Banner AG4-4E Specification sheet

Banner AG4 Series Safety Laser Scanner
Product Manual P/N 144924 05/2009 1

Banner AG4 Series Safety Laser Scanner
Important ... read this page before proceeding!
In the United States, the functions that the Banner AG4 Series Safety Laser Scanner is intended to perform are regulated by the
Occupational Safety and Health Administration (OSHA). Outside of the United States, these functions are regulated by other
agencies, organizations, and governments. Whether or not any particular Safety Laser Scanner installation meets all applicable
requirements depends upon factors that are beyond the control of Banner Engineering Corp. These factors include the way in
which the Safety Laser Scanner is applied, installed, wired, operated, and maintained.
It is the responsibility of the purchaser
and user to apply
this
Safety Laser Scanner
in full
compliance with all relevant applicable regulations and standards.
The Banner AG4 Series Safety Laser Scanner can guard against accidents only when it is properly installed and integrated into
the machine, properly operated, and properly maintained. Banner Engineering Corp. has attempted to provide complete
application, installation, operation, and maintenance instructions. In addition, please direct any questions regarding application or
use of the Scanner to the factory applications department at the telephone number or addresses shown on the back cover.
In addition to OSHA regulations, several other organizations provide information about the use of safeguarding devices. Refer to
the American National Standards Institute (ANSI), the Robotics Industries Association (RIA), the Association for Manufacturing
Technology (AMT), and others. Banner Engineering Corp. makes no claim regarding a specific recommendation of any
organization, the accuracy or effectiveness of any information provided, or the appropriateness of the provided information for a
specific application.
The user has the responsibility to ensure that all local, state, and national laws, rules, codes, and regulations relating to
the use of this safeguarding system in any particular application are satisfied. Extreme care is urged to ensure that all
legal requirements are met and that all installation and maintenance instructions contained in this manual are followed.
Safety Standards Applicable to Use of the Banner AG4 Series Safety Laser Scanner
See inside back cover for information pertaining to applicable U.S., European and International standards, and where to acquire copies.
About this Document
The information for applying and configuring the Banner AG4 Safety Laser Scanner (the Scanner) is covered in several documents to make
accessing information easier. The documents and configuration program for the Scanner are on the CD that comes with the product.
Document Title Document Content Source
User Reference Guide General product information and diagnostic
reference table. P/N 145034, Included with the product in print and on CD-ROM
AG4soft Program AG4 configuration and diagnostic software Included with the product on CD-ROM
AG4 Product Manual
(this document)
AG4 operation capabilities, functions, applications,
for the machine designer P/N 144924, Included with the product on CD-ROM
AG4soft Software Manual
AG4 software instructions:
How to: Configure operational settings,
Access diagnostic information
Manage configuration files
P/N 144923, Included with the product on CD-ROM
AG4 System Checkout Cards Instructions for daily or twice-yearly checkout of
Scanner installation
Checkout cards are within this document, to be printed as
needed and posted near the equipment being guarded
The current software version and all PDF documents can be downloaded from the Banner website http://www.bannerengineering.com.
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Banner AG4 Series Safety Laser Scanner
TABLE OF CONTENTS
1Overview ............................................................................................................................... 7
1.1 Status Display ....................................................................................................................... 8
1.2 Mounting System (Optional) .................................................................................................. 8
1.3 ConfigPlug (Optional)............................................................................................................. 8
1.4 Product Labels ...................................................................................................................... 9
1.4.1 Product identification plate ..................................................................................... 9
1.4.2 Safety Notice .......................................................................................................... 9
1.5 Proper Use and Intended Purpose ................................................................................. 10
1.6 Security Protocol ............................................................................................................. 10
1.6.1 Designated Person ............................................................................................... 10
1.6.2 Qualified Person ................................................................................................... 11
1.7 Responsibility for Safety ................................................................................................. 11
1.8 Laser ............................................................................................................................... 11
1.9 High Voltage ................................................................................................................... 11
1.10 Handling the Scanner................................................................................................ 12
1.11 Scanner Limitations ................................................................................................... 12
1.12 Providing the machine operator with information ...................................................... 13
1.13 Basic Operation Functions ............................................................................................... 13
1.14 Start/restart (reset) interlock ...................................................................................... 13
1.14.1 Start interlock ....................................................................................................... 13
1.14.2 Restart interlock - Manual Restart (reset) when PF is clear ................................. 14
1.15 Start test .................................................................................................................... 14
1.16 Automatic start/restart ............................................................................................... 14
1.17 Dust suppression ....................................................................................................... 14
1.18 Field Pairs - Independently activated protective and warning fields .......................... 14
1.19 Reference contour (surface) monitoring .................................................................... 16
2. Models and Specifications ...................................................................................................... 17
2.1 Models, Accessories and Replacement Parts ................................................................ 17
2.3 Dimensions .....................................................................................................................19
3. Application Basics ................................................................................................................... 21
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Banner AG4 Series Safety Laser Scanner
3.1 Danger zone guarding .................................................................................................... 21
3.2 Hazard point guarding (with field pairs) .......................................................................... 22
3.3 Access guarding ............................................................................................................. 23
4. Installation ................................................................................................................................. 25
4.1 Basic information ............................................................................................................ 25
4.1.1 Process steps ....................................................................................................... 25
4.2 Configuration Considerations ........................................................................................ 26
4.3 Handling unmonitored areas ........................................................................................... 27
4.4 Considerations for Adjacent Scanners ........................................................................... 28
4.5 Minimum Separation Distance ........................................................................................ 30
4.5.1 Minimum Separation Distance (US Standards) .................................................... 30
4.5.2 Scanner-Specific Additional Distance Factors ..................................................... 31
4.5.3 Minimum Separation Distance (European Standards) ......................................... 32
4.5.4 Distance adjustment C, based on the possible field intrusion .............................. 33
4.5.5 Scanner-Specific Additional Distance Factors ..................................................... 34
4.5.6 Example of separation distance formula adjustments ZSM ................................... 35
4.5.7 Horizontal Protective Field Applications (US & European Standards) ................. 36
4.5.8 C for Horizontal Protective Field Applications (parallel approach) ....................... 37
4.6 Application Examples ..................................................................................................... 38
4.6.1 Danger zone (parallel approach) .......................................................................... 38
4.6.2 Hazard guarding - approach is normal to the protective field ............................... 39
4.6.3 PF and reference surface ..................................................................................... 40
4.6.4 Access guarding ................................................................................................... 41
4.6.5 PF with Reference Surface .................................................................................. 42
5. Electrical connection ............................................................................................................... 44
5.1 Interface Connections ..................................................................................................... 44
5.1.1 X1 plug interface assignment ............................................................................... 46
5.1.2 Interface assignment, plug X2 .............................................................................. 47
5.1.3 Cable Assembly ................................................................................................... 47
5.2 Integrating the Scanner into machine control system ..................................................... 49
5.2.1 Downstream safety circuit with start/restart interlock,
contactor monitoring, without field pair switchover ......................................... 49
5.2.2 Safety PLC for field pair switch control ................................................................ 51
6. Configuration ............................................................................................................................ 52
6.1 Administrative parameters .............................................................................................. 52
6.1.1 Safety Laser Scanner name ................................................................................. 52
6.1.2 Description ........................................................................................................... 52
6.1.3 Start segment output ............................................................................................ 52
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Banner AG4 Series Safety Laser Scanner
6.1.4 Stop segment output ............................................................................................ 52
6.1.5 Output resolution .................................................................................................. 52
6.1.6 Serial interface baud rate ..................................................................................... 53
6.1.7 Alarm incident ...................................................................................................... 53
6.1.8 Pre-calculated measured values output ............................................................... 53
6.1.9 2nd measured value calculation segment............................................................ 53
6.1.10 3rd measured value calculation segment ............................................................. 53
6.2 Safety-relevant parameters ............................................................................................ 54
6.2.1 Application ............................................................................................................ 54
6.2.2 Response times ................................................................................................... 54
6.2.3 Dust suppression ................................................................................................. 54
6.2.4 Applicable field pair selection with Scanner start ................................................. 55
6.2.5 Permitted field pair switchover ............................................................................. 55
6.3 Field pair ......................................................................................................................... 55
6.3.1 PF description ...................................................................................................... 55
6.3.2 WF description 55
7Safety System Testing ....................................................................................................... 56
7.1 Prescribed Test Schedule ............................................................................................... 56
7.2 Initial Periodic Operation Check ..................................................................................... 56
7.3 Configuration Recommendations ................................................................................... 57
7.4 Restart ............................................................................................................................ 57
7.5 Starting up a replacement Scanner ................................................................................ 58
7.6 Testing - pre-startup and post machine modification ...................................................... 59
7.7 Scanner Initial Startup Checkout Card – before the machine connection ................. 60
7.8 Daily Checkout ................................................................................................................ 61
7.8.1 Daily Checkout Card ............................................................................................ 62
8Maintenance and Repairs .................................................................................................. 63
8.1 Cleaning the Scanner Front Screen ............................................................................... 63
8.2 Cleaning the scatter screens .......................................................................................... 64
8.3 Changing the scatter screens .......................................................................................... 64
8.4 Changing the front screen............................................................................................... 64
8.5 Disposal ........................................................................................................................... 66
8.6 Repairs............................................................................................................................ 66
9Diagnostics and Troubleshooting .................................................................................... 67
9.1 If an error occurs .............................................................................................................67
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Banner AG4 Series Safety Laser Scanner
9.2 LED status displays ........................................................................................................ 67
9.3 LED warning and error displays ...................................................................................... 69
9.4 Diagnostics codes ........................................................................................................... 70
EC Declaration of Conformity ..................................................................................................... 76
10. Glossary .................................................................................................................................. 77
10.1 List of Abbreviations .................................................................................................. 77
10.2 List of terms ............................................................................................................... 77
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Banner AG4 Series Safety Laser Scanner
Product Manual P/N 144924 05/2009 7
1Overview
The Banner AG4 is an optical, two-dimensional measuring Safety Laser Scanner.
The Scanner emits periodic light pulses via a rotating deflection unit. The light pulses reflect back from objects in the field and are then detected
by the Scanner receiver. The Scanner calculates the precise position of the obstruction from the light travel time and the angle of the deflection
unit when the pulse was emitted. If the obstruction is within the user-defined protective field (PF), the Scanner switches the safety outputs OFF.
Only when the PF is free of obstructions does the Scanner turn the safety outputs back ON, either automatically or following a manual restart
(reset) signal, depending on the operating mode.
1 Configured Warning Field (WF) User defines shapes
and ranges
2 Configured PF User defines shapes
and ranges
3 Object (person) in the PF Example
4 AG4 Scanner
a Maximum measurement range 50 meters
d Configurable PF and WF field
of view extension -5°
e Configurable PF and WF field
of view extension +5°
PF Maximum PF range 4 meters
WF Maximum WF range 15 meters
Figure 1. Scanner detection ranges
1 X1 interface for controlling the
machine, with protective cap
2 X2 interfaces for PC/laptop, with
protective cap
3 Status display
4 Scatter screens
5 Front screen
Figure 2. Scanner features

Banner AG4 Series Safety Laser Scanner
8 P/N 144924 05/2009 Product Manual
1.1 Status Display
Five LEDs on the housing front show the Scanner's operating status.
LED Diagnostic Key
LED Meaning
ON Sensor function is active; the
active PF is clear.
1, green
Flashes @
2 Hz
Fault on the field pair control
inputs.
ON Active WF is selected.
Flashes @
2 Hz Front screen is dirty.
2, yellow
Flashes @
4 Hz
ConfigPlug configuration is not
compatible with the Scanner.
3, red ON
Safety outputs or switching
function (OSSD 1 and 2) are
switched off.
4, green ON
Safety outputs or switching
function (OSSD 1 and 2) are
switched on.
ON Start/restart interlock is active.
Flashes @
2 Hz Front screen is dirty.
5, yellow
Flashes @
4 Hz Fault
Figure 3. Status LEDs
1.2 Mounting System (Optional)
The mounting system makes it easier to install and align the Scanner. The mounting system is available as an accessory (see Section 2).
1.3 ConfigPlug (Optional)
The ConfigPlug, included as part of some control cables, is an optional accessory used to store the Scanner configuration and transfer it to
another Scanner. This accessory simplifies the exchanging of a faulting or damaged Scanner. The plug saves the configuration when the PC
transfers the operational parameters to the Scanner. When the original Scanner is replaced and connected to power with the ConfigPlug, the
plug automatically transfers the configuration into the new Scanner.

Banner AG4 Series Safety Laser Scanner
1.4 Product Labels
1.4.1 Product identification plate
The product identification plate is located on the top of the AG4 and details information as shown below.
Figure 4. Product identification plate
1.4.2 Safety Notice
A Safety notice is located on the AG4 as shown.
Figure 5. Safety notice location
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Banner AG4 Series Safety Laser Scanner
WARNING . . . USER RESPONSIBILITY
It is the responsibility of the Qualified Person who configures, installs, or maintains the AG4 to:
• Carefully read, understand and follow the information in this manual.
• Perform a risk assessment of the specific machine guarding application.
• Determine what safeguarding devices and methods are appropriate per the requirements defined in ISO 13849-1 and EN 945-1 and
that are referenced in the AG4 manual.
• Create and confirm each AG4 configuration and then verify that the entire safeguarding system (including output devices) is
operational and working as intended.
• Periodically re-verify as needed, that the entire safeguarding system is working as intended.
Failure to follow any of these recommendations can potentially create a dangerous condition that may lead to serious injury or
death.
Carefully read, understand and follow the Product Manual which is also available on the CD ROM which is included with the product.
Before working with the AG4 Scanner, read and follow the instructions applicable to the designated machine.
Print out the relevant instructions to make reading and handling the documents easier.
1.5 Proper Use and Intended Purpose
The Scanner is used to protect people in danger zones or at hazards on machines and to protect objects and machine parts against
the dangers of collision.
The Scanner may only be used after it has been put into operation in accordance with the applicable instructions, relevant rules and
regulations on occupational health and safety at work and the recognized safety rules and regulations have been placed on the
machine by an appropriately.
The Scanner must be integrated into the machine's electrical control system in such a way that an activation of the safety function
safely stops or interrupts the dangerous process before a person can be endangered.
If the machine does not allow the dangerous movement to be stopped at all times, the Scanner should not be installed. Do
not use the Scanner, for example, with full-revolution clutched machinery.
1.6 Security Protocol
WARNING . . . PERIODIC CHECKOUTS
The commissioning, periodic and daily safety system checks must be performed by appropriate personnel at the appropriate
times in order to ensure that the safety system is operating as intended. Failure to perform these checks may create a
potentially dangerous situation which could lead to serious injury or death.
1.6.1 Designated Person
A Designated Person is identified and designated in writing, by the employer, as being appropriately trained to perform the specified checkout
procedures on the Scanner. A machine operator so designated may be a Designated Person. The Designated Person is empowered to:
Perform manual resets and hold possession of the reset key
Perform the daily Scanner checkout procedure
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