection zone can be set in the user program RS4soft Restart At least 2 seconds must elapse following the release of a violated detection zone before the AGV is allowed to start up again in accordance with DIN EN 1525 The restart can be initiated either manually or automatically In case of automatic restart the delay time of up to 10 s can be set in advance using the program RS4soft If a restart button is provided it must be mounted outside the danger zone at a position from which the entire danger zone can be viewed Calculating the dimensions of the detection zone for an AGV Application Following are the specifications and calculation examples for the mobile safeguarding of automatic guided vehi
37. ese hazardous areas it is necessary to imple ment a safeguarding system that adapts to the changing conditions For this purpose the ROTOSCAN RS4 4 provides four field pairs each consisting of one detection zone and one warning field which the user can select among and freely configure This feature allows the ROTOSCAN RS4 4 to fulfill the diverse safeguarding demands of an extremely wide range of applications The necessary contours of the field pair can be set in the user friendly software program RS4soft To activate the field pairs apply 24 V to the corresponding inputs provided at connector X1 on the scanner Please refer to Chapters 8 2 and 10 for more detailed information on wiring the scanner Note the following points if the ROTOSCAN RS4 4 is going to be started up again or if you are going to switch among different field pairs When selecting the field pair for the startup pay careful attention to the danger zones that are valid at the moment of startup Always switch on the second field pair before switching off the first field pair The changeover must take place within 1 s Atno time during the switching process may all of the field pairs be deactivated simultaneously e Only one field pair may be active at any one time except during the changeover process e The sequence of the activated monitoring fields must ensure that the application specific minimum detection zone size is met at all ti
38. ety transformer or comparable for DC DC converters Overload protec tion Provide by 1 25 A semi delay fuse in the electronics cabinet Current consump tion approx 300 mA use a power supply with 2 5 A Power consump tion 8 W at 24 V plus the output load Excess voltage protection Over voltage protection with safe end cut off Voltage drops In accordance with DIN EN 61496 1 Non fused earth conductor Connection not allowed RS4 4 Leuze Inputs Restart Reset For connecting a command device for operating mode with restart inter lock and or device reset dynamically monitored 24 VDC optically isolated Field pair changeover For selecting among 4 field pairs via 4 control cables with internal monitor ing field pair 1 detection zone and 1 warning field 24 VDC optically isolated Signal definition High logical 1 Low logical 0 16 30 V lt 3 V 15 8 Outputs Detection zone 2x failsafe semiconductor output PNP max 250 mA short circuit monitored overload protected Warning field contamination error PNP transistor output max 100 mA Load characteris tics maximum Low pass behavior frequency fy lt 1 kHz Choad lt 100 nF Level high OSSD active Level low OSSD inactive Level high alarm active Level low alarm inactive Up 3 2 V lt 2 0V Up 4V lt 2 0V
39. g to be stored Mouse RS4 4 Leuze Leuze 11 2 e RS 232 serial interface or alternatively RS 422 interface Microsoft Windows 95 98 NT 2000 Installing RS4soft and Starting Up the ROTOSCAN RS4 4 First run the installation program Setup exe in order to install the program on the PC Start the software by calling up the program Connect the control cable and the PC cable Then apply the supply voltage to the ROTOSCAN RS4 4 The scanner will now attempt to communicate with the PC this process is displayed on the screen Ifthe connection between the ROTOSCAN RS4 4 and the PC was successful you can enter the appropriate pass word and then change the parameters and field pairs of the ROTOSCAN RS4 4 to meet the needs of the particu lar application The standard password to be entered in the autho rized level Authorized Customer of the ROTOSCAN RS4 4 is RS4LEUZE Please note that the password must be changed following the initial configuration of the scanner and that the data carrier must be kept locked up in a secure location The ROTOSCAN RS4 4 is ready for operation once the scanner settings and detection zone configurations have been transferred Every ROTOSCAN RS4 4 is factory equipped with the maxi mum safety parameters For this reason first the device set tings and then the detection zones must be adapted to the requirements of the application before the scanne
40. ge from overload OSSD 1 X1 12 and OSSD 2 X1 11 When the detection zone is interrupted the two semiconduc tor outputs switch off and by way of elements such as posi tively guided relays cause the monitored machine s to shut down It is not admissible to control different safety circuits with a single OSSD Connected loads must exhibit a low pass behavior in accordance with the plausibility control conducted by the scanner fg lt 1 kHz C lt 100 nF The OSSDs are equipped with an internal electronic current limit to protect them against damage from overload For connection examples see Chapter 9 Data Communication The interface X2 allows the ROTOSCAN RS4 4 to support two types of connections to the PC or laptop Communication via the X2 connector in RS232 mode does not require any further bridging To enable data transfer in RS 422 mode connect pin 5 with pin 6 This scanner auto matically adjusts itself to the appropriate transfer type and baud rate The interface X2 is used for configuring and setting parameters for the ROTOSCAN RS4 4 e transferring the measurement data e evaluating the coordinates during parameter setting e g for AGV applications e diagnosing and or localizing faults RS4 4 165 166 The interface X2 may not be used during guard operation It is intended solely for use in configuring and setting parame ters for the ROTOSCAN RS4 4 which in turn stores the data received f
41. h and then automatically bring the vehicle to a halt The operating mode with restart interlock must be selected RS4 4 Leuze The demands placed on the geometrical shape of the detection zone are determined by the vehicle width speed stopping distance and response time Here as well factors such as additions in the direction of travel for tolerances in the measurement value and reduced braking power due to wear and tear must be taken into consideration 5 4 Other Possible Applications Object and contour measurement e Logistics counting measuring controlling e Access control detecting or counting people e Projection control e g in fully automatic parking ramps or lots Safeguarding or monitoring enclosed spaces and many more Leuze RS4 4 125 126 Information for Planning and Mounting It is essential that the following key points be complied with so that the ROTOSCAN RS4 4 can provide optimum perfor mance The ROTOSCAN RS4 4 must be placed so that areas of access to the danger zone being monitored are com pletely covered by the detection zone The mounting position of the scanner should provide protection from humidity dirt and extreme temperatures below 0 C or over 50 C The mounting position must be selected in such a way as to minimize the possibility of mechanical damage Additional protective cover panels or safety bars must be installed at exposed positions Reinforcements cover pan
42. in length 1000 200 mm in diameter reflectance factor approx 1 8 RS4 4 Leuze 14 1 Coding of the Control Cable X1 The following table defines the pin assignments for the 12 pin connector cable Pin No Color Code Meaning 1 blk GND 2 blu Restart 3 rd UB 4 or FP 1 5 ye Alarm 6 grn FP 2 7 vio FP 3 8 gray FP 4 9 n c 10 n c 11 wh OSSD 1 12 wh blk OSSD 2 13 n c 14 wh br 15 br Leuze RS4 4 189 15 15 1 15 2 Detection Zone Technical Specifications Test Pieces The following test pieces are defined for the purpose of controlling the effectiveness of the monitoring function by the detection zones Cylinder 500 mm in length 70 mm in diameter reflectance factor 1 8 0 2 for use in an upright position Cylinder 1000 mm in length 200 mm in diameter reflectance factor 1 8 0 2 for use in a prone position e g for AGV applications Detection range 0 4m Reflectance factor min 1 8 Object size diameter 70 mm cylindrical test piece Response time Double evaluation 80 ms corre sponds to 2 scans up to 16 scans can be selected 640 ms Number of detec 4 changeover via switch inputs tion zones Output 2 failsafe PNP transistor outputs 24 V 250 mA Safety category Specification class 4 in accordance with DIN V 19250 single fault proof Category 3 a
43. in reference to detection zones that cover an angle range of 180 If it is not possible to comply with these values or if unmonitored zones result due to the shape or movement of the machine additional safety measures must be taken The effectiveness of the detection zones can be optimized by changing the depth at which the scanner is installed or by adjusting the angle range e g from 180 to 190 If after such changes have been made the danger zone analysis indicates that the dead zone is covered by the detection zone additional safeguarding measures need not be taken for this zone For information on how to configure the scanner in this way please refer to the RS4soft user manual ROTOSCAN RS4 4 f Lateral access safe Machine guarding if needed Lateral unmonitored zones Detection zone Maximum recessing 40 mm Front machine edge Installation niche Detection zone addition ea0o0w a a uu NIQ oui Fig 11 Recessed installation within the machine contour RS4 4 Leuze Unmonitored zones require the use of restart interlock If it is not possible to mount the ROTOSCAN RS4 4 directly onto the machine it can also be positioned lateral to or across from the machine 6 4 4 3 External mounting lateral to or across from the machine d a ROTOSCAN RS4 4 b Machine Vee c Distance max 35 mm ee d Detection zone Fig 12 Lateral external scanner mount
44. ing without an undercut If the machine contour runs parallel to the 90 beam of the laterally placed RS4 4 the distance between the detection zone boundary and the machine may not exceed 35 mm ge a UMN le EP a ROTOSCAN RS4 4 b Machine 1 a c Minimum distance from l ae 1 4 E the environment p d Detection zone u Z Required detection zone eed additions Zumin Minimum depth of the pase undercut if m Fig 13 Mounting the scanner across from the machine with an undercut Leuze RS4 4 137 6 4 5 Additions The axis of the rotating mirror midpoint of the scanner is of critical importance when configuring the detection zones This axis is assigned a value of 67 mm from the front edge of the scanner when calculating detection zones Add 81 mm or 98 mm for the maximum radial measurement error as described in Chapter 6 3 5 Add an addition Zpgr as described in Chapter 6 3 5 if reflectors could be present in the area Please note that safety additions must principally be added to the safety distance throughout the entire detection zone In other words additions may not be added to just one side or only to certain sections Please consult the operating instructions provided by the machine or system manufacturer 138 RS4 4 Leuze Leuze 6 4 6 6 4 7 System availability There must be a buffer distance of 81 mm between the surrounding contour and the detec
45. ject with a diameter of 100 mm The maximum available range for an object with a diameter of 150 mm is 15 meters Both of these figures assume a reflectance factor of 20 resolution in mm 1000 500 200 150 7 7 100 Ha HH b 80 ve 60 40 20 1 gt 0 0 2 0 5 1 2 4 6 10 20 50 100 distance in m a Detection zone b Warning field Fig 8 Detecting objects in the detection zone and in the warning field Leuze RS4 4 131 132 Reflectors 6 3 4 Measurement field range The maximum distance for contour measurement at a reflectance factor of 20 is 50 m Reflectance factor 10000 1000 White plaster 1 Writing paper Gray cardboard Black corduroy 6 3 5 00 10 1 8 1 0 1 4 10 100 distance m Fig 9 Detection of objects depending on the reflectance factor Required detection zone additions Z The ROTOSCAN RS4 4 is equipped with a selectable dust algorithm to ensure optimum freedom from interference The following detection zone additions must be taken into account Addition Zgy for 81mm deacti
46. la Leuze lumiflex ROTOSCAN RS4 4 Laser Scanner for Personnel Protection and Measurement Tasks Technical Description Subject to technical changes 50034330 08 2001 TABLE OF CONTENTS 2 1 2 2 2 3 2 4 3 1 3 2 4 1 4 2 4 3 4 4 4 5 4 6 5 1 5 2 5 3 5 4 6 1 6 2 6 2 1 6 2 2 6 3 6 3 1 6 3 2 6 3 3 6 3 4 6 3 5 6 4 6 4 1 6 4 2 6 4 3 6 4 4 6 4 4 1 6 4 4 2 6 4 4 3 6 4 5 6 4 6 6 4 7 6 4 8 6 4 8 1 6 4 8 2 6 4 8 3 6 4 8 4 6 4 8 5 About This Technical Description Approvals and Certificates uunnesnnansnsnnunennunnanannanunnnnnnnnnn 106 Manufacturer Certification Approval and Declaration of EC Conformity Specialized Technical Terms and Abbreviations Guidelines and Standards System Overview Brief Description and Functional Principle of the ROTOSCAN RS4 4 Special Features of the ROTOSCAN RS4 4 Safety Precautions and Intended Use General Safety Information Operating Conditions and Proper Use Restrictions for Use oo eects u 117 General Information On Defining the Contours of Detection Zones 118 Additional Safety Precautions for Stationary Use unee 120 Additional Safety Precautions for Mobile Use uruunuene nennen 121 Applications for the ROTOSCAN RS4 4 qu 122 Stationary Safeguarding of Danger Zones Mobile Safeguarding of Automatic Guided Vehicles Protecting Transporter Trolleys against Collisi
47. lemented not only on machines and systems stationary safeguarding of danger zones but also on vehicles mobile safeguarding of transport vehicles Due to its wide range of measurement and its non contact electro sensitive measurement principle the ROTOSCAN RS4 4 can be effectively used as a protective device for virtually any application RS4 4 113 114 3 2 Special Features of the ROTOSCAN RS4 4 Four freely programmable detection zones up to a maximum of 4 m Four freely programmable warning fields up to a maximum of 15 m Expanded monitoring range of up to 190 Compact design W x D x H 140 mm x 135 mm x 155 mm Low weight 2 kg Low power requirements 300 mA plus the load at the outputs max 25 W Two types of interfaces at one Sub D jack RS232 and RS422 User friendly software RS4 4 Leuze Leuze 4 1 4 2 Safety Precautions and Intended Use General Safety Information Leuze lumiflex products are developed and manufactured with careful attention to recognized codes of engineering practice However the protective function of the equipment can be impaired if the devices are used improperly or for any purpose other than the intended purpose Such instances can jeopardize the health and lives of the personnel located in the area of the machine or system Caution Laser radiation The ROTOSCAN RS4 4 is a laser device belonging to laser class 1 The valid legal and local regulations for oper
48. ler must ensure that the mounting position of the ROTOSCAN RS4 4 allows the danger zone to be monitored completely If a restart button is being used make certain that the entire detection zone area can be viewed by the person pressing the button Refer to the safety precautions in Chapter 4 5 with regard to lateral access into the danger zone Mounting height According to DIN EN 999 the lowest admissible height of the scanning plane for people as measured from the base level is calculated according to the following formula Hyin 15 d 50 mm Hain Lowest admissible scanning plane from the base level d Resolution of the scanner in mm object size 70 mm throughout the detection zone The admissible height range of the RS4 4 scanning plane lies between 300 and 1000 mm above the base level If the application requires a scanning plane higher than 300 mm or if children have access to the area the analysis of the danger zone must consider the hazard caused by persons crawling below the scanning plane Mounting recommendations for preventing unmonitored zones Unmonitored zones can result if the scanner is mounted onto a protruding attachment or if the contour of the machine system is varied in depth RS4 4 Leuze Leuze 6 4 4 1 Recessed installation undercut under the machine table The undercut must be at least as deep as the zone not monitored by the detection zone lateral to and in front of the sca
49. liches Institut f r Arbeitssicherheit BIA Alte HeerstraBe 111 53757 Sankt Augustin Charged to do EC type examination Examination certificate no 2001 1026 CE marking The compliance with the directives 73 23 EWG and 89 336 EWG is certified by the CE mark Munich April 12 2001 A L Beilke Managing Director Leuze lumiflex GmbH Co Postbank M nchen BLZ 700 100 80 185 734 807 Kommanditgeselischaft Sitz M nchen Amtsgericht M nchen Ehrenbreitsteiner Stra e 44 Dresdner Bank BLZ 700 800 00 847 690 100 HRA 40417 pers haftende Gesellschaft Leuze electronic D 80993 M nchen Deutsche Bank BLZ 700 700 10 1972 900 Gesch ftsf hrungs GmbH Owen Amtsgericht Kirchheim Teck Telefon 089 14365 0 UST ID Nr DE 129 999 527 HRB 550 Gesch ftsf rer Hans Jochen Beilke Michael Heyne Telefax 089 143 65 190 Vorsitzender des Verwaltungsrats Meinert Hahnemann E Mail lumitiex leuze de internet http Awww leuze de RS4 4 Leuze 2 3 Specialized Technical Terms and Abbreviations AGV Automatic guided vehicle AOPD Active optoelectronic protective device AOPDDR Active optoelectronic protective device responsive to diffuse reflection BWS See ESPE ESPE Electro sensitive protecting equipment FTF See AGV N O Normal open contact OSSD Output signal switching device PC Personal computer SF Detection zone Reset Reset of the ROTOSCAN RS4 4 RS 232 RS 232 interface RS
50. m RS4 4 119 120 The effectiveness of the switch off function must be tested for the detection zone contours along the entire driving route during the initial startup and following any changes made to an AGV In the event that there is insufficient room available to allow the full dimensions of a detection zone additional safety measures e g safety grids must be installed Following each definition of and change to the detection zones the configuration must be checked to see whether the possibility of people standing in the danger zone as well as any barriers provided have been considered by an appropriate layout of the detection zone s 4 5 Additional Safety Precautions for Stationary Use If the danger zone can be accessed from the side and if the detection zone cannot be extended sufficiently in this direction additional safety measures e g safety fences must be installed We recommended marking the contour of the detection zone on the floor by painting a colored line or applying col ored adhesive tape Check the mounting regularly in particular the angle of inclination in order to guarantee the reliability of detec tion RS4 4 Leuze 4 6 Additional Safety Precautions for Mobile Use Leuze There are additional requirements for the use of scanners on automatic guided vehicles AGV and transporter trolleys according to DIN EN 1525 If possible expanded detection zones to each side should be provid
51. m at a cable cross section of 0 5 mm shielded Connect shield with PE to the electronics cabinet only Data cable length X2 RS 232 Max 10 m Data cable length X2 RS 422 Max 50 m twisted pair Transmitter Infrared laser diode A 905 nm Housing Die cast aluminum plastic Weight Approx 2 kg Dynamic stress across 3 axes In accordance with IEC 60068 Part 2 6 10 150 Hz max 5 G RS4 4 195 196 Continuous shock across 3 axes In accordance with IEC 60068 Part 2 29 10 G 16 ms Interference immunity In accordance with DIN EN 61496 1 corresponding to the requirements for Type 4 in addition in accordance with DIN 40839 1 3 Test pulses 1 2 3a 3b and 5 not for use for vehicles with internal combustion engines Rotating mirror drive Brushless direct current motor Rotating mirror bearing Maintenance free ball bearing RS4 4 Leuze Leuze 16 Error Codes and Causes Lo Description Description cat ion 102 Processing of com Invalid command mands processing of received messages 103 Control of command Invalid command processing received 104 Processing of com Invalid command mands processing of received configuration 105 Processing of com Command not allowed mands generation of at current level of output messages authorization 201 Processing of the re
52. mes RS4 4 Leuze e It must be impossible for changeover signals to change simultaneously as the result of a systematic error This is achieved by using independent circuits e g separately actuated binary switches under consideration of the switching behavior described in this chapter Please see the assignments of connections and or interfaces in Chapter 10 5 7 1 Sequence of a Field Pair Changeover from FP 2 to FP 4 Example Field pair 2 X1 6 is the active field pair Field pair 4 X1 8 is then activated in addition e In this state both field pair monitors are switched on Field pair 2 X1 6 must be switched off within one second Field pair 4 X1 8 is now active 7 2 Practical AGV Application Example The following example shows the sequence of field pair changeovers for an efficiently implemented AGV under consideration of the ambient conditions Please observe the particular danger zone analysis for each detection zone in combination with the corresponding route segments Also note the safe sequences of changeovers and starts For information on programming the startup detection zones detection zones enabled for starting up the scanner and on determining the sequence in which the detection zones are to be activated please see the RS4soft user manual Leuze RS4 4 159 160 Activat AGV Position Deacti AGV Steering ing an vating Position FP an FP FP1 Straight se
53. n zone This specification is limited due to such factors as uneven floors or the deflection of the springs in the AGV The maximum mounting height must be selected so that an object cylinder with a diameter of 200 mm in the prone position is reliably detected see DIN EN 1525 The de tection must be tested at the position of maximum depth within the detection zone For AGV applications sufficient resolution of detection is achieved when an object upright cylinder with a diameter of 70 mm can be detected through out the detection zone Leuze RS4 4 147 S D S E Zaes a al f i 67 mm 3 68 mm wr s 3 at 7 gt a ROTOSCAN RS4 4 b AGV c Height of the test piece max 200 mm d Recommended maximum height of the scanning plane 150 mm e Axis of the rotating mirror S Safety distance St Depth of the detection zone Zes Detection zone additions in the direction of travel Fig 16 Mounting height on an AGV Depending on the application further additions may be necessary Consult Chapter 6 5 5 for more information 148 RS4 4 Leuze Leuze 6 5 4 Recommendations for mounting in order to prevent unmonitored zones The creation of unmonitored zones is dependent upon the following factors e the vehicle width e the design of the vehicle e g attachments shape e the position of the scanner the installation depth the selected angle range If the detection zone
54. ng heights to prevent indirect irradiation RS4 4 Leuze Leuze 6 3 6 3 1 Information on Setting the Dimensions of Detection Zones The hazards caused by machines and systems place a wide range of demands on safety distances and detection zones which must be appropriately defined Methods for configuring detection zones using the PC With its user program RS4soft the ROTOSCAN RS4 4 offers various methods for setting the configurations of detection zones Numerical input A separate dialogue within the user program RS4soft allows the right left and front edges of the detection zone to be set using numerical values in mm Graphic input A separate dialogue within the user program RS4soft allows the basic contours of the detection zone to be entered The contours can be adapted infinitely to the desired size of the detection zone The following shapes are available e circle rectangle polygon In addition the contours can be infinitely varied by changing limiting and deleting partial segments as desired RS4 4 129 BLANK PAGE 130 RS4 4 Leuze 6 3 2 Range of the detection zone resolution The maximum range of the detection zone Syax may not exceed 4 m including the additions for an object with a diameter of 70 mm and a reflectance factor of 1 8 e g black corduroy 6 3 3 Range of the warning field resolution A maximum range of 10 meters is available for an ob
55. nner The minimum depth Zyy n is 135 mm If is it possible to recess the scanner this is allowed up to a maximum of 40 mm the depth of the undercut is reduced by the depth value of the recess If the mounting system is being used the necessary dimensions of the undercut depth must be increased accordingly see inside back cover The height of the undercut must be limited to prevent people from being able to step beneath it Machine side view Machine view from above m az f i x a SrH d I 1 b emis a e a j Sg iar IN l ss es l f Zumin S Zul wi ati sti i Y a ROTOSCAN RS4 4 S Safety distance b Machine Sg Entire width of the c Unmonitored zone detection zone d Detection zone St Depth of the e Height of the undercut detection zone f Mounting surface Z Detection zone g Scanning plane additions Zyumin Depth of the undercut Fig 10 Recessed scanner installation with undercut The additional safeguarding required for the particular application must be taken into account Please note that the undercut must cover any unmonitored zones RS4 4 135 136 6 4 4 2 Recessed installation within the machine contour Furthermore the scanner can be recessed into the contours of a machine The recess can have a depth of up to 40 mm without the mounting system RS4 MS or up to 65 mm with the mounting system RS4 MS This is
56. o leave the detection zone in the direction of the danger point For information on how to set the scanner appropriately please refer to RS4soft user manual Chapter 6 5 3 RS4 4 139 140 6 4 8 The restart button must be mounted so that the entire danger zone or detection zone area can be viewed from the operating position e itis not possible to directly step or reach into the danger zone or danger point from the operating position Calculating the detection zone dimensions for safeguarding an area According to IEC 61496 3 and DIN EN 999 the following formulas apply for calculating the safety distance and the minimum depth of the detection zone when the direction of approach runs parallel to the detection zone S KxT C Cmn 850 mm C 1200 mm 0 4 H Hmn 15 d 50 mm S Safety distance minimum distance from the danger zone to the point of detection to the plane of detection or to the detection zone in mm K Approach speed of a person or one of their body parts 1600 mm s in mm s T Lag time of the entire system response time and braking time until standstill in s C Safety related constant to consider entry into the danger zone before the protective device is triggered in mm CMiN Minimum value of the safety related constant 850 mm in mm H Height of the scanning plane from the reference point in mm Hin Minimum height of the scanning plane from the reference plane in mm
57. of field 2 Signal of a field monitoring light barrier monitoring light barrier data above upper limit 1906 Test of the external 1 Watchdog not watchdog enabling the OSSDs 1906 Test of the external 2 Watchdog not switch watchdog ing off the OSSDs 1906 Test of the external 5 State of switch watchdog outputs inconsistent with that shown by the internal memory 1906 Test of the external 6 Watchdog not switch watchdog ing the cutoff path for the laser RS4 4 Leuze Leuze Lo Description N Description cat 0 ion 1907 Test of the external 4 Fault detected by watchdog watchdog watchdog switched off motor speed error 1907 Test of the external 7 Fault detected by watchdog watchdog watchdog switched off motor speed error 2002 Processing of the 12 Timeout while parameter commands transmitting the configuration data 2007 Test of received 18 Date of the currently parameter data transmitted detection zone is older than the date of the detection zone in the scanner 2201 Area monitoring 5 Number of measure ments in the scan too small due to motor speed error or switch off of the watchdog 2401 Reference measure 10 No distance value ment on the dark calculable for refer reference element ence measurement glare from another light source or motor speed error 2402 Reference measure 10 No distance value ment on the light calculable for
58. one has an additions area in which detection is not guaranteed under all conditions Please refer to Chapter 6 3 5 Read Chapters 6 4 6 and 6 5 6 for information on optimiz ing system availability The required safety distances must be taken into account when making detection zone configurations Safety dis tances are calculated according to formulas found in either the machine specific C standards or the general B standards IEC 61496 3 in combination with DIN EN 999 see Chapter 2 5 Tolerance fields and or additions see Chapters 6 7 and 8 must be taken into account After the detection zones have been set make a printout of the following information Detection zone contour with the X and Y coordinates Date Serial number of the scanner Name of the safety official When calculating the additions be sure to consider whether the dust algorithm is deactivated or activated see Chapter 6 3 5 When calculating the safety distances be sure to con sider all delay times such as the response time of the scanner response time of the control elements and brak ing times and or stopping times of the machine system or AGV Variations in delay time caused by factors such as reduced braking power must also be taken into consider ation The effectiveness of the switch off function must be tested along the defined contour of the detection zone during the initial startup and subsequent to any changes made to a machine or syste
59. onnecting the ROTOSCAN RS4 4 to a failsafe PLC with a safety level at least Cat 3 EN 954 and field pair changeover example In this connection example all of the switching functions are controlled directly by the PLC The changeover of 4 field pairs is achieved by way of the inputs X1 4 FP1 X1 6 FP2 X1 7 FP3 and X1 8 FP4 RS4 4 171 172 For applications in which the scanner must be separately enabled for its detection zone the signal can be given either by the machine controls or by connecting a command unit for restart interlock The ROTOSCAN RS4 4 itself must be configured using the RS4soft program so that the operating mode with restart interlock is active RS4 4 Leuze 10 Electrical Connection 10 1 Electrical Power Supply The ROTOSCAN RS4 4 requires a direct voltage of 24 V and 8 W of power plus the load at the outputs max 25 W The power must be supplied by way of an external 1 25 A semi time lag fuse e g in an electronics cabinet In addition a permanent current of 2 5 A must be ensured before safe guarding begins in order to guarantee that the fuse will be triggered in case of a fault In keeping with electrical safety requirements the power to the ROTOSCAN RS4 4 and all connected input and output circuits must be provided by a power supply unit with protec tive isolation from a safety transformer according to IEC 742 or comparable this also applies for the use of battery charger
60. ons Other Possible Applications Information for Planning and Mounting Attachment and Dimensions Mounting Adjacent Sensors Direct irradiation Indirect irradiation Information on Setting the Dimensions of Detection Zones 129 Methods for configuring detection zones using the PC a Range of the detection zone resolution Range of the warning field resolution Measurement field range Required detection zone additions Z Safeguarding Stationary Danger Zones Purpose of safeguarding Mounting position is Mo nting hight manaa cc ng Eh een Mounting recommendations for preventing unmonitored zones Recessed installation undercut under the machine table Recessed installation within the machine contour External mounting lateral to or across from the machine Additions System availability Restart interlock Calculating the detection zone dimensions for safeguarding an area Additions and minimum depth of the detection zone Maximum range of the detection zone Example for calculating the depth of a detection zone Example for calculating maximum detection zone range Example for calculating an undercut 6 5 6 5 1 6 5 2 6 5 3 6 5 4 6 5 5 6 5 6 6 5 7 6 5 8 6 5 8 1 6 5 8 2 6 5 8 3 6 5 8 4 7 1 7 2 8 1 8 2 8 3 8 4 8 5 9 1 9 2 9 3 10 10 1 10 2 10 3 10 4 10 5 11 11 1 11 2 11 3 11 4 1
61. ons The axis of the rotating mirror midpoint of the scanner is of critical importance when configuring the detection zones This axis is assigned a value of 67 mm from the front edge of the scanner when calculating detection zones Add 81 mm or 98 mm for the maximum radial measurement error as described in Chapter 6 3 5 Add an addition Zpgr as described in Chapter 6 3 5 if reflectors could be present in the area Without information from the AGV manufacturer take into account the wear and tear on the brakes by adding an addition Lannatt Of at least 10 of the braking distance as long as this is not already included in the braking distance SANHALT RS4 4 151 152 6 5 6 If there is a very small distance between the bottom of the AGV and the floor the detection difference between the leg and the toes must be considered in the calculation For AGVs with a floor clearance of less than 120 mm an addition Zaruss Must be added as shown in the following diagram for the direction of travel only Floor clearance in mm 120 100 80 60 40 20 0 O 20 40 60 80 100 120 140 160 Addition Zaryss in mm Fig 18 Diagram for calculating the addition to compensate for inadequate AGV floor clearance System availability There must be a buffer distance of 81 mm between the surrounding contour and the detection zone contour including the additions This distance increas
62. ored Suax V2454mm 3029mm Sgpicr 700 mm 2248 mm 81 mm 3029 mm SMAX 3899 mm 6 4 8 5 Example for calculating an undercut This example is based on the following application data Ifthe scanner is mounted across from the machine see Fig 13 the undercut dimension can be reduced by d 70 mm The formula Zumin Z 81 mm d results in a minimum undercut ZumIN 81 mm 81 mm 70 mm 92 mm It is not allowed for a person to be able to step beneath the undercut RS4 4 145 SOR RETTEN RESESSIE ONNA RES ER I ECT SS SENOS w SONS SAIN Ox SRK RS ROSSINS SEN Fig 15 The undercut 146 RS4 4 Leuze 6 5 Safeguarding Mobile Machines Please comply with the safety precautions in Chapter 4 6 5 1 Purpose of safeguarding to protect people when entering variable danger zones to protect objects located in the vehicle path e to protect the automatic guided vehicle and its load 6 5 2 Mounting position For the purpose of safeguarding the path of a vehicle the ROTOSCAN RS4 4 is mounted on the front of a vehicle in each direction of travel preferably in the center The scanner and hence the beam axis must be aligned horizontally in order to achieve a consistent scanning height Please comply with the safety precautions in Chapter 4 6 6 5 3 Mounting height As a rule the scanner should be mounted as low as possible in order to prevent people from crawling beneath the detec tio
63. ovided 4 4 General Information On Defining the Contours of Detection Zones 118 Shadow effects e g surfaces or areas located behind stationary objects must be considered As a rule insufficient safeguarding must be adequately supplemented by further safety measures such as barrier grids light curtains and the like It must be impossible to step behind the detection zone in the direction of the danger zone When setting the dimensions of the detection zone you must comply with the formulas cited in Chapters 6 4 8 and 6 5 8 Be sure to comply with higher level machine standards e g DIN EN 1525 if applicable These contain individual specifications for example on points of access to the danger zone and if applicable detection zone additions that must be given special con sideration They also provide information on how to measure safety distances at machines Detection zones with a radius smaller than 20 cm at or close to the scanner are not admissible 20 cm is the preset minimum contour When setting the dimensions of the detection zones please comply with the maximum angle error stated in the technical specifications Chapter 15 11 RS4 4 Leuze Leuze Pin shaped detection zone contours are not admissible since they do not guarantee a protective function For more detailed information consult the RS4soft user manual Chapters 6 5 3 and 7 0 Due to possible measurement errors every detection z
64. pply for all connected input and output circuits The supply voltage must be provided to the scanner by way of a separate branch using a 1 25 A semi delay fuse in the electronics cabinet Guard operation is allowed only after the PC cable X2 has been removed The corresponding connector on the scanner must be protected with the provided dummy connector This also applies for transport and storage The safety output is equipped with double OSSDs As a rule both OSSDs must always be connected into the stop circuit of the machine so that each of the two is indepen dently able to shut down the dangerous movement Do not use the alarm output pin 5 on X1 in order to switch safety relevant signals System tests of the scanner machine control compo nents and switch components may only be performed when they do not result in potential hazards for people Tampering with or making changes to the ROTOSCAN RS4 4 can result in the loss of the safety function RS4 4 Leuze Leuze 4 3 Only expert trained personnel is allowed to perform start up maintenance parameter settings or detection zone configurations Familiarity with the safety precautions in this Technical Description and in the operating instruc tions for the program RS4soft constitutes part of this expert knowledge The password required for configuring safety relevant settings must be kept in a secure location by the safety official Information
65. r is put into operation After configuring the scanner remove the PC inter face cable from position X2 slip on the dummy cap provided with delivery and screw it tight For a list of parameters please see the instructions for the user software RS4soft RS4 4 179 11 3 ROTOSCAN RS4 4 Status Indicator There are five LEDs located on the front of the scanner behind the cover with the matte finish These LEDs indicate the status of the ROTOSCAN RS4 4 ai Association to 1 function k E A Easy to interpret me VAN E 4 SE pictographs on the A ROTOSCAN RS4 4 explain the meaning of each of the LEDs Green Yellow Red Green Yellow ahwon nou ou uu Fig 26 The ROTOSCAN RS4 4 status indicator 180 RS4 4 Leuze Meaning of the individual LEDs LED Color Function Meaning Picto graph 1 green Sensor function is active ok active detection zone is clear 2 yellow Warning field is occupied A 3 red OSSD outputs are switched off Q IS J 4 green OSSD outputs are switched on ok 5 yellow constantly lit MN restart interlock g e flashing slowly 1 warning message approx 0 25 Hz HW e flashing quickly 1 error message approx 4 Hz Leuze RS4 4 181 182 11 4 Status information for the ROTOSCAN RS4 4 1 Scanner Display LED Numbers 23 4 5 Indicator Status 1 0 LED 3 The O
66. refer reference element ence measurement glare from another light source or motor speed error 2701 Processing of 1 Invalid diagnostics messages for system command received diagnostics RS4 4 199 200 Lo Description N Description cat 0 ion 2702 Processing of 3 Invalid diagnostics Requests for diagnos value requested tics data 2800 Processing of inputs 2 2 detection zones for detection zone active longer than 1 s changeover 2800 Processing of inputs 3 Changeover to new for detection zone detection zone after changeover parameter setting not allowed 2800 Processing of inputs 4 Invalid number of for detection zone detection zones changeover during operation selected 2800 Processing of inputs 6 No valid detection for detection zone zone info could be changeover gained from the data from the input cables 2801 Test of inputs for 1 Error during testing of detection zone inputs for detection changeover zone changeover 2802 Initialization of detec 3 Selected detection tion zone changeover zone not allowed during start after parameter setting 2802 Initialization of detec 4 Invalid number of tion zone changeover detection zones selected during Power On 2802 Initialization of detec 6 No valid detection tion zone changeover zone info could be gained from the data from the input cables 3016 Monitoring the access 11 Confirmed one shot autho
67. reports dirt buildup on the window even after cleaning the window glass must be replaced Disconnect the ROTOSCAN RS4 4 from its power supply before beginning with the replacement The exchange may be made only by trained specialist personnel in a clean environment preferably by the manufacturer or persons authorized by the manufacturer After the window has been replaced the window sensors must be adjusted using the RS4 configuration software RS4soft Because of the maintenance free technology of the ROTOSCAN RS4 4 it is not allowed to tamper with or make changes to the system Repairs may be made only by the manufacturer If the scanner signals an error at LED 5 helpful information can be queried from the user program A list of possible errors can be called up from the menu RS4 Diagnostics For fur ther information please see Chapter 16 If the scanner needs RS4 4 Leuze Leuze 12 1 12 2 12 3 to be sent back to us for repairs be sure that the connectors are screwed on or that the interfaces are adequately protect ed Please enclose a detailed description of the problem with the shipment List of Test Points e Check the front screen for dirt buildup clean if necessary Check the front screen for damage or scratches replace if necessary Make sure that the connector caps are firmly in place Make sure that the scanner mounting screws are firmly in place Make sure that the mounting sy
68. rization with one shot password password was entered incorrectly RS4 4 Leuze Leuze RS4 4 201 202 RS4 4 Leuze Sales and Service J Austria Ing Franz Schmachtl KG Postfach 362 A 4021 Linz Donau Tel Int 43 0 732 76 46 0 Fax Int 43 0 732 78 50 36 E mail office linz schmachtl at http www schmachtl at Argentina Nortecnica S R L 103 ex Heredia 638 1672 Villa Lynch Pcia de Buenos Aires Argentinien Tel Int 54 0 11 47 57 3129 Fax Int 54 0 11 47 57 1088 E mail awigutow nortecnica com ar Australia New Zealand Balluff Leuze Pty Ltd 2 Rocco Drive AUS Scoresby VIC 3179 Melbourne Australia Tel Int 61 0 3 97 64 23 66 Fax Int 61 0 3 97 53 32 62 E mail balluff_leuze matcol com au E Belgium Leuze electronic nv sa Steenweg Buda 50 B 1830 Machelen Tel Int 32 0 2 253 16 00 Fax Int 32 0 2 253 15 36 E mail Leuze info leuze be Brazil Leuze electronic Ltda Av Jurua 150 Alphaville BR 06455 010 Barueri S P Tel Int 55 0 11 41 95 61 34 Fax Int 55 0 11 41 95 61 77 E mail leuzeelectronic originet com br 32 Switzerland Leuze electronic AG Ruchstuckstrasse 25 CH 8306 Br ttisellen Tel Int 41 0 1 834 02 04 Fax Int 41 0 1 833 26 26 E mail leuze leuze ch http www leuze de Columbia Componentes Electronicas Ltda P O Box 478 CO Medellin Tel Int 57 0 4 351 10 49 Fa
69. rom the PC until the next change After configuring the scanner remove the interface cable slip on the provided dummy cap at position X2 and screw it tight Please note the pin assignments specified in Chapter 10 5 For additional information on using the X2 interface refer to the user manual for the program RS4soft RS4 4 Leuze Leuze 9 1 Integrating the ROTOSCAN RS4 4 into Machine Controls The following examples illustrate possibilities for integrating the ROTOSCAN RS4 4 into machine controls Once the operating voltage pin X1 3 UB has been con nected to pin X1 1 GND and a detection zone has been activated X1 4 X1 6 X1 7 or X1 8 the unit is ready for operation Please see the point Start detection zone in the user manual for the program RS4soft Integrating the ROTOSCAN RS4 4 with External Wiring with Relays and Quadruple Field Pair Changeover In this connection example the restart interlock function is provided by the connected command unit WA which applies the voltage of 24 V to the input RESTART X1 2 The ROTOSCAN RS4 4 itself must be configured using the RS4soft user software so that the operating mode with restart interlock is active RS4 4 167 168 24 V t GND PE a x y z Kl K an mala b c dlelf K3 K3 amp K1 Ka K2 K3 xy zz N DE re L 1
70. s If this time period is exceeded or if the previous field pair is switched off too soon the ROTOSCAN RS4 4 reports an error by switching off the two OSSDs and the alarm output In addition this state is shown in the indicator field on the scanner LED 3 middle and LED 5 right will both be lit up and flashing quickly at approx 4 Hz Alarm X1 5 As long as the output X1 5 is switched on the system signals trouble free operation If it is switched off the following states are reported e Interruption of the warning field is shown by the continu ously lit LED 2 in the indicator field of the scanner Warning state For instance the system may detect a slight dirt buildup on the window To signal this state LED 5 on the scanner flashes 0 25 Hz The user should clean the window before it gets dirtier waiting too long will cause a device error to be reported and the outputs OSSD 1 and OSSD 2 to be switched off e Device error Such as an erroneous reference measurement or extreme dirt buildup on the window This state is signaled by LED 5 flashing quickly 4 Hz RS4 4 Leuze Leuze 8 4 8 5 Both the reporting of a warning field interruption and the sig nalling of the warning and error state can be selected either separately or in combination This procedure is described in the user manual for the program RS4soft Output X1 5 is equipped with an internal electronic current limit to protect it against dama
71. s for AGV applications 10 2 Connecting the PC and Control Cables to the Scanner Three connector adapters with cable screw coupling are supplied with the ROTOSCAN RS4 4 Two of these are needed to accommodate the 9 pin Sub D connector and the 15 pin Sub D jack PC cable and control cable One adapter is intended to protect the interface X2 when the PC cable has been removed in accordance with enclosure rating IP 65 The cable screw couplings can accommodate cable diameters from 6 5 mm to 10 5 mm Leuze RS4 4 173 174 10 3 Jack X1 b Connector X2 a Fig 25 Preparing the connectors The connector adapter of control cable X1 must be connected with interface X1 and screwed tightly to the ROTOSCAN RS4 4 The connector adapter of cable X2 or else the X2 dummy cap without a cable must also be screwed tightly to the ROTOSCAN RS4 4 Threaded drill holes are located on the top of the scanner housing for this purpose Both of the connector adapters must be attached in order for the ROTOSCAN RS4 4 to comply with the enclosure rating IP 65 Please refer to the inside front cover of this technical descrip tion to see the layout of the connectors Connector Assembly Every connector adapter consists of the following individual parts Adapter with sealing ring and Phillips mounting screws e Cable screw coupling M16 with dummy plugs e Sub D9 connector and or Sub D15 connector each with a solder connection RS4 4
72. stem screws are firmly in place e Check that the scanner is in the correct mounting position and aligned properly Service Your partner in all matters of occupational safety Leuze lumiflex GmbH Co offers additional services Annual maintenance of the ROTOSCAN RS4 4 laser scanner Training seminars on the topic Safety at Work Training seminars on the topic Information about Laser Scanners Our customer service department is available to answer any questions you may have You can reach them by calling 49 89 143 65 122 Disposal Laser scanners that are no longer in use must be disposed of in an appropriate manner RS4 4 185 13 Delivery Package The basic unit consists of e ROTOSCAN RS4 4 e RS4 4 connector complete 15 pin interface X1 RS4 4 connector complete 9 pin interface X2 e 1 protective cover interface X2 e User program RS4soft on four diskettes e Technical description of the ROTOSCAN RS4 4 User manual for RS4soft 186 RS4 4 Leuze Leuze 14 Accessories Description Abbreviation Order No RS4 4 mounting system for attaching and aligning the RS4 4 RS4 MS 50033346 RS4 4 scanner adapter plate for existing mount ing systems RS4 Adap P 50035814 RS4 4 scanner window with seal RS4 Win 50035816 RS4 4 picto foil gt LEDs lt RS4 Foil PIC 50035855 RS4 4 connector complete 15 pin interface X1 RS4 MG
73. tain cases the concrete requirements of the application will necessitate the application of additional guidelines and standards Copies of safety standards can be purchased from the Beuth Publishing Company in Berlin Germany RS4 4 111 SF WF 112 3 1 System Overview Brief Description and Functional Principle of the ROTOSCAN RS4 4 The ROTOSCAN RS4 4 is an optical distance sensor that takes two dimensional measurements It could also be referred to as an optical area radar device The sensor uses a rotating deflecting unit to periodically emit light pulses within a working range of 190 If these pulses strike a person or an obstacle the reflected light is received and evaluated by the ROTOSCAN RS4 4 The scanner calculates the precise coordinates of the person or object based on the travel time of the reflected light and the current angle of the deflecting unit If the person or obstacle is within the bounds of a previously defined area called a detection zone a safety oriented switching function is per formed This switching function causes the semiconductor outputs to be switched off The safety oriented switching function cannot be reset until the detection zone is clear Depending on the operating mode the reset can be initiated either automatically or manually Detection zone max 4m Warning field max 15 m Maximum registration of measurement values max 50 m Detection zone programmed in the ROTOSCAN RS4 4
74. the detection zone in mm Gpp rr Largest width of the danger zone in mm Zs Sum of the system specific and application specific additions to the side in mm Zs Zsm ZReEFL Zau ZSM Measurement error of the scanner in mm Z er Addition to consider reflectors in mm see Chapter 6 3 5 Zau Application specific addition in mm RS4 4 Leuze ZGES an an ER f GBDIFF SBDIFF SMAX b AGV c Detection zone d Axis of the rotating mirror Ggpirr Largest width of the danger zone Sgpirr Largest width of the detection zone Smax Geometrical maximum distances xX Depth of the detection zone Zags Sum ofthe additions in the direction of travel ze Sum of the additions to the side Fig 19 Considering the maximum measurement distance for safeguarding AGVs In accordance with DIN EN 1525 a minimum safety distance of 0 5 m width between the vehicle and its environment must be maintained Leuze RS4 4 155 156 6 5 8 3 Example for calculating the depth of a detection zone This example is based on the following typical application data without access against the direction of travel and without retro reflectors Largest width of the 1400 mm danger zone from the axis of the rotating mirror GBDIFF Maximum speed VmAXFTF 1800 mm s Response time RS4 4 0 08 s selectable Tscan Response time AGV 0 1s controls TFTF Braking distance SA
75. tion zone contour includ ing the additions This distance increases the up time of the machine or system since it prevents the surrounding contour from being detected as relevant for generating a switch off signal If there is an undercut across from the scanner that is impossible for a person to step beneath see Fig 13 the depth of the undercut can be calculated according to the following formula ZUMIN Z 81mm d Zumin Depth of the undercut in mm Required detection zone additions in mm d Resolution of the scanner d 70 mm This is possible since it is absolutely certain that a person in front of the undercut will be detected Furthermore the dust algorithm of the RS4 4 can be implemented if floating particles may be present in the area This algorithm which can be activated in the user program RS4soft prevents the machine or system from being switched off unintentionally Please refer to Chapter 6 3 5 If the danger zone analysis allows a multiple evaluation detection errors caused by floating particles can be decreased The number of evaluations that is decisive for the response time of the scanner Tscan and thus also requires a larger detection zone can be set in the user program RS4soft Restart interlock The ROTOSCAN RS4 4 is equipped with a restart interlock function This function which can be selected or unselected links the restart of the machine to a manual approval if it is possible t
76. tp www la2p pt Poland Balluff Sp z 0 0 ul Powsinska 106 PL 02 903 Warszawa Tel Int 48 0 22 651 96 79 Fax Int 48 0 22 842 97 28 E mail balluff balluff pl http www leuze de Chile Imp Tec Vignola S A I C Plaza Justicia Sub El Peral 25 Casilla 93 V RCH Valparaiso Tel Int 56 0 32 25 65 21 Fax Int 56 0 32 25 85 71 E mail vignoval entelchile net Taiwan Great Cofue Technology Co Ltd 4F 8 39 Sec 4 Chung Hsin Road San Chung City Taipei Hsien Taiwan R O C Tel Int 886 0 2 29 83 80 77 Fax Int 886 0 2 29 85 33 73 E mail gcofue mail eranet net South Korea Useong Electrade Co No 3325 Gadong Chungang Civc No 1258 Guro Bondong Guroku Seoul Korea Tel Int 82 0 2 6 86 73 14 5 Fax Int 82 0 2 6 86 73 16 E Mail haegon97 unitel co kr http www leuze co kr Philippines JMTI Industrial Corporation No 5 Saturn Street Bricktown Moonwalk Paranaque Metro Manila Philippines Tel Int 63 0 2 844 63 26 Fax Int 63 0 2 893 22 02 South Africa Countapulse Controls PTY Ltd P O Box 40393 RSA Cleveland 2022 Tel Int 27 0 11 615 75 56 8 Fax Int 27 0 11 615 75 13 5 Sweden Jokab Safety A S Boplatsgatan 3 S 21376 Malm Tel Int 46 0 40 14 36 30 Fax Int 46 0 40 22 92 88 E mail info jokabsafety se http www jokabsafety se Singapor
77. use 1 25 A semi time lag d lt lt b Restart button x Y ia c Fuse 4 A delay action d Fuse 1 A delay action 2 Fig 23 Wiring the ROTOSCAN RS4 4 with external restart interlock and relay monitoring and without field pair changeover In this example the relay monitoring is performed by an external safety module e g MSI SR2 F Relays K4 and K5 must be equipped with positively guided contacts A suitable arc suppressor is required Please note that this results in an increase of the switching times RS4 4 169 170 Please refer to the operating instructions for the components According to DIN EN 954 1 channels x and y must be integrated for Categories 3 and 4 A single channel integra tion comprising z is only admissible for a single channel control and under consideration of the results of a risk analysis Serial machine controls are admissible only insofar the valid regulations allow RS4 4 Leuze Leuze 9 3 Connecting the ROTOSCAN RS4 4 to a PLC with Corresponding Safety Level Cat 3 or higher EN 954 and Field Pair Changeover 24 V GND PE 12345 67 8 9 10 11 12 13 1415 l gt X1 ROTOSCAN RS4 4 Nee _ __ a Fuse1 25A b Restart button c Decentralized peripherals e g ET200M with failsafe signal subassembly d Further processing by a failsafe PLC e g SIMATIC S7 400F Fig 24 C
78. vated dust suppression Addition Zgy for 81 mm for a detection zone size activated dust lt 3 5 m suppression 98 mm for a detection zone size gt 3 5 m RS4 4 Leuze Information on activating and deactivating this function is located in the RS4soft user manual If retro reflectors or very shiny surfaces such as certain metals or ceramics may be present in the scanning plane the following table applies Addition Zper_ if 0 mm for reflectors more than 1 2 m retro reflectors or behind the detection zone line very shiny surface treated materials 110 mm for reflectors up to 1 2 m e g metals and behind the detection zone line ceramics are present in the scanning plane Z Zsm ZREL Z Required detection zone addition in mm ZsM Measurement error of the scanner in mm Zp e Addition for considering reflectors in mm 6 4 Safeguarding Stationary Danger Zones Please comply with the safety precautions in Chapter 4 6 4 1 Purpose of safeguarding to protect people when entering a danger zone to protect people from reaching a danger point with their extremities to protect objects from the danger of collision due to variable machine or part movements Leuze RS4 4 133 134 6 4 2 6 4 3 6 4 4 Mounting position The ROTOSCAN RS4 4 can be mounted either in a station ary position e g on a wall or a machine or on moving parts e g machine table The qualified instal
79. x Int 57 0 4 351 10 19 E mail rigogigu col3 telecom com co Czech Republic Schmachtl CZ spol s r o Videnska 185 CZ 25242 Vestec u Praha Tel Int 420 0 2 44 00 15 00 Fax Int 420 0 2 44 91 07 00 E mail office schmachtl cz http www schmachtl cz Germany Lindner electronic GmbH Schulenburger Landstr 128 D 30165 Hannover Tel Int 49 0 511 96 60 57 0 Fax Int 49 0 511 96 60 57 57 E mail lindner leuze de W M Plantechnik Dipl Ing W rtler GmbH Co Tannenbergstra e 62 D 42103 Wuppertal Tel Int 49 0 202 371 12 0 Fax Int 49 0 202 31 84 95 E mail wmplan rga net de Leuze electronic GmbH Co Gesch ftsstelle Owen In der Braike 1 D 73277 Owen Teck Tel Int 49 0 70 21 98 50 910 Fax Int 49 0 70 21 98 50 911 E mail vgo leuze de Leuze electronic GmbH Co Gesch ftsstelle Dresden Niedersedlitzer Stra e 60 D 01257 Dresden Tel Int 49 0 351 284 11 05 Fax Int 49 0 351 284 11 03 E mail vgd leuze de Leuze electronic GmbH Co Gesch ftsstelle Frankfurt Moselstra e 50 D 63452 Hanau Tel Int 49 0 6181 91 77 0 Fax Int 49 0 6181 91 77 15 E mail vgf leuze de Leuze electronic GmbH Co Gesch ftsstelle M nchen Ehrenbreitsteiner Stra e 44 D 80993 M nchen Tel Int 49 0 89 143 65 200 Fax Int 49 0 89 143 65 220 E mail vgm leuze de Denmark Jokab Safety DK A S Rugmarken 15 1 DK 3520 Farum
80. y IVO Leuze Vogtle Malanca s r l Via Soperga 54 I 20127 Milano Tel Int 39 02 284 04 93 Fax Int 39 02 26 11 06 40 E mail ivoleuze tin it http www leuze de Israel Galoz electronics Ltd P O Box 35 IL 40850 Rosh Ha ayin Tel Int 972 0 3 902 34 56 Fax Int 972 0 3 902 19 90 India Global Tech Corp 403 White House 1482 Sadashir Peth Tilak Road Pune 411030 India Tel Int 91 0 2 12 47 00 85 Fax Int 91 0 2 12 47 00 86 E mail globtech giaspn01 vsni net in J Japan Riken Optech Corporation 2 6 9 Higashi Ohi Shinagawa Ku Tokyo 140 8533 Japan Tel Int 81 3 3474 86 02 Fax Int 81 3 3450 52 95 Malaysia Ingermark M SDN BHD No 29 Jalan KPK 1 8 Kawasan Perindustrian Kundang MAL 48020 Rawang Selangor Darul Ehsan Tel Int 60 0 3 60 34 27 88 Fax Int 60 0 3 60 34 21 88 E mail ingmal tm net my N Norway Automasjon og Sikkerhet Skolhusveien 25 N 1433 Vinterbro Tel Int 47 64 94 58 60 Fax Int 47 64 94 61 60 The Netherlands Leuze electronic B V Postbus 1276 NL 3430 BG Nieuwegein Tel Int 31 0 30 606 63 00 Fax Int 31 0 30 606 09 70 E mail info leuze nl http www leuze nl Portugal LA2P Lda Rua Teofilo Braga 156 A F Edif S Domingos Cabeco do Mouro P 2785 122 S Dom de Rana Tel Int 351 21 444 70 70 Fax Int 351 21 444 70 75 E mail la2p ip pt ht

ROTOSCAN RS4-4 Laser Scanner for Personnel Protection and

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