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SD3-A1 (Connection and Operation)

1. O 20 40 60 80 100 120 140 160 Additional distance Zarar in mm Fig 5 7 3 Diagram for calculating the addition to compensate for inadequate AGV floor clearance 51 5 7 7 5 7 8 52 System availability There must be a buffer distance of 83mm between the surrounding contour and the detection zone contour including the additions This distance increases the up time of the AGV since it prevents the surrounding contour from being detected as relevant for generating a switch off signal due to a measurement error Furthermore the dust algorithm of the SD3 A1 can be implemented if floating particles may be present in the area This algorithm can be activated in the user program SD3SOFT and prevents the AGV from being switched OFF unintentionally Please note Chapter 5 3 5 If the danger zone analysis allows a multiple evaluation detection errors caused by floating particles can be decreased The number of evaluations that is decisive for the response time of the scanner Tscan and thus also requires a larger detection zone can be set in the user program SD3SOFT In the event of an error event that lasts only briefly for example the effect of extraneous light the scanner performs a one time reboot If automatic startup restart are activated the scanner turns the OSSDs back ON after this brief error event and after the detection zone has been free for about 25s This one time reboot results
2. o LA Easy to interpret pictographs on E VAN B Do S SD3 A1 provide information on the meaning of the LEDs Green Yellow Fig 10 3 1 The SD3 A1 status indicator 75 76 Meaning of the individual LEDs 1 Green Sensor function is active active ok detection zone is free Fault input zone pairs Light flashing at 2Hz 2 Yellow Configuration conflict Light A flashing at 4Hz Warning zone is assigned 3 OSSD outputs are switched OFF cE OSSD outputs are switched ON Yellow Constantly lit Start interlock Restart interlock Flashing slowly 1 Warning message approx 2Hz Optical window dirty Flashing quickly 1 device message approx 4Hz Table 10 3 1 Meaning of the SD3 A1 LED displays 10 4 Status information of the SD3 A1 Scanner display LED numbers 1 2 3 4 5 1 0 LED 3 The OSSD outputs are switched OFF e g during booting LED 1 The sensor function is active measurement LED 4 operation without an interruption of the activated zone pair The OSSDs are switched active high The sensor function is active measurement operation without a violation of the activated detection zone Violation of the activated warning zone The OSSDs are switched active high 0 1 1 0 LED 2 Violation of the warning zone Violation of the LED 3 detection zone The OSSDs are switched OFF LED 1 The sensor function is active measurement LED 4 operation without a violation of the
3. 10 3 SD3 A1 status indicator 10 4 Status information of the SD3 A1 10 5 Restart and device swap out 11 12 13 14 15 Maintenance and Testing 11 1 Test before first startup by person qualified and authorized to perform the task 5 11 2 Extended shutdowt of the SD3 A siiicar aE a aaa aeeai 11 3 Regular tests by a person qualified and authorized to perform the task 11 4 Daily test by with test piece performed by responsible operating personnel s 11 4 1 Checklist for daily test of stationary applications by responsible operating personnel 81 11 4 2 Checklist for daily test of mobile applications by responsible operating personnel 82 11 5 Checklist for testing stationary applications 11 6 Checklist for testing mobile applications 11 7 Replacing the optical window 11 71 General intOnMallOnt vccccceccecceccectectectecteckeeddea maces 11 7 2 Initial measurement of the new optical window 11 7 3 Procedure when using the SD3SOFT user software version 1 09 or later 11 8 Cleaning 11 8 1 Cleaning the optical window when dirty 11 8 2 Cleaning the optical window cleaning diffusing light panes Delivery Package 12 1 Disposal 12 2 Accessories and spare parts 12 3 Coding of the control Cable Xi ecreis eari 95 Technical Data 13 1 Test pieces 13 2 Detection zone 96 13 3 Detection zone additions 13 4 Warning zone 13 5 Contour measurement 1
4. Yes Yes Yes Yes Yes Yes No No No No No No No No No No If the answer to any of the questions above is No the vehicle should be checked by a trained specialist Checklist for testing stationary applications The following checklist represents an aid It helps in but does not replace the test before the initial startup as well as the regular tests performed by a trained specialist 1 Is the mounting position and adjustment of the SD3 A1 correct and is the possibility of misusing the SD3 A1 for example to climb on excluded Is the external condition of the additional safety equipment and control devices free of problems Are all connection pieces and connection cables in flawless condition Are the two safety outputs OSSDs connected to the following machine control system in accordance with the corresponding safety category Are the following switch elements that are controlled by the SD3 A1 for example contactors with forced contacts or safety valves monitored by the feedback loop EDM Does the actual connection of the SD3 A1 to the machine control system match the circuit diagrams Was the safety distance calculated according to the applicable formulas for safeguarding danger areas and is this minimum distance observed between the detection zone contour and the danger areas Is the effect of any potentially reflective surfaces taken into consideration with an addition
5. 14 Diagnostic codes and causes Loca Description No Cause tion 102 Processing of commands 2 Data transmission error on the X2 processing of messages interface 103 Control of command 2 Data transmission error on the X2 processing interface 104 Processing of commands 2 Data transmission error on the X2 Processing of configuration interface 105 Processing of commands 6 Function access command not generation of output permitted with currently selected messages access level 201 Processing of the receive 4 Too much data sent over the X2 protocol interface Message will be overwritten by new message 302 Processing of the transmit 2 The verification of displayed data protocol remained unacknowledged for too long 306 Output of measurement 5 Previous message not yet values completely output 801 Event processing 2 Event memory cannot be read internal fault 805 Processing of the commands 6 Event memory cannot be to the event memory transferred Data transmission error on interface X2 1002 Motor control during 1 Motor does not reach rated speed initialization after start Internal fault 1002 Motor control during 2 Motor speed not constant after initialization start Internal fault 1110 Test of the switch outputs 4 Switch outputs OSSD have a state other than the one the scanner expected Possible wiring or control error 1110 Test of the switch outputs
6. Integrating one channel based on z is only permitted with a one channel control system and taking into consideration the results of a risk analysis Serial machine controls are admissible only insofar the valid regulations allow 67 8 3 Connecting the SD3 A1 to a PLC with corresponding safety level Category 3 or higher EN 954 and zone pair changeover Fuse 1 25A RESTART button Decentralized peripherals Further processing by a failsafe PLC Qaoowp I Fig 8 3 1 Connecting the SD3 A1 to a failsafe PLC with a safety level at least Category 3 EN 954 and zone pair changeover example All switching functions in this sample connection are controlled directly by the PLC The changeover of 4 zone pairs is achieved by way of the inputs X1 4 FP 1 X1 6 FP 2 X1 7 FP 3 and X1 8 FP 4 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 SD3 A11 itself must be configured using the SD3SOFT user program so that the operating mode with restart interlock is active 68 9 1 9 2 Electrical Connection Electrical power supply The SD3 A1 requires a direct voltage of 24V and 8W of power plus the load at the outputs max 25W The power must be supplied by way of an external 1 25A semi time lag fuse e g in an electronics cabinet In addition a perma
7. e Allows lateral tilting of up to approx 9 to either side from the midpoint setting infinitely adjustable within this range e Enables quick replacement of the scanner without requiring realignment For information on which parts and dimensions are required for mounting please refer to Chapter 13 13 and 13 14 Installing adjacent laser scanners The SD3 A1 has been developed in a way that prevents several laser scanners from interfering with one other as much as possible An increase in the response time can however be caused by the installation of several adjacent laser scanners If none of the constructive measures section 5 2 1 described in the following sections or the specific adjustment section 5 2 2 are implemented then the SD3 A1 response time set and shown in the configuration and diagnosis software SD3SOFT is extended by 40ms This extension in the response time must be taken into account when calculating the safety distance Constructive measures The direct external light irradiation from laser scanners of the same kind 905nm laser light wavelength in a line and at the same installation height can be prevented with shielding plates at scan level Shielding as high as the scanner front screen and flush with the front housing edge is sufficient The same also applies with installation in parallel alignment and overlapping of the scan levels b E __I L a A Hw c c d 5 2 2 a SD3 A1
8. Event detected by watchdog watchdog switched OFF motor speed deviation scanner housing may be rotating 1907 Test of the external watchdog Event detected by watchdog watchdog switched OFF motor speed deviation scanner housing may be rotating 2002 Processing of parameter commands 12 The verification of displayed data remained unacknowledged for too long 2007 Verification of parameter data received 18 The date of the detection zone currently being transferred is older than the date of the detection zone in the scanner 2201 Area monitoring Number of measurements in the scan too small due to motor speed error or switch off of the watchdog Internal fuse faulty 2302 Control of software sequence Error occurred while starting the scanner Sequential error 2401 Reference measurement on the dark reference element 10 No distance value can be calculated for reference measurement Glare from another source of light 905nm or deviation in motor rotation speed Loca Description No Cause tion 2401 Reference measurement on 13 No removal value can be the dark reference element calculated for reference measurement Dust in device because connector housing or dummy connector not screwed on 2402 Reference measurement on 10 No distance value can be the light reference element calculated fo
9. If the scanner is mounted across from the machine see Fig 5 4 4 the undercut dimension can be reduced by d 70mm The formula Zumn Z 83 mm d results in a minimum undercut Zumin 83 mm 83 mm 70 mm 96 mm It is not allowed for a person to be able to step beneath the undercut atte saat COSROE SANS alee COCR ie Fig 5 4 6 The undercut 5 5 5 5 1 5 5 2 5 5 3 Access protection Please have regard to the general safety notes in Chapter 3 Object of protection The object of protection is the safeguarding e of individuals when they access a danger zone The SD3 A1 will detect the passage of individuals and the intrusion of an entire human body into the scanning field of the laser scanner Installation position Access protection is based on passage monitoring This is a suitable system when the access to a machine or to a hazardous zone can be precisely defined in structural terms and there is no other unprotected access to the area In addition the danger area must be open to inspection and the button for manual triggering of the restart interlock must be situated outside the area It is best if the laser scanner is firmly installed above the passage in question in vertical alignment and in such a way that it cannot be manipulated Care must be taken to ensure that the positioning of the laser scanner SD3 A1 does not leave any areas through which a person might slip through without being
10. e Height of the undercut Zymin Depth of the undercut f Mounting surface g Scanning plane Fig 5 4 1 Recessed scanner installation with undercut The additional safeguarding required for the particular application must be taken into account Please note that the undercut must cover any unmonitored zones 33 5 4 4 2 34 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 40mm without the mounting system MS SD3 1 or up to 65mm with the mounting system MS SD3 1 This is in reference to detection zones that cover an angle range of 180 If it is not possible to comply with these values or if unmonitored zones result due to the shape or movement of the machine additional safety measures must be taken The effectiveness of the detection zones can be optimized by changing the depth at which the scanner is installed or by adjusting the angle range e g from 180 to 190 For information on how to configure the scanner in this way please refer to the instruction manual software operation for the SD3SOFT a SD3 A1 f Lateral access safe b Machine guarding if needed c Lateral access protection g Detection zone d Maximum recessing 40mm h Front machine edge e Installation niche Z Detection zone addition Fig 5 4 2 Recessed installation within the machine contour If it is
11. section 5 2 2 are implemented then the SD3 A1 response time set and shown in the configuration and diagnosis software SD3SOFT is extended by 40ms This extension in the response time must be taken into account when calculating the safety distance Mounting position For the purpose of safeguarding the path of a vehicle the SD3 A1 is mounted on the front of a vehicle in each direction of travel preferably in the center The scanner and hence the beam axis must be aligned horizontally in order to achieve a consistent scanning height Please comply with the safety notes in Chapter 3 7 Mounting height As a rule the scanner should be mounted as low as possible in order to prevent people from crawling beneath the detection zone This specification is limited due to such factors as uneven floors or the deflection of the springs in the AGV The maximum mounting height must be selected so that an object cylinder with a diameter of 200mm in the prone position is reliably detected see DIN EN 1525 The detection must be tested at the position of maximum depth within the detection zone For AGV applications sufficient resolution of detection is achieved when an object upright cylinder with a diameter of 70mm can be detected throughout the detection zone 5 7 5 NONDAY j Q m i Height of the test piece max 200mm Recommended maximum height of the scanning plane 150mm Axis of the rotating mirror Safety distanc
12. 1 25A delayed action fuse Zone pair control input Alarm 1 Semiconductor output that switches OFF when the warning zone is violated as well as for warning messages such as optical window slightly dirty error messages such as optical window very dirty and for internal errors the functions can also be selected in combination Zone pair control input Zone pair control input Zone pair control input Internally connected Internally connected OSSD 1 Semiconductor output switches OFF when the detection zone is violated Channel 1 OSSD 2 Semiconductor output switches OFF when the detection zone is violated Channel 2 Internally connected Internally connected Alarm 2 Semiconductor output with shut off when warning and malfunction message Table 9 5 1 Pin assignments for connector X1 2 3 4 5 7 1 10 11 12 13 14 15 71 72 Pin assignments for connector X2 used as an RS 232 port fami owen o 5 GND shield Ground shield RS 232 Internally connected Reserved for testing purposes Table 9 5 2 Pin assignments for connector X2 used as an RS 232 port Pin assignments for connector X2 used as an RS 422 port Table 9 5 3 Pin assignments for connector X2 used as an RS 422 port For the pin arrangement please refer to Chapter 2 2 and 9 5 in the instruction manual connection and operation of the SD3 A1 10 10 1 10 2 Commissioning Communication with the PC needs to be es
13. 13 3 Detection zone additions Addition with deactivated dust suppression 83mm Addition for activated dust suppression 83mm for a detection zone size lt 3 5m 100mm for a detection zone size 3 5m Addition if retro reflectors or very shiny surfaces such as certain metals or ceramics are present in the scanning plane Omm more than 1 2m behind the detection zone line 110mm in the detection zone or up to 1 2m behind detection zone line Table 13 3 1 Detection zone additions 13 4 Warning zone Detection range 0 to 15m Reflectance factor Min 20 Object size 150 x 150mm Response time Double evaluation 80ms corresponds to 2 scans up to 16 scans can be selected 640ms Number of warning zones 8 selectable via switch inputs Output PNP transistor output max 100mA Table 13 4 1 Technical data warning zone 13 5 Contour measurement Measurement range 0 to 50m Reflectance factor Min 20 Output Serial interface RS 232 10m RS 422 50m Radial resolution 5mm Lateral resolution 0 36 Table 13 5 1 Technical data contour measurement 97 13 6 13 7 13 8 98 Electrical power supply Power supply 24V DC 20 30 supply according to IEC 742 with safety transformer or comparable for DC DC converters Overload protection Provide by 1 25A semi delay fuse in th
14. 5 Switch output OSSD cannot be switched OFF 1110 Test of the switch outputs 6 Switch output OSSD cannot be switched ON 1111 Short circuit test of switch 7 Short circuit of a switch output outputs OSSD with ground 1111 Short circuit test of switch 8 Short circuit of a switch output outputs OSSD with Vcc 1606 Motor speed monitoring 4 Motor speed deviation zero pulse not detected properly internal fault 1607 Monitoring of duration of a 5 Motor speed deviation motor not scan at rated speed 103 104 Loca tion Description No Cause 1705 Processing of field monitoring light barrier data Signal of a light barrier in optical window monitoring is under the lower limit Dirty optical window 1705 Processing of field monitoring light barrier data Signal of a light barrier of optical window monitoring is above the upper limit Fluid media on the optical window 1906 Test of the external watchdog Watchdog is not enabling the OSSDs There may be a wiring or control error 1906 Test of the external watchdog Watchdog not switching OFF the OSSDs Internal fault 1906 Test of the external watchdog Switch outputs OSSD have a state other than the one the scanner expected Possible wiring or control error 1906 Test of the external watchdog Watchdog not switching the cut off path for the laser Internal fault 1907 Test of the external watchdog
15. 9 Be sure to comply with higher level machine standards e g DIN EN 1525 if applicable These contain individual specifications for example on points of access to the danger zone and if applicable detection zone additions that must be given special consideration They also provide information on how to measure safety distances at machines Detection zones with a radius smaller than 20cm at or close to the scanner are not admissible 20cm is the preset minimum contour When setting the dimensions of the detection zones please comply with the maximum angle range stated in the technical specifications Chapter 13 11 Needle shaped detection zone contours are not permitted since they do not ensure any protective effect For additional information please refer to the SD3SOFT user software Chapter entitled Definition of detection zones Due to possible measurement errors every detection zone has an additions area in which detection is not guaranteed under all conditions Please consider as well Chapter 5 3 5 Read Chapter 5 4 6 and 5 7 7 for information on optimizing system availability The required safety distances must be taken into account when making detection zone configurations Safety distances are calculated according to formulas found in either the machine specific C standards or the general B standards IEC 61496 3 in combination with DIN EN 999 see Section 2 and 5 of the standard Tolerance fields and or additio
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17. are also available for questions related to safety In general the following usage requirements must be observed e This device has been developed produced for industrial use only e Ifthe scanner is enclosed in a protective housing additional window material such as plastic or glass must not be used as it may impair the detection e Avoid touching the scanner optical window and the six diffusing light screens e The SD3 A1 is not suitable for use as a protective device if it is possible that dangerous fluids will be spewed out or objects will be ejected for machines with long braking times max depth of the detection zone 4m e The SD3 A1 corresponds to Type 3 in accordance with IEC 61496 1 and 3 A safety category of 3 in accordance with EN 954 1 can be achieved with the SD3 A1 if all other elements in the safety chain are set up to stop the dangerous motion in accordance with that safety category e The electrical connection of the SD3 A1 to the control system must only be made by an electrician e The 24V DC 20 30 power supply must be ensured by a safe network disconnect_in accordance with IEC 742 The same requirements apply to all connected input and output circuits 13 The 24V DC power must be supplied to the scanner through a separate branch with a 1 25A delayed action fuse in the control cabinet You must ensure that protective caps are screwed onto interfaces X1 and X2 This will protect the interfa
18. connector in RS 232 mode does not require any further bridging To enable data transfer in RS 422 mode connect pin 5 with pin 6 The scanner automatically adjusts itself to the appropriate transfer type and baud rate The interface X2 is used for e configuring and setting parameters for the SD3 A1 e transferring measurement data while the scanner is in operation e evaluating the coordinates during parameter setting e g for AGV applications e advanced status and control diagnostics Guard operation is only permitted with the PC cable X2 or dummy connected screwed ON This also applies for transport and storage Please note the pin assignments specified in Chapter 9 5 For additional information on using the X2 interface refer to the instruction manual software operation for the program SD3SOFT Integrating the SD3 A1 into Machine Controls The following examples illustrate possibilities for integrating the SD3 A1 into machine controls Once the operating voltage pin X1 3 Ug has been connected to pin X1 1 GND and a detection zone has been activated X1 4 X1 6 X1 7 or X1 8 the unit is ready for operation Please see the point Define Detection Warning Zones in the instruction manual software operation for the program SD3SOFT 8 1 Integrating the SD3 A1 with external wiring with relays and eightfold zone pair changeover In this connection example the restart interlock function is provided by
19. edge of the 64mm housing to the axis of the rotating mirror Connection 2 connectors plugged in from above Control cable length X1 Max 50m at a cable cross section of 0 5mm shielded Connect shield with PE to the electronics cabinet only Data cable length X2 RS 232 Max 10m Data cable length X2 RS 422 Max 50m twisted pair Housing Die cast aluminum plastic Weight Approx 2kg Dynamic stress across 3 axles In accordance with IEC 60068 Part 2 6 10 to 150Hz max 5G Continuous shock across 3 axes In accordance with IEC 60068 Part 2 29 10G 16ms Interference immunity In accordance with DIN EN 61496 1 corresponds to requirements for type 4 additionally in accordance with DIN 40839 1 3 test pulses 1 2 3a 3b and 5 not used for vehicles with internal combustion engines Rotating mirror drive Brushless direct current motor Rotating mirror bearing Maintenance free ball bearing Table 13 12 1 Technical data on the environment and material 13 13 Dimensional drawings of the SD3 A1 Front view Side view 195 R Smallest bending radius 50mm SUNX accessory a Axis of the rotating mirror b Scanning plane All dimensions given in mm View from above 101 13 14 Dimensional drawings of the mounting system Side view Scanner mounting re surface Overview of parts All dimensions given in mm 102
20. guided vehicles AGV been calculated and observed according to applicable formulas Is the effect of any potentially reflective surfaces taken into consideration with an addition in the calculation of the safety related distance As an alternate solution have the surfaces been changed e g matted Does the risk assessment take into consideration the fact that the height of the detection zone must be as low as possible DIN EN 1525 10 Is an installed protection to prevent walking behind recessing the SD3 A1 in effect 11 Has the effectiveness of the activated detection zone been tested with the black test pieces 70mm diameter standing and 200mm diameter on their sides 12 Is the start restart button for resetting the SD3 A1 positioned according to requirements and does it work properly 13 Does the SD3 A1 work in all necessary operating modes and during the entire motion of the vehicle that is causing a hazard Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes No No No No No No No No No No No No No 85 86 14 Is the motion causing the hazard stopped when electrical power to the SD3 A1 is disconnected and is a confirmation of the start restart button necessary to reset the vehicle after the power is restored 15 Are all test and parameter inaccessible to unauthorized personnel 16 Is an identifying sign placed on the machi
21. have been changed turn OFF the machine or vehicle immediately Provisional measures are not permitted Please comply with the safety notes in Chapter 3 Test before first startup by person qualified and authorized to perform the task e Check in accordance with the directives cited above using the checklists provided following if necessary to verify that the protective equipment has been properly attached is connected to the control system electrically and that its effect works in all operating modes of the machine or vehicle e The result of the test must be documented along with the scanner setting in an understandable form Printouts of scanner parameters and all defined detection zone contours must be included with the materials Keep these where they are inaccessible for unauthorized personnel e During initial startup you should anticipate unexpected behavior in the machine or vehicle Because of this people must be kept out of the danger area e Operating personnel must be instructed by trained specialists before starting work Instruction is part of the area of responsibility of the machine operator e Ensure that a daily test is performed Please take note in this regard of the Daily test with the test piece performed by responsible operating personnel Extended shutdown of the SD3 A1 If a system is taken out of operation and the SD3 A1 is placed in storage for later use with other machines vehicles the factory set
22. in an additional increase in availability This function does not have any effect if detection zone activation is faulty If startup test startup interlock and or manual restart are included they will not be removed Safety notes Automatic startup restart must only be used in cases where there is absolutely no possibility that the effective detection zone could be entered or bypassed in some other way Depending on the hazard assessment visual and or acoustic startup warnings should be provided If parameters are set for the function Manual restart the required enable from the startup restart button affects all detection zones and is independent of any detection zone changeover If the current detection zone is manually enabled this enable also applies even if the system switches to another detection zone and this detection zone becomes free If startup restart interlock is in effect in the current detection zone it is also in effect for the other detection zone to which the system switches even if this detection zone is free Restart At least 2s must elapse following the release of a violated detection zone before the AGV is allowed to startup 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 10s can be set in advance using the program SD3SOFT If a restart button is provided it must be mounted outside the dan
23. interlock DZ2 Detection zone 2 deactivated b SD3 A1 WZ1 Warning zone 1 activated WZ2 Warning zone 2 deactivated Fig 4 1 1 Danger area guarding at stationary machinery with two alternating work areas Please comply with the safety notes in Chapter 3 and Chapter 5 4 7 For an example of how to calculate detection zone measures please refer to Chapter 5 4 8 19 4 2 20 Access guarding by passage monitoring Access guarding by passage monitoring whole body trip control is a suitable method when the access to a machine or to a hazardous zone can be precisely defined in structural terms and there is no other unprotected access to the area It is best to mount the laser scanner above the passage in question in vertical alignment In order to secure the protective equipment laser scanner and fence against inadvertent misadjustment and manipulation the detection zones of the SD3 A1 must be defined on the basis of a reference boundary In this operating mode the scanner will use the polled environment as a reference and so check for changes in the layout of the protective equipment as well as checking every one of the individual measurements it carries out with a view to detecting an intrusion An example of the configuration of the SD3 A1 to give access protection by passage monitoring will be found in Chapter 5 5 a SD3 A1 DZ1 Detection zone 1 enabled b Reference boundary of the detection zone c Emergency st
24. not possible to mount the SD3 A1 directly onto the machine it can also be positioned lateral to or across from the machine 5 4 4 3 External mounting lateral to or across from the machine b a SD3 A1 b Machine c Distance max 35mm d Detection zone Fig 5 4 3 Lateral external scanner mounting without an undercut If the machine contour runs parallel to the 90 beam of the laterally placed SD3 A1 the distance between the detection zone boundary and the machine may not exceed 35mm Zumin SD3 A1 Machine Minimum distance from the environment Detection zone Required detection zone additions UMIN Minimum depth of the undercut NNQO FD i Ln Fig 5 4 4 Mounting the scanner across from the machine with an undercut 35 5 4 5 5 4 6 36 Additions The axis of the rotating mirror midpoint of the scanner is of critical importance when configuring the detection zones This axis is assigned a value of 64mm from the front edge of the scanner when calculating detection zones Add 83mm or 100mm for the maximum radial measurement error Zsm as described in Chapter 5 3 5 Add an addition Zrer as described in Chapter 5 3 5 if reflectors could be present in the area Please note that safety additions must principally be added to the safety distance throughout the entire detection zone In other words additions may not be added to just one side or only to certain sections Please consult the ope
25. of a person at this point If a laser scanner resolution finer than 150mm is additionally required for the safe position detection of the load then this can also be selected in this application The person in the in between space continues to be safely detected 6 1 Details on Switching Over Detection and Warning Zones During the course of an optimum machine utilization an alternate infeed or machining cycle often occurs which brings the most diverse danger areas with it Automated guided vehicle system applications by their very nature include various danger areas depending on the operating status If the approach or presence of people is now to be expected in these areas the need exists of a precisely adjusting safety system With its eight switchable and freely configurable detection and warning zones zone pairs the SD3 A1 satisfies multifaceted requirements with regard to guarding the most diverse applications The definition of the necessary zone pair contours is possible with the convenient and easy to use configuration and diagnostics software SD3SOFT The zone pairs are activated via the connection of 24V DC to the corresponding control inputs FP 1 to FP 4 which are provided on the X1 plug of the scanner Please find detailed information on the scanner connection in Chapter 7 2 and Chapter 9 If the SD3 A1 is to be restarted or switching is to be made between different zone pairs the following points must be observed e
26. 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 oi the system and application specific additions in the direction of trave Sum of the system and application specific additions to the side Three possibilities for mounting the SD3 A1 onto an AGV 5 7 6 Additions The axis of the rotating mirror midpoint of the scanner is of critical importance when configuring the detection zones This axis is assigned a value of 64mm from the front edge of the scanner when calculating detection zones Add 83mm or 100mm for the maximum radial measurement error Zsy as described in Chapter 5 3 5 Add an addition Zrer as described in Chapter 5 3 5 if reflectors could be present in the area Without information from the AGV manufacturer take into account the wear and tear on the brakes by adding an addition Lstop of at least 10 of the braking distance as long as this is not already included in the braking distance Sstop 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 120mm an addition Zarr must be added This refers only to the travel of direction Floor clearance in mm 120 100 80 60 40 20 0
27. of the danger zone Access speed 1 600mm s constant Response time of the SD3 A1 Tscan 0 08s adjustable Response time of the machine or TmacH 0 1s system Stopping time or lag time of the TLac 0 5s time for braking the machine or system dangerous movement until standstill Factor for increase in lag time Liac 1 1 fixed addition to account for increased lag time SI AU Addition for system specific Zsu 83mm when dust algorithm is measurement error switched OFF Addition caused by the mounting Z 125mm distance between the position that is selected front edge of the undercut to the beam axis of the scanner Height of the sensor H 300mm scanning plane Safety related constant C 1 200mm 0 4 x Height H 1 080mm The formula S K x Tscan TmacH Thac Liag C results in a safety distance of S 1 600mmis x 0 08s 0 1s 0 5s x 1 1 1 080mm 2 248mm The formula S7 S Zsm Zau results in the detection zone depth Sy 2 248mm 83mm 125mm 2 456mm 41 5 4 8 4 Sample calculation of a maximum range of a detection zone The formulas Smax S SppirF Senir Gepirr S Zsm yield under consideration of the width of the danger zone results in the maximum distance to be monitored Smax 42 456mm 3 031mm Sgpirp 700mm 2 248mm 83mm 3 031mm Smax 3 901mm 5 4 8 5 Sample calculation of an undercut 42 This example is based on the following application data
28. one detection zone and one warning zone enable the scanner to be optimally adapted to the needs of each particular application The SD3 A1 can be implemented not only on machines and systems stationary safeguarding of danger zones but also on vehicles mobile safeguarding of transport vehicles Due to its wide range of measurement and its non contact electro sensitive measurement principle the SD3 A1 can be effectively used as a protective device for virtually any application Special features of the SD3 A1 e Eight freely programmable detection zones up to a maximum of 4m e Eight freely programmable warning zones up to a maximum of 15m e Expanded monitoring range of up to 190 e ConfigPlug for easy device exchange without configuration expense e Compact design W x D x H 140mm x 135mm x 155mm e Light weight 2kg e Low power consumption requirements 300mA plus the load at the outputs e Two types of interfaces at one Sub D jack RS 232 and RS 422 e User friendly software 11 12 Status displays on the SD3 A1 Assignment of Protective caps interface X1 wv ia 3 A oe FP 2 z 14Reserved Aimi igReserved pei 120SSD 2 Us 4 110SSD 1 Restart 1oReserved GND g Reserved Reserved Assignment of interface X2 as RS 232 port TxD o s RS 232 detection 2 o0 RxD slo 7 ets Reserved Re sd Z GND shied 9 ey la 2a 3 4 5a 1b 2b 5b 2c 5c 1a Sensorfunchon Assignment of int
29. only briefly for example the effect of extraneous light the scanner performs a one time reboot If automatic startup restart are activated the scanner turns the OSSDs back ON after this brief error event and after the detection zone has been free for about 25s This one time reboot results in an additional increase in availability This function does not have any effect if detection zone activation is faulty If startup test startup interlock and or manual restart are included they will not be removed 5 4 7 Safety notes Automatic startup restart must only be used in cases where there is absolutely no possibility that the effective detection zone could be entered or bypassed in some other way Depending on the hazard assessment visual and or acoustic startup warnings should be provided If parameters are set for the function Manual restart the required enable from the startup restart button affects all detection zones and is independent of any detection zone changeover If the current detection zone is manually enabled this enable also applies even if the system switches to another detection zone and this detection zone becomes free If startup restart interlock is in effect in the current detection zone it is also in effect for the other detection zone to which the system switches even if this detection zone is free Restart interlock The SD3 A1 is equipped with a restart interlock function You can select or dese
30. rubber seal is not damaged Make certain it is in the groove in the housing designed for that purpose Check to make sure the optical window is seated correctly There should be no gap between the optical window and the housing that lets light through Find the correct position to avoid a light gap Then fasten the new optical window in place again with the fastening straps As you screw in the screws you can apply a little pressure on the outermost edge of the optical window with your thumbs The new fastening strap which has been available since 2002 is the one to use 11 7 2 5 Assembling the housing When assembling the housing note that the two retaining bolts slide into the rubber sleeves provided for them To do this carefully join the two housing parts on a level surface Retaining bolts Rubber sleeves After that carefully screw in the screws on the rear wall of the housing working back and forth around the circle from screw to screw Remove any finger prints on the optical window Initial measurement of the new optical window After the optical window has been properly mounted it is essential to perform a calibration of the optical window Correct functionality of the scanner cannot be guaranteed without calibrating the optical window Please note The calibration should be performed with an ambient temperature of 20 C to 25 C Safety Notes The optical window dark red must be clean and i
31. s Lag time of the entire system in s Factor for increase in lag time Safety related constant in mm Maximum range of detection zone Smax q Sr SenirF Sppirr Gepirr S Z Smax Sr SspirF GepirF S Z Maximum range of the detection zone considering the diagonals in mm Depth of the detection zone in mm Largest width of the detection zone between the axis of the rotating mirror and the outer edge of the detection zone in mm Largest width of the danger zone between the axis of the rotating mirror and the boundary of the danger zone in mm Safety distance minimum distance from the danger zone to the point of detection to the plane of detection or to the detection zone in mm Required detection zone additions in mm 39 40 SD3 A1 Dangerous machine danger zone Safety fence to prevent stepping behind Axis of the rotating mirror Detection zone Largest width of the hazardous zone Safety distance Entire width of the detection zone Largest width of the detection zone Maximum geometrical distance Depth of the detection zone Detection zone addition application specific Detection zone additions Undercut Considering the maximum measurement distance when safeguarding an area 5 4 8 3 Sample calculation of the depth of a detection zone This example is based on the following application data see 5 4 5 Largest width between the axis of Gppirr 700mm the rotating mirror and the boundary
32. the connected command unit start interlock which applies the voltage of 24V to the input RESTART X1 2 The SD3 A11 itself must be configured using the SD3SOFT user software so that the operating mode with restart interlock is active a Fuse 1 25A semi time lag d DZ2 WZ2 b RESTART button e DZ3 WZ3 c DZ1 WZ1 f DZ4 WZ4 Fig 8 1 1 Wiring the SD3 A1 with evaluation of the OSSDs zone pair changeover and restart interlock example Relays K1 and K2 must have forced contacts They are operated directly at the two failsafe semiconductor outputs OSSD 1 X1 12 and OSSD 2 X1 11 Relay K3 has a deenergizing delay A suitable mechanism must be provided for extinguishing sparks Please note that doing this will cause the switching time to be extended Channels x and y must be integrated for Category 3 in accordance with DIN EN 954 1 Integrating one channel based on z is only permitted with a one channel control system and taking into consideration the results of a risk analysis Serial machine controls are admissible only insofar the valid regulations allow 65 66 a Fuse 1 25A semi time lag d DZ2 WZ2 b RESTART button e DZ3 WZ3 c DZ1 WZ1 f DZ4 WZ4 Fig 8 1 2 Wiring the SD3 A1 with evaluation of the OSSDs zone pair changeover restart interlock and static relay monitoring Relays K1 and K2 must have forced contacts They are operated directly at the two failsafe semicondu
33. the control unit must concur with the laser scanner s configuration which was set beforehand with SD3SOFT If these points are not observed the laser scanner will fail within 40ms and will show this with the additional 2Hz flashing of the green LED 1 7 3 7 4 Alarm 4 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 Interruption of the warning zone is shown by the continuously lit LED 2 in the indicator field of the scanner Warning state For instance the system may detect a slight dirt buildup on the optical window To signal this state LED 5 on the scanner flashes 2Hz The user should clean the optical window before it gets dirtier waiting too long will cause a device error to be reported and the outputs OSSD 1 and OSSD 2 to be switched OFF Device error Such as an erroneous reference measurement or extreme dirt buildup on the optical window This state is signaled by LED 5 flashing quickly 4Hz Both the reporting of a warning zone interruption and the signaling of the warning and error state can be selected either separately or in combination This procedure is described in the instruction manual software operation for the program SD3SOFT Output X1 5 is equipped with an internal electronic current limit to protect it against damage from overload Alarm 2 X1 15 As long as the output X1 15 is switched O
34. throughout the detection zone The admissible height range of the SD3 A1 scanning plane lies between Omm presettings leg detection and 1 000mm above the base level If the application requires a scanning plane higher than 300mm or if children have access to the area the analysis of the danger zone must consider the hazard caused by persons crawling below the scanning plane Recommendations for mounting to prevent unmonitored zones 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 5 4 4 1 Recessed installation undercut under the machine table The undercut must be at least as deep as the zone not monitored by the detection zone lateral to and in front of the scanner The minimum depth Zum is 135mm If it is possible to recess the scanner this is allowed up to a maximum of 40mm the depth of the undercut is reduced by the depth value of the recess If the mounting system is being used the necessary dimensions of the undercut depth must be increased accordingly see Chapter 13 13 and 13 14 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 E l Zumin a SD3 A1 S Safety distance b Machine Sg Entire width of the detection zone c Unmonitored zone Sr Depth of the detection zone d Detection zone Z Detection zone additions
35. 3 6 Electrical power supply 13 7 Inputs 13 8 Outputs 13 9 Software 13 10 Interfaces 13 11 Optics 13 12 Environment and material 13 13 Dimensional drawings of the SD3 A1 13 14 Dimensional drawings of the mounting system Diagnostic Codes and Causes sii cicicicicicccecscccenet ccc cccesecs seececceaseescacsccceccccccscccscessacceasssncssnesssazacceae 103 CE Marking Declaration of Conformity c ccsscsseseeesseeeeeeeeeeeeeeeeeseeeseeeeneeeneeseeseeeeeneeseeeaeees 106 1 1 Approvals Approval and declaration of EC conformity EC type examination in accordance with DIN EN 61496 1 and IEC 61496 3 TUV PRODUCT SERVICE GMBH IQSE Ridlerstr 65 80339 Munich cE 1 2 Specialized technical terms and abbreviations AGV Automatic Guided Vehicle FTS in German AOPD Active Optoelectronic Protective Device AOPDDR Active Optoelectronic Protective Device responsive to Diffuse Reflection EDM External Device Monitoring Monitoring of external control parts relay monitoring ESPE Electro Sensitive Protecting Equipment BWS in German N O Normal open contact OSSD Output Signal Switching Device Safety relevant switch output PC Personal Computer DZ Detection Zone SF in German Reset Defined Reset or SD3 A1 RS 232 RS 232 interface RS 422 RS 422 interface ZP Zone Pair contains 1 x detection zone and 1 x warning zone FP in German WZ Warning Zone WF in
36. 5 1 Attachment and dimensions 5 2 Installing adjacent laser scanners 5 2 1 Constructive measures 0 04 5 2 2 Adjusting adjacent laser scanners 5 3 Information on setting the dimensions of detection zones 5 3 1 Methods of configuring detection zones using the PC 5 3 2 Range of the detection zone resolution 5 3 3 Range of the warning zone resolution 5 3 4 Range of the measurement field 5 3 5 Required detection zone additions Z 5 4 Safeguarding stationary danger zones 5 4 1 The purpose of safeguarding 5 4 2 Mounting position ve 5 4 3 Mounting height 5 4 4 Recommendations for mounting to prevent unmonitored zones 5 4 5 Additions 5 4 6 System availability 5 4 7 Restart interlock 5 4 8 Calculating the detection zone 5 5 Access protection 5 5 1 Object of protection 5 5 2 Installation position 5 5 3 Safety relevant settings and calculation of the safety distance 5 5 4 Definition of the reference boundary imensions for safeguar Ing an area 10 5 6 Protecting danger points 5 6 1 Object of protection 5 6 2 Installation position 5 6 3 Safety related settings and calculation of the safety distance 5 6 4 Defining the reference boundary 5 7 Safeguarding mobile machines 5 7 1 The purpose of safeguarding 5 7 2 Installing adjacent laser scanners 5 7 3 Mounting position 5 7 4 Mounting height 5 7 5 Recommendations for mounting to prevent unmonitored zones 5 7 6 Additions 5 7 7 System availabil
37. German Table 1 2 1 Specialized technical terms and abbreviations Directives and standards The following directives and standards are of critical importance for the implementation of laser scanner Directives providing particularly relevant information for users of such systems are marked with an asterisk EU Directive Standard Designation EU Directives 2006 42 EC EU Machinery Directive 2004 108 EC EMC Directive 2011 65 EU RoHS Directive A Standards ISO 12100 Safety of machinery General principles for design Risk assessment and risk reductionbasic concepts B1 Standards ISO 13852 ISO 13849 1 2006 ISO 13855 Safety of machinery safety distances to prevent danger zones being reached by the upper limbs Safety of machinery Safety related parts of control systems Part 1 General principles for design Safety of machinery The positioning of protective equipment in respect of approach speeds of parts of the human body B2 Standards IEC 60204 1 IEC 60825 1 IEC 61496 1 IEC 61496 3 Safety of machinery Electrical equipment of machines Part 1 General requirements Safety of laser products Part 1 Equipment classification and requirements Safety of machinery Electro sensitive protective equipment General requirements and tests Safety of machinery Electro sensitive protective equipment Part 3 Particular requirements for Active Opto electronic Protective Devices
38. N the system signals trouble free operation If it is switched OFF the following states are reported Warning state For instance the system may detect a slight dirt buildup on the optical window To signal this state LED 5 on the scanner flashes 2Hz The user should clean the optical window before it gets dirtier waiting too long will cause a device error to be reported and the outputs OSSD 1 and OSSD 2 to be switched OFF Device error Such as an erroneous reference measurement or extreme dirt buildup on the optical window This state is signaled by LED 5 flashing quickly 4Hz Output X1 15 is equipped with an internal electronic current limit to protect it against damage from overload 63 7 5 7 6 64 OSSD 1 X1 12 and OSSD 2 X1 11 When the detection zone is interrupted the two semiconductor outputs switch OFF and by way of elements such as positively guided relays cause the monitored machine s to shut down It is not admissible to control different safety circuits with a single OSSD Connected loads must exhibit a low pass behavior in accordance with the plausibility control conducted by the scanner fy lt 1kHz CL lt 100nF The OSSDs are equipped with an internal electronic current limit to protect them against damage from overload For some sample connections see Chapter 8 Data communication The interface X2 allows the SD3 A1 to support two types of connections to the PC Communication via the X2
39. Panasonic Safety Laser Scanner SD3 A1 User s Manual Connection and Operation ME SD3A1CON 05 2015 10 panasonic net id pidsx global About the instruction manual connection and operation of the SD3 A1 and the SD3SOFT instruction manual software operation The instruction manual connection and operation for the SD3 A1 contains important information on proper usage of laser scanner and usage in accordance with intended purpose For additional information on the configuration of the SD3 A1 please refer to the SD3SOFT instruction manual software operation It is essential to observe all information in the instruction manual connection and operation and in the instruction manual software operation especially the safety notes The instruction manual connection and operation and the instruction manual software operation must be kept in a safe place They must be available during the entire period when the SD3 A1 is in use Documents are also automatically installed on the PC when SD3SOFT is installed and can be viewed at any time with the Help menu Safety and warning notices are identified by the symbol A References to important information are identified by the symbol References to the safety of laser devices are identified with the symbol A r Panasonic Industrial Devices SUNX Co Ltd is not liable for damage caused by improper usage The user must also be familiar with all the SD3 A1 manuals to be able to u
40. The zone pair planned for the start must be defined with special consideration of the danger areas valid for this moment e The sequence of the monitoring zones to be activated must ensure that the lower threshold of the application related detection zone minimum values is never crossed e With selection of zone pair 8 the monitoring function of the scanner is deactivated i e no detection zones are monitored and the safety outputs OSSDs remain constantly active With zone pair 8 the laser scanner may not be started Zone pair 8 is planned for application related situations in which it has been absolutely ensured that there is no danger for any people present These are for example vehicles with crawler mode or in completely partitioned OFF and secured areas vehicles in approach mode in the area of loading or parking positions as well as machines in the setup operating mode Please observe the connection and interface assignment in Chapter 9 5 and the safety notes in Chapter 3 Sequence of zone pair switchovers The SD3 A1 safety laser scanner has eight detection warning zones Switchover between these zone pairs is possible at all times provided the operating situation allows this During the switchover process the SD3 A1 monitors the zone pair activated before the switchover until a new one has been clearly activated The rules for the switchover depend on the amount of the selected zone pairs and their numbers The procedures descr
41. When the X1 standard plug is used the configuration must be transferred with the PC to the replacement device All procedures and specifications of the first startup apply here A technical expert should look at the device If the ConfigPlug is used with integrated configuration memory the SD3 A1 reads the saved configuration automatically from the ConfigPlug when it is switched ON The ConfigPlug must be clearly identified with a nameplate and the switch in the plug must be at the 1 left default position During the startup with the automatic configuration read back the laser scanner signals the successful transfer with a brief flashing of the two yellow LEDs 2 and 5 In this case it does not have to be looked at by a technical expert but the test in accordance with the specifications for daily testing must also be performed Fig 10 5 1 SD3 A1 ConfigPlug with switch setting 1 11 Maintenance and Testing When placing the system in service for the first time when it has been out of service for some time after conversions and repair work make certain the scanner and any other safety parts are checked specifically for the application and operation by the responsible trained specialist This must be done taking into consideration applicable local requirements especially for directives on machines and using work material and work safety directives If the correct functionality is not clearly confirmed or if safety related parameters
42. activated LED 5 detection zone The OSSDs are switched active high Warning message signaled by slow flashing at approx 2Hz e g with optical window dirty The OSSDs are switched OFF Fault message indicated by fast flashing at about 4Hz e g with defect or safety related fault The sensor function is active measurement operation without an interruption of the activated zone pair The OSSDs are switched OFF Restart interlock is active Interruption of the zone pair The OSSDs are switched OFF Restart interlock is active 1 LEDis lit up 0 LED is dark Undefined Table 10 4 1 Status information of the SD3 A1 Upon delivery the SD3 A1 is programmed with the largest possible detection zone and with activated startup interlock and manual restart For this reason LED 5 is constantly lit up when the scanner is switched ON When starting up your SD3 A1 please modify the parameters to meet the specific needs of your application 77 10 5 78 Restart and device swap out The SD3 A1 can be connected via the X1 standard plug or the ConfigPlug with integrated configuration memory With a restart the laser scanner starts in every case with the configuration that was set when it went out of operation Thereafter a technical expert does not have to look at it but the test in accordance with the specifications for daily testing must be performed With a device exchange however the procedure is different
43. ady made at scanner side 50m straight D3 CP C10 L SD3 A1 control cable with ConfigPlug ready made at scanner side 10m angled SD3 RS232 C3 SD3 A1 PC cable RS 232 ready made on both sides 3m SD3 RS232 C5 SD3 A1 PC cable RS 232 ready made on both sides 5m SD3 RS232 C10 SD3 A1 PC cable RS 232 ready made on both sides 10m SD3 CP ConfigPlug for SD3 A1 straight without cable for automatic configuration at device exchange SD3 RS232 SD3 A1 plug sock 15 pins for X1 interface SD3 PS SD3 A1 plug sock 9 pins for X2 interface SD3 RS232 L SD3 A1 plug sock 15 pins for X1 interface cable routing to the rear SD3 PS L SD3 A1 plug sock 9 pins for X2 interface cable routing to the rear SD3 CLEAN1 Cleaning fluid for synthetic materials 150ml 25 cleaning cloths soft and lint free SD3 CLEAN2 Cleaning fluid for synthetic materials 1 000mlI 100 cleaning cloths soft and lint free SD3 WINDOW SD3 A1 scanner optical window with seal Table 12 2 141 Accessories and spare parts for the SD3 A1 12 3 Coding of the control cable X1 The following table defines the pin assignments for the 15 pin connector cable Pin No Color code Meaning 1 Black GND 2 Blue Restart 3 Red Us 4 Orange FP 1 5 Yellow Alarm 1 6 Green FP 2 7 Violet FP 3 8 Gray FP 4 9 N C 10 N C 11 White OSSD 1 12 White Blac
44. al input A separate dialog within the user program SD3SOFT allows the right left and front edges of the detection zone to be set using numerical values in mm Graphic input A separate dialog within the user program SD3SOFT allows the basic contours of the detection zone to be entered The contours can be adapted infinitely to the desired size of the detection zone The following shapes are available e circle e rectangle e polygon In addition the contours can be infinitely varied by e changing e limiting and e deleting partial segments as desired Range of the detection zone resolution The maximum range of the detection zone Smax 4m including the additions for an object with a diameter of 70mm and a reflectance factor of 1 8 e g black corduroy The reference point of the measurement is the axis of the rotating mirror on the scanner 64mm behind the front edge of the scanner 5 3 3 Range of the warning zone resolution A maximum range of 10m is available for an object with a diameter of 100mm The maximum available range for an object with a diameter of 150mm is 15m Both of these figures assume a reflectance factor of 20 Resolution in mm 0 0 2 0 5 1 2 4 6 10 150 50 100 Distance in m a Detection zone b Warning zone c Measurement field Fig 5 3 1 Detecting objects in the detection zone and in the warning zone The reference point of the distance measurement is the axis of the rotat
45. alarm inactive lt 2 0V Table 13 8 1 Technical data outputs 13 9 13 10 13 11 Software User software SD3SOFT under Windows 95 98 2000 NT XP 7 with safe protocol for programming Table 13 9 1 Interfaces Technical data software RS 232 RS 422 For device configuration and data exchange Table 13 10 1 Technical data interfaces Optics Angle range Max 190 Angle resolution 0 36 Lateral tolerance without mounting system with mounting system 0 18 with respect to the back wall of the housing 0 22 with respect to the mounting surface Scanning rate 25 scans s or 40ms scan Laser protection class Class 1 as per EN 60825 1 1994 A1 2002 A2 2001 Wavelength 905nm Repeat frequency 25kHz Table 13 11 1 Technical data optics 99 13 12 Environment and material 100 Protection type IP65 in accordance with IEC 60529 Operating temperature 0 to 50 C Storage temperature 20 to 60 C Humidity DIN 40040 Table 10 Identifying letter E moderately dry PFHd Probability of dangerous failure per hour 1 57 x 107 MTTFd Mean time to dangerous failure More than 100 years Dimensions 140 x 155 x 135 W x H x D in mm Distance from the middle of the 48 75mm scanning plane to the bottom edge of the housing Distance from front
46. ane Z Zsm ZREFL Z Required detection zone addition in mm Zsm Measurement error of the scanner in mm ZrerL Addition for considering reflectors in mm Safeguarding stationary danger zones Please comply with the safety notes in Chapter 3 The purpose of safeguarding is for protection e to protect people when entering a danger zone e to protect people from reaching a danger point with their extremities e to protect objects from the danger of collision due to variable machine or part movements Mounting position The SD3 A1 can be mounted either in a stationary position e g on a wall or a machine or on moving parts e g machine table The qualified installer must ensure that the mounting position of the SD3 A1 allows the danger zone to be monitored completely If a restart button is being used make certain that the entire detection zone area can be viewed by the person pressing the button It must not be possible to activate the button from the danger area Refer to the safety notes in Chapter 3 6 with regard to lateral access into the danger zone 31 5 4 3 5 4 4 32 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 Hmn 15 x d 50mm Hmn Lowest admissible scanning plane from the base level d Resolution of the scanner in mm object size 70mm
47. b Machine view from above c Detection zones d Shield plate flush with the housing Fig 5 2 1 Shielding to prevent direct irradiation Adjusting adjacent laser scanners In order to prevent faulty deactivation and scanners interfering with each other as much as possible when using several laser scanners you must install these as shown in the following examples Installation on the basis of the MS SD3 1 mounting system makes precise adjustment significantly easier Installation with height offset or a crossed alignment also prevents interference from beam reflections onto surrounding objects When safeguarding danger zones please also ensure that it is not possible to crawl under the detection zone so that gaps do not occur with access guarding 100mm Fig 5 2 2 Installation with height offset parallel alignment 100mm Fig 5 2 3 Installation without height offset crossed alignment 27 5 3 5 3 1 5 3 2 28 A 100mm Fig 5 2 4 Opposing installation without height offset crossed alignment Information on setting the dimensions of detection zones The hazards caused by machines and systems place a wide range of demands on safety distances and detection zones which must be appropriately defined Methods of configuring detection zones using the PC With its SD3SOFT configuration and diagnostic software the SD3 A1 offers various methods for setting the configurations of detection zones Numeric
48. ces against dust The safety output has a double design The two OSSDs must always be included in the shut off circuit of the machine in such a manner that either of the two is completely sufficient by itself to turn OFF the motion that presents a danger The alarm output 1 Pin 5 on X1 must not be used to switch safety related signals System tests of the scanner machine control components and switch components may only be performed when they do not result in potential hazards for people Tampering with or making changes to the SD3 A1 can result in the loss of the safety function Only expert trained personnel is allowed to perform startup maintenance parameter settings or detection zone configurations Familiarity with the safety notes in this instruction manual connection and operation and in the instruction manual software operation for the SD3SOFT program constitutes part of this expert knowledge The password required for configuring safety relevant parameters must be kept in a secure location by the safety official Information about password levels can be found in the instruction manual software operation for the SD3SOFT If the machine is designed for start interlock manual restart all detection zones must be checked before enable no one is permitted in the danger area 3 3 Restrictions for use 14 Glass highly reflective materials such as mirrors reflectance gt 10 000 or objects that do no
49. cked to see whether the possibility of people standing in the danger zone as well as any barriers provided have been considered by an appropriate layout of the detection zone s Additional safety notes for stationary use e 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 protective grids must be installed e We recommended marking the contour of the detection zone on the floor by painting a colored line or applying colored adhesive tape e Check the mounting regularly in particular the angle of inclination in order to guarantee the reliability of detection 17 3 7 18 Additional safety notes for mobile use There are additional requirements for the use of scanners on automatic guided vehicles AGV and transporter trolleys according to DIN EN 1525 If possible expanded detection zones to each side should be provided in order to safeguard access from the side and directly in front of the vehicle If is it not possible to completely safeguard the contour of the vehicle including its trailer and the dimensions of its load while making curves additional protective devices such as switch strips must be attached to the side of the vehicle There must be a minimum safety distance Sag of 500mm to the side of the vehicle on both sides A one sided minimum safety distance is admissible in certain exceptional cases The speci
50. ctor outputs OSSD 1 X1 12 and OSSD 2 X1 11 A suitable mechanism must be provided for extinguishing sparks Please note that doing this will cause the switching time to be extended Channels x and y must be integrated for Category 3 in accordance with DIN EN 954 1 Integrating one channel based on z is only permitted with a one channel control system and taking into consideration the results of a risk analysis Serial machine controls are admissible only insofar the valid regulations allow 8 2 Connecting the SD3 A1 to a safety sequence circuit with manual restart interlock relay monitoring without zone pair changeover 1234567 8 9 101112131415 X1X3 S828114 24 Boor i i SD3 A1 l SF C13 BRD ee eee eij ete a eee a x y z a Fuse 1 25A semi time lag d lt d b RESTART button x Y k c Fuse 4A delay action N Fig 8 2 1 Wiring the SD3 A1 with manual restart interlock and relay monitoring and without zone pair changeover In this example the relay monitoring is performed by an external safety module e g SF C13 Relays K4 and K5 must be equipped with positively guided contacts A suitable mechanism must be provided for extinguishing sparks Please note that doing this will cause the switching time to be extended Please refer to the operating instructions for the components ar 6 Channels x and y must be integrated for Category 3 in accordance with DIN EN 954 1
51. detected The distance of the scanning field limiting the passage and the boundaries of the detection zone must be defined in such a way that no gaps measuring more than 150mm can arise Safety relevant settings and calculation of the safety distance To safeguard the protective equipment against inadvertent misadjustment or manipulation the detection zones of the SD3 A1 must be defined on the basis of a reference boundary In addition the response time must be defined as 80ms and the restart interlock must be set To enable the system to recognize an entire human body the laser scanner must have a resolution of 150mm These safety related settings will be automatically enabled in the SD3SOFT configuration and diagnosis software when the presetting Passage monitoring has been selected For effective passage monitoring a safety distance S must be observed between the detection zone of the laser scanner and the danger zone The SD3 A1 can fulfill its protective function only if it has been installed and positioned in such a way as to allow for an adequate safety distance The safety distance ensures that no body part whatever can reach the danger point until the hazardous movement of the machine has come to a complete standstill 43 The safety distance for an access protection system may be calculated based on EN 999 by means of the following formula S KxT C S _ Safety distance in mm K Approach velocity in mm s Here 1 600m
52. diagnosis software Protecting danger points Please have regard to the general safety notes in Chapter 3 Object of protection The object of protection is the safeguarding e of individuals who work with a machine or spend time in the danger zone associated with it The SD3 A1 will detect the body parts of individuals and the intrusion of these body parts into the scanning field of the laser scanner In this operating mode hand and arm protection is effectively realised Installation position Safeguarding of danger points on the basis of hand and arm protection is a suitable method if the machine operator in close proximity to the danger zone needs to halt the hazardous movement of the machine or to coordinate the handling of workpieces or their removal from the machine It is best if the laser scanner is firmly installed above the danger zone in such a way that it cannot be manipulated The health and safety officer must ensure that the installation position of the SD3 A1 does not leave any areas free through which manual intrusion could be effected If appropriate additional protective facilities should be installed to exclude any possibility of the operator s reaching over or around or getting behind the barrier To prevent the latter the distance from the scanning field to the machine table must not be more than 75mm This can be guaranteed if suitable screens are installed for the monitoring of the reference boundary see the il
53. e e The new detection zone must be activated before turning OFF the previous detection zone The time at which the changeover is made must be based on a risk analysis e Braking paths response and coast down times must be taken into consideration for example overlapping detection zones e A Start interlock function is provided e If the machine has a restart key it must not be possible to operate it from inside the detection zones All danger areas must be visible from the position of the button Before releasing the start restart interlock all detection zones must be tested No one is permitted inside the danger areas e There must be no unmonitored zones inside the danger areas e There must be no possibility for direct access to the danger area that shortens the necessary safety distance use a protective grid for example e The information on required detection zone additions in Chapter 5 must be observed 15 3 5 16 General information related to determining detection zone contours Shadow effects e g surfaces or areas located behind stationary objects must be considered As a rule insufficient safeguarding must be adequately supplemented by further safety measures such as protective grid light curtains and the like Access to the detection zone in the dangerous area is not permitted When setting the dimensions of the detection zone you must comply with the formulas cited in Chapters 5 4 8 and 5 7
54. e Depth of the detection zone Detection zone additions in the direction of travel Fig 5 7 1 Mounting height on an AGV Depending on the application further additions may be necessary Additional information is available in Chapter 5 7 6 Recommendations for mounting to prevent unmonitored zones The creation of unmonitored zones is dependent upon the following factors the vehicle width the design of the vehicle e g attachments shape the position of the scanner the installation depth the selected angle range If the detection zone of a SD3 A1 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 49 50 If this is not possible due to constructional limitations additional safety measures such as mechanical cover panels switch strips or bumpers must be implemented Please comply with the safety notes in Chapter 3 7 oa oogpw nan f SaB ZGES Zs Fig 5 7 2 SD3 A1 mounted on the front of a vehicle SD3 A1 recessed into the front of a vehicle SD3 A1 mounted on a protruding vehicle SD3 A1 Automatic guided vehicle The distance from the back wall of the scanner to the axis of the rotating mirror is 68mm The 190 detection zone enables an expanded monitored range The detection zone is limited by the scanner recess at the front
55. e SD3 A1 The scanner will now attempt to communicate with the PC this process is displayed on the screen 73 74 e When the connection between the SD3 A1 and the PC was successful you can enter the appropriate password and then change the parameters and zone pairs of the SD3 A1 to meet the needs of the particular application The standard password to be entered in the access level Authorized User of the SD3 A1 is SD3SUNX Please note that the password must be changed following the initial configuration of the scanner and that the data carrier must be kept locked up in a secure location e The SD3 A1 is ready for operation once the scanner settings and detection zone configurations have been transferred Every SD3 A1 is factory equipped with the maximum safety parameters For this reason first the device settings and then the detection zones must be adapted to the requirements of the application before the scanner is put into operation After configuring the scanner remove the PC interface cable from position X2 put on the dummy cap provided with delivery and screw it tight For a list of parameters please see the instruction manual software operation for the SD3SOFT Please observe Chapter 11 Maintenance and Testing 10 3 SD3 A1 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 SD3 A1 Association to function
56. e electronics cabinet Current consumption Approx 300mA use a power supply with 2 5A Power consumption 8W at 24V 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 ground conductor Connection not allowed Table 13 6 1 Inputs Technical data electrical power Restart reset For connecting a command device for operating mode with restart interlock and or device reset 24V DC insulated by photocoupler Zone pair changeover For selecting among 8 zone pairs via 5 control cables with internal monitoring zone pair 1 detection zone and 1 warning zone 24V DC insulated by photocoupler Signal definition High logical 1 Low logical 0 16 to 30V lt 3V Table 13 7 1 Outputs Technical data inputs Detection zone 2 x failsafe semiconductor output PNP max 250mA short circuit monitored overload protected Warning zone Dirt Fault 2 x PNP transistor output max 100mA Load characteristics maximum Low pass behavior limit frequency fy lt 1kHz Croaa lt 100nF Leakage current 0 1mA or less Maximum load capacity 0 1uF Length load line Maximum 50m with diameter of 0 5mm Level high OSSD active Us 3 2V Level low OSSD inactive lt 2 0V Level high alarm active Us 4V Level low
57. erface 1b Errors on the zone pair control inputs Light flashing at 2Hz X2 as RS 422 port 2a Warning zone is occupied 2b Optical window is dirty Light flashing at 2Hz TX jo gt s j Tx e RS 422 detection 2c ConfigPlug configuration not compatible X 2le N C Light flashing at 4Hz Rx alel uc 3 OSSDs are turned OFF Rx alol 7 4 OSSDs are turned ON GND shield o g Reserved 5a Restart inhibit locked Continuous light 5 Connection Pin 5 to Pin 6 5b Optical window is dirty Light flashing at 2Hz 5c Fault light flashing at 4Hz 3 1 3 2 Safety Notes and Usage in Accordance with Intended Purpose General safety notes The protective function of the devices can be negatively affected however if they are used improperly or not in accordance with their intended purposes If this occurs it may not be possibly to safeguard danger areas completely or at all which may result in danger to life and or limb for persons who are in the general area of the machines or systems Caution laser radiation The SD3 A1 is a laser device belonging to laser class 1 The valid legal and local regulations for operating laser systems must be complied with Avoid positioning the scanner at eye level Usage requirements and usage in accordance with intended purpose The relevant regulations for machine safety apply for the use of the laser scanner SD3 A1 Responsible authorities for example professional trade unions OSHA
58. f danger points based on hand and arm protection with alternation of detection zones 21 4 4 4 5 22 Mobile safeguarding of automatic guided vehicles For this application the SD3 A1 is installed on automatic guided vehicles in order to monitor the vehicle path The aim is 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 SD3 A1 as a non contact advance bumper results in the creation of a substantially larger safety zone The vehicles can move faster and down times are reduced to the necessary minimum DZ1 Detection zone 1 for slow DZ3 Detection zone 3 for a route speed curving to the left DZ2 Detection zone 2 for high DZ4 Detection zone 4 for a route speed curving to the right a Traveling straight ahead Fig 4 4 1 Safeguarding an automatic guided vehicle Please comply with the safety notes in Chapter 3 For an example of how to calculate detection zone measures please refer to Chapter 5 7 9 Protecting transporter trolleys against collisions Transporter trolleys are generally guided along a system of rails or grooves in the floor Hence the vehicle paths are usually just slightly wider than the trolleys themselves This represents an increased hazard for people since it is impossible to get out of the
59. fications of DIN EN 1525 must be complied with The basic value of the detection zone width for an AGV corresponds to the maximum vehicle width including the trailer and the dimensions of the load plus the detection zone additions Zs Furthermore the greatest possible lateral shift of the AGV while making curves must be considered when defining detection zones If the SD3 A1 is mounted on vehicles the mounting especially the angle of inclination the vehicles braking power and if applicable play in the vehicle guidance the difference between the optimum and actual line of guidance must be regularly checked in order to guarantee the reliability of detection 4 1 Applications for the SD3 A1 Due to its continuous coverage of the area its wide range and the ability to select among eight zone pairs the SD3 A11 is able to handle even complex applications Stationary safeguarding of the danger area The SD3 A1 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 SD3 A1 can be mounted directly at the machine table or on the side or in front of the machine DZ1 Detection zone 1 activated a Emergency stop and manual restart
60. g the interruption of a detection zone e Enables the start interlock following a system start e Restarts after a device error has been eliminated e Recognizes a defined enable signal after a device error after a detection zone interruption for enabling the restart interlock To activate the functions apply 24V 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 0 12s and 5s The restart input X1 2 must be connected to an external permanently installed button X1 2 must not be connected with the remaining controls in order to prevent an unintended release with a restart pulse under some circumstances Force guided normally closed contacts can be monitored in the restart circuit relay monitoring Please note the Chapter 5 Information for Planning and Mounting and 9 1 Electrical power supply Channels for zone pair changeovers FP 1 to FP 4 To activate the zone pairs apply 24V see Chapter 9 1 to the following inputs X1 4 FP 1 X1 6 FP 2 X1 7 FP 3 e X1 8 FP 4 The following points also apply for the switchover e The switchover must be made within 40ms i e after 40ms one of the input connections shown in Table 6 1 1 must be valid and provided stable During the switchover time the old zone pair is monitored the new one after max 80ms e The switchover process executed by
61. ger zone at a position from which the entire danger zone can be viewed The areas that will be released must also be referred to in an easily understandable manner The startup restart interlock affects all detection zones and does not depend on any detection zone changeovers Please comply with the safety notes in Chapter 3 and Chapter 5 7 7 5 7 9 5 7 9 1 5 7 9 2 Calculating the dimensions of the detection zone of an AGV application Following are the specifications and calculation examples for the mobile safeguarding of automatic guided vehicles According to IEC 61496 3 the following formulas apply for calculating the safety distance S Vmaxacv T Sstop Vmaxacy Maximum speed of the AGV in mm s T Response time of the scanner and the AGV ins Sstop Braking distance of the AGV until standstill in mm Direction related minimum depth of the detection zone and additions The depth of the detection zone in the direction of travel with respect to the distance between the edge of the roadway and the boundary of the detection zone is calculated according to the following formula St Vmaxacv Tscan Tacv Sstop Lstop Ztot Sr Depth of the detection zone in the direction of travel in mm Vmaxacv Maximum speed of the AGV in mm s Tscan Response time of the scanner in s Tacv Response time of the AGV ins Lstop Factor for wear and tear on the brakes Ztot Total of the system and applicat
62. hly reflective surfaces made of metal or ceramic in the area of the detection zone and at the height of the scanning plane Such objects can cause measurement errors e In order to ensure a consistent detection height at every point of the detection zone the scanner and hence the scanning plane must be placed parallel to reference section e f the Restart interlock function is included the restart button must be located outside the detection zone in a place that is visible from the entire danger area e Ifthe scanner is used without a start interlock or startup test with automatic start restart a startup warning visual or acoustic must be provided e The scanner must not be used as an aid for climbing If there is any risk a suitable diagonal protection 45 should be set up Please comply with the safety notes in Chapter 3 Chapter 5 4 7 and 5 7 8 25 5 1 5 2 5 2 1 26 Attachment and dimensions For attaching the SD3 A1 four drill holes are located at the back of the unit Any laser scanner installation point is possible with mounting The SD3 A1 can for example also be mounted on the head or inclined facing down The mounting system MS SD3 1 is available as an accessory offering following advantages e Speeds up the mounting process by providing screws that are accessible from the front e Allows vertical inclinations of up to 9 either up or down infinitely adjustable within this range
63. ibed in the following tables apply 57 58 Table 6 1 1 applies with activation start or switchover of zone pairs 1 to 8 Zone pair Control input e FP3 FP4 zi a C EE eoreparoietne C E Table 6 1 1 Connection of control inputs FP 1 to FP 4 with activation of zone pairs 1to8 The following points also apply for the switchover e The switchover must be made within 40ms i e after 40ms one of the input connections shown in Table 6 1 1 must be valid and provided stable During the switchover time the old zone pair is monitored the new one after max 80ms e The switchover process executed by the control unit must concur with the laser scanner s configuration which was set beforehand with SD3SOFT If these points are not observed the laser scanner will fail within 40ms and will show this with the additional 2Hz flashing of the green LED 1 6 2 Practical AGV application example The following example shows the sequence of zone 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 instruct
64. in excess of 500mm K may be taken to be 1 600mm s But in this case the safety distance is subject to a minimum value of 500mm T Overall time of delay in seconds a total consisting of Response time of the laser scanner Adjustable max 200ms Overtravel time of the machine including the Based on measurement of controls overtravel time C 8x d 14 inmm Added margin dependent on the depth of penetration of the detection zone based on the resolution of the laser scanner C 30mm 128mm C 40mm 208mm d The resolution to which the laser scanner Here 30mm or 40mm has been set In this connection please also have regard to the illustrations given in this chapter 5 6 4 Defining the reference boundary a SD3 A1 DZ1 Detection zone 1 enabled b Reference boundary of the detection DZ2 Detection zone 2 disabled zone S Safety distance G Danger point m Screen e Distance from the screen to the intrusion zone of the danger point e gt 150mm tolerance zone the reference boundary must be defined with reference to the screen Fig 5 6 1 Safeguarding of danger point based on hand and arm protection with monitoring of a reference boundary The reference boundary must cover at least two sides of the detection zone The detection zone itself must be defined in such a way that no gaps can arise through which or over which a person could reach without being detected The detection zone must also provide safeg
65. in the calculation of the safety related distance As an alternate solution have the surfaces been changed e g matted Does the risk assessment take into account the fact that detection zone heights above 300mm are considered high enough to crawl under in the Standard EN 999 10 Is access to the danger area only possible through the activated detection zone of the SD3 A1 in question or are other entrance or access possibilities safeguarded with suitable safety parts for example guard fences 11 Is the possibility of being between the activated detection zone and the danger area reliably ruled out 12 Is an installed protection to prevent walking behind e g undercut in effect 13 Is the SD3 A1 able to cover the entire danger area Are dead zones excluded Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes No No No No No No No No No No No No No 83 84 14 Has the effectiveness of the activated detection zone been tested with the black test piece 70mm diameter 15 Does the base mark match the correctly identified detection zone 16 Is the start restart button for resetting the SD3 A1 positioned according to requirements and does it work properly 17 Does the SD3 A1 work in all necessary operating modes and during the entire motion of the machine that is causing a hazard 18 Is the motion causing the hazard stopped when e
66. ing mirror 29 5 3 4 Range of the measurement field The maximum distance for contour measurement at a reflectance factor of 80 white gypsum is 50m Remission in 10000 Reflectors 1000 White gypsum 100 Writing paper Gray carton 10 He _ Black corduroy 1 8 Distance in m a Detection zone b Measurement field Fig 5 3 2 Detection of objects depending on the reflectance factor The reference point of the distance measurement is the axis of the rotating mirror 5 3 5 Required detection zone additions Z The SD3 A1 is equipped with a selectable dust algorithm to ensure optimum freedom from interference The following detection zone additions must be taken into account Addition Zsm if dust suppression is deactivated Addition Zsmif dust 83mm for a detection zone size lt 3 5m suppression is activated 100mm for a detection zone size 2 3 5m Activation and deactivation of the function is performed by SD3SOFT 30 5 4 5 4 1 5 4 2 If retro reflectors or very shiny surfaces such as polished or enameled metals or ceramics may possibly be present in the scanning plane the following table applies Addition Zreet if retro Omm for reflectors more than 1 2m behind the reflectors or very shiny detection zone line surface treated materials 110mm for reflectors up to 1 2m behind the e g metals and ceramics detection zone line are present in the scanning pl
67. ion also apply for side guarding on AGVs With AGVs that drive along conveyor segments it should always be ensured that big enough undercut is provided see also details in Chapter 5 4 4 If the structure of the conveyor segment does not allow an undercut then it must be assumed that a person is in the space between the vehicle and the conveyor This is especially the case with spaces of more than 100mm This person in the space between vehicle and conveyor should be detected simultaneously with a person in the driveway which must be taken into consideration with the dimensioning of the detection and warning zones The same safety distance calculations therefore apply A laser scanner resolution of 150mm is required to detect an entire person This safety relevant setting is automatically set in the SD3SOFT configuration and diagnostics software with selection of the person detection presetting The definition of a reference contour as with access guarding is not necessary as the approach of the person to be protected is made in the direction of the detection zone If the conveyor segment height is over 500mm and the distance between vehicle and conveyor is more than 100mm then the detection zone between vehicle and conveyor can be aligned With conveyor segment heights below 500mm there is the increased danger of the conveyor segment being crossed over In this case the alignment of the detection zone with the conveyor edge guarantees detection
68. ion cannot be reset until the detection zone is clear Depending on the operating mode the reset can be initiated either automatically or manually DZ Detection zone max 4m WZ Warning zone max 15m a Maximum registration of measurement values max 50m b Detection zone programmed in the SD3 A1 example c Warning zone programmed in the SD3 A1 example d Configurable detection zone and warning zone expansion 5 e Configurable detection P F 7 TI zone and warning zone 4g expansion 5 f Object in the detection zone c b DZE 1 1 i 1 Fig 2 1 1 The 190 angle range of the SD3 A11 is divided into 0 36 angle segments A laser diode coupled with transmitter optics produces focused light pulses These pulses are projected across the monitored surface by a rotating mirror in such a way that a light pulse is triggered in each of the angle segments within 40ms scanning rate 25 scans s Fig 2 1 2 Functional principle of the SD3 A1 The SD3 A1 can detect people up to a distance of 4 0m even if they are wearing very dark clothing or exhibit a low degree of reflectance Dangerous movements are brought to a standstill by two failsafe semiconductor outputs 10 2 2 Objects min 150 x 150mm are detected up to a distance of 15m corresponds to the warning zone and signaled by way of a non safety related semiconductor output Eight programmable zone pairs each of which consists of
69. ion manual software operation for the SD3SOFT Activating AGV position Deactivating AGV control of an ZP an a A Straight section Highspeed o O speed z3 3 Beginning of the curve Steering lock curve ZP 1 Straight section ZP 3 Steering lock straight High speed FP 1 x detection zone 1 x warning zone Table 6 2 1 Practical AGV application If the AGV is controlled by a PLC for instance which corresponds to Category 3 or higher according to DIN EN 954 1 the previous zone pair ZP can be deactivated immediately after the next zone pair has been activated with no time delay This results in a faster switching sequence The applicable safety directives and standards as well as the operating instructions for the systems must be strictly complied with 59 60 a AGV at high speed b AGV at low speed c AGV curving to the left at low speed d AGV at high speed Fig 6 2 1 Example of a zone pair changeover for an AGV on a curved route Fig 6 2 2 a AGV driving fast b AGV driving slowly c AGV maneuvering d Loading ramp Example of zone pair changeover with combined with reducing speed of the AGV 61 7 1 7 2 62 Functions of the SD3 A1 The SD3 A1 is equipped with the X1 and X2 interfaces The following functions are available through them Restart Depending on the operating state the restart input X1 2 has several functions e Enables the restart interlock followin
70. ion specific additions in the direction of travel in mm Zrot Zsm Zreri Zarur Zau Zsm Scanner measurement error in mm ZrerL Addition of the reflectors taken into account in mm Zar ar Addition for inadequate floor clearance by the AGV in mm Zau Application specific addition in mm Maximum range of detection zone Smax S Sppier SenirF GenirFF Zs Smax Maximum range of the detection zone in mm St Depth of the detection zone in the direction of travel in mm Ssorr Largest width of the detection zone in mm Ggpirr Largest width of the danger zone in mm Zs Sum of the system and application specific additions to the side in mm Zs Zsm Zrer Zau Zsm Scanner measurement error in mm ZrerL Addition of the reflectors taken into account in mm see Chapter 5 3 5 Zau Application specific addition in mm 53 54 GBDIFF SBDIFF SD3 A1 AGV Detection zone Axis of the rotating mirror gpiFF Largest width of the hazardous zone Sgpirr Largest width of the detection zone Smax Geometrical maximum distances a b c d G Str Depth of the detection zone Ztot Total of the additions in the direction of travel Zs Total of the additions to the side Fig 5 7 4 Considering the maximum measurement distance for safeguarding AGVs In accordance with DIN EN 1525 a minimum safety distance of 0 5m width between the vehicle and its environment must be maintai
71. ity 5 7 8 Restart 5 7 9 Calculating the dimensions of the detection zone of an AGV application 5 7 10 Side guarding configuration on AGVs Details on Switching Over Detection and Warning Zones 6 1 Sequence of zone pair switchovers 6 2 Practical AGV application example 7 1 7 2 Channels for zone pair changeovers FP 1 to FP 4 7 3 Alarm 1 X1 5 7 4 Alarm 2 X1 15 7 5 OSSD 1 X1 12 and OSSD 2 X1 11 T6 Data commUNICaAON isseire Aaaa AAAA AAAA AAAA REEE Integrating the SD3 A1 into Machine Controls ssssessessessuseuseureurunrunnunnunnunnunnunnunnunnunennennnnnnnne 64 8 1 Integrating the SD3 A1 with external wiring with relays and eightfold Zone pair CHANGE OVE sissit rn EREE EE 65 8 2 Connecting the SD3 A1 to a safety sequence circuit with manual restart relay monitoring without Zone pair changeover ceceeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeteeetteeeeeeaeees 67 8 3 Connecting the SD3 A1 to a PLC with corresponding safety level Category 3 or higher EN 954 and zone pair changeover cccceeeeeeeeteeeeeeeeeeteeeeeneeens 68 Electrical Connection 9 1 Electrical power supply 9 2 Connecting the PC and control cables to the scanner 9 3 Connector assembly 9 4 Points to consider when preparing and laying the cables 9 5 Interface pin assignments Commissioning 10 1 Hardware and software requirements 10 2 Installing SD3SOFT and starting up the SD3 A1
72. k OSSD 2 13 N C 14 White Brown 15 Brown Alarm 2 Table 12 3 1 Coding of the control cable X1 95 13 13 1 13 2 96 e Cylinder Technical Data Test pieces 500mm in length The following test pieces are defined for the purpose of controlling the effectiveness of the monitoring function by the detection zones reflectance factor 1 8 0 2 for stationary applications diameter 30 40 50 70 150mm mobile systems e g AGV Detection zone Cylinder 1 000mm in length 200mm in diameter reflectance factor 1 8 0 2 for from housing Detection range SD3 A1 at a resolution of 30mm 1 60m at a resolution of 40mm 2 20m at a resolution of 50mm 2 80m at a resolution of 70mm 4 00m at a resolution of 150mm 4 00m Reflectance factor Min 1 8 Min adjustable range 200mm Detection range of test piece Min Omm Response time Min 80ms 2 scans Adjust up to 640ms 16 scans Number of detection zones 8 changeover via switch inputs Output 2 failsafe PNP transistor outputs 24V 250mA Safety category Requirement class 4 as per DIN V 19250 fail safe Category 3 PLd as per EN ISO 13849 1 2006 Type 3 as per DIN EN 61496 1 and IEC 61496 3 SIL 2 acc to IEC 61508 Startup The startup test and start interlock can be adjusted separately Restart Automatic or manual adjustable from 160ms to10s Table 13 2 1 Technical data detection zone
73. klist for daily test of mobile applications by responsible operating personnel 82 1 7 8 9 Are there any problems in the external state of the protective equipment the cable cable connections and any command devices Are the fastening screws in the mounting system firmly tightened Are the fastening screws in the SD3 A1 firmly tightened Are both protective caps X1 and X2 screwed on and are the firmly in place Do the safety equipment and command devices show any safety relevant changes or gaps in safety e g by widening the vehicle If the protective function of the SD3 A1 is present for all required monitoring cases e g testing the switch off function with a test piece along the detection zone contour the LED 3 for SD3 A1 must light up with each attempt and the movement that poses a danger must be stopped immediately Possibility of danger to the person running the test must be excluded Does the vehicle actually stop within the limits defined by the responsible specialist test of switch off function using a test piece Is the possibility of danger to the person running the test excluded Is the startup test restart interlock if there is one working Do the necessary detection zones match the configuration protocol 10 If correct functionality is not certain or id the SD3 A1 LED 5 is flashing take the vehicle out of operation immediately Are any doubts resolved Yes Yes Yes Yes
74. lect this function as needed to connected restarting of the machine to a manual approval It affects all detection zones and does not depend on any detection zone changeovers For information on how to configure the scanner appropriately please refer to SD3SOFT Section Safety relevant parameters folder The restart button must be mounted so that e the entire danger zone or detection zone area can be viewed from the operating position e itis not possible to directly step or reach into the danger zone or danger point from the operating position The button refer to the areas to be enabled in a easily understandable manner Please comply with the safety notes in Chapter 3 and 5 4 6 37 5 4 8 38 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 Cc Cmn Hin Hmax KxT C Cun 850mm 1 200mm 0 4H Hun 15 d 50mm Hmax 1 000mm Safety distance minimum distance from the danger zone to the point of detection to the plane of detection or to the detection zone in mm Approach speed of a person or a person s body parts 1 600mm s in mm s Lag time of the entire system response time and braking time until standstill ins Safety related constant to consider entry int
75. lectrical power to the SD3 A1 is disconnected and is a confirmation of the start restart button necessary to reset the machine after the power is restored 19 Are all test and parameter inaccessible to unauthorized personnel 20 Is an identifying sign placed on the machine for the daily test of the SD3 A1 where it is clearly visible for operating personnel Yes Yes Yes Yes Yes Yes Yes No No No No No No No Checklist for testing mobile applications The following checklist represents an aid It helps in but does not replace the test before the initial startup as well as the regular tests performed by a trained specialist 1 Is the mounting position and adjustment of the SD3 A1 correct and is the possibility of misusing the SD3 A1 for example to climb on excluded Is the external condition of the additional safety equipment and control devices free of problems Are all connection pieces and connection cables in flawless condition Are the two safety outputs OSSDs connected to the following vehicle control system in accordance with the corresponding safety category Are the following switch elements that are controlled by the SD3 A1 for example contactors with forced contacts or safety valves monitored by the feedback loop EDM Does the actual connection of the SD3 A1 to the vehicle control system match the circuit diagrams Has the safety distance for safeguarding automatic
76. lustrations in this chapter Safety related settings and calculation of the safety distance In order to safeguard the protective equipment against inadvertent misadjustment and manipulation the detection zones of the SD3 A1 must be defined on the basis of a reference boundary To make it possible to recognise the hand or arm of a person the laser scanner must have a resolution of 30 or 40mm These safety related values will be automatically set in the SD3SOFT configuration and diagnosis software when the presetting Hand protection or Arm protection has been selected At the same time the detection zone limits will be limited to 1 60m or 2 20m and cannot be extended beyond this 45 To safeguard the danger point a safety distance S must be observed between the detection zone of the laser scanner and the danger zone The SD3 A1 can fulfill its protective function only if it has been installed and positioned in such a way as to allow for an adequate safety distance The safety distance ensures that no body part whatever can reach the danger point until the hazardous movement of the machine has come to a complete standstill The safety distance S when safeguarding a danger point may be calculated based on EN 999 by means of the following formula S KxT C S _ Safety distance in mm K Approach velocity in mm s At a close distance of 500mm a velocity of 2 000mm s should be assumed If the calculation involves a distance
77. m s T Overall time of delay in s a total consisting of Response time of the laser scanner Here 80ms Overtravel time of the machine including the Based on measurement of controls overtravel time C Added margin on account of the possibility of manual intrusion Here 850mm Please also have regard in this connection to the diagrams given in this chapter 5 5 4 Definition of the reference boundary o AX A SD3 A1 DZ1 Detection zone 1 enabled O gt A i b Reference boundary of the detection zone S Safety distance e Height of frame with reference boundary G Danger zone recommended value e gt 1 200mm Fig 5 5 1 Access protection by passage monitoring with system check of a reference boundary 44 5 6 5 6 1 5 6 2 5 6 3 The reference boundary must cover at least two sides of the detection zone The detection zone itself must be defined in such a way that no gaps can arise through which a person could pass through the passage without being detected The reference boundary is defined with reference to the non moving parts of the passage These will then be constantly monitored by the laser scanner so that any individuals intruding or other manipulative intervention will be detected beyond the possibility of doubt In defining the reference boundary please also have regard to the indications given in the instruction manual software operation for the SD3SOFT configuration and
78. n new condition Dirty and scratched panes must not be calibrated and used They would represent a safety risk since the laser light would be weakened under some circumstances 89 11 7 3 90 Procedure when using the SD3SOFT user software version 1 00 or later 1 Starting the PCs 2 Connection of X1 electrical power supply with zone pair activated and X2 RS 232 cable 1 1 Start SD3SOFT user software Select the Authorized user access level 5 Confirm the echo data shown by the scanner Click on the Calibrate optical window monitoring icon under System data Start the optical window calibration with Calibration lasts a few seconds typically with values between 100 and 700 8 Click on the Close button 11 8 11 8 1 Cleaning Cleaning the optical window when dirty Different methods will work better under different conditions depending on load and medium What is the best approach Note SD3 A1 clean sets are available for cleaning the optical window They contain a special cleaning agent and suitable cleaning cloths Two sizes are available For z more information see the chapter entitled Accessories and spare parts Please note Generally it is sufficient to remove particles relatively 4 quickly moving the cleaning cloth horizontally If i cleaning takes longer for example because of p fingerprints the scanner will report the fault in optical
79. n on AGVs can be found in Chapter 5 7 9 and 5 7 10 Other possible applications e Object and contour measurement e Logistics counting measuring controlling e Projection control e g in fully automatic parking ramps or lots e Safeguarding or monitoring enclosed spaces e and many more Information for Planning and Mounting It is essential that the following key points be complied with so that the SD3 A1 can provide optimum performance e The SD3 A1 must be placed so that areas of access to the danger zone being monitored are completely covered by the detection zone e The mounting position of the scanner should provide protection from humidity dirt and extreme temperatures below 0 C or over 50 C e 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 e Reinforcements cover panels mounting niches and other machine elements may not in any way impair the field of view of the scanner e If there are areas of shadow caused by fixed obstacles that were defined as part of the detection zone boundary these should be safeguarded e g by protective 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 e Be sure that there are no retro reflectors or hig
80. ne for the daily test of the SD3 A1 where it is clearly visible for operating personnel Yes Yes Yes No No No Replacing the optical window General information e Only professionally trained personnel are permitted to replace optical windows e Be careful everything stays clean during all jobs If possible work in a dust free environment An adverse environment is not good for working on the device 1 Loosening the housing parts Loosen the four Allen screws on the rear housing wall Take the two housing parts carefully apart P from each other and place them on a level surface 2 Dismounting the optical window Loosen the screws on the fastening straps Remove the fastening straps Press the old optical window out through the rear through the housing 87 88 3 Checking the condition of the scanner 4 Inserting the new optical window Old fastening strap New fastening strap Please do not fail to observe Check the mirror optics and housing parts to make certain they are free of dust Dry if necessary with a dry oil free light jet of compressed air with appropriate components Do not touch any parts in the device Avoid leaving fingerprints grease from fingers may cause the device to function improperly Hold the new optical window by the sides and carefully insert it in the correct position pressing the optical window together slightly as you do so Make certain the
81. ned 5 7 9 3 5 7 9 4 Sample calculation of the depth of a detection zone This example is based on the following typical application data without access against the direction of travel and without retro reflectors Largest width of the danger zone from the axis of the rotating mirror Gppirr Response time SD3 A1 selectable Tscan Factor for wear and tear on the brakes Lstop 1 1 fixed addition to account for wear and tear on the brakes Distance between AGV and floor 90mm results in an addition of 50mm according to Fig 5 7 3 for calculating the addition for inadequate floor clearance The formula S Vaaxacv Tscan Tacv Sstop Lstop results in a safety distance of S 1 800mm s x 0 08s 0 1s 1 900mm x 1 1 2 414mm The formula S7 S Zsm ZrerL Zaria Zau results in the following required depth of the detection zone in the direction of travel Sr 2 414mm 83mm 0mm 50mm 0mm 2 547mm Sample calculation of a maximum range of a detection zone The formula Smax S1 Sepirr Sspirr Gepirr Zs yields under consideration of the width of the danger zone results in the maximum distance to be monitored 1 2 547mm 1 483mm Smax SspirrF 1 400mm 83mm 1 483mm 2 947mm Smax 55 5 7 10 56 Side guarding configuration on AGVs All previous considerations and the Chapter 5 7 9 Calculating the dimensions of the detection zone of an AGV applicat
82. nent current of 2 5A must be ensured before safeguarding begins in order to guarantee that the fuse will be triggered in case of a fault In keeping with electrical safety requirements the power to the SD3 A1 all connected input and output circuits must be provided by a power supply unit with protective isolation from a safety transformer according to IEC 742 or comparable this also applies for the use of battery chargers for AGV applications Connecting the PC and control cables to the scanner Two connector adapters with cable screw coupling are supplied with the SD3 A1 Two of these are needed to accommodate the 9 pin Sub D connector and the 15 pin Sub D jack PC cable and control cable A housing is used as protection of the X2 interface when data communication with the PC is not desired The cable screw couplings can accommodate cable diameters from 6 5mm to 10 5mm a Jack X1 b Connector X2 Fig 9 2 1 Preparing the connectors 69 9 3 9 4 70 The connector adapter of control cable X1 must be connected with interface X1 and screwed tightly to the SD3 A1 The connector adapter of cable X2 or else the X2 dummy cap without a cable must also be screwed tightly to the SD3 A1 Screw thread bolts are located on the top of the scanner housing for this purpose If one of the two connection housings is missing the SD3 A1 no longer meets the requirements of protection type 65 For information on the assignment of the connect
83. ns make sure to consider Chapter 5 4 and 5 7 After the detection zones have been set make a printout of the following information Detection zone contour with the X and Y coordinates Date Serial number of the scanner Name of the safety official When calculating the additions be sure to consider whether the dust algorithm is deactivated or activated see Chapter 5 3 5 3 6 e When calculating the safety distances be sure to consider all delay times such as the response time of the scanner response time of the control elements and braking times and or stopping times of the machine system or AGV Variations in delay time caused by factors such as reduced braking power must also be taken into consideration e The effectiveness of the switch off function must be tested along the defined contour of the detection zone during the initial startup and subsequent to any changes made to a machine or system e 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 e Inthe event that there is insufficient room available to allow the full dimensions of a detection zone for example because of the position of the scanner additional safety measures e g protective grids must be installed e Following each definition of and change to the detection zones the configuration must be che
84. o the danger zone before the protective device is triggered in mm Minimum value of the safety related constant 850mm in mm Height of the scanning plane from the reference point in mm Minimum height of the scanning plane from the reference plane in mm Maximum height of the scanning plane from the reference plane in mm Resolution of the scanner 70mm throughout the detection zone in mm 5 4 8 1 5 4 8 2 Additions and minimum depth of detection zone The sum of the system specific and application specific detection zone additions see Chapter 5 3 5 is calculated according to the following formula Zrot Zsm ZreFL Zau Zrot Zsm ZREFL Zau Sum of the system specific and application specific detection zone additions inmm Scanner measurement error in mm Addition of the reflectors taken into account in mm 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 Sr K x Tscan TmacH Trac Liac Zror Sr K Tscan TMACH TLac Liac Depth of detection zone distance from danger area to detection point or line including system and application specific additions in mm Approach speed of a person or a person s body parts 1 600mm s in mm s Response time of the scanner in s Response time of the machine or system in
85. op and triggering of the manual restart interlock Fig 4 2 1 Access guarding by whole body trip control with system check of a reference boundary 4 3 Safeguarding of danger points based on hand and arm protection If the machine operator in close proximity to the danger zone needs to halt the hazardous movement of the machine or to coordinate the handling of workpieces or their removal from the machine the machine must be provided with protection at the danger point To safeguard danger points in this way a protective system needs to be installed The SD3 A1 is certified as a system providing hand and arm protection and is able in such a situation to guarantee flexible safety conditions in the workplace This may be combined with alternation of the detection zones In order to safeguard the protective equipment laser scanner and side mounted panels which serve as a reference and provide additional access protection against inadvertent misadjustment or manipulation the detection zones of the SD3 A1 must be defined on the basis of a reference boundary An example of the configuration of the SD3 A1 for the protection of danger points based on hand and arm protection may be found in Chapter 5 6 a D3 A1 b Reference boundarys of the detection zones DZ1 Detection zone 1 enabled DZ2 Detection zone 2 disabled c Emergency stop and manual triggering of restart interlock acknowledgement for switchover Fig 4 3 1 Safeguarding o
86. or please refer to Chapter 2 2 and 9 5 Connector assembly Every connector adapter consists of the following individual parts e Housing with sealing ring and fastening nuts e Cable screw coupling M16 with dummy plugs e Sub D9 connector and or Sub D15 jack each with a solder connection Points to consider when preparing and laying the cables e The cross section of cable X1 must be at least 0 5mm e The outer diameter of the cable must be between 6 5mm and 10mm e The maximum cable length for X1 is 50m e The maximum cable length for X2 is 10m for RS 232 e The maximum cable length for X2 is 50m for RS 422 twisted pair e Use shielded cables e Connect the cable shielding with PE to the electronics cabinet only e The cables must not be laid loose Scanner control cables may not be laid in a stand parallel to power supply cables for machines This minimizes the effects of inductive interference factors from motors carrying high current In addition the cables should be laid so that they cannot be damaged e g by being crushed or pinched Cabling prepared for connection to the scanner is available as an optional accessory in various lengths and for both interfaces For further information see Chapter 13 9 5 Interface pin assignments Pin assignments for connector X1 soma osm O Power supply ground UB Restart Input scanner reset and connecting of the restart button 24V DC power supply protected by a
87. p cleaning materials and cloths that scratch must never be used a 4 p Fig 11 8 2 Cleaning diffusing light panes Note Dirt can often be eliminated in a work step If the optical window is cleaned within 4 seconds the scanner is not turned OFF Note The order designations are available in Chapter 12 2 92 12 12 1 Delivery Package The basic unit consists of SD3 A1 SD3 A1 connector complete 15 pin interface X1 SD3 A1 connector complete 9 pin interface X2 Instruction manual connection and operation for SD3 A1 instruction manual software operation for SD3SOFT Configuration and Diagnostic Software SD3SOFT on CD ROM including the SD3SOFT instruction manual Mounting screws 4 pieces Instruction manual safety instructions for SD3 A1 Disposal Laser scanners that are no longer in use must be disposed of in an appropriate manner 93 12 2 94 Accessories and spare parts Brief description Description MS S3 1 SD3 A1 mounting system for securing and adjusting the SD3 A1 SD3 DEMO 24V SD3 A1 configuration and test equipment 24V DC SD3 CP C5 SD3 A1 control cable with ConfigPlug ready made at scanner side 5m straight SD3 CP C10 SD3 A1 control cable with ConfigPlug ready made at scanner side 10m straight D3 CP C25 SD3 A1 control cable with ConfigPlug ready made at scanner side 25m straight SD3 CP C50 SD3 A1 control cable with ConfigPlug re
88. r reference measurement Glare from another source of light 905nm or deviation in motor rotation speed 2701 Processing of messages for 1 Invalid diagnostic command system diagnostics received Software and firmware incompatible 2702 Processing of requests for 3 Invalid diagnostic value requested diagnostics data Software and firmware incompatible 2800 Processing of inputs for 2 2 detection zones active longer detection zone changeover than 1s 2800 Processing of inputs for 3 The detection zone changeover detection zone changeover that occurred does not correspond to the requirement programmed in the scanner 2800 Processing of inputs for 4 More than 2 detection zones detection zone changeover selected during operation 2800 Processing of inputs for 6 Unevaluatable data or defective detection zone changeover data quality for activation of detection zone 2800 Processing of inputs during 8 No detection zone activated during scanner operation scanner operation 2801 Test of inputs for detection 1 Error during testing of inputs for zone changeover detection zone changeover internal fault 2802 Initialization of detection zone 3 The detection zone deactivation changeover that occurred does not correspond to the requirement programmed in the scanner 2802 Initialization of detection zone 4 More than 2 detection zones changeover selected during power ON 2802 Initialization of detection zone 6 Unevaluatable data or defective changeover data quali
89. rating instructions provided by the machine or system manufacturer System availability There must be a buffer distance of 83mm between the surrounding contour and the detection zone contour including the additions This distance increases the up time of the machine or system since it prevents the surrounding contour from being detected as relevant for generating a switch off signal If there is an undercut across from the scanner that is impossible for a person to step beneath see Fig 5 4 4 the depth of the undercut can be calculated according to the following formula Zumn 2Z 83mm d Zumin Depth of the undercut in mm Z Required detection zone additions in mm d Resolution of the scanner d 70mm This is possible since it is absolutely certain that a person will be detected in front of the undercut Furthermore the dust algorithm of the SD3 A1 can be implemented if floating particles may be present in the area This algorithm which can be activated in the user program SD3SOFT prevents the machine or system from being switched OFF unintentionally Please note Chapter 5 3 5 If the danger zone analysis allows a multiple evaluation detection errors caused by floating particles can be decreased The number of evaluations that is decisive for the response time of the scanner Tscan and thus also requires a larger detection zone can be set in the user program SD3SOFT In the event of an error event that lasts
90. responsive to Diffuse Reflection AOPDDR C Standards DIN EN 775 DIN EN 1525 DIN EN 12895 Industrial robots Safety Safety of industrial trucks Driverless trucks and their systems Industrial trucks Electromagnetic compatibility 2 1 Directive Standard Designation National Standards DIN 15185 2 Warehousesystems with powered industrials trucks Table 1 3 1 Directives and standards This list does not claim to be complete In certain cases the concrete requirements of the application will necessitate the application of additional Directives and standards System Overview Brief description and functional principle of the SD3 A1 The SD3 A1 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 object the reflected light is received and evaluated by the SD3 A1 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 object is within the bounds of a previously defined area called a detection zone a safety oriented switching function is performed This switching function causes the semiconductor outputs to be switched OFF The safety oriented switching funct
91. se the system properly English and Japanese version of this instruction manuals are original Version V5 5 Reprinting and duplication is prohibited in whole or in part without prior approval of Panasonic Industrial Devices SUNX Co Ltd Contents 1 a E 1 1 Approval and declaration of EC conformity 1 2 Specialized technical terms and abbreviations 1 3 Directives and standards 2 System Overview 2 1 Brief description and functional principle of the SD3 A1 2 2 Special features of the SD3 A1 3 Safety Notes and Usage in Accordance with Intended Purpose 3 1 General safety notes 3 2 Usage requirements and usage in accordance with intended purpose 3 3 Restrictions for use 3 4 Information related to detection zone changeover 3 5 General information related to determining detection zone contours 3 6 Additional safety notes for stationary use 3 7 Additional safety notes for mobile use 4 Applications for the SD3 A1 4 1 Stationary safeguarding of the danger area 4 2 Access guarding by passage monitoring 4 3 Safeguarding of danger points based on hand and arm protection 4 4 Mobile safeguarding of automatic guided vehicles 4 5 Protecting transporter trolleys against collisions 4 6 Guarding the sides on AGVs AT Other possible ap Plicatl OMS seseceecsezvsevesecseseseecesessevseeveeeseseessassvisssissitsuitsuiesuesuibasessieesesetes 5 Information for Planning and Mounting
92. t reflect any light back to the sensor can falsify the measurement result More information is available in Chapter 5 3 5 Do not expose the SD3 A1 to flying sparks for example a welding flash Doing so may cause damage to the optical window Vapor smoke dust and all particles visible in the air have a significant negative effect on measurement values and will result in the semiconductor outputs being turned OFF Avoid extreme variations in temperature 3 4 e Make sure that the following types of light sources are not present on the scanning plane Laser light from one or more other scanners or sensors Infrared light Fluorescent light Stroboscopic light Please consider as well Chapter 5 2 e It must not be used for vehicles with internal combustion engines e The SD3 A1 is conceived for use inside enclosed spaces and with the operating parameters listed in the technical specifications temperature humidity shock vibration etc Please refer to the list of parameters in Chapter 13 e Avoid having reflective surfaces such as glass mirrors retro reflectors etc at fixed contours in the scanning plane If this is not possible an additional detection zone must be provided Information related to detection zone changeover If alternating operation is included in the design and thus detection zone changeover the activation and effect of the detection zone in question must match the alternating operating mod
93. tablished so that the SD3 A1 can be configured and the detection zones and warning zones can be programmed This is also necessary for displaying the measurement contours and for the system check The program SD3SOFT which is included with delivery makes this easy and convenient to do Refer to the instruction manual software operation to find additional important information and helpful explanations Hardware and software requirements The following components are required for the initial startup e D3 A1 e RS 232 interface cable 1 1 without cross connection e Shielded control cable for the power supply and for activating a zone pair e Power supply that meets the requirements specified in Chapter 9 1 e PC color monitor e SD3SOFT program The PC should fulfill the following requirements e Intel processor Pentium class or higher or compatible models such as AMD or Cyrix e Atleast 64MB RAM e CD drive e Hard drive with at least 50MB of free memory more if detection zone data and or configuration data are going to be stored e Mouse e Interface RS 232 serial e Microsoft Windows 95 98 NT 2000 XP 7 Installing SD3SOFT and starting up the SD3 A1 e First run the installation program start exe in order to install the program on the PC e Start the software by calling up the program e Connect the control cable and the PC cable e Then apply the supply voltage to th
94. there any problems in the external state of the protective equipment the cable cable connections and any command devices Are the fastening screws in the mounting system firmly tightened Are the fastening screws in the SD3 A1 firmly tightened Are both protective caps X1 and X2 screwed on and are the firmly in place Do the safety equipment and command devices show any safety relevant changes or gaps in safety e g changes in access possibilities or changes in the surrounding area If the protective function of the SD3 A1 is present for all required monitoring cases e g testing the switch off function with a test piece along the detection zone contour the LED 3 for SD3 A1 must light up with each attempt and the movement that poses a danger must be stopped immediately Possibility of danger to the person running the test must be excluded Is the startup test restart interlock if there is one working Does the base marking match the detection zone contour Do the necessary detection zones match the configuration protocol 10 If correct functionality is not certain or id the SD3 A1 LED 5 is flashing take the machine out of operation immediately Are any doubts resolved Yes Yes Yes Yes Yes Yes Yes Yes Yes Yes No No No No No No No No No No If the answer to any of the questions above is No the machine should be checked by a trained specialist 81 11 4 2 Chec
95. tings should be restored Please see the chapter entitled Set default configuration values in the instruction manual software operation for the SD3SOFT 79 80 Regular tests by a person qualified and authorized to perform the task Regular tests must be performed taking into consideration applicable local requirements especially for directives on machines and using work material and work safety directives The purpose of these tests is to discover changes for example lag times or manipulations on a machine vehicle or piece of safety equipment To do this see the checklists under Chapter 11 5 or 11 6 e Have the effectiveness of the safety equipment checked within the required periods but at least once a year by a trained and knowledgeable person e The checklists mentioned above are ideal for regular tests especially checks for safety related changes to the machine the vehicle or the piece of safety equipment Daily test by with test piece performed by responsible operating personnel The SD3 A1 is a safety oriented laser scanner of Category 3 It is extremely important however to check the effectiveness of the detection zone with the test piece daily or after a shift change This ensures that if the parameters or operating mode is changed the protective function is ensured at every point in the detection zone 11 4 1 Checklist for daily test of stationary applications by responsible operating personnel 1 Are
96. ty for deactivation of detection zone 2802 Initialization of inputs during 8 No detection zone activated during power ON scanner starting 3016 Monitoring the access 11 Confirmed one time password was authorization with one time entered incorrectly password Table 14 0 1 Diagnostic codes and causes 105 15 CE Marking Declaration of Conformity Itemized Essentials of EC Declaration of Conformity Manufacturer s Name Panasonic Industrial Devices SUNX Co Ltd Manufacturer s Address 2431 1 Ushiyama cho Kasugai Aichi 486 0901 Japan EC Representative s Name Panasonic Marketing Europe GmbH Panasonic Testing Center EC Representative s Address Winsbergring 15 22525 Hamburg Germany Product Electro Sensitive Protective Equipment Model Name Safety Laser Scanner SD3 A1 Trade Name Panasonic Application of Council Directive 2006 42 EC Machinery Directive 2004 108 EC EMC Directive 2011 65 EU RoHS Directive Tested according to EN ISO 13849 1 2008 Cat 3 PL d IEC 61508 2010 SIL 2 EN 62061 2005 A1 2013 SIL CL 2 IEC 61496 1 2012 IEC 61496 3 2008 EN 55022 2003 IEC 60825 1 A2 2001 Type Examination Certified by TUV SUD Product Service GmbH Ridlerstrasse 65 80339 M nchen Germany 106 107 Please contact Panasonic Industrial Devices SUNX Co Ltd H Overseas Sales Division Head Office 2431 1 Ushiyama cho Kasugai shi Aichi 486 0901 Japan W
97. uards against a person getting behind the barrier This can be very effectively managed by screening the sides of the danger zone The reference boundary should be defined with reference to the non moving parts of the screen arrangement The detection zone must be defined as large enough to ensure an overlapping greater than the tolerance zone of the reference boundary The detection zone will then be constantly monitored so that any body parts intruding or other manipulative intervention will be detected beyond the possibility of doubt In defining the reference boundary please also have regard to the indications given in the instruction manual software operation for the SD3SOFT configuration and diagnosis software 47 5 7 5 7 1 5 7 2 5 7 3 5 7 4 48 Safeguarding mobile machines Please comply with the safety notes in Chapter 3 The purpose of safeguarding is for protection e to protect people when entering variable danger zones e to protect objects located in the vehicle path e to protect the automatic guided vehicle and its load Installing adjacent laser scanners The SD3 A1 has been developed in a way that prevents several laser scanners from interfering with one other as much as possible An increase in the response time can however be caused by the installation of several adjacent laser scanners If none of the constructive measures section 5 2 1 described in the following sections or the specific adjustment
98. way of the trolley For this reason transporter trolley are used in enclosed areas equipped with suitable access safeguarding 4 6 DZ1 Detection zone 1 for slow speed DZ2 Detection zone 2 for slow speed Fig 4 5 1 Safeguarding a transporter trolley Please comply with the safety notes in Chapter 3 and Chapter 5 7 8 In these cases the SD3 A1 is used to detect people or objects in the vehicle path and then automatically bring the vehicle to a halt Select Manual restart mode The demands placed on the 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 Guarding the sides on AGVs In addition to the danger area guarding of the path of an AGV application in some cases it is also necessary to set up a side guarding This side guarding detects people in the space between vehicle and conveyor or detects people that stand on the conveyor edge in the vehicle area Furthermore the side guarding also enables the correct position of the load to be monitored so that a transport with overhanging load is not initiated 23 4 7 24 Fig 4 6 1 Bild 6 3 1 guarding the sides on AGVs Please observe the safety notes in Chapter 3 An example for the side guarding configuratio
99. window monitoring after cleaning press Restart Description Solution S Particles loose abrasive e Remove with no contact using suction or blow off with oil free air Wipe clean with a cleaning cloth wiping in one direction only Particles loose not abrasive e Suction off with no contact or blow off with oil free air Wipe clean with a cleaning cloth wiping in one direction only Particles adhering e Wet or moisten the cloth with cleaning agent Wipe clean with a cleaning cloth wiping in one direction only Particles statically charged Suction off with no contact e Wipe clean with cloth moistened in cleaning agent Particles drops greasy e Wet or moisten the cloth with cleaning agent Wipe clean with a cleaning cloth wiping in one direction only Drops of water Wipe clean with a cleaning cloth wiping in one direction only Drops of oil e Wet or moisten the cloth with cleaning agent e Wipe clean with a cleaning cloth wiping in one direction only Fingerprints e Wet or moisten the cloth with cleaning agent Wipe clean with a cleaning cloth wiping in one direction only Scratches e Replace optical window 91 11 8 2 Cleaning the optical window cleaning diffusing light panes The front and light panes and diffusion screens must be washed depending on the load on the application in question Generally this is a quick process q ra Fig 11 8 1 Cleaning the optical window Shar

SD3-A1 (Connection and Operation)

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