Sunx SD3-A1 User manual

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About the instruction manual (connection and operation) of the SD3-A1
and the SD3SOFT instruction manual (software operation)
The instruction manual (connection and operation) for the SD3-A1 contains important
information on proper usage of laser scanner and usage in accordance with intended
purpose. For additional information on the configuration of the SD3-A1, please refer to
the SD3SOFT instruction manual (software operation).
It is essential to observe all information in the instruction manual (connection and
operation) and in the instruction manual (software operation), especially the safety notes.
The instruction manual (connection and operation) and the instruction manual (software
operation) must be kept in a safe place. They must be available during the entire period
when the SD3-A1 is in use. Documents are also automatically installed on the PC when
SD3SOFT is installed and can be viewed at any time with the Help menu.
Safety and warning notices are identified by the symbol .
References to important information are identified by the symbol .
References to the safety of laser devices are identified with the symbol .
SUNX Limited is not liable for damage caused by improper usage. The user must also be
familiar with all the SD3-A1 manuals to be able to use the system properly.
Version: V5.5
Reprinting and duplication is prohibited in whole or in part without prior approval of
SUNX Limited.

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Contents
1 Approvals .........................................................................................................................................6
1.1 Approval and declaration of EC conformity............................................................................ 6
1.2 Specialized technical terms and abbreviations ......................................................................7
1.3 Guidelines and standards.......................................................................................................8
2 System Overview.............................................................................................................................9
2.1 Brief description and functional principle of the SD3-A1........................................................9
2.2 Special features of the SD3-A1............................................................................................ 11
3 Safety Notes and Usage in Accordance with Intended Purpose .............................................13
3.1 General safety notes ............................................................................................................13
3.2 Usage requirements and usage in accordance with intended purpose............................... 13
3.3 Restrictions for use...............................................................................................................14
3.4 Information related to detection zone changeover............................................................... 15
3.5 General information related to determining detection zone contours ..................................16
3.6 Additional safety notes for stationary use ............................................................................17
3.7 Additional safety notes for mobile use .................................................................................18
4 Applications for the SD3-A1.........................................................................................................19
4.1 Stationary safeguarding of the danger area......................................................................... 19
4.2 Access guarding by passage monitoring .............................................................................20
4.3 Safeguarding of danger points based on hand and arm protection.....................................21
4.4 Mobile safeguarding of automatic guided vehicles .............................................................. 22
4.5 Protecting transporter trolleys against collisions.................................................................. 22
4.6 Guarding the sides on AGVs ................................................................................................23
4.7 Other possible applications ..................................................................................................24
5 Information for Planning and Mounting......................................................................................25
5.1 Attachment and dimensions .................................................................................................26
5.2 Installing adjacent laser scanners ........................................................................................26
5.2.1 Constructive measures.........................................................................................................26
5.2.2 Adjusting adjacent laser scanners........................................................................................27
5.3 Information on setting the dimensions of detection zones ...................................................28
5.3.1 Methods of configuring detection zones using the PC ......................................................... 28
5.3.2 Range of the detection zone, resolution...............................................................................28
5.3.3 Range of the warning zone, resolution.................................................................................29
5.3.4 Range of the measurement field .......................................................................................... 30
5.3.5 Required detection zone additions Z.................................................................................... 30
5.4 Safeguarding stationary danger zones ................................................................................ 31
5.4.1 The purpose of safeguarding ...............................................................................................31
5.4.2 Mounting position .................................................................................................................31
5.4.3 Mounting height ....................................................................................................................32
5.4.4 Recommendations for mounting to prevent unmonitored zones .........................................32
5.4.5 Additions ...............................................................................................................................36
5.4.6 System availability ................................................................................................................ 36
5.4.7 Restart interlock....................................................................................................................37
5.4.8 Calculating the detection zone dimensions for safeguarding an area ................................. 38
5.5 Access protection .................................................................................................................43
5.5.1 Object of protection ..............................................................................................................43
5.5.2 Installation position ...............................................................................................................43
5.5.3 Safety-relevant settings, and calculation of the safety distance ..........................................43
5.5.4 Definition of the reference boundary ....................................................................................44

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5.6 Protecting danger points.......................................................................................................45
5.6.1 Object of protection ..............................................................................................................45
5.6.2 Installation position ...............................................................................................................45
5.6.3 Safety-related settings, and calculation of the safety distance ............................................45
5.6.4 Defining the reference boundary ..........................................................................................47
5.7 Safeguarding mobile machines ............................................................................................48
5.7.1 The purpose of safeguarding ...............................................................................................48
5.7.2 Installing adjacent laser scanners ........................................................................................48
5.7.3 Mounting position .................................................................................................................48
5.7.4 Mounting height ....................................................................................................................48
5.7.5 Recommendations for mounting to prevent unmonitored zones .........................................49
5.7.6 Additions ...............................................................................................................................51
5.7.7 System availability ................................................................................................................ 52
5.7.8 Restart ..................................................................................................................................52
5.7.9 Calculating the dimensions of the detection zone of an AGV application ...........................53
5.7.10 Side guarding configuration on AGVs ..................................................................................56
6 Details on Switching Over Detection and Warning Zones........................................................57
6.1 Sequence of zone pair switchovers......................................................................................57
6.2 Practical AGV application (example).................................................................................... 59
7 Functions of the SD3-A1...............................................................................................................62
7.1 Restart .................................................................................................................................. 62
7.2 Channels for zone pair changeovers, FP 1 to FP 4 .............................................................62
7.3 Alarm 1 (X1-5) ......................................................................................................................63
7.4 Alarm 2 (X1-15) ....................................................................................................................63
7.5 OSSD 1 (X1-12) and OSSD 2 (X1-11)................................................................................. 64
7.6 Data communication.............................................................................................................64
8 Integrating the SD3-A1 into Machine Controls ..........................................................................64
8.1 Integrating the SD3-A1 with external wiring with relays and
eightfold zone pair changeover ............................................................................................ 65
8.2 Connecting the SD3-A1 to a safety sequence circuit with manual restart,
relay monitoring, without zone pair changeover ..................................................................67
8.3 Connecting the SD3-A1 to a PLC with corresponding safety level
(Category 3 or higher, EN 954) and zone pair changeover .................................................68
9 Electrical Connection....................................................................................................................69
9.1 Electrical power supply.........................................................................................................69
9.2 Connecting the PC and control cables to the scanner.........................................................69
9.3 Connector assembly .............................................................................................................70
9.4 Points to consider when preparing and laying the cables....................................................70
9.5 Interface pin assignments.....................................................................................................71
10 Commissioning..............................................................................................................................73
10.1 Hardware and software requirements ..................................................................................73
10.2 Installing “SD3SOFT” and starting up the SD3-A1 ..............................................................73
10.3 SD3-A1 status indicator........................................................................................................75
10.4 Status information of the SD3-A1.........................................................................................77
10.5 Restart and device swap-out ................................................................................................78

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11 Maintenance and Testing.............................................................................................................. 79
11.1 Test before first startup by person qualified and authorized to perform the task ................79
11.2 Extended shutdown of the SD3-A1 ......................................................................................79
11.3 Regular tests by a person qualified and authorized to perform the task .............................80
11.4 Daily test by with test piece performed by responsible operating personnel.......................80
11.4.1 Checklist for daily test of stationary applications by responsible operating personnel........81
11.4.2 Checklist for daily test of mobile applications by responsible operating personnel............. 82
11.5 Checklist for testing stationary applications ......................................................................... 83
11.6 Checklist for testing mobile applications ..............................................................................85
11.7 Replacing the optical window ...............................................................................................87
11.7.1 General information: .............................................................................................................87
11.7.2 Initial measurement of the new optical window....................................................................89
11.7.3 Procedure when using the SD3SOFT user software version 1.09 or later..........................90
11.8 Cleaning................................................................................................................................91
11.8.1 Cleaning the optical window when dirty ............................................................................... 91
11.8.2 Cleaning the optical window; cleaning diffusing light panes ................................................92
12 Delivery Package ...........................................................................................................................93
12.1 Disposal ................................................................................................................................93
12.2 Accessories and spare parts ................................................................................................94
12.3 Coding of the control cable X1 .............................................................................................95
13 Technical Data ...............................................................................................................................96
13.1 Test pieces ...........................................................................................................................96
13.2 Detection zone......................................................................................................................96
13.3 Detection zone additions ......................................................................................................97
13.4 Warning zone........................................................................................................................97
13.5 Contour measurement..........................................................................................................97
13.6 Electrical power supply.........................................................................................................98
13.7 Inputs ....................................................................................................................................98
13.8 Outputs .................................................................................................................................98
13.9 Software................................................................................................................................99
13.10 Interfaces ..............................................................................................................................99
13.11 Optics....................................................................................................................................99
13.12 Environment and material...................................................................................................100
13.13 Dimensional drawings of the SD3-A1 ................................................................................101
13.14 Dimensional drawings of the mounting system..................................................................102
14 Diagnostic Codes and Causes...................................................................................................103

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1 Approvals
1.1 Approval and declaration of EC conformit
y
EC type examination in accordance with
DIN EN 61496 - 1 and IEC 61496 - 3
TUV
PRODUCT SERVICE GMBH IQSE
Ridlerstr. 65 80339 Munich

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1.2 Specialized technical terms and abbreviations
Table 1.2-1: Specialized technical terms and abbreviations
AGV Automatic Guided Vehicle (FTS in German)
AOPD Active Optoelectronic Protective Device
AOPDDR Active Optoelectronic Protective Device responsive to Diffuse
Reflection
EDM External Device Monitoring
Monitoring of external control parts (relay monitoring)
ESPE Electro-Sensitive Protecting Equipment (BWS in German)
N.O. Normal open contact
OSSD Output Signal Switching Device Safety-relevant switch output
PC Personal Computer
DZ Detection Zone (SF in German)
Reset Defined Reset or SD3-A1
RS-232 RS-232 interface
RS-422 RS-422 interface
ZP Zone Pair (contains 1 × detection zone and 1 × warning zone)
(FP in German)
WZ Warning Zone (WF in German)

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1.3 Guidelines and standards
The following guidelines and standards are of critical importance for the implementation of laser
scanner. Guidelines providing particularly relevant information for users of such systems are
marked with an asterisk (*).
Guideline / Standard Designation
European Guidelines
98 / 37 / EG Machine guideline
73 / 23 / EWG Low voltage guideline
89 / 336 / EWG EMC guideline
A Standards
ISO 12100-1 and 2 Safety of machinery - basic concepts
ISO 14121 Safety of machinery - principles for risk assessment *
B1 Standards
ISO 13852 Safety of machinery - safety distances to prevent danger
zones being reached by the upper limbs *
ISO 13849-1 Safety of machinery - Safety related parts of control
systems; Part 1: General principles for design
ISO 13855 Safety of machinery. The positioning of protective
equipment in respect of approach speeds of parts of the
human body
*
B2 Standards
IEC 60204-1 Safety of machinery - Electrical equipment of machines -
Part 1: General requirements
IEC 60825-1 Safety of laser products - Part 1: Equipment classification
and requirements
IEC 61496-1 Safety of machinery. Electro-sensitive protective
equipment. General requirements and tests *
IEC 61496-3 Safety of machinery - Electro-sensitive protective
equipment - Part 3: Particular requirements for Active
Opto-electronic Protective Devices responsive to Diffuse
Reflection (AOPDDR)
*
C Standards
DIN EN 775 Industrial robots - Safety *
DIN EN 1525 Safety of industrial trucks - Driverless trucks and their
systems *
DIN EN 12895 Industrial trucks - Electromagnetic compatibility

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Table 1.3-1: Guidelines and standards
This list does not claim to be complete. In certain cases, the concrete requirements of the
application will necessitate the application of additional guidelines and standards!
2System Overvie
w
2.1 Brief description and functional principle of the SD3-A1
The SD3-A1 is an optical distance sensor that takes two-dimensional measurements. I
t
could also be referred to as an optical area radar device. The sensor uses a rotating
deflecting unit to periodically emit light pulses within a working range of 190°.
If these pulses strike a person or an object, the reflected light is received and evaluated
by the SD3-A1. The scanner calculates the precise coordinates of the person or object
based on the travel time of the reflected light and the current angle of the deflecting unit.
If the person or object is within the bounds of a previously defined area called a detection
zone, a safety-oriented switching function is performed. This switching function causes
the semiconductor outputs to be switched OFF. The safety-oriented switching function
cannot be reset until the detection zone is clear. Depending on the operating mode, the
reset can be initiated either automatically or manually.
Guideline / Standard Designation
National Standards
DIN 15185-2 Warehousesystems with powered industrials trucks *

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Fig. 2.1-1: The 190° angle range of the SD3-A1 is divided into 0.36° angle
segments.
A laser diode coupled with transmitter optics produces focused light pulses. These pulses
are projected across the monitored surface by a rotating mirror in such a way that a light
pulse is triggered in each of the angle segments within 40ms (scanning rate: 25 scans/s).
Fig. 2.1-2: Functional principle of the SD3-A1
The SD3-A1 can detect people up to a distance of 4.0m even if they are wearing very
dark clothing or exhibit a low degree of reflectance. Dangerous movements are brought to
a standstill by two failsafe semiconductor outputs.