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SafeZone Mini Safety Laser Scanner User Manual

1. 27 BIG LOL ACCESS PIOLECHION PRA maana O 28 Fig 19 Minimum distance to the hazardous area cece cece eee aaa aaa 29 FIGs 207 Stopping danna e 31 Fig 21 Stopping distance as a function of the vehicle velocity aaa 31 Fig 22 Supplement due to lack of ground clearance aaa 32 Fig 23 Diagram of ground clearance of the vehicle c cece eee kaaa aaa aaa 32 Fig 24 Mounting height MM IA wee oe Med KNANG AGE a 33 FIG 25 Unpr tecten areas A REINER elssltehisiter 33 Fig 26 Preventing unprotected areas cc cece cence ee ccenecenceseeecasseseeseueennes 34 Fig 27 Mounting example for front and side protection in a direction oftravel 34 Fig 28 Mounting example for all round protection in all directions of travel 34 Fig 29 Prevent crawling beneath standing behind climbing over aaa 35 FIG 3 OF DIFECLMOUNUING AA 36 Fig 31 Mounting with mounting kit 2 including protection for the optics cover 36 Fig 32 Mounting with mounting kit2 cc cece cee cece BA e eee e eee a 37 El 33 Opposite MOUNTING ASS 37 Fig 34 Offset parallel mounting aasam 37 A AA a ANNA TANANG BULA AN ARA AA 38 Fig 36 Reverse mounting parallel offset aasawa aaa aaaaa an 38 Fig 37 Reverse mounting of two SafeZone Mini with parallel offset 38 Fig 38
2. Ground clearance of the vehicle in mm 60 50 0 50 100 150 Supplement 2 in mm Protective field width The width of the protective field must cover the width of the vehicle and the supplements for the measurement error and the lack of ground clearance How to calculate the protective field width Sp see EN ISO 13855 gt Calculate the protective field width Sp using the formula Sp Fg 2Xx Z Zp Zr Where Fg Vehicle width Z General safety supplement of the SafeZone Mini 100 mm 3 94 in Zp Supplement for any reflection related measurement error of the SafeZone Mini le Supplement for any lack of ground clearance of the vehicle 32 Rockwell Automation Publication 10000337275 Ver 00 December 2012 Chapter5 Mounting Height of the scan plane ATTENTION Mount the SafeZone Mini such that the scan plane is at a maximum height of 200 mm 7 87 in In this way also persons lying down will be reliably detected Tilting the protective field so that objects with a diameter of 200 mm 7 87 in are not detected is not allowed We recommend aligning the scan plane horizontally at 70 mm 2 76 in Fig 24 Mounting height mm in Set protective s field length y 150 5 91 i 190 7 48 Set protective a field length 4 150 5 91 110 4 33 Note To produce the optimal scan plane you can also mount the SafeZone Mini reversed Methods of p
3. The SafeZone Mini safety laser scanner operates correctly as a protective device only if the following conditions are met e The control of the machine system or vehicle must be electrical e It must be possible to transfer the dangerous machine system or vehicle state to a safe state using the OSSDs on the SafeZone Mini at any time i e before a person has reached the hazardous point or hazardous area Or It must be possible to transfer the dangerous state of the machine the system or the vehicle to a safe state at any time using the OSSDs on a safety controller connected to the SafeZone Mini e The SafeZone Mini must be mounted and configured such that it detects objects as they enter the hazardous area see Chapter 5 Mounting on page 35 and Chapter 9 Commissioning on page 47 e The safety laser scanner optical path must always remain clear and is not allowed to be covered by transparent objects such as protective windows Plexiglas lenses etc The safety laser scanner s protective function can only be ensured if the contamination measurement function is not bypassed by such measures Principle of operation The SafeZone Mini is an optical sensor that scans its surroundings in two dimensions using infrared laser beams It is used to monitor hazardous areas on machines or vehicles Send pulses SafeZone Mini Send pulses Receive pulses Rockwell Automation Publication 10000337275 Ver 00 December 2012
4. gt Check the wiring for short circuit to OV AE gt Check the wiring for short circuit to 24V connection 2 Short circuit to OV at OSSD gt Check the wiring for short circuit to OV connection 2 Rockwell Automation Publication 10000337275 Ver 00 December 2012 53 Chapter 11 Diagnostics Extended diagnostics 54 Note Bein Short circuit between OSSD gt Check the wiring and rectify the error ba connection 1 and 2 Flag General OSSD wiring error gt Check the complete wiring of the OSSDs The SafeZone Mini is receiving gt For the correct function of the safety laser scanner no measured values within a always ensure that measured values are received within range of at least 90 a range of 90 this range can be moved as required ASA measuring range maximum within the scan range 29 9 m 98 1 ft it thus is not detecting any obstacles such as e g building walls Device is faulted Check whether the SafeZone Mini is being affected by an external light source e g headlight infrared light Hole sources stroboscopic light sun etc If necessary re mount the device Temperature error The Check whether the SafeZone Mini is operated as per the AGE operating temperature of the permissible ambient conditions 1 SafeZone Mini has exceeded the permissible range Invalid configuration of the gt Verify that the machine side EDM is connected correctly M a g fy y LO Undervoltage of the supply gt Check
5. See Chapter 12 OSSD response times on page 55 How to calculate the distance S ans covered during the response time of the safety laser scanner gt Calculate the distance Saps using the formula Sans Ts X Vimax Where Ts Response time of the safety laser scanner Vax Maximum velocity of the vehicle from the related vehicle documentation Rockwell Automation Publication 10000337275 Ver 00 December 2012 31 Chapter5 Mounting Supplement Zp for measurement errors caused by reflection With retroreflectors in the background at a distance of less than 1 m 39 4 in from the boundary of the protective field the supplement Zp is 200 mm 7 87 in Supplement Zp due to lack of ground clearance This supplement is necessary because a person is generally detected above the foot and the braking action can therefore not take into account the length of the foot in front of the detection point If a vehicle has no ground clearance a person may receive foot injuries Fig 22 Supplement due to lack of ground clearance SafeZone Mini lag Protective field length ml 2 lag Ground clearance gt The flat rate supplement for ground clearance below 120 mm 4 7 in is 150 mm 5 91 in This supplement can be further reduced in specific cases For this purpose read off the actual supplement necessary for the ground clearance of your vehicle from the diagram below Fig 23 Diagram of ground clearance of the vehicle 120
6. The machine operator is to be instructed in the use of the device by qualified safety personnel and must be instructed to read the operating instructions e To meet the requirements of the relevant product standards e g EN 61496 1 the external voltage supply for the devices must be able to bridge a brief mains failure of 20 ms Power supplies according to EN 60204 1 satisfy this requirement Suitable power supplies are available as accessories from Rockwell Automation gt Enclosed with these operating instructions is a checklist for checking by the manufacturer and OEM see Chapter 14 Checklist for the manufacturer on page 69 Use this checklist when checking the system that is protected with the SafeZone Mini The SafeZone Mini safety laser scanner is constructed in such a way that it adversely affects the environment as little as possible and uses only a minimum of power and natural resources gt Atwork always act in an environmentally responsible manner Chapter2 On safety Note ATTENTION Table 1 Overview on disposal by components Applicable directives and standards Disposal Unusable or irreparable devices should always be disposed as per the applicable national regulations on waste disposal e g European waste code 16 02 14 e Information on the individual materials in the SafeZone Mini is given in Chapter 12 Technical specifications on page 55 Separation of materials Only qualified safety per
7. Basic concepts general principles for design EN ISO 12100 e Industrial automation systems Safety of integrated manufacturing systems Basic requirements ISO 11161 e Safety of machinery Electrical equipment of machines Part 1 General requirements EN 60204 1 e Safety of machinery safety distances to prevent hazard zones being reached by the upper and lower limbs EN ISO 13857 e Safety requirements for robots EN ISO 10218 1 e Safety of industrial trucks Driverless trucks and their systems EN 1525 e Safety of machinery The positioning of protective equipment in respect of approach speeds of parts of the human body EN ISO 13855 e Safety of machinery Principles for risk assessment EN ISO 14121 1 e Safety of machinery Safety related parts of control systems Part 1 General principles for design EN ISO 13849 1 as well as part 2 Validation EN ISO 13849 2 e Safety of machinery electro sensitive protective equipment Part 1 General requirements EN 61496 1 as well as part 3 Special requirements for AOPDDR CLC TS 61496 3 e Safety of machinery Application of protective equipment to detect the presence of persons IEC TS 62046 8 Rockwell Automation Publication 10000337275 Ver 00 December 2012 Chapter2 On safety Regional standards for example e Performance Criteria for Safeguarding ANSI B11 19 e Machine tools for manufacturing systems cells ANSI B11 20 e Safety require
8. Chapter2 Onsafety Pay attention to the safety notes Please observe the following items in order to ensure the correct use of the SafeZone Mini safety laser scanner Repair only by authorized persons The improper repair of the protective device can result in the loss of the protective function The protective device is only allowed to be repaired by the manufacturer or persons authorized by the manufacturer The SafeZone Mini safety laser scanner is of laser safety class 1 Additional measures for screening the laser radiation are not necessary eye safe CLASS 1 LASER PRODUCT IEC 60825 1 2007 Complies with 21 CFR 1040 10 and 1040 11 except for deviations pursuant to ine 2007 Laser Notice No 50 Jul e This device meets the norms IEC 60825 1 as well as CDRH 21 CFR 1040 10 and 1040 11 excluded are deviations due to Laser Notice No 50 dated 24 06 2007 In the standards CDRH 21 CFR 1040 10 and 1040 11 the following note is required Caution use of controls adjustments or performance of procedures other than those herein specified may result in hazardous radiation exposure e During the mounting installation and usage of the SafeZone Mini observe the standards and directives applicable in your country You will find an overview of the most important regulations in Chapter 2 Applicable directives and standards on page 8 e Thenational international rules and regulations apply to the installation commi
9. Fig 2 Principle of operation rotation of the SafeZone Mini Fig 3 Field set with one protective field and two warning fields Chapter3 Product description The SafeZone Mini works on the principle of time of flight measurement It sends out very short pulses of infrared light send pulses At the same time an electronic stopwatch is started When the light hits an object it is reflected and received by the safety laser scanner receive pulses From the time between sending and reception At the SafeZone Mini calculates the distance to the object 225 Ay naaa Q In the SafeZone Mini there is also a mirror rotating at constant speed that deflects the light pulses such that they cover an arc of 270 In this way an object can be detected in the protective field within 270 The first beam of a scan starts at 45 relative to the back of the safety laser scanner The SafeZone Mini sends a pulse of light with an angular resolution of 0 5 As a result resolutions between 30 mm 1 18 in and 70 mm 2 76 in can be achieved Due to its active scanning principle the SafeZone Mini does not require receivers or reflectors This has the following advantages e Your installation effort is lower e You can easily adapt the monitored area to the hazardous area on a machine e In comparison with contact sensors electro sensitive scanning is nearly wear free Field set comprising protective field and warning fie
10. No LI No L No L This checklist does not replace the initial commissioning nor the regular inspection by qualified safety personnel Rockwell Automation Publication 10000337275 Ver 00 December 2012 Annex 69 Chapter14 Annex Glossary AOPDDR External device monitoring EDM Field set Optics cover OSSD Protective field Remission Resolution object resolution Restart interlock Universal 1 0 Warning field Active opto electronic protective device responsive to diffuse reflection e g SafeZone Mini see also CLC TS 61496 3 A device that electronically monitors the relay or contactor operated by the protective device prior to each new start Protective fields and warning fields form the so called field set Plastic part with window for light output The optics cover is available as a spare part Output signal switching device The OSSD output is the switching output on the SafeZone Mini This is a semiconductor output and is periodically tested for correct function The SafeZone Mini has two OSSD outputs that operate in parallel for safety reasons these must be evaluated using two channels The protective field secures the hazardous area on a machine or vehicle As soon as the safety laser scanner detects an object in the protective field it switches the OSSDs to the OFF state and thus initiates the shutdown of the machine or stop of the vehicle Reflection of luminance A measure of the remission is the le
11. 4 Generic standards Emission standard for industrial environments TUV Rheinland Industrie Service GmbH Alboinstrasse 56 12103 Berlin Germany EC Type Examination Registration No 01 205 0616 09 and 01 205 5264 12 Authorised representative see details above AOPDDR devices for use in applications up to Safety Category 3 PL d EN ISO 13849 1 and SIL2 SIL CL2 EN 61508 EN 62061 Signed for and on behalf of the above named manufacturer Place and date of issue Name function Signature Chelmsford MA USA 15 Dec 2012 Daniel L Nachtigall Technical Leader Product Certification Engineering Dad Nackticall Document Control Number SEN 0354 E EN 142 Rockwell Automation Publication 10000337275 Ver 00 December 2012 67 Chapter14 Annex Rockwell Automation na Directive Catalogue number Series Description Directive 442L SFZNSZ Hr Safezone single zone safety laser scanner tes ro 442L SFZNMZ kt Safezone multi zone safety laser scanner Yes Yes 442L SFZNMN BEE Safezone mini safety laser scanner Ca la 1 If no series number is given then all series are covered 2 Yes Product is certified to this directive Document Control Number SEN 0354 E EN 272 68 Rockwell Automation Publication 10000337275 Ver 00 December 2012 Checklist for the manufacturer Checklist for the manufacturer installer for installing electro sensitive protective equipment ESPE Chapter 14 Details a
12. Round plug connector SafeZone Mini ccc cece cece cee KA aaa 40 Fig 39 Pin assignment configuration connection M8 X4 aasawa eee eee aaa aaa 41 Fig 40 Hazardous area protection with SafeZone Mini ooooooocoooocccorccccnnccnarroo 42 Fig 41 Access protection with SafeZone Mini sasama aaa 4 Fig 42 Vehicle monitoring with SafeZone Mini aasam 43 Fig 43 Connection diagram for SafeZone Mini with restart interlock and external device monitoring 44 Fig 44 Connection diagram for SafeZone Mini in combination with a GSR SI safety relay 44 Rockwell Automation Publication 10000337275 Ver 00 December 2012 Chapter14 Annex Fig 45 SafeZone Mini in combination with a GSR DI safety relay cece cece eee ee ee eee eee ees 45 Fig 46 Configuration CONNECTION aaa aaa 46 Fig 47 Undo the mounting screws for the Optics cover aasawa aaa 50 Fig 48 Diagram scanning range SafeZone Mini 0 cece cece cece ee eee eeeeeeeeeeeaeneees 55 Fig 49 Diagram of the test pulses at the OSSDS kc cece aasa c teen ence eee eeeeeeeeaeneees 56 Fig 50 Voltage test after switching on the OSSDs cece cece eect ence ene eeeeeneeaeneees 57 AR SNUECOWN AA teahausautensbetaneeeeuues 5 119 52 Voltage lest an 2 NANANA AA ANNA NAA NONA ANAN 57 Fig 53 Dimensional drawing SafeZone Mini aasam aa 61 Fig 54 Dimensiona
13. This safety distance ensures that the hazardous point can only be reached after the dangerous state of the machine has been completely stopped You can operate the SafeZone Mini in stationary horizontal operation with 30 40 50 or 70 mm 1 2 1 6 2 0 or 2 8 in resolution The maximum protective field range for the SafeZone Mini is given by the resolution Ensure that a human leg can be detected with 70 mm 2 8 in resolution As per EN ISO 13855 mount the scan planes for horizontal stationary applications with 70 mm 2 8 in resolution at least 300 mm 11 8 in above the floor see Height of the scan plane at 70 mm resolution on page 33 Kx Iy 1 2 2p 0 Dangerous state The minimum distance S depends on e Approach speed of the body or parts of the body Stopping run down time of the machine or system The stopping run down time is shown in the machine documentation or must be determined by taking a measurement e Response time of the SafeZone Mini e Supplements for general measurement errors and any measurement errors related to reflection e Supplement for prevention of reaching over e Height of the scan plane e Possibly the time for switching between the monitoring cases How to calculate the minimum distance S see EN ISO 13855 gt First calculate S using the following formula S Kx Ty T5 Ze Z Where K Approach speed 1600 mm s 63 in s defined in EN ISO 13855 Ty Stoppi
14. arc suppressors may lengthen the response time e The arc suppressors must be in parallel with the relays contactors not across the contacts Rockwell Automation Publication 10000337275 Ver 00 December 2012 43 Chapter 7 44 Application examples and connection diagrams SafeZone Mini with restart interlock and external device monitoring Fig 43 Connection diagram for 124V DC SafeZone Mini with restart interlock and external device monitoring KI SafeZone Mini u a vers LN a LI ka ee 7 Color Pin Signal Shld Gry pnk Blu Y K2 Wht 1 Output Warning Field1 mn Brn 2 24VDC Grn 3 Universal I O1 Reset Yel 4 Universal 1 02 EDM Gry 5 0SSD1 Pnk 6 OSSD2 Blu 7 OV DC Shld 8 Earth Ground Q Not configured for this application No Connection Software Configured for Reset input Software Configured for EDM OV DC SafeZone Mini in conjunction with relays contactors operating mode with restart interlock universal 1 0 1 must be configured as reset and external device monitoring universal 1 0 2 must be configured as EDM SafeZone Mini in combination with a GSR SI safety relay Fig 44 Connection diagram for 24V DC SafeZone Mini in combination with a GSR SI safety relay Color Pin Signal SafeZone Mini Wht 1 Output Warning Field1 Wht Grn Yel Brn 2 24V DC Grn 3 Universal 1 01 Yel 4 Universal 1 02 Reset Gry 5 OSSD 1 Pnk 6 OSSD 2 Blu 7 OVDC L1 L2 L3 Shid 8 Ea
15. data saved in the SCD software will be notified that the application name does not match He may then exchange these devices for those with the correct application name Name of the scanner Enter a device name for each of the safety laser scanners in the system You can enter names with a maximum of eight characters Use meaningful names e g front and rear for vehicle monitoring Unique device names make the subsequent configuration steps easier for example on allocating the control inputs or the OSSDs User data You can enter your name in the field Name of the user You can enter a name with a maximum of 22 characters This is then added to the configuration protocol and in the diagnostics report Display direction of the seven segment display The depiction of numbers on the seven segment display can be rotated by 180 with the aid of the SCD software This is useful for example when the SafeZone Mini must be rotated by 180 owing to the specific assembly If you rotate the numbers of the seven segment display the point in the seven segment display goes out How to determine the display direction of the seven segment display gt Under seven segment display activate the Rotated by 180 option After the configuration draft has been transferred to the SafeZone Mini the numbers of the seven segment display are rotated by 180 Rockwell Automation Publication 10000337275 Ver 00 December 2012 15 Chapter4 Config
16. fence or floor protection Rockwell Automation Publication 10000337275 Ver 00 December 2012 Fig 11 Reading the protective field Note ATTENTION Fig 12 Schematic diagram of contour as reference Chapter4 Configurable functions Protective field or warning field suggested by the safety laser scanner The SCD software can suggest the protective field or warning field in the field set editor The safety laser scanner scans the visible surrounding contour several times From the data obtained the SCD software suggests the contour and size of the field The following figure shows an example for the reading of a protective field LILY PATTI LLL 0 a In those places at which the surrounding contour is smaller than the maximum protective field range e g at the protective field corresponds to the surrounding contour The measuring error tolerances for the SafeZone Mini are automatically subtracted from the protective field size As a result the protective field is slightly smaller than the surface covered In those places where the surrounding contour is larger than the protective field range the protective field corresponds to the possible scanning range Check the protective field suggested by the SCD software The protective field suggested by the SCD software is not a replacement for the calculation of the minimum distance Calculate the minimum distance and check the effectiveness of the protective fields prior
17. in the hazardous area and on all SafeZone Mini devices If you discover any non conformance of this function the machine system must be shut down immediately and checked by qualified safety personnel gt For stationary applications check that the hazardous areas marked out on the floor match the shapes of the protective fields stored in the SafeZone Mini and that any gaps are protected by additional safety measures In the case of mobile applications check that the moving vehicle actually stops in a timely manner at the protective field boundaries which are set in the SafeZone Mini and listed on the information label on the vehicle or in the configuration protocol If you discover any non conformance of this function the machine system vehicle must be stopped immediately and checked by qualified safety personnel Rockwell Automation Publication 10000337275 Ver 00 December 2012 ATTENTION Cleaning optics cover Note Replacing the optics cover ATTENTION Notes Chapter10 Maintenance and care Chapter 10 Maintenance and care Do not make any repairs to the device The SafeZone Mini does not contain any repairable components For this reason do not open the SafeZone Mini components and only replace the parts that are described in the following chapters as replaceable Switch the entire machine system off line The system could inadvertently start up while you are replacing the optics cover As a matter of principle always is
18. instructions in different languages for viewing and printing Automated Guided Vehicle American National Standards Institute American Wire Gauge standardization and classification of wires and cables by type diameter etc External device monitoring Electromagnetic compatibility Rockwell Automation Publication 10000337275 Ver 00 December 2012 Symbols used ESD ESPE FPLC OSSD RIA SCD software Recommendation ma Pd al Idi LP OOAD gt Take action Warning Rockwell Automation Publication 10000337275 Ver 00 December 2012 Chapter1 About this document Electrostatic discharge Electro sensitive protective equipment Fail safe programmable logic controller Output signal switching device signal output of the protective device that is used to stop the dangerous movement Robotic Industries Association Rockwell Automation Safety Configuration and Diagnostic Software SCD software software for configuration and diagnostics on the SafeZone Mini Recommendations are designed to give you some assistance in your decision making process with respect to a certain function or a technical measure Refer to notes for special features of the device Display indicators show the status of the seven segment display on the SafeZone Mini o 5 Constant indication of characters e g 8 jak Flashing indication of characters e g 8 LP Alternating indication of characters e g Land 2 LED symbols describe th
19. on the mounting kits During mounting please observe the dimensional drawings in Chapter 12 Technical specifications see Dimensions on page 61 Information label Important information gt gt On completion of mounting you must affix the self adhesive information label Important information supplied Use only the information label in the language which the operators of the machine can read and understand Place the information label such that it is clearly visible for the operators during operation The information label must not be covered even after additional items have been mounted Using multiple SafeZone Mini safety laser scanners The SafeZone Mini is designed so that mutual interference between several safety laser scanners is unlikely To completely exclude erroneous switching you must mount the safety laser scanners as shown in the following examples In any circumstance observe EN ISO 13855 when calculating the minimum distance Use mounting kits 1 or 2 and 3 to adjust the safety laser scanners to different angles see Chapter 13 Mounting kits on page 65 Min 100 mm Rockwell Automation Publication 10000337275 Ver 00 December 2012 37 Chapter5 Mounting Fig 35 Mounting on a cross Fig 36 Reverse mounting parallel offset Min 100 mm 3 94 in Fig 37 Reverse mounting of two SafeZone Mini with parallel offset Min 100 mm 3 94 in 38 Rockwell Automation Publication
20. plane is at fibula height and the leg is also detected with an object resolution of 70 mm 2 8 in Access protection can be used when the access to the machine can be defined by physical means For access protection the SafeZone Mini detects the entry of an entire body e To ensure adequate access protection a response time of lt 90 ms and a resolution of 150 mm 5 91 in or finer are required e To protect the protective device against inadvertent adjustment or manipulation you must use the contour of the surroundings as a reference for the SafeZone Mini see Chapter 4 Using the contour as a reference on page 21 Minimum distance For access protection a minimum distance S must be maintained between protective field and hazardous area This safety distance ensures that the hazardous point can only be reached after the dangerous state of the machine has been completely stopped Rockwell Automation Publication 10000337275 Ver 00 December 2012 27 Chapter 5 28 Mounting Fig 18 Access protection ATTENTION Protective field Contour of the floor as reference The minimum distance S as defined in EN ISO 13855 and EN ISO 13857 depends on e Reach or approach speed Stopping run down time of the machine or system The stopping run down time is shown in the machine documentation or must be determined by taking a measurement e Response time of the SafeZone Mini e Supplement C against reaching through
21. reason the calculation of the minimum distance must take into account a supplement to prevent persons from finding themselves in a hazardous situation by reaching over see EN ISO 13857 before the SafeZone Mini triggers The necessary supplement for the minimum distance is dependent on the height of the scan plane for the protective field At low heights the supplement is larger than at greater heights and h 1 1200 47 2 C 850 33 5 In summary there are three usual variations of mounting the scan plane for the SafeZone Mini The optimal variation depends on the related application Table 8 provides assistance making the selection Mounting orientation Disadvantage Safety laser scanner low Hs lt 300 11 81 in Low external effects due to ambient Higher supplement C Low inclination of the scan plane Hp Hs light interference crawling beneath not possible Safety laser scanner high H 5 300 11 81 in Lower protective field supplement C Danger of crawling beneath at Low inclination of the scan plane Hp Hs the front and side Safety laser scanner low Hs lt 3300 11 81 in Lower protective field supplement C Danger of crawling beneath at High inclination of the scan plane Hp gt Hs the front external effect due to ambient light interference possible In case of scan planes at a height of more than 300 mm 11 81 in ensure that people cannot reach the hazardous area by crawling
22. test After a further half basic response time of the SafeZone Mini there is a shut down test 120 ms later a further voltage test Then the SafeZone Mini performs a shut down test and a voltage test alternately at an interval of 120 ms Fig 51 Fig 52 and Fig 53 show the pulse duration for the individual tests Rockwell Automation Publication 10000337275 Ver 00 December 2012 Chapter 12 Technical specifications Fig 50 Voltage test after switching on the OSSDs Approx 650 us 055D2 Fig 51 Shut down test Approx 650 us y l 05501 la us OSSD2 lt 300 us Fig 52 Voltage test OSSD1 lt 300 Hs 055D2 Rockwell Automation Publication 10000337275 Ver 00 December 2012 57 Chapter12 Technical specifications Data sheet Table 17 Data sheet SafeZone Mini General data Type Safety Integrity Level SIL claim limit Category Performance Level PFHd mean probability of a dangerous failure per hour Ty mission time Laser protection class Enclosure rating Protection class Operating temperature range Storage temperature range Humidity taking into account the operating temperature range Vibration Frequency range Amplitude Shock resistance Single shock Continuous shock Sender Wavelength Divergence of the collimated beam solid angle Pulse duration Average output power Light spot size at optics cover mm in Size of light spot at 2 0 m 6 6 ft scanning rang
23. the device back in operation proceed as follows gt Rectify the cause of the fault per Table 15 on page 53 gt Switch off the power supply for the SafeZone Mini wait at least three seconds and then switch back on the power supply Or gt Restart the safety laser scanner with the aid of the SCD software Rockwell Automation Publication 10000337275 Ver 00 December 2012 Chapter11 Diagnostics Table 15 Error and status Lai Hi Display Rectification of the error seven Segment display Power up cycle all No error MOE segments are activated AMA sequentially 7 Object in protective field No error Object in warning field 1 No error C Object in warning field 2 No error Initialization of the device gt The display goes out automatically when the SafeZone Mini has been initialized and or the connection to the second device has been made If the display 2 does not go off gt Check whether the partner device is in operation J gt Check the wiring If no partner device is connected gt Check the system configuration with the aid of the SCD software Transfer the corrected configuration to the SafeZone Mini again Waiting for configuration or gt The display goes off automatically once the configuration not completed configuration has been successfully transferred If the display does not go off gt Check the system configuration with the aid of the SCD software Transfer the corrected configuration
24. therefore only suitable for use in an industrial environment e The device is a type 3 ESPE as defined by EN 61496 1 and CLC TS 61496 3 and is therefore allowed for use with category 3 PL d controls as per EN ISO 13849 1 or SIL2 as per IEC 61508 e The SafeZone Mini is suitable for Hazardous area protection Hazardous point protection Access protection Vehicle protection electrically powered industrial trucks Depending on the application other protective devices and measures may be required in addition to the safety laser scanner The SafeZone Mini safety laser scanner must be used only as defined in Chapter 2 Applications of the device on page 6 It must be used only by qualified personnel and only on the machine where it has been installed and initialized by qualified safety personnel in accordance with these operating instructions It is only permitted to be used on machines on which the dangerous state can be stopped immediately by the SafeZone Mini and or it is possible to prevent the machine being placed in operation If the device is used for any other purposes or modified in any way also during mounting and installation any warranty claim against Rockwell Automation shall become void Rockwell Automation Publication 10000337275 Ver 00 December 2012 General safety notes and protective measures ATTENTION Environmental protection Rockwell Automation Publication 10000337275 Ver 00 December 2012
25. to commissioning the application Pay attention to the descriptions in Chapter 5 Mounting on page 24 the notes in Chapter 9 Commissioning on page 47 and the Checklist on page 69 Using the contour as a reference In addition to the protective field the SafeZone Mini can also monitor a contour e g the floor in vertical applications For contour monitoring you define a contour segment The contour segment comprises a positive and a negative tolerance band Rockwell Automation Publication 10000337275 Ver 00 December 2012 21 Chapter4 Configurable functions Notes Fig 13 Contour as reference for vertical operation Protective field Contours of the machine opening 3 Contour segment Recommendation Monitoring cases ATTENTION The OSSDs on the SafeZone Mini change to the OFF state or the SafeZone Mini Remote signals if e There is an object in the protective field e The monitored surrounding contour is no longer in the tolerance band e g if the position of the SafeZone Mini is changed e You can define any number of contour segments e The contour segments must not be narrower than the configured resolution Atthe points where a contour has been configured as a reference you cannot define warning fields If for example you use the floor as a reference for access protection you cannot configure a warning field there However you can e g configure a warning field to t
26. to multiple sampling gt 2 Multiple sampling On the SafeZone Mini at least double multiple sampling is always set For a multiple sampling of three or higher you must add a supplement of 80 ms to the basic response time 55 Chapter 12 Technical specifications Table 16 Supplements for multiple sampling Multiple sampling Basic response time supplement 2 times basic setting Oms 80 ms 3 times 40 ms 120 ms Fine CO CT 5 times 120 ms 200 ms 6 times 160 ms 240 ms 7 times 200 ms 280 ms 8 times 240 ms 320 ms 9 times 280 ms 360 ms 10 times 320 ms 400 ms 11 times 360 ms 440 ms 12 times 400 ms 480 ms mes CO som 14 times 480 ms 560 ms 15 times 520 ms 600 ms 16 times 560 ms 640 ms Timing behavior of the OSSDs _ The SafeZone Mini tests the OSSDs immediately after switch on and then at regular intervals For this purpose the of the SafeZone Mini SafeZone Mini briefly switches off both OSSDs for 300 us and checks whether the OSSDs switch to the OFF state during this time Note Ensure that the safety inputs on the controller used do not respond to these test pulses and as a result cause the machine or system to unintentionally shutdown Fig 49 Diagram of the test pulses at the OSSDs 40 ms 56 IN 120 ms 120 ms 120 ms OSSD1 055D2 Approx t 35 ms 000 O O O Approximately 35 ms after the switch on of the OSSDs the SafeZone Mini performs the first voltage test and then after a half basic response time 40 ms a second voltage
27. underneath the scan plane If you mount the protective device higher than 300 mm 11 81 in you must prevent crawling beneath by means of additional measures For applications that are accessible to the public the mounting height may need to be reduced to 200 mm 7 87 in on this subject see the appropriate regulations 26 Rockwell Automation Publication 10000337275 Ver 00 December 2012 Note Fig 17 Relationship between resolution and protective field mounting height Stationary vertical operation for access protection Notes Chapter5 Mounting How to calculate the supplement C gt If there is enough empty space in front of your machine or system use 1200 mm 47 2 in for the supplement C gt Ifthe minimum distance is to be kept as small as possible calculate C using the following formula C 1200 mm 0 4 x Hp Here Hp is the height at which the protective field is mounted The minimum supplement C to prevent reaching over is 850 mm 33 5 in arm length Height of the scan plane at 70 mm 2 8 in resolution Due to the radial sampling of the protective field the optical resolution will be lower the further away you get from the safety laser scanner Q If you choose a resolution of 70 mm 2 8 in in the SCD software for hazardous area protection a human leg may in certain circumstances not be detected e g scan to left and right of the bone If you mount the SafeZone Mini higher the scan
28. warning field Object in one of the warning fields No error output D u On the universal 1 0 At the OSSDs No operating voltage or voltage too gt Check the voltage supply and T activate if necessary On the universal 1 05 Lo On the universal 1 0 Reset required gt Operate the control switch for CI NU restart O No level change Restart delay is counting down gt No action is required pea On the universal 1 O No error a On the universal 1 0 Optics cover contaminated no gt Clean the optics cover operation On the universal 1 0 Optics cover contaminated stillin gt Clean the optics cover operation If warning field 1 is infringed If this is configured as the output for warning field 2 and warning field 2 is infringed If this is configured as the output for Reset required If this is configured as the output for a contamination error warning If this is configured as the output for a contamination error If this is configured as the output for a contamination warning This section explains the meaning of the error indications on the seven segment display and how to respond to the messages You will find a description of the positions and symbols on the SafeZone Mini in Chapter 3 LEDs and seven segment display on page 14 The lock out operational status In case of certain faults or an erroneous configuration the device can go into the lock out operational status To place
29. warranty will be rendered void Wiring in accordance with EMC regulations The quality of the shield is essentially dependent on the quality of the connection of the screen In principle the best screening action can only be achieved with the connection of the shield at both ends using large area connections gt Ifit is not possible to connect the screen via threaded fittings connect the screen physically close e g to a control cabinet chassis using a metal clamp e fthere is a PE in an installation it can be used for the connection of the FE However a functional earth connection FE is never allowed to be used as a PE Functional earth To achieve the specified EMC safety the functional earth FE must be connected e g to the vehicle s or system s central earth star point Round plug connector SafeZone Mini NN 17 SS 7 NS 3 2 Pin assignment Pin Signal Function 1 Output for warning field 1 2 Supply voltage SafeZone Mini 3 Universal 1 0 4 Universal 1 0 5 Output signal switching device 6 Output signal switching device 7 Supply voltage 8 Functional earth shield Housing Functional earth shield Use the cordsets listed in Table 18 Ordering information on page 65 to connect the SafeZone Mini Rockwell Automation Publication 10000337275 Ver 00 December 2012 Chapter6 Electrical installation Core assignment of the SafeZone Mini extension cable Table 10 Core assignment ofthe Core Color Func
30. 10000337275 Ver 00 December 2012 ATTENTION Rockwell Automation Publication 10000337275 Ver 00 December 2012 Electrical installation Switch the entire machine system off line Chapter6 Electrical installation Chapter O The machine system could unintentionally start up while you are connecting the devices gt Ensure that the entire machine system is disconnected during the electrical installation Connect 0SSD1 and 0SSD2 separately You are not allowed to connect OSSD1 and OSSD2 together otherwise signal safety will not be ensured gt Ensure that the machine controller processes the two signals separately Downstream contactors must be positively guided and monitored Only ever connect one downstream switching element to an OSSD Each output signal switching device OSSD is only allowed to be connected to one switching element e g relay or contactor If several switching elements are required you must choose a suitable form of contact duplication Prevent the occurrence of a potential difference between the load and the protective device gt Ifyou connect loads that are not reverse polarity protected to the OSSDs or the safety outputs you must connect the 0 V connections of these loads and those of the corresponding protective device individually and directly to the same 0 V terminal strip This is the only way to ensure that in the event of a defect there can be no potential difference between the 0 V connectio
31. 2 45 Chapter 8 Configuration Default delivery status Preparation of the configuration 46 Fig 46 Configuration connection Notes Note Chapter O Configuration The SafeZone Mini is delivered in a non configured default state e The operational status is Waiting for configuration e The seven segment display indicates al OQnthe SafeZone Mini the output signal switching devices OSSDs are in the OFF state the red LED is illuminated How to prepare the configuration gt Make sure that the safety laser scanner has been correctly mounted and that the electrical connections are correct and in place gt Have the necessary tools at hand To configure the safety laser scanner you need SCD Software on CD ROM or downloaded from www ab com safety e PC notebook with Windows NT 4 2000 Professional XP Vista 7 32 Bit and a serial RS 232 interface PC notebook not included e Service cable for connecting PC and SafeZone Mini How to configure the SafeZone Mini with the aid of the SCD software To configure and perform diagnostics on the SafeZone Mini directly connect the PC to the configuration connection to the SafeZone Mini Configuration connection Two service cables of different lengths are available for the connection of the PC notebook see Chapter 13 Accessories on page 65 e Ensure that the service cable is not laid in close proximity to high power electrical drives or cables carr
32. 275 Ver 00 December 2012 71 Chapter14 Annex List of illustrations 72 Fig 1 Principle of operation time of flight measurement by the SafeZone Mini 10 Fig 2 Principle of operation rotation of the SafeZone Mini ccc cece ec ne cee e eae eeeees 11 Fig 3 Field set with one protective field and two warning fields oo ooooooooom 11 FIG 24 DEVICE COMPONENIS reiten ATA NANANA a A pad edie 12 Fig 5 Protective Field Range 2 ee 12 Fig 6 Status indicators on the SafeZone Mini 2a aasa aaa 14 Fig 7 Configuration example universal 1 0 connections of the SafeZone Mini 17 Fig 8 Schematic outline of the operation with restart interlock ooooooooommmmomo 19 Fig 9 Creating a field set in the SCD software ccc cece cece cence ene e aaa 20 Fig 10 Configuring protective field and warning field aaa 20 Fig 11 Reading the protective field da aanak Dna kaaa a 21 Fig 12 Schematic diagram of contour as reference 6 cece ccc eee aaa aaa aaa aaa 21 Fig 13 Contour as reference for vertical operation 0 cece asaan 22 Fig 14 Horizontal stationary application aaa 24 Figs los MINIMUM MISCO u een 25 Fig 16 Mounting variations for the scan plane mm in mama 26 Fig 17 Relationship between resolution and protective field mounting height
33. 2L ACABL2O SafeZone mini cordset 20 meters Accessories 4421 AMBSZMN1 442 AMBSZMN1 SafeZone mini mounting bracket 1a 4421 AMBSZMN2 442 AMBSZMN2 SafeZone mini mounting bracket 1b 442L AMBSZMN3 442L AMBSZMN3 SafeZone mini mounting bracket 2 Rockwell Automation Publication 10000337275 Ver 00 December 2012 65 Chapter 13 Items supplied for SafeZone Mini 4421 AMBSZMN4 442 AMBSZMNA4 SafeZone mini mounting bracket 3 u 442L 5SZMNW 442L SZMNW SafeZone mini replacement window kit S 442L ACUSB 2 2 m 6 6 ft USB programming cable 4421 ACUSB 10 10 m 32 8 ft USB programming cable 66 Rockwell Automation Publication 10000337275 Ver 00 December 2012 Identification of the product Name and address of the manufacturer Rockwell Automation Inc 2 Executive Drive Chelmsford MA 01824 USA EU Declaration of Conformity Chapter14 Annex Chapter 14 Annex Rockwell Automation Safezone Safety Laser Scanner Name and address of the authorised representative Rockwell Automation B V Rivium Promenade 160 2909 LM Capelle aan den Ijssel The Netherlands This declaration of conformity is issued under the sole responsibility of the manufacturer Object of the declaration Allen Bradley GuardMaster 442L SFZ Series reference the attached list of catalogue numbers The object of the declaration described above is in conformity with the relevant EU harmonisation legislation 2004 108 EC 2006 42 EC
34. 3 3 9 1 49 Rockwell Automation Publication 10000337275 Ver 00 December 2012 61 Chapter12 Technical specifications 62 Fig 55 Dimensional drawing mounting kit 2 442L AMBSZMN2 Fig 56 Dimensional drawing mounting kit 3 442L AMBSZMN3 100 3 94 dia 102 5 4 03 110 4 33 gt DIN74 F5 139 4 5 49 al om Z 130 5 12 AN 118 5 4 67 Rockwell Automation Publication 10000337275 Ver 00 December 2012 Chapter 12 Technical specifications Fig 57 Dimensional drawing mounting kit 4 442 AMBSZMN4 Rockwell Automation Publication 10000337275 Ver 00 December 2012 63 Chapter 12 Fig 58 Dimensional drawing of the scan plane with 64 Technical specifications Scan plane origin mounting kit 1 3 and 4 130 5 12 D No gt KKK KKK KK KK KK RI MAAAAAAAAAAAAG 74 7 2 94 Min 15 Min 15 Rockwell Automation Publication 10000337275 Ver 00 December 2012 Chapter 13 Items supplied for SafeZone Mini Chapter 13 Items supplied for SafeZone Mini e Safety laser scanner e Operating instructions and SCD software on CD ROM e Adhesive label Important information Note Cordsets for the SafeZone mini not included Table 18 Ordering information Image Catalog number Product description 4421 SFZNMN SafeZone mini safety laser scanner 2 meter safety field Cord sets 4421 ACABL2 SafeZone mini cordset 2 5 meters 4421 ACABL10 SafeZone mini cordset 10 meters 44
35. C AL EC AE AKA KANAN 68 Checklist for the manufacturer a 70 A pene ee Ona lat agin out a a r Nanana Alan tenes 70 LIST OF CAD IES sand enter 71 SEO do 72 Rockwell Automation Publication 10000337275 Ver 00 December 2012 3 Chapter1 About this document Function of this document Target group Scope Depth of information Abbreviations used Note AGV ANSI AWG EDM EMC Chapter 1 About this document Please read this chapter carefully before working with this documentation and the SafeZone Mini These operating instructions are designed to address the technical personnel of the machine manufacturer or the machine operator in regards to correct mounting electrical installation commissioning operation and maintenance of the SafeZone Mini safety laser scanner These operating instructions do not provide instructions for operating the machine the system or the vehicle on which the safety laser scanner is or will be integrated Information on this is to be found in the appropriate operating instructions for the machine the system or the vehicle These operating instructions are addressed to planning engineers machine designers and the operators of machines and systems which are to be protected by one or several SafeZone Mini safety laser scanners They also address people who integrate the SafeZone Mini into a machine a system or a vehicle initialize its use or who are in charge of servicing and maintaini
36. EMC Directive EMC Machinery Directive MD References to the relevant harmonised standards used or references to the specifications in relation to which conformity is declared EN 61496 1 2004 A1 2008 IEC 61496 3 2008 EN ISO 13849 1 2008 EN 62061 2005 IEC 61508 Parts 1 7 2010 EN 60204 1 2006 A1 2009 EN 50178 1997 EN 61000 6 2 2005 EN 61000 6 4 2007 Notified Body performed and issued the certificate Additional information Person authorised to compile the technical file MD Product Safety Function MD Safety of machinery Electro sensitive protective equipment Part 1 General requirements and tests Safety of machinery Electro sensitive protective equipment Part 3 Particular requirements for Active Opto electronic Protective Devices responsive to Diffuse Reflection AOPDDR Safety of Machinery Safety related parts of control systems Part 1 General principles for design Safety of machinery Functional safety of safety related electrical electronic and programmable electronic control systems Functional safety of electrical electronic programmable electronic safety related systems Safety of machinery Electrical equipment of machines Part 1 General requirements Electronic equipment for use in power installations Electromagnetic compatibility Part 6 2 Generic standards Immunity for industrial environments Electromagnetic compatibility Part 6
37. ENTION Table 7 Recommended multiple sampling Recommendation Chapter4 Configurable functions Multiple sampling If multiple sampling is set an object must be scanned several times before the SafeZone Mini switches its OSSDs to the OFF state In this way you can reduce the probability that insects welding sparks or other particles result in the shutdown of the system If a multiple sampling of three is configured for instance an object must be detected in the protective field three times in succession before the SafeZone Mini switches the OSSDs to the OFF state The total response time is increased by the multiple sampling With a multiple sampling greater than two note that you must add a supplement to the basic response time see Chapter 12 OSSD response times on page 55 On the SafeZone Mini a multiple sampling of two is the minimum setting You can set the multiple sampling to up to 16 with the aid of the SCD software The supplement to the basic response time resulting from your setting is displayed in the SCD software Application Recommended multiple sampling Stationary under clean ambient conditions 2 times Vertical applications 2 times Mobile 4 times Stationary under dusty ambient conditions 8 times Using multiple sampling you can increase the availability of a system You can configure the multiple sampling in the SCD software You can set individual multiple sampling for each monitoring case Stand by m
38. How to calculate the minimum distance S see EN ISO 13855 gt First calculate S using the following formula S KX Ty Ts C Where K Approach speed 1600 mm s 63 in s defined in EN ISO 13855 Ty Stopping run down time of the machine or system Ts Response time of the SafeZone Mini C Supplement against reaching through 850 mm 33 5 in Response time Ts of the SafeZone Mini The total response time of the SafeZone Mini must not be more than 80 ms for access protection If a critical response time is exceeded a person may no longer be detected under certain circumstances In specific cases agreed with the responsible authorities higher response times may be allowed for example by increasing the detection time available by positioning the safety laser scanner at an angle In this case ensure that the areas the safety laser scanner cannot see are protected by additional measures The response time Ts of the SafeZone Mini depends on e The basic response time of the SafeZone Mini e The multiple sampling set See Chapter 12 OSSD response times on page 55 Rockwell Automation Publication 10000337275 Ver 00 December 2012 Stationary vertical operation for hazardous point protection Note ATTENTION ATTENTION Fig 19 Minimum distance to the hazardous area Chapter5 Mounting Hazardous point protection is necessary if the operator must remain near the dangerous state of the machine Hand pr
39. Mini a safety laser scanner connected or on a safety controller switch correctly to the OFF State as soon as there is an object in the protective field This test should be performed along all protective field boundaries as per the specific regulations for the application see Chapter 9 Test notes on page 47 Power up sequence After power up the SafeZone Mini runs through a power up cycle During the power up cycle the seven segment display indicates the device status During the initial commissioning of an SafeZone Mini the following indications are possible Step Display Meaning LIEI Power up cycle testing the seven segment display All segments are activated HINEIN sequentially 2 GH Power up cycle during initial commissioning device in configuration mode Safety lock activated Malfunction in external conditions or in the device itself Other display See Chapter 11 Error and status indications on the seven segment display on page 52 Display Meaning O Tae slolo Device self test Device status waiting for configuration or object in the protective field OSSDs in the OFF state Safety lock activated Malfunction see Chapter 11 Error and status Other display indications on the LEDs on page 52 Pre commissioning tests The purpose of the pre commissioning tests is to confirm the safety requirements specified in the national international rules and regulations EC conformity This applies p
40. SafeZone Mini Allen Bradley Safety Laser Scanner oe Guard Imaster User Manual PF la a a AU MM HB Bann Rockwell Allen Bradley Rockwell Software Automation Important User Information Because of the variety of uses for the products described in this publication those responsible for the application and use of this control equipment must satisfy themselves that all necessary steps have been taken to assure that each application and use meets all performance and safety requirements including any applicable laws regulations codes and standards The illustrations charts sample programs and layout examples shown in the guide are intended solely for purposes of example Since there are many variables and requirements associated with any particular installation Rockwell Automation does not assume responsibility or liability to include intellectual property liability for actual use based upon the examples shown in this publication Rockwell Automation publication SGI 1 1 Safety Guidelines for the Application Installation and Maintenance of Solid State Control available from your local Rockwell Automation sales office describes some important differences between solid state equipment and electromechanical devices that should be taken into consideration when applying products such as those described in this publication Reproduction of the contents of this copyrighted publication in whole or part without written permissio
41. Zone Mini Universal 1 0 O 3 4 Inputs 1 01 1 02 gt Stand by gt F External device monitoring ES Reset Dutputs 1 01 702 Error u Contamination error u u Contamination warning 2nd Warning field EH jv Reset required Stand by If in mobile applications vehicles are not moved for a time the OSSDs can be switched to the OFF state and the laser on the SafeZone Mini can be switched off In this way the power consumption of the device is reduced Use this function if e g you use several vehicles and do not move them for a time The SafeZone Mini remains in the stand by mode as long as the related input information is present Rockwell Automation Publication 10000337275 Ver 00 December 2012 17 Chapter4 Configurable functions OSSDs Table 6 Behavior of the SafeZone Mini on a contactor malfunction Note Restart of the SafeZone Mini Standard 18 ATTENTION Internal OSSDs of the SafeZone Mini If there is an object in the protective field the internal OSSDs on the SafeZone Mini always switch This can not be configured differently in the SCD software External device monitoring EDM SafeZone Mini The EDM checks if the contactors actually de energize when the protective device is tripped If you activate external device monitoring then the SafeZone Mini checks the contactors after each interruption of the protective field and prior to the machine restart The EDM can so
42. adley distributor 58 Rockwell Automation Publication 10000337275 Ver 00 December 2012 Functional data Resolution of the SafeZone Mini mm in Protective field of the SafeZone Mini Medium Range m fl Chapter12 Technical specifications Typical Maximum 30 40 50 70 1 2 1 6 2 0 2 8 CU Bao At 30 mm 1 2in resolution ne At 40 mm 1 6 in resolution Pt 160 5 25 At 50 mm 2 0 in resolution 2 00 6 56 At 70 mm 2 8 in resolution EO si rx 2 00 6 56 Scan angle eee 270 Remission Angular resolution 1 8 Several 1000 reflectors Ooo Protective field supplement generally necessary mm in 100 3 9 Supplement for retroreflectors in scan plane at a distance of NA 200 7 87 less than 1 m 39 4 in to the protective field boundary mm in Evenness of the scan field at 2 m 6 56 ft mm in Pf YF 50 2 0 Distance from mirror axis of rotation zero point on the X and j 55 2 17 Y axis to the rear of the device mm in Distance between center of the scan plane and the bottom 80 3 15 edge of the housing mm in Warning field m ft o J8 2625 Distance measuring range m ft Bar a 30 98 4 Number of multiple samplings PO 16 configurable via SCD software Power up delay of a configured device O E Restart after configurable 2s 60s Basic response time 80 ms A Electrical data SEE TEEN Supply voltage SELV 24V 30V Permissible residual
43. aoa 6 General safety notes and protective measures a aaa 7 Environmental proteto ssri edu ee icine AA AA AP AN ANA AA ee ON ee 8 Separation of materials is 8 Applicable directives and standards is 8 Product description scsccsccccecsccccsccececcecescecescecevcecess Chapter 3 E e do sad o o 10 O PR inated 10 Principles aras 10 Field set comprising of protective field and warning field s aasawa aaa 11 Sale LONG M Niese Maam O ANA ee 12 DEVICECOMPONCINS a kaaa kata gia Ga GA et is 12 ADDITION an 4S SAGALA aan choses te BG Ka dios 13 Status IMUICA ONS o de mbaba 14 LEDS and seven segment displays daa a a A NLA ete Kain 14 Configurable functions ceececcceccscceccecceccesccscceccecceses Chapter 4 A O NA ed 15 ADPIC ONE sg ss paghithit isis aah weave KAG eam a pens dd neh DAG ahat gata 15 Name of esca Mes tia PU A of pA NANANG GAAN KUA 15 AAA A E A nia neat 15 Display direction of the seven segment display 0c ccc ce cece eee e eee ee eee eeeneeeeneneeeanes 15 ADDITION errata te RP RIA PIN PA 16 a PAN 16 BASICTESDORSE INE kaaa dao kanda Ah nak Ga a ented 70h Gya 16 Maximum protective field range brene darat Cau rn kugn teat 16 Universal 1 0 connections of the SafeZone Mini aaa 17 AN thea AA AA 18 Internal OSSDs of the SafeZone Mini aasa 18 External device monitoring EDM SafeZone Mini aasa cc cee eee e nee eeeeeeeeeeaeeeenaeeees 18 Restart Of t
44. articularly to the safety requirements in the machinery directive or work equipment directive Ensure that you do not place anybody at risk during initial commissioning of the machine Always expect that the machine system or the protective device does not yet behave as you have planned gt Ensure that there are no persons in the hazardous area during initial commissioning Rockwell Automation Publication 10000337275 Ver 00 December 2012 47 Chapter 9 48 Commissioning Recommendation Note ATTENTION gt Check the effectiveness of the protective device mounted to the machine using all selectable operating modes as specified in the checklist in the annex see Chapter 14 Checklist for the manufacturer on page 69 gt Ensure that the operating personnel of the machine protected by the safety laser scanner are correctly instructed by qualified safety personnel before being allowed to operate the machine Instructing the operating personnel is the responsibility of the machine owner gt Ensure that the information label Important information which is included with the safety laser scanner on delivery is affixed to the machine in a place where it is clearly visible for the operators Ensure that the operators have the possibility to perform this daily check correctly gt The annex to this document includes a checklist for review by the manufacturer and OEM Use this checklist as a reference before commissioning the
45. bout the points listed below must be present at least during initial commissioning they are however dependent on the respective application the specifcations of which are to be controlled by the manufacturer installer IMPORTANT 10 11 12 13 14 15 16 17 18 during recurring tests Have the safety rules and regulations been observed in compliance with the directives standards applicable to the machine Are the applied directives and standards listed in the declaration of conformity Does the protective device fulfill the required PL SILCL and PFHd according to EN ISO 13 849 1 EN 62 061 and the type according to EN 61 496 1 Is the access to the hazardous area hazardous point only possible through the protective field of the ESPE Have measures been taken to prevent and monitor unauthorized presence in the hazardous area when hazardous area hazardous point protection mechanical protection and have these been secured against removal Are additional mechanical protective measures fitted and secured against manipulation which prevent reaching under over and around the ESPE Has the maximum stopping and or stopping run down time of the machine been measured specified and documented at the machine and or in the machine documentation Has the ESPE been mounted such that the required minimum distance from the nearest hazardous point has been achieved Are the ESPE devices properly mounted and sec
46. due to the mounting and the unprotected near range of the SafeZone Mini see Chapter 5 Methods of preventing unprotected areas on page 33 Configuration of the SafeZone Mini without restart interlock After the OSSDs on the SafeZone Mini have been switched to the OFF state due to an object in the protective field the OSSDs are re enabled again immediately when there is no longer an object in the active protective field This configuration is only allowed e fan external restart interlock is realized on the machine controller or e Ifthe protective field cannot be left in the direction of the hazardous point and if people can be detected by the SafeZone Mini at every point in the hazardous area Restart delay for mobile applications In mobile applications you can configure a restart delay from 2 to 60 seconds on the SafeZone Mini The OSSDs on the SafeZone Mini change to the ON state if there is no object in the protective field for the duration given This configuration is only allowed if the protective field cannot be left in the direction of the hazardous point and if a person can be detected at every point in the hazardous area by the SafeZone Mini Rockwell Automation Publication 10000337275 Ver 00 December 2012 Chapter4 Configurable functions Configuration of the SafeZone Mini with restart interlock Fig 8 Schematic outline of the operation with restart interlock Note Do not confuse the restart interlock with th
47. e mm in Housing Material Color Optics cover Material Surface finish Dimensions SafeZone Mini Height mm in Width mm in Depth mm in Dimensions connecting cable Length mm in Diameter of round plug connector mm in Total weight without connecting cables kg Ib Minimum Typical Maximum bo fp EJ 3 EN 61496 1 SIL2 IEC 61508 SILCL2 EN 62061 Category 3 EN ISO 13849 1 PL d EN ISO 13849 1 8x 10 20 years EN ISO 13849 Laser class 1 according to IEC 60825 1 as well as CDRH 21 CFR 1040 10 and 1040 11 excluded are deviations due to Laser Notice No 50 dated 24 06 2007 IP 65 EN 60529 III EN 50178 and EN 60950 a BE E 25 C 50 C 25 C 70 C lt 24 h EN 61496 1 CLC TS 61496 3 Chapter 5 Protective field width EN 61496 1 as well as CLC TS 61496 3 oF CO 508 l 0 35mmor5g EN 61496 1 Chapter 5 as well as CLC TS 61496 3 15g 11 ms 109 16 ms Pulsed laser diode 895 nm 905 nm 915 nm fremd 5 0 ns 5 5 ns Il Ww gt NI 3 NI Co de Aluminium die cast RAL 1021 rapeseed yellow and RAL 9005 black Polycarbonate Outside with scratch resistant coating O My N M 4 57 4 02 05 4 13 GUI 9 84 15 0 59 0 8 1 76 NM oO For detailed information on the safety design of your machine system please contact your local Rockwell Automation sales office or Allen Br
48. e SafeZone Mini gt Take the SafeZone Mini to a clean place office repair shop or similar gt First clean the outside of the SafeZone Mini This prevents foreign bodies entering the device when it is opened gt Undo the mounting screws to for the optics cover gt Then remove the optics cover gt Check whether the mirror on the motor is clean and remove any contamination with an optic brush gt Take the new optics cover out of the packaging and remove the protection for the seal gt Remove any remnants of packaging gt Place the optics cover on the safety laser scanner and fit the new mounting screws to 2 gt When fitting the new cover ensure the arrow on the top of the cover points to the front and that the optics cover is fully in contact without a gap gt Then tighten the front screws with the torque set gt Make sure the optics cover is free of dirt and that it is not damaged Re commissioning the SafeZone Mini gt Correctly re mount the SafeZone Mini see Chapter 5 Mounting on page 24 gt Connect the round plug connector on the end of the connection cable for the SafeZone Mini gt Then perform an optics cover calibration with the aid of the SCD software Rockwell Automation Publication 10000337275 Ver 00 December 2012 Chapter 11 Diagnostics Chapter 1 Diagnostics This chapter describes how to identify and remedy errors and malfunctions during the operation of the safety las
49. e cece cece aaa 13 Table 3 Status indicators on the SafeZone Mini cee cece eee e een e eee eeeeeeeeaee eens 14 Table 4 Comparison of mobile and stationary applicationS cece cece aa 16 Table 5 Maximum protective field range at different resolutions a 16 Table 6 Behavior of the SafeZone Mini on a contactor malfunction 18 Table 7 Recommended multiple sampling 0 0 cece cee cence eee e eee e eee e een eeaeennees 23 Table 8 Advantages and disadvantages of mounting variations mm in 26 Table 9 Pin assignment of the SafeZone Mini saaan 40 Table 10 Core assignment of the SafeZone Mini cable ccc cece cece cence cence eee eaeeeees 4 Table 11 Pin assignment configuration connection M8 X4 aasa 41 Table 12 Seven segment display during and after the power up sequence on initial commissioning 47 Table 13 LED indication of the SafeZone Mini after the power up SEQUENCe ooooooocoooomooo 4 Table 14 Error and status indications of the LEDs on the SafeZone Mini o o ooo ooooo 52 Table 15 Error and status indications on the seven segment display oo ooooooommmom 53 Table 16 Supplements for multiple sampling aaa aaa 56 Table 17 Data sheet SafeZone Mini ccc cece cece cence Aa 58 Table 18 Ordering information aa 65 Rockwell Automation Publication 10000337
50. e starting interlock on the machine The starting interlock prevents the machine starting after switching on The restart interlock prevents the machine starting again after an error or a protective field infringement The OSSDs on the SafeZone Mini change to the OFF state to initiate a machine or vehicle stop as soon as there is an object in the protective field They do not change to the ON state even if there is no longer an object in the protective field The OSSDs only change to the ON state if the operator operates the control switch for restart or reset ATTENTION Place the control switch for restart or reset outside the hazardous area in a place where it can clearly be seen from the hazardous area Place the control switch for restart or reset outside the hazardous area such that it cannot be operated by a person in the hazardous area Ensure that the person who operates the control switch has a full view of the hazardous area Notes You will find examples on the connection of the internal restart interlock in Chapter 7 Connection diagrams on page 43 e Ifyou do not use the internal restart interlock then do not configure any of the universal I Os as an input for resetting see Chapter 4 Universal 1 0 connections of the SafeZone Mini on page 17 Reset Note The reset function is often also called preparation for restart In these operating instructions the term reset is used If you want to activate t
51. e status of an LED The OSSDs in the OFF state LED is illuminated continuously The Error contamination LED is flashing A The Warning field interrupted LED is off Instructions for taking action are shown by an arrow Read carefully and follow the instructions for action A warning indicates an actual or potential risk or health hazard Observation and implementation of the warning will protect you from accidents Read carefully and follow the warning notices Information is displayed in the software indicating to you which settings you can make in the SCD software Safety Configuration and Diagnostic Software The term dangerous state The dangerous state standard term of the machine is always shown in the drawings and diagrams of this document as a movement of a machine part In practical operation there may be a number of different dangerous states e Machine movements e Vehicle movements e Electrical conductors e Visible or invisible radiation e Combination of several risks and hazards Chapter2 8 On safety Qualified safety personnel Applications of the device Correct use Note Note Chapter 2 On safety This chapter deals with your own safety and the safety of the system operators gt Please read this chapter carefully before working with the SafeZone Mini or with the machine protected by the SafeZone Mini The SafeZone Mini safety laser scanner must be installed connected c
52. ective device must be checked daily by a specialist or by authorized personnel The test must also be performed if the operating mode is changed No further operation if errors occur during the test If any one of the following points is not met it is not permitted to continue to work on the machine or operate the vehicle In this case the installation of the SafeZone Mini must be checked by qualified safety personnel see Chapter 9 Regular inspection of the protective device by qualified safety personnel on page 48 gt The test must be carried out for the relevant preset monitoring case gt Check the mechanical installation to ensure that all mounting screws are secure and that the is properly aligned SafeZone Mini Check each SafeZone Mini device for visible changes such as damage manipulation etc Switch on the machine system Watch the LEDs on each SafeZone Mini If not at least one LED of each SafeZone Mini is permanently lit when the machine system is switched on it is to be assumed that there is a fault in the machine or system In this case the machine must be shut down immediately and checked by qualified safety personnel VV VV gt Deliberately infringe the protective field while the machine is running in order to test the protective function for the entire system The LEDs of the SafeZone Mini must change from green to red and the dangerous movement must stop immediately gt Repeat this test at different points
53. eneath stand behind or climb over the protective field by means of appropriate mounting of the SafeZone Mini The origin of the scan plane is 80 mm 3 15 in above the bottom edge of the SafeZone Mini see Fig 54 on page 61 There are three possible ways of fixing the SafeZone Mini e Direct mounting without mounting kit e Mounting with mounting kit 1 or 2 e Mounting with mounting kit 3 only in conjunction with mounting kit 1 or 2 You will find the part numbers for the mounting kits in Chapter 13 Mounting kits on page 61 Pay attention to the maximum torque of the M5 fixing screws on the SafeZone Mini of max 5 9 Nm 4 4 ft lb Rockwell Automation Publication 10000337275 Ver 00 December 2012 35 Chapter 5 36 Mounting Fig 30 Direct mounting Notes Fig 31 Mounting with mounting kit 2 including protection for the optics cover Note Direct mounting The SafeZone Mini has two threaded holes M5X8 on the rear Using them you can mount the SafeZone Mini directly on the intended mounting surface To avoid a possible tendency to vibrate if necessary the reference surface on the rear can be used as the third mounting point During mounting please observe the dimensional drawings in Chapter 12 Dimensions on page 61 Mounting with mounting kit 1or 2 With the aid of mounting kit 1 or 2 you can mount the SafeZone Mini indirectly on the mounting surface Mounting kit 1 is available as a mounting k
54. equate minimum distance to the hazardous area is protection by the SafeZone Mini ensured gt Mount the SafeZone Mini in a dry place and protect the device from dirt and damage gt Avoid the installation of the SafeZone Mini in the vicinity of strong electric fields These can e g be produced by welding cables induction cables in the immediate vicinity and also by mobile telephones operated nearby gt Ensure that there are no obstacles in the area to be monitored in the field of view of the SafeZone Mini that could cause interference or shadowing Such shadowed areas cannot be monitored by the SafeZone Mini If there are unavoidable shadowed areas check whether there is a risk Take additional safety precautions as necessary gt Keep the area to be monitored free of smoke fog steam or other forms of air impurities There must not be any condensation on the optics cover Otherwise the function of the SafeZone Mini may be impaired and incorrect switching may occur gt Avoid placing highly reflective objects in the scan plane of the SafeZone Mini Examples Retroreflectors can affect the measurement results of the SafeZone Mini Highly reflective objects within the protective field can blank a part of the area to be monitored in certain circumstances gt Mount the SafeZone Mini such that it is not saturated by incident sunlight Do not position stroboscopic and fluorescent lights or other strong light sources directly in the scan plane a
55. er scanner In the event of faults or errors ATTENTION BR Do not operate if behavior is unclear Stop the machine the system or the vehicle if you cannot clearly identify or allocate an error and if you cannot safely remedy the malfunction Repair only by authorized persons The improper repair ofthe protective device can result in the loss of the protective function The protective device is only allowed to be repaired by the manufacturer or persons authorized by the manufacturer Rockwell Automation SUppo rt Ifyou cannot rectify an error with the help of the information provided in this chapter please contact your local Rockwell Automation representative Rockwell Automation Publication 10000337275 Ver 00 December 2012 51 Chapter 11 Diagnostics Error and status indications on the LEDs Table 14 Error and status indications of the LEDs on the SafeZone Mini Error and status indications on the seven segment display 52 This section describes the meaning of the error and status indications of the LEDs and how you can respond You will find a description of the indicators in Chapter 3 Status indicators on page 14 the connections for the outputs of the SafeZone Mini in Chapter 6 System connection on page 40 Display Output level Rectification of the error At the OSSDs Object in the protective field OSSDs No error N At the OSSDs Protective field unoccupied OSSDs No error in ON state At the
56. fety laser scanner then indicates 6 al la El El 1 L In Pl or lu To place the device back in operation proceed as follows gt Rectify the cause of the fault as per Tab 18 gt Switch off the voltage supply for the SafeZone Mini for at least two seconds and then switch it back on Or gt Restart the safety laser scanner with the aid of the SCD software The SCD software is supplied with the devices It allows you to narrow down the problem if the error is non specific or if you experience usage downtime problems Find detailed information in the online help for the SCD software Rockwell Automation Publication 10000337275 Ver 00 December 2012 Chapter 12 Technical specifications Chapter 12 Technical specifications Fig 48 Diagram scanning range OSSD response times SafeZone Mini Rockwell Automation Publication 10000337275 Ver 00 December 2012 500 Reflectors gt 2000 Reflective films gt 300 Remission 200 100 White plaster Writing paper 50 BAN Hr 20 HMM Mon cardboard 7 CHE T HAH Scanning range m Protective field Warning field The total response time of your application is dependent on e The basic response time of the SafeZone Mini e The multiple sampling set e The OSSDs used e The control inputs used How to calculate the total response time Ts Ts tg T Tura T Where tg Basic response time 80 ms Tura Supplement due
57. he SateZone MINE ai iia 18 LOTUS CUS AA E E O E EE T 20 Configuring the protective field and warning field umaasa 20 Protective field or warning field suggested by the safety laser scanner aaaa naaa 21 USING the CONLOUT AS a referentes o pg buta 21 MONITORING CASCS a digs td cias 22 M ltiple SANDING aai ee oar ttc cnet a ma LALA ngn hin uae ba aata KGG paa Gan ia o oda 23 Stand Dy NO maa O CR OE ARTE Se NAIG NG DAONG APA NADAANAN 23 MMM ra pe Stationary application in horizontal operation aasa aaa 24 Protective held Szean ee tae intend pn GL een 25 Stationary vertical operaton for access protectiOn sce e cece eects eee cece e eee e eect ee cnn 2 MINIMUM ANC cal 27 Stationary vertical operation for hazardous point protection asaan 29 Rockwell Automation Publication 10000337275 Ver 00 December 2012 1 Contents A ee ee A Pre ee 29 MODE APPlIcCA ON Asse een See a cae cated nal ne 30 Mounting continued ooooooocoocoosommrcsssrscrorororo22 2 2 Chapter 5 Protective tieid ONG Ulcer Gee an 3A ag kaa ka mta akala AGA Tma ene Bhi ta seine neu nanu Meee ed 30 AI nerd AA Ana KAG aa 32 Heightoftnescan DIAM ese ns corte aan en ee DUAL carded Gaara 33 Methods of preventing unprotected areas 2 aaa 33 NGA NANG GG aos 35 A UL ES es NADA GAI TANAN NG LAAN BA aaa ete Raabe Aka Ba 35 DIrEckmOURUINg ee redest 36 Mounting with mounting kit Ta or 1b se
58. he left and right of the contour segment to control a warning signal on approach from the side e The contour as reference function and the warning field 2 function are mutually exclusive You define the contour as a reference in the SCD software field set editor Vertical operation In vertical operation for access protection and hazardous point protection according to CLC TS 61496 3 you must always configure the protective fields used with the contour as reference function Use lateral vertical boundaries of the opening e g door frame and the floor as reference If in this case the position of the SafeZone Mini is changed in one or more planes the distance to the reference changes and the SafeZone Mini switches its OSSDs to the OFF state The SafeZone Mini supports a configuration with monitoring cases Ensure for each monitoring case that the minimum distance to the hazardous area is maintained See Chapter 5 Mounting on page 24 You can configure the monitoring cases in the SCD software Each monitoring case includes e The input conditions the so called control signals that control the activation of the monitoring case e Afield set comprising of protective field and warning field or fields e The multiple sampling for the field set Monitoring cases can be switched with the following input information e Static information 22 Rockwell Automation Publication 10000337275 Ver 00 December 2012 ATT
59. he restart interlock on the SafeZone Mini internal and also a restart interlock on the machine external then each restart interlock has its own control switch After operating the control switch for the internal restart interlock with protective field unoccupied e The SafeZone Mini switches its OSSDs to the ON state e The LED Y on the SafeZone Mini illuminates green The external restart interlock prevents the machine from restarting After resetting the SafeZone Mini the operator must press the control switch to restart the machine controller ATTENTION Ensure that the correct sequence is followed The controller must be realized such that the machine only restarts if the SafeZone Mini is first reset and then the control switch for restarting the machine controller is operated Reset signals If the SafeZone Mini safety laser scanner is operated using the With restart interlock function then after a protective field infringement and the subsequent clearing of the protective field it requests a reset signal from the control system reset required ATTENTION The reset signal must be safety related single failure proof Rockwell Automation Publication 10000337275 Ver 00 December 2012 19 Chapter4 Configurable functions Field sets para Fig 9 Creating a field set in the SCD software Note ATTENTION Note Fig 10 Configuring protective field and warning field ATTENTION 20 Configuring
60. ic motor e In the following calculations only take into account the velocity of the vehicle not the speed of the person walking This is based on the assumption that the person will recognize the danger and stand still e For vehicle protection observe EN 1525 Safety of industrial trucks Driverless trucks and their systems e Ifthe application is to protect vehicles from collisions then you may need to use different assumptions For a horizontally mounted mobile application determine e Protective field length e Protective field width e Height of the scan plane e Restart behavior e Methods of preventing unprotected areas Protective field length You must configure the protective field such that a minimum distance to the vehicle is maintained This ensures that a vehicle monitored by the SafeZone Mini comes to a stop before a person or object is reached How to calculate the protective field length S see EN ISO 13855 gt Calculate the necessary protective field length S using the formula 5 St 24H 1p eH Zg Where Sa Stopping distance l General safety supplement of the SafeZone Mini 100 mm 3 94 in Zp Supplement for any reflection related measurement error of the SafeZone Mini le Supplement for any lack of ground clearance of the vehicle Zg Supplement for the reduction in the braking performance of the vehicle to be found in the related vehicle documentation Stopping distance Sa The stopping d
61. ications Applications with one monitored area SafeZone Mini Fig 40 Hazardous area protection with SafeZone Mini SafeZone Mini with one protective field and one warning field mounted horizontally The area is permanently monitored by the SafeZone Mini Fig 41 Access protection with SafeZone Mini SafeZone Mini with one protective field mounted vertically Floor as reference The access is monitored permanently For safety against manipulation on the SafeZone Mini e g the floor is used as a reference If the alignment of the SafeZone Mini changes e g due to changes to the bracket the SafeZone Mini switches its OSSDs to the OFF state 42 Rockwell Automation Publication 10000337275 Ver 00 December 2012 Chapter7 Application examples and connection diagrams Mobile applications Vehicle monitoring for unidirectional travel SafeZone Mini Fig 42 Vehicle monitoring with SafeZone Mini SafeZone Mini with one protective field and two warning fields The SafeZone Mini monitors the area in the direction of travel and switches its OSSDs to the OFF state to stop the vehicle as soon as there is an object in the protective field Connection diagrams Notes Only use relays contacts with positively guided contacts The protection elements connected in parallel with the relays contactors are used for arc suppression e Ensure that there is adequate arc suppression at the relays contactors Take into account that
62. identify if one of the contactors has welded for instance In this case the external device monitoring places the system in a safe operational state and the OSSDs are not switched back to the ON state The table shows how the SafeZone Mini reacts if the external device monitoring detects a contactor malfunction Without internal restart interlock The system locks completely lock out or with restart delay e The error message 8 appears in the seven segment display With restart interlock e The SafeZone Mini switches its OSSDs to the OFF state e TheLED illuminated e The error message L93 e appears in the seven segment display You can configure the external device monitoring in the SCD software You will find examples on the connection of the external device monitoring in Chapter 7 Connection diagrams on page 43 You can configure the restart behavior of the SafeZone Mini as follows e Without restart interlock e With restart delay e With restart interlock You can configure the type of restart in the SCD software It is imperative that you configure the SafeZone Mini or the application with restart interlock if the protective field can be left to approach the hazardous point or if a person cannot be detected by the SafeZone Mini at every point in the hazardous area During the assessment pay attention to whether the protective field can be left in the direction of the hazardous point to areas that are unprotected
63. istance comprises the braking distance for the vehicle the distance covered during the response time of the safety laser scanner and the response time of the vehicle controller Rockwell Automation Publication 10000337275 Ver 00 December 2012 Fig 20 Stopping distance Note Fig 21 Stopping distance as a function of the vehicle velocity Chapter5 Mounting SafeZone Mini H Sang Ans SBr Take into account that the braking distance for a vehicle is not linear with increasing velocity but increases in a square function Stopping distance SY Stopping distance FA safety supplements EA N aly protective field length How to calculate the stopping distance Sp gt Calculate the stopping distance S4 using the formula SA Br Sank Sans Where Sgr Braking distance to be found in the vehicle documentation Sant Distance covered during the response time of the vehicle controller to be found in the vehicle documentation Sans Distance covered during the response time of the safety laser scanner Distance covered during the response time of the safety laser scanner The distance covered during the response time of the safety laser scanner depends on e The response time of the safety laser scanner e The maximum velocity of the vehicle in your mobile application The response time Ts of the SafeZone Mini depends on e The basic response time of the SafeZone Mini e The multiple sampling set
64. it without protection device for the optics cover and as mounting kit 2 with protection device for the optics cover Mounting screws Mounting kit 2 Mounting screws Wh 5 M Threaded holes M5 x 8 gt Mount mounting kit 1 or 2 on the mounting surface gt Then mount the SafeZone Mini on the mounting kit 1 or 2 During mounting please observe the dimensional drawings in Chapter 12 Technical specifications see Dimensions on page 61 Mounting with mounting kit 3 and 4 With the aid of mounting kits 3 and 4 only in conjunction with mounting kit 1 or 2 you can align the SafeZone Mini in two planes The maximum adjustment angle is 11 in both planes Rockwell Automation Publication 10000337275 Ver 00 December 2012 Fig 32 Mounting with mounting kit 2 Note Note Fig 33 Opposite mounting Fig 34 Offset parallel mounting Chapter5 Mounting Mounting kit 1 Mounting kit 3 Mounting kit 4 Mounting screws gt Mount mounting kit 1 or 2 to the SafeZone Mini gt Mount the mounting kit 4 on the mounting surface gt Fit the centering pin 4 mm 0 16 in in the central hole on mounting bracket 4 gt Fit mounting kit 3 to mounting kit 4 and mount it using two fixing screws M4 x 10 gt Then mount the SafeZone Mini on mounting kit 3 with the aid of the threaded holes in mounting kit 1 gt Adjust the SafeZone Mini longitudinally and transversely and then tighten the six fixing screws
65. l drawing mounting kit 1 aaa 61 Fig 55 Dimensional drawing mounting Kit 2 awa 62 Fig 56 Dimensional drawing mounting kit3 aaa 62 Fig 57 Dimensional drawing mounting Kit 4 aaa 63 Fig 58 Dimensional drawing of the scan plane with mounting kit 1 3 and4 64 Rockwell Automation Publication 10000337275 Ver 00 December 2012 73 Chapter14 Annex 74 Rockwell Automation Publication 10000337275 Ver 00 December 2012 Chapter14 Annex Rockwell Automation Publication 10000337275 Ver 00 December 2012 75 Chapter14 Annex 76 Rockwell Automation Publication 10000337275 Ver 00 December 2012 www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation Vorstlaan Boulevard du Souverain 36 1170 Brussels Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication 10000337275 Ver 00 January 2013 Copyright 2013 Rockwell Automation Inc All Rights Reserved Printed in USA
66. ld s Protective fields and warning fields form the so called field set You can configure these field sets with the aid of the SCD software The fields can be configured as circular rectangular or of arbitrary shape If the area to be monitored changes then you can re configure the SafeZone Mini in software without additional mounting effort You can configure field sets comprising one protective field and one or two warning fields The SafeZone Mini secures the hazardous area on a machine or vehicle As soon as the safety laser scanner detects an object in the protective field it switches the OSSDs to the OFF state and thus initiates the shutdown of the machine or stop of the vehicle Protective field Warning field 1 Warning field 2 TC You can define the warning fields such that the safety laser scanner detects an object before the actual hazardous area Warning field 1 can be used in particular for vehicle protection to detect an object even before the actual hazardous area and to slowly retard the movement of the vehicle or bring it to a standstill In this way the wear on the brakes on an AGV can be reduced Warning field 2 can also be used to trigger a warning signal Rockwell Automation Publication 10000337275 Ver 00 December 2012 11 Chapter3 Product description Note A warning field on the SafeZone Mini is not allowed to be used for tasks related to the protection of people Contour monitoring In addition to the p
67. ma 4 Pre COMMISSIONING TESIS sr A A 4 Regular inspection of the protective device by qualified safety personnel ooo0ooooocococo ooo 48 Daily testing of the protective device by a specialist or authorized persomnel oooooococccccccom o 48 Maintenance and Care scceccecsccececcccsccsceccccscescscesceeees Chapter 10 AE AAA AA 49 Replacing TNE Optics Cr aaa 49 DIAM MS irradia aia Maple k11 Ne evento TAUNTS OF error an 51 A een IR 51 Errorand statusindicationson the LEDs aan AGANG A 52 Error and status indications on the seven segment display masa aaaa anan a aaa aaa 5 The lock out operational status u ein Bo He 54 AAA diagnostic sa es een eier 54 Technical specificationS cscccecceccscccccccccsccsccescevcesceees Chapter 12 OSSD ESOS MES dsd 55 Timing behavior of the OSSDs of the SafeZone Mini cece eee cece cee e ence eee eseee eee eeeaaeneees 56 A E 5 nar aa panigan al ing isara BUD OPIN eS SRP UOT aa ee ee 58 DIMENSION OPA WINGS ne A AAA ae eas 61 Rockwell Automation Publication 10000337275 Ver 00 December 2012 Contents A A Gaan GAAN taal init aed die da cia 61 MOUNUNG KIS aga Kiana O Md cian af es 61 Scan Plane OIM 64 Ordering information cscceccccccecceccecceccecccscceccesees Chapter 13 items supplied Safezone MN restren eE da eae a ch Nos i rei 65 Accessories Date PANG Gamma kakarga dota 65 A A AA AA AK A 65 ULO OPPA AA AA APP Ma 3
68. ments for Industrial Robots and Robot Systems ANSI RIA R15 06 e Safety Standard for guided industrial vehicles and automated functions of named industrial vehicles ANSI B56 5 Note To some extent these standards require the protective device to have the safety level Control reliable The SafeZone Mini safety laser scanner meets this requirement Rockwell Automation Publication 10000337275 Ver 00 December 2012 Chapter3 Product description Special features Function 10 Fig 1 Principle of operation time of flight measurement by the SafeZone Mini Chapter 3 Product description This chapter provides information on the special features and properties of the SafeZone Mini safety laser scanner It describes the construction and the operating principle of the device e Small design e 270 scan area e Increased dust and particle tolerance due to light saturation and particle algorithms e With scanning ranges up to two meters maximum protective field radii e Configuration using PC or notebook with Rockwell Automation SCD software e Field sets comprising of one protective field and up to two warning fields e Contour monitoring of the protective field if only one warning field is used e Only standalone operation e One field set e One monitoring case e Integrated external device monitoring EDM e Integrated restart interlock restart interlock delay for which the parameters can be set e Two universal 1 0 connections
69. mum distance S see EN ISO 13855 gt First calculate S using the following formula S 2000x Ty Ts 8 x d 14 mm Where S Minimum distance mm Ty Stopping run down time of the machine or system Ts Response time of the SafeZone Mini d Resolution of the SafeZone Mini mm Rockwell Automation Publication 10000337275 Ver 00 December 2012 29 Chapter5 Mounting Mobile applications 30 Note Notes The reach approach speed is already included in the formula gt Ifthe result Sis lt 500 mm 19 7 in then use the determined value as the minimum distance gt Ifthe result S is gt 500 mm 19 7 in you may be able to reduce the minimum distance using the following calculation S 1600 x Ty Ts 8 x d 14 mm gt Ifthe new value S is gt 500 mm 19 7 in then use the newly calculated value as the minimum distance gt Ifthe new value S is lt 500 mm 19 7 in then use 500 mm 19 7 in as the minimum distance Response time Ts of the SafeZone Mini The response time Ts of the SafeZone Mini depends on The basic response time of the SafeZone Mini e The multiple sampling set See Chapter 12 OSSD response times on page 55 If the dangerous state is produced by a vehicle e g AGV or fork lift the hazardous area that is produced by the movement of the vehicle is protected by the SafeZone Mini e The SafeZone Mini may only be used to protect vehicles powered by electr
70. n of Rockwell Automation is prohibited Throughout this manual we use notes to make you aware of safety considerations Identifies information about practices or circumstances that can cause an explosion in a hazardous environment which may lead to personal injury or death property damage or economic loss Identifies information that is critical for successful application and understanding of PIO ALAN the product ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attentions help you identify a hazard avoid a hazard and recognize the consequences TVA Labels may be on or inside the equipment for example drive or motor to alert people that dangerous voltage may be present BURN HAZARD Labels may be on or inside the equipment for example drive or motor to alert people that surfaces may reach dangerous temperatures A A KA A It is recommended that you save this user manual for future use Contents Contents About this document scceccsccccscsccccecsscececcecesccsceceeces Chapter 1 FUNCTION OF TIS GOUMEN ee APA APA AA AA 4 A iene AA AA AA AA AN AE 4 UV ea oe ewes 4 Depto INMI ee dla ey Rew 4 Abbreviations A ng 4 SVU ONS MISCO AA PAA 5 Mitad per Dual ied Satety personnel asi lod Baa ANAN AG AA T eh 6 Applications OF NG TENGGA naaa e bere a nc GU maong ea 6 Conrod Eea A Lat axa tte Mora KANA ANG Ala Bowes
71. nctions ATTENTION You are not allowed to use the universal 1 0 connections for safety relevant functions Note yuna Fig 7 Configuration example universal 1 0 connections of the SafeZone Mini Recommendation You are only allowed to use the universal 1 0 connections for signaling You must never use the signals for controlling the application or for safety relevant functions The SafeZone Mini has two universal 1 0 connections see Chapter 6 Round plug connector SafeZone Mini on page 40 You can configure these two connections for the following functions e Inactive factory default setting As inputs it is only possible to select one function per universal 1 0 connection Stand by e External device monitoring EDM see page 18 e Resetting the restart interlock see page 18 As outputs it is possible to select several functions per universal 1 0 connection these functions are linked together using an OR operator e Device error e Contamination error e Contamination warning e Second warning field e Reset required Other functions that can be configured are dependent on the configuration of the universal 1 0 connections For example you can only realize a restart interlock if you configure one of the universal I Os as an input for resetting the restart interlock The universal 1 0 connections are configured in the SCD software in the Universal 1 0 area Fig 7 shows a configuration example Safe
72. ng run down time of the machine or system Ts Response time of the SafeZone Mini and the downstream controller Z General safety supplement of the SafeZone Mini 100 mm 3 94 in Zp Supplement for measurement error related to reflection C Supplement for prevention of reaching over Rockwell Automation Publication 10000337275 Ver 00 December 2012 25 Chapter5 Mounting ATTENTION Fig 16 Mounting variations for the scan plane mm in Table 8 Advantages and disadvantages of mounting variations mm in Hp Detection height Hs Scanner mounting height ATTENTION Response time Ts of the SafeZone Mini The response time Ts of the SafeZone Mini depends on The basic response time of the SafeZone Mini e The multiple sampling set See Chapter 12 OSSD response times on page 55 Supplement Zp for measurement errors caused by reflection Avoid mounting retroreflectors at a distance of less than one meter from the boundary of the protective field With retroreflectors positioned at a distance of less than 1 m 39 4 in from the boundary of the protective field a supplement Zp of 200 mm 7 87 in must be added to the protective field Supplement C for protection against reaching over With a protective field installed horizontally there is a risk that people may reach over the protective field and in this way reach the hazardous area before the SafeZone Mini shuts down the dangerous state For this
73. ng the device These operating instructions are original operating instructions These operating instructions are only applicable to the SafeZone Mini safety laser scanner with the following entry on the type label in the field Operating Instructions Pub No 10000337275 For the configuration and diagnostics of these devices you require the SCD version 3 0 or higher programming software To determine the software version select the Module Info option in the Help menu These operating instructions contain information on the SafeZone Mini safety laser scanner They have the following parts e Mounting e Fault diagnosis and troubleshooting e Electrical installation Catalog numbers e Commissioning and configuration e Accessories e Care and maintenance e Conformity and approval Planning and using protective devices such as the SafeZone Mini also require specific technical skills which are not detailed in this documentation General information on accident prevention using opto electronic protective devices can be found in the competence brochure Guidelines Safe Machinery When operating the SafeZone Mini the national local and statutory rules and regulations must be observed Please refer also to the Rockwell Automation home page on the Internet at www rockwellautomation com Here you will find information on e Application examples e A list of frequently asked questions regarding the SafeZone Mini e These operating
74. ns of the loads and those of the corresponding protective device a a 2 L i N 5 5 o o o 3 N TAT KAT m N gt e 2 gt gt EH an O DERE Qe ue 8388 Ll 1 44 J o LY EO n o AEAN A ee ee en 39 Chapter6 Electrical installation Notes System connection Notes Notes Fig 38 Round plug connector SafeZone Mini Table 9 Pin assignment of the SafeZone Mini 40 gt Route all cables and connection cables such that they are protected from damage gt Ensure that also the controller connected and all devices related to safety have the required category as per EN ISO 13849 1 or the required performance level as per EN ISO 13849 1 gt Ifyou use screened cables lay the screen evenly around the connection terminal gt Ensure that the SafeZone Mini is adequately protected electrically You will find the electrical data necessary for determining the correct fuse in Chapter 12 Data sheet on page 58 You will find all the inputs and outputs on the SafeZone Mini on the round plug connector on the connecting cable Connect the SafeZone Mini using pre assembled extension cables see Table 10 on page 41 e All inputs and outputs on the SafeZone Mini are to be used only in the context specified e The round plug connectors are coded If you use plug connectors other than the connectors intended any claims against Rockwell Automation under the
75. nse 36 Mounting with mounting kit 2and Sita A A cas 36 Information label Important information a 37 Using multiple SafeZone Mini safety laser scanners 00 cece cece eee e eee e cece cece nn 37 Electrical installation cceccccsccccsceccecsccecescecescececcecess Chapter 6 SYSLEICONNIELHION a ee guns KAG NANA nice ee Deere 40 Round plug connector SafeZone Mini cece ccc ceseccceenceeceenseeeeneseeneseesensseeeees 40 Configuration connection M8 x 4 serial interface aaa 4 Application examples and connection diagrams Chapter 7 SA AA O A O LUNG 4 Applications with one monitored area SafeZone Mini aaa 4 MODINE AD DICH ONS naaa este ance aie Tara pad Anya Deemer PO NG BULL aa Pack a ane BG PALAG Bina Po 43 Vehicle monitoring for unidirectional travel SafeZone Mini aaa 43 CONNECION dada a a aoe ween A LL 43 SafeZone Mini with restart interlock and external device monitoring maa 44 SafeZone Mini in combination with a UE10 safety relay 0 0 0 cee cece cece cece ee ee eee eeeeaneneeees 44 Protective field switching using a Flexi Classic safety controller aaa 45 Configuratio euere Chapter DEFAU LOEWE SAL ee ren u ONEEN 46 Preparation of the configuration ae ee ee ee 46 COMMISSIONING 2 0 0 uni cher 3 EA ee ee een 4 POWET UP SEQUE nahawa bA NTG EAR ANA AA PAGA a 4 AA Ni tale ods ean ne Mes A ae i
76. ode If in mobile applications vehicles are not moved for a time e g for battery charging the OSSDs can be switched to the OFF state and the laser on the SafeZone Mini can be switched off In this way the power consumption of the device is reduced In this way you also prevent the safety laser scanners from optically interfering with each other and entering an error condition The function can be realized with the aid of the stand by mode In order to switch to the stand by mode on the SafeZone Mini one universal 1 0 connection must be configured as stand by input see Chapter 4 Universal 1 0 connections of the SafeZone Mini on page 17 Note Amonitoring case is not occupied by the stand by mode Rockwell Automation Publication 10000337275 Ver 00 December 2012 23 Chapter5 Mounting Notes Stationary application in horizontal operation Fig 14 Horizontal stationary application Chapter 5 Mounting This chapter describes the preparation and completion of the mounting of the SafeZone Mini safety laser scanner Mounting requires four steps e Definition of the application and the necessary mounting location for the safety laser scanner e Calculation of the protective field sizes and minimum distances see EN ISO 13855 e Mounting the safety laser scanner with or without mounting kits No protective function without sufficient minimum distance Only if you configure the protective field such that there is an ad
77. olate the machine from the power supply during all work on the machine and safety laser scanner The SafeZone Mini safety laser scanner is largely maintenance free The optics cover on the safety laser scanner should however be cleaned regularly and if it is contaminated gt Do not use aggressive cleaning agents gt Do not use abrasive cleaning agents Static charges cause dust particles to be attracted to the optics cover You can diminish this effect by using the anti static plastic and the lens cloth How to clean the optics cover gt Use a clean and soft brush to remove dust from the optics cover gt Moisten the optics cloth with the anti static plastic cleaner and wipe off the window for light output on the optics cover with the cloth Perform an optics cover calibration with the aid of the SCD software after the replacement of the optics cover The level of contamination is measured continuously during the operation of the SafeZone Mini For this purpose the optics cover calibration must first be performed this then serves as a reference for the contamination measurement status not contaminated The optics cover calibration is only allowed to be performed with a new optics cover The new optics cover must be free of contamination at the time of the optics cover calibration The optics cover calibration should be performed at room temperature 10 30 C 50 86 F If the optics cover is scratched or damaged
78. ommissioned and serviced only by qualified safety personnel Qualified safety personnel are defined as persons who e Due to their specialist training and experience have adequate knowledge of the power driven equipment to be checked e Have been instructed by the responsible machine owner in the operation of the machine and the current valid safety guidelines e Are sufficiently familiar with the applicable official health and safety regulations directives and generally recognized engineering practice e g DIN standards VDE stipulations engineering regulations from other EC member states that they can assess the work safety aspects of the power driven equipment and e Have access to these operating instructions and have read them As arule these are qualified safety personnel from the ESPE manufacturer or also those persons who have been appropriately trained at the ESPE manufacturer are primarily involved in checking ESPE and are allocated the task by the organization operating the ESPE The SafeZone Mini safety laser scanner is used to protect persons and systems It is intended to be used to monitor hazardous areas indoors e Itis not allowed to use the SafeZone Mini outdoors e The SafeZone Mini cannot provide protection from parts thrown out of the machine or emitted radiation e The SafeZone Mini complies with the requirements in the standard on the radiated emissions as defined for class A industrial application the SafeZone Mini is
79. otection is required for hazardous point protection The SafeZone Mini must therefore be configured with a resolution of at least 40 mm 1 6 in Never use the SafeZone Mini for safety applications in which finger protection is required Due to the finest possible resolution of 30 mm 1 2 in the SafeZone Mini is not suitable for finger protection To protect the protective device against inadvertent adjustment or manipulation you must use the contour of the surroundings as a reference for the SafeZone Mini see Chapter 4 Using the contour as a reference on page 21 Minimum distance For hazardous point protection a minimum distance must be observed between protective field and hazardous point This safety distance ensures that the hazardous point can only be reached after the dangerous state of the machine has been completely stopped Prevent reaching around or reaching behind the protective field Always mount the safety laser scanner such that reaching around and behind is impossible Provide suitable additional precautions as necessary Contour as reference The minimum distance S as defined in EN ISO 13855 and EN ISO 13857 depends on Stopping run down time of the machine or system The stopping run down time is shown in the machine documentation or must be determined by taking a measurement e Response time of the SafeZone Mini e Reach or approach speed e Resolution of the SafeZone Mini How to calculate the mini
80. reventing During mounting the SafeZone Mini areas may be found that are not covered by the safety laser scanner unprotected areas Fig 25 Unprotected areas 1111111111117 III 1111114141 ATTENTION Prevent or secure unprotected areas e Mount the SafeZone Mini such that there are no unprotected areas e For mobile applications if the vehicle is accelerated to a maximum velocity of 0 3 m s 11 8 in s in less than three seconds when in operation you must prevent personnel from entering the unprotected areas by means of mechanical trim panels switch strips or fitting the SafeZone Mini in the vehicle trim panels Rockwell Automation Publication 10000337275 Ver 00 December 2012 33 Chapter5 Mounting Fig 26 Preventing unprotected areas BANA NABANG NAA ANG BAGA ET re LALABA Mount the SafeZone Mini for example on a corner to prevent unprotected areas Fig 27 Mounting example for front and side protection in a direction of travel Protective field and warning field safety laser scanner 1 PN Protective field and warning field safety laser scanner 2 With two SafeZone Mini mounted at an angle of 45 on the front corners of a vehicle you can configure the protective fields so that there are no unprotected areas and the hazardous areas in narrow aisles can also be protected Fig 28 Mounting example for gt all round protection in N all directions of travel Protective field and warning field
81. ripple a as 5 Switch on current Bl A Operating current without output load SafeZone Mini la 0 16A 0 20A Operating current with max output load SafeZone Mini 4 moy Power consumption without output load SafeZone Mini 3 9W 4 8 W Power consumption with max output load SafeZone Mini 8 1 a Power consumption in the stand by mode or park mode Tan without output load SafeZone Mini 3 6W 4 8 W Electrical connection Connecting cable with round plug connector Cable length for power supply tolerance 10 m ft o eo Cable length for power supply tolerance 5 m ft PF Ba 11 5 Cable length for power supply tolerance 1 m ft o oD Universal 1 05 EO di Input resistance when HIGH a Voltage for HIGH 24V 30V Voltage for LOW 0V 5V Complies with Diamond Grade 3000X approx 1250 cd Ix x m el The detection capability of the warning field is dependent on the remission of the objects to be detected The total response time of your application is dependent on further factors To meet the requirements of the relevant product standards e g EN 61496 1 the external voltage supply for the device must be able to bridge a brief mains failure of 20 ms Power supplies according to EN 60204 1 satisfy this requirement Suitable power supplies are available as accessories from Rockwell Automation The absolute voltage level must not drop below the specified minimum voltage The load currents for the inp
82. rotective field the SafeZone Mini can also monitor a contour e g the floor in vertical applications SafeZone Mini Device components The SafeZone Mini safety laser scanner comprises three components e The sensor with the opto electronic detection system the LEDs the seven segment display and the connecting cable with the electrical connections e The optics cover with the window for the light output Fig 4 Device components Optics cover Window for light output Round plug connector Connecting cable LEDs and seven segment display Fig 5 Protective Field Range 12 Rockwell Automation Publication 10000337275 Ver 00 December 2012 Chapter3 Product description Applications Table 2 Possible applications for the SafeZone Mini SafeZone Mini Hazardous area protection on an insertion station SafeZone Mini Hazardous point protection on an insertion station SafeZone Mini Presence detection for a safety light curtain SafeZone Mini Protection of an automated guided vehicle AGV for one velocity Rockwell Automation Publication 10000337275 Ver 00 December 2012 13 Chapter3 Product description Status indicators LEDs and seven segment display The LEDs and the seven segment display indicate the operational status of the SafeZone Mini They are on the front face of the safety laser scanner Fig 6 Status indicators on the SafeZone Mini The symbols have the following meaning Table 3 Stat
83. rth Ground f F KI not configured for this AD S11 21 S12 22 Frl application t no connection 0 IN o e a K2 O Allen Bradiey AM Guard maste MM 13 14 23 24 L11 Y32 S34 13 14 23 24 O O OV DC Monitored Manual Reset SafeZone Mini in combination with a GSR SI safety relay operating mode of SafeZone Mini is ON OFF and GSR SI is configured for monitored manual reset Rockwell Automation Publication 10000337275 Ver 00 December 2012 Fig 45 SafeZone Mini in combination with a GSR DI safety relay Chapter7 Application examples and connection diagrams Two SafeZone Mini safety laser scanners with GSR DI 24V DC Color Pin Signal SafeZone Mini Wht 1 Output Warning Field1 Brn 24V DC Grn Universal 1 01 Wht Grn Yel 3 Yel 4 Universal 1 02 5 6 7 Gry 5 OSSD 1 Blu Pnk OSSD 2 Blu 0V DC Shid 8 Earth Ground not configured for this application Reset no connection Wht Grn Yel ii L2 L3 OL R O O Q O O O S11 S21 S12 S22 S32 S42 hal a L Test Out L N N2 I Power 24VDC 0 In1 DI LOGIC 5 NX In2 BD Allen Bradley 8 XI Out Guard mare 4 XI Logic 112 L11 Y32 S34 OV DC Monitored Manual Reset Two SafeZone Mini safety laser scanners connected to a GSR DI safety relay The GSR DI is configured for monitored manual reset SafeZone Mini scanners are configured for ON OFF Rockwell Automation Publication 10000337275 Ver 00 December 201
84. s these may affect the SafeZone Mini in specific circumstances gt Mark the protective field on the floor if this is reasonable for the application see EN 61496 1 in Chapter 7 The following steps are necessary after mounting e Completing the electrical connections Chapter 6 Electrical installation e Configuration of the protective field Chapter 8 Configuration e Commissioning and checking of the installation Chapter 9 Commissioning e Checking the function and safe shutdown Chapter 9 Test notes This type of protective device is suitable for machines and systems on which e g a hazardous area is not completely enclosed by a guard 24 Rockwell Automation Publication 10000337275 Ver 00 December 2012 Note Note ATTENTION Fig 15 Minimum distance S Chapter5 Mounting For a horizontal stationary application determine e The protective field size to observe the necessary minimum distance e The height of the scan plane e The restart behavior e Measures to protect any areas not covered by the SafeZone Mini Once you have defined the protective field size mark the boundaries of the protective field on the floor In this way you will make the protective field boundaries visible for the operator and ease subsequent testing of the protective function Protective field size The protective field must be so configured that a minimum distance S to the hazardous area is maintained
85. safety ye laser scanner 2 Protective field and warning field safety laser scanner 1 With two SafeZone Mini mounted diagonally opposite you can implement protective fields on the vehicle for all round protection in all directions of travel 34 Rockwell Automation Publication 10000337275 Ver 00 December 2012 Chapter5 Mounting Mounting steps ATTENTION Fig 29 Prevent crawling beneath standing behind climbing over Note Near range Make the near range impassible using a bar or a recess or additionally protect the near range 50 mm 2 0 in wide area in front of the optics cover using a proximity switch with 50 mm 2 0 in acquisition range The vehicle may then be accelerated as required Only qualified safety personnel are allowed to separate materials Caution is required when dismantling devices There is a risk of injuries Special features to note during mounting gt Mount the SafeZone Mini such that it is protected from moisture dirt and damage gt Ensure that the entire field of view of the SafeZone Mini is not restricted gt Mount the safety laser scanner such that the indicators are easy to see gt Avoid excessive shock and vibration loading on the safety laser scanner gt Onsystems that suffer from heavy vibration prevent the fixing screws from coming loose using screw locking devices gt Regularly check the tightness of the fixing screws gt Prevent personnel from being able to crawl b
86. sonnel are allowed to separate materials Caution is required when dismantling devices There is a risk of injuries Before you send the devices for appropriate recycling it is necessary to separate the different materials in the SafeZone Mini gt Separate the housing from the rest of the parts in particular the circuit boards gt Send the separated parts for recycling as appropriate see Tab 1 Components Disposal Product Housing Metal recycling aluminium Motor bracket Metal recycling zinc die cast housing Optics cover Plastic recycling Circuit boards cables connectors and electrical Electronic recycling connecting pieces Packaging Cardboard paper Paper cardboard recycling Polyethylene packaging Plastic recycling The most important directives and standards valid for the use of opto electronic protective devices in Europe are listed below Further regulations may be of importance to you depending on the application You can obtain further information of machine specific standards from national institutions e g DIN BSI AFNOR etc the authorities or your trade association If you operate the machine or vehicle in a country outside the European Union please contact the manufacturer of the system and the local authorities and obtain information on the regulations and standards applicable there Application and installation of protective devices Machinery Directive 2006 42 EC e g e Safety of machinery
87. ssioning use and periodic technical inspections of the SafeZone Mini safety laser scanner in particular Machinery Directive 2006 42 EC Work Equipment Directive 2009 104 EC The work safety regulations safety rules Other relevant health and safety regulations e Manufacturers and operators of the machine on which the SafeZone Mini is used are responsible for obtaining and observing all applicable safety regulations and rules e Thenotes in particular the test notes see Chapter 9 Commissioning on page 47 in these operating instructions e g on use Mounting installation or integration into the machine control must be observed e Changes to the configuration of the devices can degrade the protective function After every change to the configuration you must therefore check the effectiveness of the protective device The person who makes the change is also responsible for the correct protective function of the device When making configuration changes please always use the password hierarchy provided by Rockwell Automation to ensure that only authorized persons make changes to the configuration e The tests must be carried out by qualified safety personnel or specially qualified and authorized personnel and must be recorded and documented to ensure that the tests can be reconstructed and retraced at any time e The operating instructions must be made available to the operator of the machine where the SafeZone Mini is used
88. system for the first time see Chapter 14 2 Checklist for the manufacturer on page 69 gt Document the adjustment of the safety laser scanner and the results of the testing during initial commissioning in a traceable manner For this purpose also print out the complete configuration of the safety laser scanner including protective field shapes and include these with the documentation gt Use the Create development dump function in the SCD software right click on the COM interface to which the safety laser scanner is connected You can keep these data as a backup and in this way document the state during initial commissioning at any time Your Rockwell Automation representative will be pleased to provide you with advice on initial commissioning Regular inspection of the protective device by qualified safety personnel gt Check the system following the inspection intervals specified in the national rules and regulations This procedure ensures that any changes on the machine or manipulations of the protective device after the initial commissioning are detected gt If major changes have been made to the machine or the protective device or if the safety laser scanner has been modified or repaired check the system again as per the checklist in the annex see Chapter 14 Checklist for the manufacturer on page 69 Daily testing of the protective device by a specialist or authorized personnel The effectiveness of the prot
89. tective field range at the resolutions that can be set Configured resolution mm in Maximum protective field range m ft 30 1 2 hand detection 1 25 4 1 40 1 6 hand detection 1 60 5 2 50 2 0 leg detection 2 00 6 6 70 2 8 leg detection 2 00 6 6 The warning field can be configured to up to 8 m 26 25 ft for all resolutions The detection capability within the warning field is dependent on the remission of the objects to be detected see Chapter 12 Technical Specifications on page 55 Basic response time The basic response time of the SafeZone Mini is 80 ms You may need to add supplements to the basic response time due to multiple sampling see Chapter 12 OSSD response times on page 55 Maximum protective field range Depending on the configured resolution used see Chapter 4 Resolution on page 16 the maximum protective field range of the safety laser scanner is shown in the SCD software The maximum protective field range of the SafeZone Mini must be sufficient to cover the calculated protective field size including the necessary supplements see Chapter 5 Protective field size on page 25 In mobile applications a resolution of only 70 mm 2 8 in is required for leg detection 2 Radial distance to the safety scanner 16 Rockwell Automation Publication 10000337275 Ver 00 December 2012 Universal I O connections of the SafeZone Mini Chapter4 Configurable fu
90. the power supply or the connecting cables Lila voltage There is a short circuit between gt Check the wiring for cross circuits the input for the control switch for restart or reset and another input or output Park stand by mode No error If the criteria for the park mode or the stand by the OSSDs of the SafeZone Mini mode are withdrawn readiness for operation is re are in the OFF state the laser is established deactivated If the display 23 does not go off gt Test the level s at the universal 1 0 and at the control inputs that switch to the monitoring case with park mode Optics cover calibration active gt No error Cai Window for light output on the gt Clean the window for the light output on the optics optics cover contaminated cover Optical saturation of the gt Check whether the SafeZone Mini is being affected by an contamination measurement external light source e g headlight infrared light lug KA there may not be an optics source stroboscopic light sun etc and cover fitted Or Me gt Fit the new optics cover then perform optics cover calibration If you have problems during troubleshooting contact Rockwell Automation support Keep a copy of the print out of the results of the diagnostics at hand The lock out operational status In case of certain faults or an erroneous configuration the system can go into the lock out status The seven segment display on the sa
91. the protective field and warning field With the aid of the SCD software you can configure the field set which comprises a protective field and two warning fields During this process you configure the shape and size of the protective and warning fields You can realize any field shape required The area to be monitored is scanned radially by the SafeZone Mini The SafeZone Mini cannot see through objects during this process The area behind objects that are in the area to be monitored pillars grilles etc can thus not be monitored Protective fields and warning field can cover up an angle of up to 270 and have different radial scanning ranges depending on the resolution configured see Chapter 4 Resolution on page 16 Check the protective fields configured Prior to commissioning the machine or vehicle check the configuration of the protective fields using the instructions in Chapter 9 Commissioning on page 47 and using the Checklist on page 69 If the protective field or the warning fields stretch as far as a wall or another object pillar neighboring machine shelf there should be a distance of 100 mm 3 94 in between the protective field or warning field and the object to prevent false triggering NNNNN Secure unprotected areas If it is possible to access a narrow strip between the protective field and a wall or another object you must protect this strip using additional measures e g
92. tion SafeZone Mini cable White Output for warning field 1 2 Brown Supply voltage 24V DC 3 Green Universal 1 0 connection 1 4 Yellow Universal 1 0 connection 2 Gray Output signal switching device OSSD1 6 Pink Output signal switching device OSSD2 Supply voltage OV DC 8 FE shield Functional earth shield UI Universal I O connections of the SafeZone Mini ATTENTION Do not use the universal 1 0 connection outputs for safety related tasks The universal 1 0 connection outputs are purely application diagnostics outputs e g for the transfer of information to controllers Configuration connection M8 x 4 serial interface Fig 39 Pin assignment configuration 3 4 connection M8 x 4 1 2 Table 11 Pin assignment configuration Pin SafeZone Mini PC side RS 232 D Sub connection M8 x 4 OO fend O o LLEGE a Naa E 3 OV DC voltage supply Pin 5 4 TxD Pin 2 Notes gt After configuration always remove the connecting cable from the configuration connection gt After the configuration of the device has been completed locate the attached protection cap to cover the configuration connection Rockwell Automation Publication 10000337275 Ver 00 December 2012 41 Chapter7 Application examples and connection diagrams Chapter Application examples and connection diagrams The examples shown are only provided as an aid for your planning You may need to consider additional protection measures for your application Stationary appl
93. to the SafeZone Mini again NEE Waiting for restart of the device gt Switch off the voltage supply for the SafeZone Mini for at least two seconds and then switch it back on Error of the external device gt Check whether the contactors are working correctly or if monitoring EDM they are wired incorrectly and rectify any error gt If JEK is displayed also switch off the voltage supply or Jal for the SafeZone Mini for at least two seconds and switch it back on Error in the control switch for gt Check the functionality of the control switch The button restart or reset may be defective or permanently operated gt Check the wiring of the control switch for short circuit to 24V SafeZone Mini has a gt Switch off the voltage supply for the SafeZone Mini for at malfunction or is faulty least two seconds and then switch it back on ECN EE If the display does not go off gt Send the SafeZone Mini to the manufacturer for repair Overcurrent on OSSD gt Check the switching element connected contactor FL connection 1 relay Replace if necessary gt Check the wiring for short circuit to OV Short circuit to 24V atOSSD gt Check the wiring for short circuit to 24V JI Short circuit to OV at OSSD gt Check the wiring for short circuit to OV connection 1 gt Display Rectification of the error Overcurrent on OSSD Check the switching element connected contactor connection 2 relay Replace if necessary
94. urable functions Application pna Table 4 Comparison of mobile and stationary applications Table 5 Maximum protective field range at different resolutions Note Note Note With the help of the SCD software you can configure the SafeZone Mini for the required application Depending on whether you select a stationary or a mobile application different configuration options are available Mobile applications mm in Resolution e 30 1 2 hand detection with smaller protective field size e 40 1 6 hand detection with larger protective field size e 50 2 0 leg detection with smaller protective field size e 70 2 8 leg detection with larger protective field size Manipulation prevention The safety laser scanner checks whether in any 90 segment all measured values correspond to the maximum distance value that can be measured Ifthis is the case the SafeZone Mini shuts down after 2 hours and signals SL Stationary applications mm in 30 1 2 hand detection with smaller protective field size 40 1 6 hand detection with larger protective field size 50 2 0 leg detection with smaller protective field size 70 2 8 leg detection with larger protective field size If this the case the SafeZone Mini shuts down after 5 seconds and signals Hell Resolution The maximum protective field range depends on the configured resolution The following table shows the related maximum pro
95. ured against manipulation after adjustment Are the required protective measures against electric shock in effect protection class Is the control switch for resetting the protective device ESPE or restarting the machine present and correctly installed Are the outputs of the ESPE OSSDs ASInterface Safety at Work integrated in compliance with the required PL SILCL according to EN ISO 13 8491 EN 62 061 and does the integration comply with the circuit diagrams Has the protective function been checked in compliance with the test notes of this documentation Are the given protective functions effective at every setting of the operating mode selector switch Are the switching elements activated by the ESPE e g contactors valves monitored Is the ESPE effective over the entire period of the dangerous state Once initiated will a dangerous state be stopped when switching the ESPE on or off and when changing the operating mode or when switching to another protective device Has the information label for the daily check been attached so that it is easily visible for the operator Yes CI Yes CI Yes CI Yes CI Yes CI Yes CI Yes CI Yes CI Yes CI Yes CI Yes CI Yes CI Yes 1 Yes 1 Yes 1 Yes 1 Yes 1 Yes CI This checklist should be retained and kept with the machine documentation to serve as reference No 1 No 1 No 1 No 1 No 1 No 1 No 1 No 1 No 1 No L No 1 No 1 No LI No L No 1
96. us 50 ms 2 PNP semiconductors short circuit protected cross circuit monitored nr om som TO A parson CU TO py 2 50 230 us 300 us 20 ms 20 ms 2 ms RS 232 proprietary 38400 Baud CT TA No sv SV EEE EL 5 C5 I CO pay Ni ps Bm a fon ECETIA EEE E av iv Switching currents up to 500 mA are allowed briefly lt 100 ms 19 In the case of a fault 0 V cable open circuit maximally the leakage current flows in the OSSD cable The downstream controller must detect this status as LOW An FPLC fail safe programmable logic controller must be able to identify this status 2 Make sure to limit the individual line core resistance to the downstream controller to this value to ensure that a cross circuit between the outputs is safely detected Also note EN 60 204 1 Na 3 When active the outputs are tested cyclically brief LOW When selecting the downstream controllers make sure that the test signals do not result in deactivation Rockwell Automation Publication 10000337275 Ver 00 December 2012 Chapter12 Technical specifications Dimensions mm in SafeZone Mini Fig 53 Dimensional drawing SafeZone Mini 94 3 7 dia 73 2 87 dia 102 4 02 dia 200 7 87 max 104 4 09 54 5 2 15 O j patas IT 0 41 433 pee act wi NG TS 250 9 84 Mounting kits Fig 54 Dimensional drawing mounting kit 1 442 AMBSZMN1 DIN74 F5 110 4 3
97. us indicators on the Symbol SafeZone Mini SafeZone Mini zume afeZone Mini OSSDs in the OFF state e g in case of object in the protective field monitored contour changed reset required lock out Warning field interrupted object in one of the warning fields 0SSDs in the ON state no object in protective field Reset required OOO Optics cover contaminated al Seven segment display for the indication of the status and errors Note You will find detailed information in Chapter 11 Error and status indications on the LEDs on page 52 and in Error and Status indications on the seven segment display on page 52 14 Rockwell Automation Publication 10000337275 Ver 00 December 2012 System parameters Recommendation Chapter4 Configurable functions Chapter 4 Configurable functions A name can be assigned to the application configured as well as to the safety laser scanner s The names are saved in the devices after the configuration is transferred The name chosen may be for example the identifier for the vehicle system or the machine You enter the application name and the names of the safety laser scanners used in the SCD software Application name Enter a name for your application You can enter a name with a maximum of 16 characters If you assign unique application names you may reserve the devices for certain duties A machine maintenance person comparing exchanged devices with the configuration
98. ut capacitors are not taken into account With the typical supply voltage of 24V Rockwell Automation Publication 10000337275 Ver 00 December 2012 59 Chapter 12 60 Technical specifications Input capacitance Static input current Actuating time of the control switch for restart HIGH switching voltage at 100 mA Source switching current Current limiting after 5 ms at 25 C Power up delay Switch off delay Response time with configuration as second warning field output OSSDs Output signal switching device pair HIGH switching voltage at 250 mA Switching voltage LOW Source switching current Leakage current Load inductance Load capacity Switching sequence without switching Permissible cable resistance 42 Test pulse width Test frequency Power up delay of the OSSDs from red to green Time offset on switching the OSSDs between OSSD2 and 0SSD1 Configuration and diagnostics interface Communication protocol Transmission speed Cable length at 38400 Baud and 0 25 mm cables Galvanic isolation Output TxD HIGH Output TxD LOW Voltage range RxD Switching threshold RxD LOW Switching threshold RxD HIGH Short circuit current at TxD Max voltage level at RxD Max voltage level at TxD Applies to the voltage range between Vs and 0 V Maximum Minimum Typial E OOOO ibm gt ms 200ms ms a mA m mA m am Im 0 7 ms 2 ms Corresponds to the resulting response time of the OSSDs pl
99. vel of remission defined as the ratio of the luminance reflected from a surface in the measuring direction and the luminance of a completely matte white surface white standard The minimum size of an object that is acquired by the protective device and is guaranteed by the manufacturer The restart interlock is a protective device In certain situations it prevents the machine from automatically restarting This applies e g after the scanner function has triggered during a dangerous machine state after a change to the operating mode or the method of activation of the machine or after the change to the start control device on the machine The SafeZone Mini has two universal 1 0 connections These two connections can be configured as inputs e g for stand by EDM or reset or as outputs e g for device error contamination or second warning field The warning field is a field with a radius of up to 8 m 26 25 ft see Chapter 12 Technical specifications on page 55 Using this field larger areas can be controlled and simple switching functions e g warning functions triggered The warning field is not allowed to be used for tasks related to personnel protection 70 Rockwell Automation Publication 10000337275 Ver 00 December 2012 List of tables Chapter14 Annex Table 1 Overview on disposal by components ccc cece cence eee eee e eee crono 8 Table 2 Possible applications for the SafeZone Mini cc ce
100. ying high power In this way you will avoid EMC effects on the service cable e The service cable is only allowed to be connected for configuration and diagnostics The service cable must be disconnected and the protective cap fitted in operation Use the password function in the SCD software and protect the configuration settings from unauthorized access Also ensure that the passwords are stored protected from unauthorized access Rockwell Automation Publication 10000337275 Ver 00 December 2012 Initial commissioning ATTENTION Table 12 Seven segment display during and after the power up sequence on initial commissioning Table 13 LED indication of the SafeZone Mini after the power up sequence Test notes ATTENTION Chapter9 Commissioning Chapter 9 Commissioning Commissioning requires a thorough check by qualified safety personnel Before you operate a system protected by the SafeZone Mini safety laser scanner for the first time make sure that the system is first checked and released by qualified safety personnel The result of the test must be documented Please read the notes in Chapter 2 On safety on page 6 gt Prior to releasing the machine check whether the access to the hazardous area or the hazardous point is completely monitored by the protective devices gt Also after approval of the machine at regular intervals e g in the morning prior to starting work check whether the OSSDs on the SafeZone
101. you must replace the optics cover Order the replacement optics cover from Rockwell Automation see Chapter 13 Accessories spare parts on page 65 e The optics cover on the SafeZone Mini is an optical part that must not be soiled or scratched on replacement e The optics cover is only allowed to be replaced by qualified safety personnel in a dust and dirt free environment e Never replace the optics cover during ongoing operation as internal parts may be irreparably damaged in certain circumstances and dust particles may enter the device e Itis imperative that you avoid contamination of the inside e g with fingerprints e Do not use any additional sealant for sealing the optics cover e g silicon as these substances may affect the optics e Use a torque wrench universal joint with 2 5 mm hex socket bit e Mount the optics cover as per the following instructions to ensure that the housing is sealed to IP 65 Rockwell Automation Publication 10000337275 Ver 00 December 2012 49 Chapter 10 50 Maintenance and care Notes Fig 47 Undo the mounting screws for the optics cover MA How to replace the optics cover e Only use a new optics cover see Chapter 13 Miscellaneous on page 65 e When replacing the optics cover take ESD protection measures e Set the torque wrench to 1 2 Nm hand tight and have this at hand gt Disconnect the round plug connector on the end of the connecting cable and remove th

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