Fiessler FLSC Series User manual

FLSC
FIESSLER
E L E K T R O N I K
Notice d utilisatin
DIN EN ISO 9001
Reg.Nr. 96007

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Contents
1. General............................................................................ 166
2. System description........................................................ 167
3. Regulations and notes regarding safety .....................168
4. Mounting.........................................................................169
4.1 Mechanical mounting................................................169
4.2 Electrical installation .................................................169
5. Notes regarding commissioning..................................171
6. Tests................................................................................ 172
6.1 Testing the FLSC......................................................172
6.2 Checklist ...................................................................174
7. Diagnosis........................................................................177
7.1 Diagnostic elements .................................................177
7.2 Maintenance .............................................................177
7.3 Service...................................................................... 178
8. Accessories....................................................................178
9. Declarations of Conformity...........................................179
FLSC 101 - 312 ..............................................................179
10. Technical data FLSC 101-312 .....................................180
11. Remarks concerning FLSC 201-313........................... 189
Declaration of Conformity for FLSC 201-313 .................190
12. Appendix: Key to the diagrams..................................191
12.1 Field resolutions......................................................191
12.2 Diffuse reflectance of objects ................................. 191
12.3 Dimensional drawings.............................................192
12.4 Pin assignments .....................................................192

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1. General
This instruction manual contains information about putting into operation, function testing, servicing,
diagnosis, and about technical data and conformities. Further information, e.g. about ordering, system
implementation or programming, is to be found in the FLSC technical description.
This instruction manual refers only to the following Proximity Laser Scanner:
FLSC 101 - 312 (order no. 1016066)
These devices are certified for use as personal protection units and fulfil, when operated according to
the instructions, the appropriate regulations.
The following device is not certified as a personal protection unit; any use of this device as a personal
protection unit may, subject to risk assessment, be impermissible
FLSC 201 - 313 (order no. 1016189)
In order to avoid confusion within this document, the main part of these operating instructions refers
exclusively to the type FLSC 101-312.
You will find the relevant information about the type FLSC 201-313 in abbreviated form in chapter 11.

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2. System description
The Proximity Laser Scanner FLSC continuously monitors the contours of its surroundings with a
scanning angle of 180°. Two types of field can be programmed (warning fields and protective fields),
within which objects can activate the FLSC outputs.
Activation caused by objects in the protective field is carried out safely, i.e. the circuit outputs are
designed as 2 channels (redundant) and monitor each other.
The FLSC can be implemented as a personal protection unit in stationary applications (monitoring of
danger areas or access to danger areas) as well as in mobile applications (collision avoidance in
vehicles).
The protective field must be dimensioned according to the advice as laid down in the FLSC technical
description.
The diverse potential applications of the FLSC can be expanded still further by using the Laser
Scanner Interface LSI. The LSI allows quick and reliable switchover of protective and warning fields in
the FLSC and the simultaneous use of several FLSCs at once. Further information about the LSI can
be found in the LSI technical description and the LSI operating instructions.

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3. Regulations and notes regarding safety
1. The use/installation of the non-contact safety device, both for commissioning and for routine
technical inspections, is subject to the relevant national / international legal requirements, in particular
The Machine Directive 98/37 EC,
The Machinery Usage Directive 89/655 EEC, .
Manufacturers and users of the machinery on which our safety devices are used are responsible for
co-ordinating all applicable safety regulations/rules with the relevant authorities, and for complying
with these rules and regulations.
2. Furthermore, our instructions, and test specifications in particular (see Test chapter) in this
technical description or operating instructions (such as those concerning use, mounting, installation or
incorporation in the machine control system) must be observed and complied with.
3. The tests are to be performed by specialists or by specially authorized and nominated
personnel, and are to be documented in a form, which is comprehensible at all times.
4. Our operating instructions are to be made available to the employee (operator) of the machine on
which our safety equipment is used. The operator is to be instructed by specialists.
5. The appendix to this brochure includes a checklist for testing by the manufacturer and equipment
provider.

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4. Mounting
4.1 Mechanical mounting
The FLSC can either be mounted directly using the appropriate tapholes in the housing, or by using
mounting kits. Please refer to the dimensional drawings of the FLSC and the mounting kits in the
appendix, as well as additional notes regarding the choice of the correct mounting location in the
technical description.
Note: When installing on systems with severe vibrations you should use thread-locking agents or
mechanisms to prevent unintentional loosening of setscrews and mounting screws, and regularly
check that these screws are secure.
4.2 Electrical installation
When connecting the FLSC you can either terminate the power supply plug yourself and decide
whether you want the cable to come out of the top or the bottom, or you can use ready-made cables in
varying lengths (cable exit only out of the top).
The communication connection to the FLSC is made using a screened data cable (see chapter
Accessories in the technical description).
Please read the notes on the following page!

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Notes regarding installation
Route all lines and connecting cables so that they are protected from damage.
If you terminate the plugs and lines yourself, ensure that the power and interface supply plugs are not
reversed.
Seal off free tapholes with the dummy plugs supplied and ensure that the seals are in the correct
position.
Do not drop the plugs. The sub D plug could be pressed into the plug casing and be rendered
unusable.
Check that the seal on the connection housings is correctly seated.
Insert the plugs into the receptacles provided on the correct side of the FLSC housing. Press the plugs
gently into the FLSC housing. You will know that a correct connection has been established when the
connection housings with the plugs are flush with the FLSC housing.
Only then should you secure the connection housings with the Allen screws at the sides.
Only when both connection housings with seals have been installed and secured as described does
the housing comply with enclosure rating IP65.

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5. Notes regarding commissioning
Special safety requirements apply when putting the unit into operation. Please refer without fail to
chapter 6 of these operating instructions and to the relevant chapter in the technical description.
The device is programmed with a basic configuration. Alterations to monitoring areas as well as to the
parameter settings may only be carried out by authorized personnel (specialists).

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6. Tests
6.1 Testing the FLSC
These tests are required in order to check that the safety devices are functioning correctly and are
properly incorporated into the machine/system control, as well as to reveal any alterations or
manipulations in the system.
The following instructions must be observed to ensure proper use:
Installation and electrical connection by specialist personnel only.
A specialist is a person who, on account of his specialist training and experience, has sufficient
expertise in the field of the power-driven machinery to be tested, and who is sufficiently familiar with
the pertinent legal work-safety regulations, accident-prevention regulations, directives and generally
recognized engineering rules (e.g. DIN standards, VDE specifications, technical rules of other EC
member states) to be able assess the safe condition of the power-driven machinery. These will
generally be specialists employed by the manufacturer of the NCSD, or such persons who have
received appropriate training from the manufacturer of the NCSD, have been primarily concerned with
the testing of NCSDs and are designated by the owner of the NCSD.
1. Testing prior to first commissioning of the safety
device on the machinery by specialist personnel:
- Testing prior to first commissioning serves to verify compliance with the safety requirements of the
national / international regulations, and in particular the Machine or Machinery Usage Directive (EC
Declaration of Conformity).
- Testing of the effectiveness of the safety device on the machine in all operating modes that can be set
on the machine in accordance with the enclosed checklist.
- The operating personnel of the machine protected by the safety device must receive instruction from
specialists working for the machinery owner before commencing work on the machine. It is incumbent
upon the machinery owner to provide appropriate instruction.
Check your FLSC system by following the checklist printed in chapter 6.2.
2. Regular testing of the safety device by specialist
personnel:
- Testing in accordance with the pertinent national regulations at the intervals specified therein. These
tests serve to reveal alterations or manipulations to the safety device, which may have been made
since first commissioning.
- The tests are also to be performed after any substantial modifications to the machine or to the safety
device, and after conversion or repair work in the case of damage to the housing, front screen,
connecting cable etc.
Check your FLSC system by following the checklist printed in chapter 6.2.

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3. Daily inspection of the safety device by authorized and designated personnel:
How to test your FLSC system properly:
1. The test must be performed every time the operating mode is changed.
2. Check the mechanical installation to ensure that all mounting screws are secure and that the FLSC
is properly aligned.
3. Check the FLSC for visible changes, such as damage, manipulation etc.
4. Switch on the machine / system.
5. Watch the LEDs on the FLSC (red, green, yellow).
6. If at least one LED does not shine constantly when the machine/system is switched on, it can be
assumed that there is a fault in the machine/system. In this case the machine must be shut down
immediately and checked by a specialist.
7. Deliberately obstruct the protective field while the machine is running in order to test the
effectiveness of the entire system. The LEDs must change from green to red and the hazardous
movement must come to an immediate standstill. Repeat this test at different points in the danger
area. If you discover any deviation from the proper function, the machine/system must be shut
down immediately and checked by a specialist.
8. For stationary applications, check that the danger area marked out on the floor matches the shape
of the protective field stored in the FLSC and that any gaps are protected by additional safety
measures. In the case of mobile applications, check that the moving vehicle actually stops at the
field limits which are set in the FLSC and listed on the data plate in the vehicle or in the
configuration protocol. If you discover any deviation from the proper function, the machine / system
/ vehicle must be stopped immediately and checked by a specialist.

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Note for the operator
The instructions concerning daily inspection are also provided in the form of a self-adhesive
sign. Please affix this sign in an easily readable location near the safety device in order to
facilitate the daily inspection procedure.
6.2 Checklist
The data for the points listed below must be present by the time of first commissioning at the
latest - although this depends on the application, the requirements of which must be checked
by the manufacturer/equipment provider.
This checklist should be preserved or filed with the machine documentation so that it can be used for
reference for the routine tests.
1. Are the safety regulations based on the directives/ standards applicable to the machinery?
Yes ❏No ❏
2. Are the applied directives and standards listed in the
Declaration of Conformity?
Yes ❏No ❏
3. Does the safety device comply with the required control category?
Yes ❏No ❏
4. Is entrance / access to the danger area / zone only possible through the protective field of the
NCSD alone?
Yes ❏No ❏
5. Have measures been taken to prevent unprotected access to a protected danger area (mechanical
point-of-operation guarding) and to monitor this eventuality, and are these measures safeguarded
to prevent their removal?
Yes ❏No ❏
6. Are additional mechanical safety devices installed to prevent access above, beneath and around
the protected area, and are these secure against manipulation?
Yes ❏No ❏
7. Has the maximum stopping or run-on time of the machinery been checked and is it indicated (on
the machine and/or in the machine documents) and documented?
Yes ❏No ❏
8. Is the required safety distance maintained between the NCSD and the nearest danger area?
Yes ❏No ❏
9. Are the NCSD devices properly mounted and secured against displacement after adjustment?
Yes ❏No ❏
10. Are the required safety measures to prevent electric shock effective (protection class)?
Yes ❏No ❏
11. Is the command unit for resetting the (NCSD) safety device or for restarting the machine present
and properly installed?

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Yes ❏No ❏

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12. Are the outputs of the NCSD (OSSD) connected up in accordance with the required control
category, and do they comply with the circuit diagrams?
Yes ❏No ❏
13. Has the protective function been checked in accordance with the test instructions in this document?
Yes ❏No ❏
14. Are the specified protective functions effective at all settings of the mode selector switch?
Yes ❏No ❏
15. Are the switching elements (e.g. contactors, valves) actuated by the NCSD monitored?
Yes ❏No ❏
16. Is the NCSD effective for the entire duration of the hazardous situation? Yes
❏No ❏
17. On switching off or disabling the NCSD, and when changing the operating mode or switching to a
different safety device, is the initiated hazardous situation stopped?
Yes ❏No ❏
18. Is the notice about daily inspection affixed at a location which easily visible to the operator?
Yes ❏No ❏
This checklist is no substitute for first commissioning or regular testing by a specialist.

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7. Diagnosis
7.1 Diagnostic elements
Three LEDs displaying the operation status of the FLSC are located on the top of the FLSC housing.
The green and red LEDs are allocated to the safety output.
The yellow LED signals – depending on the setting of the FLSC – an object in the warning field and/or
dirt contamination of the front screen. In conjunction with the red LED, it also indicates whether the
system is waiting for acknowledgement by the user.
Should the device fail the self-test (system error), this is also displayed by the yellow LED.
Diagnosis with FLSC LEDs:
Status green yellow red
Protective field clear
Object in protective field
Object in warning field
Waiting for restart 1Hz
Dirt warning * 1Hz
Dirt contamination *
Self-test failed ** 4Hz
* Dirt contamination of the FLSC front screen:
see chapter 7.2 Maintenance!
** Self-test failed: see chapter 7.3 Service!
The LEDs give the first diagnosis of the system status. Authorized personnel have, with the help of the
user software supplied with the unit, access to an extensive diagnostic system (see chapter User
Software in the FLSC technical description).
7.2 Maintenance
When set up appropriately by authorized personnel using the user software, the FLSC reports minor
dirt contamination of the front screen with the dirt warning (when the device is functioning fully) as well
as severe dirt contamination of the front screen (and shuts down the outputs at the same time).
Clean the front screen if the device's dirt warning is activated. This is indicated by the slow flashing of
the yellow LED while the green LED shines constantly (protective field clear). The front screen is an
optical component and must not be scratched. Therefore clean it only with a soft cloth and plastic
cleaner. (Recommended: Antistatic plastic cleaner, 1 litre,
order no. 5 600 987)
If the screen is scratched it must be replaced. The order number of the replacement front screen
(including seals and screws) can be found in the chapter Accessories in the FLSC technical
description. As the FLSC must be readjusted after replacement of the front screen, please advise your
safety officer.
Regularly check the tightness of all mounting screws on the FLSC and the fixing brackets. Also check
all screws on the interface plugs.
Regularly check that the device is functioning correctly by reaching into the protective field along its
edges, corresponding to the appropriate application regulations.

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7.3 Service
If the FLSC displays a fault on the yellow LED, an initial diagnosis can be made by referring to the
information about the LEDs given under 7.1. Authorised personnel (see note in the FLSC technical
description) have, with the help of the user software supplied with the unit, access to an extensive
diagnostic system.
If you have any further questions please refer to your local Fiessler branch.
8. Accessories
A list of all available accessories can be found in the FLSC technical description. The replacement
parts available are also listed.
You will need different connection kits depending on whether you want to use the FLSC alone or in
conjunction with the LSI. You will find the right connection kits four your system listed under
"Accessories" in the FLSC technical description or in the LSI technical description.

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9. Declarations of Conformity
FLSC 101 – 312

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10. Technical data FLSC 101-312
The most important technical data of the FLSC are listed below.
Note:
If you wish to use one or more FLSC devices in conjunction with a FIESSLER LSI (Laser Scanner
Interface), then please also refer to the technical data of the LSI (see LSI technical description).
Electrical data
The characteristics are measured at the connection corner (unless otherwise specified).
Properties Data
min. type max.
Supply voltage (Uv) 16.8 V 24.0 V 28.8 V
Reverse-polarity protected, via isola-
ting transformer to EN 60742 (also
vehicle charger)
Permissible residual ripple (VRMS)500 mV
The supply voltage limits must not be
exceeded or undershot.
Response time (adjustable
via scan rate)
double-speed 2 x 40 ms
sixteen-speed 16 x 40 ms
Power-up times
On voltage ON 6 s
Power consumption (no load) 17 W

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Properties Data
min. type max.
RESET / RESTART input
required: command unit for operating
mode with restart inhibit: NO contact
to VCC_EXT (Uv), dynamically
monitored
Input resistance at HIGH 5.9 kOhm
Voltage for HIGH 15 V Uvmax
Voltage for LOW 0 V 4.2 V
Current consumption (HIGH)
Start impulse current (when τ= 100 µs) 3.0 mA 6.6 mA
Static input current 2.2 mA 5.2 mA
Current consumption (LOW)
Start impulse current
(when τ= 100 µs) 0.9 mA
Static input current 0.5 mA
Time behaviour of scanner
(safe restart detection)
LOW level prior to restart 120 ms
HIGH level during restart 120 ms 5 s
LOW level after restart > 1 ms
Warning field output (PNP)
Voltage: Warning field clear Uv - 2.5 V
Voltage: Warning field clear 13.4 V
at Uv = 16.8 V
Switching current
(referred to EXT_GND) 100 mA

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Properties Data
min. type max.
Time behaviour of output
without restart inhibit Deactivation depends on scan
rate, activation does not.
Deactivation after WF incursion
(double-speed scanning) 127 ms
Activation on warning field (WF) clear 40 ms
Time behaviour of output
with restart inhibit Depends on scan rate
Deactivation after WF incursion
(double-speed scanning) 127 ms
Activation on warning field (WF) clear Restart necessary
Time behaviour of output
after n seconds Depends on scan rate
Deactivation after WF incursion
(double-speed scanning) 127 ms
Activation on warning field (WF) clear 40 ms
Short-circuit protected Yes
Switching frequency 3 Hz
Load inductivity 2 H
Safety outputs (OSSD)
- dynamic (HIGH active)
Switching voltage
HIGH active (Ueff) Uv - 2.5 V

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Properties Data
min. type max.
Switching voltage
HIGH active (Ueff) 13.4 V
at Uv = 16.8 V
Voltage LOW 0 V 2.5 V
Switching current
(referred to EXT_GND) 4 mA 250 mA
Time behaviour of output
without restart inhibit Depends on scan rate
Activation on protective field (SF) clear 190 ms
Time behaviour of output
with restart inhibit Depends on scan rate
Activation on protective field (SF) clear 580 ms
Time behaviour of output
after n seconds Depends on scan rate
Activation on protective field (SF) clear 3 s
Short-circuit protected by monitoring of outputs
Fault: Leak current 2.1 mA
Fault: Interruption of GND cable.
The downstream control element
must recognise this status as Low.
Pure load capacity 100 nF
Switching frequency 3 Hz
Pure load inductivity 2H
At low switching frequencies the max.
permissible load inductivity is higher.