SICK AOS502 STS Operating instructions

SUPPLEMENTARY OPERATING INSTRUCTIONS
AOS502 STS
Object Detection Systems

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Product described
Product name: AOS502 STS
Document identification
Title: AOS502 STS Supplementary Operating Instructions
Part number: 8017621/ZPQ5
Status: 2017-08-15
Manufacturer
SICK AG
Erwin-Sick-Str. 1 · 79183 Waldkirch · Germany
Trademarks
IBM is a trademark of the International Business Machine Corporation.
MS-DOS is a trademark of the Microsoft Corporation.
Windows is a trademark of the Microsoft Corporation.
Other product names in this document may also be trademarks and are
only used here for identification purposes.
Original documents
The German version 8017619/ZPQ5 of this document is an original SICK AG
document.
SICK AG does not assume liability for the correctness of a non-authorized
translation.
In case of doubt, contact SICK AG or your local agency.
Legal notes
Subject to change without notice
© SICK AG. All rights reserved

CONTENTS
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Contents
1About these operating instructions..............................................................................5
1.1 Purpose of this document....................................................................................5
1.2 Target group .........................................................................................................5
1.3 Information depth ................................................................................................6
1.4 Abbreviations used...............................................................................................6
1.5 Symbols used .......................................................................................................7
2Safety ..............................................................................................................................8
2.1 Qualified personnel..............................................................................................8
2.2 Applications of the system...................................................................................8
2.3 Intended use.........................................................................................................9
2.4 General safety notes and protective measures .................................................9
3Product description .................................................................................................... 10
3.1 Scope of delivery ............................................................................................... 10
3.2 System components ......................................................................................... 11
3.3 System functionality.......................................................................................... 12
4Project planning.......................................................................................................... 14
4.1 Monitoring fields and evaluation cases ........................................................... 14
4.1.1 Prepared evaluation cases (EVCs) .................................................... 14
4.1.2 Input and output signals.................................................................... 15
4.2 Dimensioning the monitoring fields ................................................................. 16
4.2.1 Size and alignment of the fields for crane-to-ship collision
protection ........................................................................................... 16
4.2.2 Size and alignment of the fields for crane-to-crane collision
protection ........................................................................................... 17
4.2.3 Size and position of the test fields.................................................... 18
4.3 Scan plane......................................................................................................... 20
4.3.1 Parallelism of the scan plane ............................................................ 20
4.3.2 Inclination angle of the scan plane................................................... 21
5Mounting ..................................................................................................................... 22
5.1 Mounting the laser scanners............................................................................ 22
5.1.1 Position of the laser scanners........................................................... 22
5.1.2 Inclination of the laser scanners....................................................... 22
5.1.3 Mounting on booms with encompassing trolley............................... 23
5.2 Position of the test target ................................................................................. 24
5.3 Mounting the Flexi Soft control ........................................................................ 24
6Electrical installation ................................................................................................. 25
6.1 Electrical connection......................................................................................... 25
6.1.1 Connection by means of individual installation cables.................... 25
6.1.2 Connection by means of distributor box ........................................... 27
6.1.3 General notes about the cables........................................................ 29
6.2 Input and output signals of the AOS502 STS system ..................................... 30
7Commissioning............................................................................................................ 32
7.1 Configuration ..................................................................................................... 32
7.2 Checking the stopping and warning response of the system ......................... 32

CONTENTS
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8Electrical wiring diagram............................................................................................ 33
9Appendix....................................................................................................................... 37
9.1 List of tables.......................................................................................................37
9.2 List of figures......................................................................................................38

ABOUT THESE OPERATING INSTRUCTIONS 1
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1About these operating instructions
Please read this chapter carefully before you begin working with this documentation and
the AOS502 STS.
1.1 Purpose of this document
These supplementary operating instructions are intended to give technical personnel of
the machine manufacturer or operator instructions on the safe mounting, configuration,
electrical installation, commissioning, operation, and maintenance of the AOS502 STS
object detection system.
The supplementary operating instructions for the AOS502 STS object detection system
are only valid in conjunction with the underlying operating instructions for the AOS
Prime (8016731).
Unless otherwise specified in this document, the information in the underlying operating
instructions for the AOS Prime will apply.
1.2 Target group
These supplementary operating instructions are intended for persons who integrate the
AOS502 STS object detection system into a crane system, and initially commission and
operate it there. They are also intended for the planners, developers, and operators of
crane systems for the handling of goods and containers.
Note

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1.3 Information depth
These supplementary operating instructions contain information about the AOS502 STS
system on the following topics:
•Product description
•Project planning
•Mounting
•Electrical installation
•Commissioning
When planning and using the AOS502 STS system, technical skills are also required that
are not covered by this document.
The applicable official and legal regulations at the application site must always be
complied with when operating the system.
Further information about the device components used in the AOS502 STS can be found
in the accompanying operating instructions.
For carrying out the configuration and diagnostics of the AOS502 STS, you will need the
SOPAS SICK Engineering Tool (configuration software for the laser scanners), version
V 3.0 or higher, and the FSD Flexi Soft Designer (configuration and diagnostic software
for the control), version 1.7 or higher. Both of these tools are included in the scope of
delivery.
1.4 Abbreviations used
Advanced object detection system
Flexi Soft Designer = software for Flexi Soft control for configuration and diagnostics
Laser scanner from SICK AG
SICK Engineering Tool = software for laser scanner configuration and diagnostics
Programmable logic controller
Ship-to-shore
Note
AOS
FSD
LMS
SOPAS
PLC
STS

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1.5 Symbols used
Recommendations are designed to assist you in the decision-making process with respect
to the use of a certain function or technical measure.
Notes provide information about the features of a device, application tips, or other useful
information.
Instructions that must be carried out in the described order are referred to as step-by-step
instructions and are indicated by numbered lists. Carefully read and follow the
instructions for action.
Instructions for taking action are indicated by an arrow. Carefully read and follow the
instructions for action.
Recommendation
Note
1. / 2. ...
Step by step

Action

2SAFETY
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2Safety
This chapter concerns your own safety and the safety of the system operator.
▸Please read through this chapter carefully before using the AOS502 STS or the crane
system monitored by the AOS502 STS.
Please also observe all safety notes contained in the operating instructions for the
components used.
2.1 Qualified personnel
The AOS502 STS must only be mounted, commissioned, and maintained by adequately
qualified personnel.
A qualified person
•has sufficient skills in the field of the respective equipment based on their technical
training and experience and
•has been instructed by the manufacturer in system operation and all applicable safety
guidelines and
•is familiar with all relevant country-specific occupational safety regulations, work safety
regulations, guidelines, and generally accepted technical rules and standards (e.g.,
DIN standards, VDE regulations, country-specific rules) to such an extent that he/she is
able to evaluate the safe condition of the power-driven machinery and he/she
•has access to and has read the operating instructions.
2.2 Applications of the system
The AOS502 STS object detection system is a collision protection system on ship-to-shore
crane systems or crane systems with a corresponding boom.
The system solution offers collision protection for the boom against ship constructions
with an upstream warning zone.
It offers additional collision protection with separate monitoring zones with respect to
neighboring cranes with lateral movements.
The ambient conditions typical in ports such as rain, snow, or fog, are mastered by the
AOS502 STS system.
Note

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2.3 Intended use
The AOS502 STS may only be used as described in section 2.2 Applications of the
system. The system may only be used by qualified personnel and only in industrial
environments in which it was installed and initially commissioned by qualified safety
personnel in accordance with these supplementary operating instructions.
The AOS502 STS object detection system is not a safety device for human protection
and it therefore does not comply with any safety standards. For safety applications,
please contact SICK AG.
2.4 General safety notes and protective measures
NOTE
These supplementary operating instructions must be made available to the operator of
the crane system on which the AOS502 STS system is used, along with the basic AOS
Prime underlying operating instructions.
The operator must be instructed by qualified safety personnel and read the operating
instructions.
Note

3PRODUCT DESCRIPTION
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3Product description
This chapter provides information on the special features of the AOS502 STS system.
It describes the construction and operating principle of the system, in particular the
interaction of the different components.
Always read this chapter before you mount, install, and commission the system.
3.1 Scope of delivery
The AOS502 STS consists of two pre-configured LMS511 laser scanners and the
Flexi Soft control, which comprises the main module and two I/O expansion modules.
The system is supplied with the required accessories.
Fig. 1: Main components of the AOS502 STS
Thorough check for completeness
▸It is recommended that you carefully check for and report transport damage of any
kind as soon as possible after receiving the system.
▸Also verify that the delivery includes all components listed on the delivery note.
Part No.
Quantity
Description
1064545
1
AOS502 STS
Consisting of:
Laser scanner
1057618
2
LMS511-10100S02 laser scanner
2063034
2
Connection box for power, I/O, and RS-232/RS-422 data
(not Ethernet), with three pre-wired M12 cables
2063050
2
Weather hood (180°), vertical mounting
2018303
2
Mounting kit for wall mounting (adjustment bracket)
2059271
2
Mounting bracket for mounting the laser scanner and
terminal box
6030928
2
Ethernet connection cable SSL-2J04-G10ME
Control
1043783
1
Flexi Soft main module FX3-CPU000000
1043700
1
Flexi Soft system plug FX3-MPL000001
1044125
2
Flexi Soft I/O module FX3-XTIO84002
6034574
1
Configuration cable DSL-8U04G02M025KM1 for connecting the
configuration connection of the Flexi Soft control to the USB
interface of the configuration PC
2073337
1
USB stick with configuration file (prepared configuration for control
and laser scanner) as well as device and system documentation
Tab. 1: Scope of delivery for the AOS502 STS
The “SOPAS” and Flexi Soft Designer configuration tools can be downloaded at
www.sick.com.
Note
Important note
Note

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3.2 System components
All components of the AOS502 STS system are prepared for their use on crane systems
for the handling of goods and containers.
LMS511 laser scanner with weather hood
The LMS511 laser scanners are designed for outdoor use in harsh ambient conditions
and are fitted with a weather protection hood. All input and output signals from the laser
scanners are directly connected to the central Flexi Soft control.
Fig. 2: LMS511 laser scanner with weather hood
The LMS511 laser scanners have a monitoring radius of 80 m / 38 m for black objects
with 10% remission and a scan angle of 190°.
They feature automatic contamination measuring for the front screen. The contamination
signals can be merged using the central Flexi Soft control and can be output via a shared
application diagnostic output.
The laser scanners are also equipped with an internal heater.
The Flexi Soft control
The Flexi Soft control for the AOS502 STS system consists of the CPU0 central main
module with a configuration memory and two XTIO I/O expansion modules.
The two I/O expansion modules provide the input and output signals from the AOS502
STS. The communication with the connected laser scanners and with the higher-level
crane control occurs via the switching signals.
The test target
The self-diagnosis of the object detection system occurs via the continuous detection of
an external test target. During this process, the corresponding scanner monitoring field is
infringed by the test target. Only by using external test targets can the full functional range
of the AOS502 STS system be ensured.
At least one test target is required to continue the self-diagnosis of the system. It is also
possible to use a common test target for several laser scanners.
In crane applications, such as ship-to-shore crane systems, a part of the crane body is
defined as the test target.

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Configuration
The configuration file contains all the functions required to evaluate the system based on
the scenarios at the industrial cranes and to cyclically test the laser scanners.
It is located on the USB stick supplied and is loaded onto the Flexi Soft control via file
download.
The size and geometry of the monitoring fields must be adapted to the existing conditions
on-site.
3.3 System functionality
The AOS502 STS is a self-testing object detection system whose functionality as a whole
is monitored by the Flexi Soft control. During later movement by a boom (gantry travel),
the system prevents collisions with exposed ship superstructures, such as the radar
system, and between neighboring cranes.
The AOS502 STS provides protection against collisions by means of two laser scanners,
which are positioned on the right and left sides of the boom. These generate a horizontal
monitored area along the boom, which covers its entire length.
In addition, depending on the mounting process, the system offers protection from
collisions with neighboring cranes during lateral movements through the monitored areas
oriented to the rear.
Fig. 3: Typical layout of the monitored areas
1
Crane-to-ship collision protection
2
Crane-to-crane collision protection

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If an object is detected in the monitored area, the system sends a slow-down signal
(warning signal) to the crane, followed by a stop signal, in case the crane is to continue
traveling.
For this purpose, the output signals of the laser scanners are evaluated and processed by
the Flexi Soft control.
As an option, relays can be controlled for the purposes of electrical isolation, e.g., the
SICK UE10-3OS safety relay.
Note

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4Project planning
4.1 Monitoring fields and evaluation cases
The scanned area of the laser scanners is divided into different fields, known as
monitoring fields. The size and geometry of the monitoring fields can vary and must be
configured on-site depending on the installation position and the alignment of the laser
scanners.
The monitoring fields are adapted using the SOPAS configuration software supplied.
Each monitoring field is linked to an evaluation case (EVC). An evaluation case determines
the way the monitoring field is evaluated and which switching output is addressed.
Evaluation cases can be activated via input signals depending on the required scenarios.
Ten different evaluation cases can be configured and permanently saved in each laser
scanner. Depending on the input signals that are present for the evaluation case, the
laser scanner switches between the cases.
Fig. 4: Activating an evaluation case
4.1.1 Prepared evaluation cases (EVCs)
Every laser scanner is prepared with eight evaluation cases for use in the AOS502 STS.
Evaluation case
Field
LMS output
1
Boom stop
1
2
Test
2
3
Boom stop
2
4
Test
1
5
Boom warning
3
6
Crane-to-crane stop
4
7
Field 5*
5
8
Field 6*
5
9
Not used
Not used
10
Not used
Not used
Tab. 2: Pre-configured evaluation cases and switching signals
* Field 5 and field 6 are for additional demand. They can be used as desired, e.g. for a second
warning on the boom.
Monitoring fields
Evaluation cases
Legend

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4.1.2 Input and output signals
All input and output signals from the laser scanners are directly connected to the
Flexi Soft control.
The Out 1 to Out 5 LMS outputs signal the status of the assigned monitoring field to the
respective inputs of the Flexi Soft control.
The Flexi Soft control analyzes the status signals from the laser scanners based on the
stored monitoring scenarios and transmits corresponding stop and warning signals to
the higher-level crane control.
Fig. 5: Interaction between the input and output signals
LMS output Out 6 is used to signal the contamination of the laser scanner to the Flexi Soft
control. If contamination is low, a warning is displayed; if contamination is high, an error is
displayed.
Note

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4.2 Dimensioning the monitoring fields
With respect to their geometry, all monitoring fields must be adapted to the existing
conditions on-site.
The monitoring fields always start at the relevant laser scanner and span the stored
length and depth.
4.2.1 Size and alignment of the fields for crane-to-ship collision protection
The monitoring fields for the boom (crane-to-ship collision protection) are already pre-
defined as rectangles in the SOPAS configuration software. Typically, you will simply have
to adapt the specific dimensions.
The pre-assignment assumes that the laser scanner is positioned roughly in the center
of the monitored area.
Fig. 6: Size and alignment of the fields for crane-to-ship collision protection
By default, the monitoring fields for the booms are pre-defined with the following
dimensions:
Monitoring field
Depth
Width
Boom stop
3.5 m
50 m (± 25 m symmetrical with the center
of the LMS)
Warning/Speed reduction boom
7.5 m
50 m (± 25 m symmetrical with the center
of the LMS)
Tab. 3: Field sizes for crane-to-ship collision protection
The depth of the fields is generally based on the response time of the crane and its
stopping distance.
Fig. 7: Size of the warning field
▸Increase or decrease the output field during the test drives systematically until the
slowing-down and stop procedures start to converge.
▸Monitor the behavior of the crane during the test drives.
Warning field

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4.2.2 Size and alignment of the fields for crane-to-crane collision protection
The crane-to-crane collision protection can be used when the installation position and the
resulting inclination angle of the laser scanner allow this. Laser scanners with strong
inclination angles can only scan between the neighboring cranes to a certain degree. This
means a necessary stopping field cannot be completely covered.
A suitable layout for a stopping field can therefore not be determined. That is why the
evaluation cases and the stopping fields for the crane-to-crane collision protection are
predefined, but their geometries are not yet defined (empty).
The stopping fields should be wedge-shaped.
Due to the crane movements during operation, a suitable distance of the stopping field
to the crane body must be considered (distance din the following figure). A minimum
distance of ≥ 0.5 m is recommended.
Fig. 8: Size and alignment of the fields for crane-to-crane collision protection
If the distance is too small, the monitoring field will impinge on the crane body and trigger
a stop erroneously.
Fig. 9: Distance between stopping field and crane body too low

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4.2.3 Size and position of the test fields
The system’s self-monitoring test fields are typically aligned with a suitable flat object
on the crane or directly with a flat area of the crane body. In the figure below, one of the
crane girders is used as the test target.
Fig. 10: Crane leg as test target
The test fields are pre-defined. They are formed as triangles and must be adapted to the
existing conditions on-site.
Fig. 11: Size and position of the test fields
By default, the test fields are pre-defined with the following dimensions in SOPAS:
Monitoring field
Length
Width at maximum length
Scan angle
Test field right/left
35 m
4 m
7° symmetrical
Tab. 4: Field sizes for the test fields

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The test fields on the right and left must clearly and reliably impinge on the crane girders.
Take into account tolerances resulting from mechanical movements.
In order to avoid reflections on the surface of the external test target, the area of the test
target must not be covered with a glossy coating.
Ideally, the test target should be outside the longest monitoring field (approx. 0.5 m from
the edge of the monitoring field). A standard value for the distance from the laser scanner
is > 0.5 m. The width of the test field on the test target must be at least 100 mm.
Fig. 12: Alignment of the test target on the crane body

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4.3 Scan plane
4.3.1 Parallelism of the scan plane
The scan plane of both laser scanners must be parallel to the boom (X = control
positions).
Fig. 13: Parallelism of the scan plane from the side
Larger deviations in terms of parallelism result in unintended shutdowns or detection
failures (X = control points).
Fig. 14: Incorrect scan plane from the side
Checking that the scan plane is correct
The scan plane can be correctly aligned using the scan finder, which you can order as
a SICK accessory.
Device
Accessories
Description
Part number
LS80b scan finder Infrared receiver for locating the
laser beam 6020756
Alternatively, you can place suitable objects at two control points and check the scan
plane in the live monitor of the SOPAS configuration software.
Deviations can be corrected by swiveling the laser scanner.