Leuze RSL 440 User manual

We reserve the right to make technical changes
EN • 2020-06-15 • 50128257
Original operating instructions
RSL 440
RSL 445
Safety Laser Scanner

© 2020
Leuze electronic GmbH + Co. KG
In der Braike 1
73277 Owen / Germany
Phone: [phone]
Fax: [phone]
www.leuze.com
[email protected]
Leuze electronic GmbH + Co. KG RSL 440 2

Table of contents
Leuze electronic GmbH + Co. KG RSL 440 3
Table of contents
1 About this document ............................................................................................7
1.1 Other applicable documents ................................................................................................... 7
1.2 Downloading configuration software from the Internet ........................................................... 7
1.3 Used symbols and signal words ............................................................................................. 7
1.4 Checklists................................................................................................................................ 8
2 Safety .....................................................................................................................9
2.1 Intended use ........................................................................................................................... 9
2.1.1 Vapors, smoke, dust, particles ..........................................................................................10
2.1.2 Stray light ..........................................................................................................................10
2.1.3 Obstructions in the protective field ....................................................................................10
2.2 Foreseeable misuse ............................................................................................................. 11
2.3 Competent persons .............................................................................................................. 11
2.4 Disclaimer ............................................................................................................................. 12
2.5 Laser safety notices – Laser class1 for wavelength range outside 400-700 nm ............... 12
2.6 Responsibility for safety........................................................................................................12
3 Device description ..............................................................................................13
3.1 Device overview....................................................................................................................14
3.1.1 Protective function of RSL400 safety sensors..................................................................15
3.1.2 Parameters for protective function ....................................................................................15
3.1.3 Device and monitoring functions .......................................................................................15
3.2 USB connection .................................................................................................................... 16
3.3 Connection unit.....................................................................................................................16
3.4 Display elements .................................................................................................................. 17
3.4.1 LED indicator.....................................................................................................................17
3.4.2 Alphanumerical display .....................................................................................................17
3.4.3 Field-of-view display..........................................................................................................19
3.5 Mounting system (optional)................................................................................................... 19
3.6 Loop guard (optional)............................................................................................................ 19
4 Configuration and diagnostic software SensorStudio...................................20
4.1 System requirements............................................................................................................20
4.2 Installing software ................................................................................................................. 20
4.3 User interface........................................................................................................................ 22
4.4 FDT frame menu................................................................................................................... 23
4.4.1 Project wizard....................................................................................................................23
4.4.2 DTM change......................................................................................................................24
4.4.3 User management.............................................................................................................24
4.4.4 Exiting SensorStudio ........................................................................................................24
4.5 Using configuration projects ................................................................................................. 25
4.5.1 Selecting access level .......................................................................................................27
4.5.2 IDENTIFICATION..............................................................................................................28
4.5.3 PROCESS.........................................................................................................................28
4.5.4 CONFIGURATION ............................................................................................................28
4.5.5 DIAGNOSIS ......................................................................................................................28
4.5.6 SETTINGS ........................................................................................................................29

Table of contents
Leuze electronic GmbH + Co. KG RSL 440 4
5 Functions.............................................................................................................31
5.1 Authorization concept of safety sensor.................................................................................31
5.2 Function modes of safety sensor..........................................................................................32
5.2.1 One protective function .....................................................................................................33
5.2.2 One protective function – 100 field pairs ...........................................................................33
5.2.3 Two protective functions....................................................................................................34
5.2.4 One protective function – four field mode..........................................................................34
5.2.5 Two protective functions – four field mode........................................................................ 35
5.2.6 One protective function – multi configuration ....................................................................35
5.2.7 Two protective functions - multi configuration ...................................................................36
5.3 Selectable resolution for hand, leg and body detection ........................................................ 36
5.4 Speed-dependent protective function for vehicles................................................................36
5.5 Response time......................................................................................................................36
5.6 Configurable start-up behavior ............................................................................................. 37
5.6.1 Automatic start/restart .......................................................................................................37
5.6.2 Start interlock/automatic restart.........................................................................................37
5.6.3 Start/restart interlock (RES) ..............................................................................................38
5.7 Field pair changeover ........................................................................................................... 38
5.7.1 Fixed selection of one field pair.........................................................................................39
5.7.2 Changeover of five field pairs in changeover mode Overlapped monitoring..................... 39
5.7.3 Changeover of ten field pairs in changeover mode Fixed changeover moment ...............40
5.7.4 Changeover of 100 field pairs ...........................................................................................42
5.7.5 Changeover of 2x ten field pairs........................................................................................42
5.7.6 Changeover of 10x ten field pairs......................................................................................42
5.8 Monitoring of field pair changeover....................................................................................... 43
5.9 Reference contour monitoring .............................................................................................. 43
5.10 Field pair monitoring ............................................................................................................. 43
5.11 Internal safe time delay......................................................................................................... 44
5.12 EDM contactor monitoring .................................................................................................... 44
5.13 E-Stop linkage ...................................................................................................................... 44
5.13.1 Contact-based safety circuit ..............................................................................................45
5.13.2 Linkage of electronic safety-related switching outputs ......................................................45
5.14 Signaling functions................................................................................................................ 45
6 Applications ........................................................................................................46
6.1 Stationary danger zone guarding.......................................................................................... 46
6.2 Stationary point of operation guarding.................................................................................. 47
6.3 Stationary access guarding .................................................................................................. 48
6.4 Mobile danger zone guarding ............................................................................................... 49
6.5 Danger zone safeguarding on side-tracking skates.............................................................. 51
6.6 Vehicle navigation................................................................................................................. 52
6.6.1 Signal strength and reflector detection.............................................................................. 52

Table of contents
Leuze electronic GmbH + Co. KG RSL 440 5
7 Mounting..............................................................................................................54
7.1 Basic infos............................................................................................................................. 54
7.1.1 Calculation of safety distanceS ........................................................................................54
7.1.2 Suitable mounting locations ..............................................................................................55
7.1.3 Mounting the safety sensor ...............................................................................................55
7.1.4 Mounting examples ...........................................................................................................58
7.1.5 Information on protective field dimensioning .....................................................................59
7.2 Stationary danger zone guarding.......................................................................................... 62
7.3 Stationary point of operation guarding.................................................................................. 65
7.4 Stationary access guarding .................................................................................................. 66
7.5 Mobile danger zone guarding on AGVs................................................................................ 67
7.5.1 Minimum distanceD..........................................................................................................68
7.5.2 Protective field dimensions................................................................................................69
7.6 Mobile side guarding on AGVs ............................................................................................. 70
7.7 Mounting accessories ........................................................................................................... 70
7.7.1 Mounting system ...............................................................................................................70
7.7.2 Loop guard ........................................................................................................................71
8 Electrical connection..........................................................................................72
8.1 Electrical supply.................................................................................................................... 72
8.2 Interfaces .............................................................................................................................. 73
8.2.1 Connection cable, control..................................................................................................74
8.2.2 Connection cable with M30 connector ..............................................................................75
8.2.3 Pin assignment of M12 Ethernet interface (communication) ( D-coded)........................... 76
8.3 Connection unit CU429......................................................................................................... 77
8.4 Cable lengths according to the operating voltage................................................................. 79
8.5 Circuit diagram example ....................................................................................................... 80
9 Configuring the safety sensor ...........................................................................81
9.1 Defining safety configuration ................................................................................................ 81
9.2 Connecting safety sensor to PC ........................................................................................... 83
9.2.1 Connection via Ethernet cable ..........................................................................................83
9.2.2 Connection via Bluetooth ..................................................................................................83
9.2.3 Connection via USB ..........................................................................................................83
9.2.4 Communication between safety sensor and PC ...............................................................84
9.3 Determine the configuration project...................................................................................... 85
9.4 Configuring protective function ............................................................................................. 86
9.4.1 Creating simple safety configuration .................................................................................86
9.4.2 Entering administration parameters ..................................................................................86
9.4.3 Activating protective function and contactor monitoring ....................................................86
9.4.4 Creating and configuring protective/warning field pairs.....................................................87
9.4.5 Configuring field pair monitoring........................................................................................90
9.5 Defining permissible field pair changeovers ......................................................................... 90
9.6 Configuring signal outputs .................................................................................................... 90
9.7 Saving configuration ............................................................................................................. 91
9.8 Transferring configuration project to safety sensor............................................................... 91
9.9 Selecting access level .......................................................................................................... 93
9.10 Reset safety configuration .................................................................................................... 93

Table of contents
Leuze electronic GmbH + Co. KG RSL 440 6
10 Starting up the device ........................................................................................94
10.1 Switching on ......................................................................................................................... 94
10.2 Aligning the safety sensor..................................................................................................... 94
10.3 Unlocking start/restart interlock ............................................................................................ 94
10.4 Shutting down ....................................................................................................................... 95
10.5 Restarting.............................................................................................................................. 95
10.6 Starting up replacement scanner unit ................................................................................... 95
11 Testing .................................................................................................................97
11.1 Before the initial start-up and following modifications........................................................... 97
11.1.1 Checklist for integrator – to be performed prior to the initial start-up and following
modifications .....................................................................................................................97
11.2 To be performed periodically by competent persons............................................................ 98
11.3 Periodically by the operator .................................................................................................. 99
11.3.1 Checklist – periodically by the operator.............................................................................99
12 Diagnosis and troubleshooting .......................................................................101
12.1 What to do in case of failure? ............................................................................................. 101
12.2 Diagnostics displays ........................................................................................................... 101
13 Care, maintenance and disposal .....................................................................105
13.1 Changing scanner unit........................................................................................................ 105
13.2 Cleaning the optics cover ................................................................................................... 106
13.3 Servicing ............................................................................................................................. 107
13.4 Disposing ............................................................................................................................ 107
14 Service and support .........................................................................................108
15 Technical data ...................................................................................................109
15.1 General specifications ........................................................................................................ 109
15.2 Dimensions ......................................................................................................................... 114
15.3 Dimensioned drawings: Accessories .................................................................................. 116
15.4 Representation of safety sensor status .............................................................................. 124
16 Standards and legal regulations .....................................................................128
17 Order guide and accessories...........................................................................129
18 EC Declaration of Conformity..........................................................................134

About this document
Leuze electronic GmbH + Co. KG RSL 440 7
1 About this document
1.1 Other applicable documents
The information on the safety sensor is distributed over several documents to make working with the docu-
ments easier. You will find the documents and software for the safety sensor in the following table:
Purpose and target group of the document Document/software ti-
tle
Source
Software for users of the machine a) for safety sen-
sor diagnostics if a fault occurs and for machine de-
sign engineers for configuring the safety sensor
SensorStudio
DTM RSL400
Supplied with the safety
sensor on data carrier
Notes for the machine design engineer a) "Safe implementation
and operation"
(this document)
PDF, supplied with the
safety sensor on data
carrier
Notes for the machine design engineer a) for config-
uring the safety sensor (software instructions)
Online help for software Supplied with the safety
sensor on data carrier
Notices regarding mounting, alignment and connec-
tion of the safety sensor
"Quick Start Guide
RSL400"
Print document, supplied
with the safety sensor
a) Machine identifies the product that the safety sensor is installed in.
1.2 Downloading configuration software from the Internet
ÄCall up the Leuze home page: www.leuze.com.
ÄEnter the type designation or part number of the device as the search term.
ÄThe configuration software can be found on the product page for the device under the Downloads tab.
1.3 Used symbols and signal words
Tab.1.1: Warning symbols and signal words
Symbol indicating dangers to persons
Symbol indicating dangers from harmful laser radiation
Symbol indicating possible property damage
NOTE Signal word for property damage
Indicates dangers that may result in property damage if the measures for dan-
ger avoidance are not followed.
CAUTION Signal word for minor injuries
Indicates dangers that may result in minor injury if the measures for danger
avoidance are not followed.
WARNING Signal word for serious injury
Indicates dangers that may result in severe or fatal injury if the measures for
danger avoidance are not followed.
DANGER Signal word for life-threatening danger
Indicates dangers with which serious or fatal injury is imminent if the measures
for danger avoidance are not followed.

About this document
Leuze electronic GmbH + Co. KG RSL 440 8
Tab.1.2: Other symbols
Symbol for tips
Text passages with this symbol provide you with further information.
Symbol for action steps
Text passages with this symbol instruct you to perform actions.
Symbol for action results
Text passages with this symbol describe the result of the preceding action.
Tab.1.3: Terms and abbreviations
CS Switching signal from a control
(Controller Signal)
DTM Software device manager of the safety sensor
(Device Type Manager)
EDM Contactor monitoring
(External Device Monitoring)
FDT Software frame for management of device managers (DTM)
(Field Device Tool)
Field pair A protective field with an associated warning field
AGV Automated Guided Vehicle
LED LED, display element in the safety sensor
(Light Emitting Diode)
OSSD Safety-related switching output
(Output Signal Switching Device)
PFHdProbability of a dangerous failure per hour
(Probability of dangerous Failure per Hour)
PL Performance Level
Quad Two field pairs (four fields) that are monitored simultaneously in four field mode
TSS Transverse Side-tracking Skate
RES Start/restart interlock
(Start/REStart interlock)
SIL Safety Integrity Level
State ON: device intact, OSSDs switched on
OFF: device intact, OSSDs switched off
Locking: device, connection or actuation/operation faulty, OSSDs switched off
(lock-out)
1.4 Checklists
The checklists serve as a reference for the machine manufacturer or supplier (see chapter 11 "Testing").
They replace neither testing of the complete machine or system prior to the initial start-up nor their periodic
testing by a competent person. The checklists contain minimum testing requirements. Depending on the
application, other tests may be necessary.

Safety
Leuze electronic GmbH + Co. KG RSL 440 9
2 Safety
Before using the safety sensor, a risk assessment must be performed according to valid standards (e.g.
ENISO12100, ENISO13849-1, IEC61508, ENIEC62061). The result of the risk assessment determines
the required safety level of the safety sensor (see chapter 15.1 "Safety-relevant technical data"). For
mounting, operating and testing, this document as well as all applicable national and international stan-
dards, regulations, rules and directives must be observed. Relevant and supplied documents must be ob-
served, printed out and handed to affected persons.
ÄBefore working with the safety sensor, completely read and observe the documents applicable to your
task.
In particular, the current version of the following national and international legal regulations apply for com-
missioning, technical tests and handling of safety sensors:
• Machinery Directive
• Low Voltage Directive
• Electromagnetic Compatibility Directive
• Use of Work Equipment Directive
• Directive on the restriction of the use of certain hazardous substances in electrical and electronic equip-
ment
• OSHA
• Safety regulations
• Accident-prevention regulations and safety rules
• Ordinance on Industrial Safety and Health and employment protection act
• Product Safety Law (ProdSG)
NOTICE
For safety-related information you may also contact local authorities (e.g., industrial inspec-
torate, employer's liability insurance association, labor inspectorate, occupational safety and
health authority).
2.1 Intended use
The safety sensor protects persons or body parts at points of operation, danger zones or access points of
machines and systems.
WARNING
A running machine may result in serious injury!
ÄMake certain that the safety sensor is correctly connected and that the protective function of
the protective device is ensured.
ÄMake certain that, during all conversions, maintenance work and inspections, the system is
securely shut down and protected against being restarted.
• The safety sensor may only be used after it has been selected in accordance with the respectively ap-
plicable instructions and relevant standards, rules and regulations regarding labor protection and safety
at work, and after it has been installed on the machine, connected, commissioned, and checked by a
competent person (see chapter 2.3 "Competent persons").
• When selecting the safety sensor it must be ensured that its safety-related capability meets or exceeds
the required Performance Level PLr ascertained in the risk assessment (see chapter 15.1 "Safety-rele-
vant technical data").
• The safety sensor may only be used in North America in applications that satisfy the requirements
specified by NFPA79.
• With the “access guarding” function, the safety sensor detects persons only when they enter the danger
zone but cannot tell whether there are any persons inside the danger zone. For this reason, a start/
restart interlock in the safety chain is essential in this case.
• The construction of the safety sensor must not be altered. When manipulating the safety sensor, the
protective function is no longer guaranteed. Manipulating the safety sensor also voids all warranty
claims against the manufacturer of the safety sensor.

Safety
Leuze electronic GmbH + Co. KG RSL 440 10
• The safety sensor must be inspected regularly by a competent person to ensure proper integration and
mounting (see chapter 15.1 "Safety-relevant technical data").
• The safety sensor must be exchanged after a maximum of 20 years. Repairs or the exchange of wear
parts do not extend the mission time.
CAUTION
Observe intended use!
The protection of personnel and the device cannot be guaranteed if the device is operated in a
manner not complying with its intended use.
ÄOnly operate the device in accordance with its intended use.
ÄLeuzeelectronicGmbH+Co.KG is not liable for damages caused by improper use.
ÄRead these operating instructions before commissioning the device. Knowledge of the oper-
ating instructions is an element of proper use.
NOTICE
Comply with conditions and regulations!
ÄObserve the locally applicable legal regulations and the rules of the employer's liability insur-
ance association.
2.1.1 Vapors, smoke, dust, particles
Vapors, smoke, dust and all particles visible in the air can cause the machine to switch off unintentionally.
This can mislead the user into bypassing the safety devices.
ÄDo not use the safety sensor in environments in which heavy vapors, smoke, dust or other visible parti-
cles occur at the beam level.
2.1.2 Stray light
Light sources can impair the safety sensor's availability. Interfering light sources are:
• Infrared light
• Fluorescent light
• Strobe light
ÄEnsure that there are no interfering light sources at beam level.
ÄPrevent reflective surfaces at beam level.
ÄWhere applicable, take protective field addition distances into account.
ÄImplement all additional measures to ensure that any special application of any effected beam types
does not impair the safety sensor's operation.
2.1.3 Obstructions in the protective field
ÄDo not bring any additional window materials into the area monitored by the safety sensor.
NOTICE
No screen between optics cover and monitoring area!
ÄBetween the optics cover of the safety sensor and the monitored area, no further screen
may be mounted to protect the safety sensor.