Toposens ECHO ONE DK User manual

ECHO ONE ®
Advanced 3D Collision Avoidance
Instruction Manual Draft 1.1 | 2023
For Firmware version 1.4.1
The contents of this document are subject to change without notice.
The latest version of this document can be downloaded on toposens.com/members.

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Described Product
ECHO ONE ® 3D Ultrasonic Sensor
Hardware Version 1.0
Manufacturer
Toposens GmbH
Lyonel-Feininger-Str. 28
80807 Munich
Germany
Legal Notice
This work is protected by copyright. Any rights derived from copyright
protection are reserved by Toposens GmbH. Reproduction of this
document or parts thereof is only permitted within the limits of the statutory
provisions of the copyright laws. Modifications, abridgements and
translations of this document without the express written permission of
Toposens GmbH are prohibited. The trademarks mentioned in this
document are the property of their respective owners.
© 2022 –Toposens GmbH. All rights reserved.
Original Document
This document is an original document of Toposens GmbH.

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TOPOSENS PROCESSING UNIT
CONTENT
1ABOUT THIS DOCUMENT 6
1.1 Purpose of this Document 6
1.2 Target Group 7
1.3 Scope of Information 7
1.4 Explanation of Symbols 8
1.5 Symbols on the device 9
2SAFETY Information 11
2.1 Qualified Personnel 11
2.2 Intended Use 12
2.3 Improper Use 13
2.4 Disclaimer 14
2.5 Modifications and Conversions 15
2.6 Safety precautions and potential hazards 15
3PRODUCT DESCRIPTION 17
3.1 Product Overview 17
3.2 Device Description 17
4Specifications 18
4.1 Dimensions 18
4.2 Interfaces 19
4.3 Connection cable requirements 20
4.3.1 TPU to Sensor connection 20
5Operating principle 22
5.1 Avoidance of Possible Application Errors 23
5.2 Performance Characteristics 23
5.2.1 Multi Sensor Use 24
5.2.2 Medium Monitoring Mode (MMM) 25
5.2.3 Near Field Detection 26
5.3 Output Data 27
5.3.1 Point Cloud Examples 27
5.4 Mounting Example 29
6Storage and packaging 30
6.1 Scope of delivery 30
6.2 Unpacking 30

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TOPOSENS PROCESSING UNIT
6.3 Storage and repackaging 31
7Installation 32
7.1 Preparations 32
7.1.1 Required tools and accessories 32
7.2 System Structure 33
7.3 Mechanical Installation 34
7.4 Installation via Mounting Brackets 37
7.5 Electrical Installation 38
7.5.1 Connection instructions 39
7.5.2 Plug and Socket assingment 40
7.5.3 Wiring Diagram Single Sensor with TPU 41
7.5.4 Insulation concept 42
8Startup 43
8.1 Startup Checklist 43
8.2 First Startup 44
8.3 Checking the correct function 45
9Maintenance 46
9.1 Cleaning 47
9.2 Maintenance Measures 49
9.3 Firmware Update 52
9.3.1 Update Using Toposens Processing Unit (TPU): 52
9.3.2 Update Using Third Party Controller 52
9.4 Troubleshooting 52
9.4.1 Technical Support 53
9.5 Decommissioning 54
9.5.1 Switching off the Sensor 54
9.5.2 Disposal 55
10 Technical data 57
10.1 Parameters 57
11 Measurement curves 60
11.1 Rotation measurement standard pole target 61
11.2 Rotation measurement with plate target 61
11.3 Lateral measurement with forklift fork target 62
11.4 Lateral measurement with pallet target 62
11.4.1Safety distance due to ultrasonic emissions 63

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TOPOSENS PROCESSING UNIT
12 Accessories list 64
13 Conformity & further information 68

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1ABOUT THIS DOCUMENT
1.1 Purpose of this Document
This instruction manual contains information on the installation process,
setup and the safe use of the ECHO ONE® 3D Ultrasonic Sensor by
Toposens GmbH. This document will aid you in using the sensor in a safe
and efficient manner. Basic requirements for safe use are:
•Compliance with all supplied safety notes and handling
instructions.
•Compliance with local occupational health and safety regulations
and general safety regulations for equipment applications.
This instruction manual is intended exclusively for use by qualified
personnel, in particular trained specialists.
NOTICE
Read this instruction manual carefully to familiarize
yourself with the device and its functions before starting
to work with it.
NOTICE
This instruction manual is an integral part of the product
and must be kept available for later reference.

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1.2 Target Group
This instruction manual is intended for:
•Professionals who integrate an ECHO ONE® sensor into a
machine or vehicle.
•Professionals who perform initial commissioning, operation,
setup, testing and maintenance of the ECHO ONE® sensor.
•Professionals, that perform maintenance and checks on the
machine or vehicle, which has been equipped with an ECHO
ONE® sensor.
•Planners, developers and operators of machines and vehicles.
•Personnel who have been appointed with transporting, storing or
disposing of the ECHO ONE ® sensor.
This instruction manual does not contain any information on the
operation of the machine or vehicle on which the device has been
integrated into. Corresponding information can be found in the instruction
manual of the respective machine or vehicle. The applicable health, safety
and legal regulations must be observed when operating devices,
machines, and vehicles. Using the ECHO ONE ® sensorrequires
additional technical skills which are not covered by this document.
1.3 Scope of Information
This instruction manual contains the following information:
•Safety Information
•Product Description
•Operation/Handling
•Assembly
•Electrical Installation
•Initial Start-Up and Configuration
•Maintenance and Care/Fault Diagnosis and Correction
•Technical Data and Dimensional Drawings

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1.4 Explanation of Symbols
Safety warnings and important information contained in this document are
marked with corresponding signal words. The respective signal word
indicates the extent of the Danger. Always observe these warnings to avoid
accidents, bodily injury and property damage.
DANGER
DANGER
… indicates a dangerous situation that will result in death
or serious injury if not avoided.
WARNING
WARNING
… indicates a dangerous situation which, if not avoided,
could result in death or serious injury.
ATTENTION
ATTENTION
… indicates a dangerous situation which, if not avoided,
may result in minor or moderate injury.
FOR
ATTENTION
FOR ATTENTION
… indicates a potentially dangerous situation that may
result in property damage if not avoided.
"FOR ATTENTION" is used to draw attention to practices
that are unrelated to bodily injury.

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NOTICE
… highlights tips and recommendations as well as
information for efficient and smooth operation.
In the following, the term ECHO ONE system or just system refers to a
combination of one or more ECHO ONE sensors and a Toposens
Processing Unit (TPU) or another controller with Toposens software.
When referring to the ECHO ONE sensor or sensor only, the text refers to a
sensor as a single device.
1.5 Symbols on the device
FOR
ATTENTION
Product markings
The product label attached to the device must not be
removed
Symbol
Description
Complies with EU regulations
FCC conformity mark

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Read Manual before installation,
use or maintenance
This device complies with EU
directive 2011/65/EU
When disposing of electronic
equipment, observe local and
national regulations

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2SAFETY INFORMATION
2.1 Qualified Personnel
WARNING
Risk of injury due to inadequate training/education
Improper handling of this device can result in significant
bodily injury and property damage.
»All work must be carried out by personnel with
appropriate qualifications.
The following qualifications are required to perform work on the device:
•Instructed personnel that have been briefed by the operator on
their tasks and potential hazards due to improper procedures.
•Qualified personnel that have specialized training, competencies
and experience as well as knowledge related to the relevant
regulations. These personnel can independently perform tasks
and recognize and avoid potential hazards.
The following qualifications are required for the performance of the
corresponding activities:
Activities
Qualifications
Assembly,
Maintenance
•Basic practical-technical training/education.
•Knowledge of work safety regulations
Electric
Installation,
Device
Replacement
•Practical electrical training/education
•Knowledge of current safety regulations
•Knowledge of how to operate and control equipment for
the specific application
Start-Up and
Configuration
•Basic knowledge of the operating system used
•Basic knowledge of the structure and setup of the
described connections and interfaces
•Basic knowledge of data transmission

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Activities
Qualifications
Operation of the
device for the
respective
application
•Knowledge of the operation and control of the devices
for the respective application
•Knowledge of the software and hardware environment
for the respective application
2.2 Intended Use
The ECHO ONE sensor is a 3D ultrasonic sensor that perceives its
environment via echolocation and distance measurement and locates each
echo reflected from the environment in three-dimensional space.
The ECHO ONE system consists of 3D ultrasonic sensors (ECHO ONE)
which in combination with the Toposens Processing Unit (TPU) is intended
for collision avoidance of partially or fully autonomous vehicles with
obstacles or other vehicles. The system does not have a personal safety
level. As a Class A device, the sensor is intended for use in industrial
environments only. The ECHO ONE sensor, its accessories and software
components are provided "as is".
Typical applications are:
Integration in machines as a sensor system for collision avoidance with; or
approaching objects, as well as non-safety-related areas of application
developed by customers themselves.
Toposens GmbH assumes no liability for loss or damage resulting directly
or indirectly from the use of the ECHO ONE sensor.
The ECHO ONE sensor as well as the Toposens Processing Unit (TPU) must
not be used as the only sensor system for collision avoidance on vehicles
if the vehicle is operated outside of cordoned-off areas that can also be
entered by untrained persons.
Any use outside the specification shall result in the expiry of all claims
against Toposens GmbH.

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2.3 Improper Use
All uses deviating from the "Intended use" are considered improper use.
Modifications to the device or the software are considered improper use.
In particular, use of the device is not permitted in the following cases:
•Outside the technical specifications and other areas of
application
•As a safety component in accordance with the relevant applicable
machine safety standards
•As a safety component for occupational safety
•In potentially explosive atmospheres
•In corrosive environments
•Under extreme environmental conditions
The use of accessories not approved by Toposens GmbH is at the user's
own risk.
WARNING
Danger due to improper use
Any kind of improper use can lead to dangerous
situations.
»The device may only be operated in accordance with
its intended use.
»All information contained in this instruction manual
must be strictly observed.
»If the device is mechanically damaged or defective, it
must be removed from operation immediately.

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2.4 Disclaimer
This instruction manual has been prepared based on the relevant standards
and regulations, the latest technical developments and our knowledge and
experience. The manufacturer accepts no liability for damage caused by
the following:
•Non-compliance with the product documentation (e.g. the
instruction manual)
•Incorrect or improper use
•Use of untrained or unqualified personnel
•Modifications to the hardware or software
•Damages resulting from excessive mechanical stresses
•Disregarding installation requirements
•Use of unauthorized spare parts, consumables, and accessories
Toposens GmbH cannot be held liable for any direct or indirect damages or
losses that may arise from the use of the product.
The safety and conformity of the machine or vehicle in which this product
is integrated is the responsibility of the system installer and/or operator.
Observe the operating and safety instructions for the machine or vehicle in
which this product is integrated. These operating instructions do not
contain any information or safety instructions relating to the machine or the
vehicle in which this product has been integrated.

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2.5 Modifications and Conversions
WARNING
Danger due to changes to the device or software
Changes and modifications to the device or to the
Toposens TPU software can lead to unforeseeable
dangers or damage.
Any warranty claims against Toposens GmbH shall become invalid if the
device or the Toposens software are used for purposes other than those
for which they are intended or if they are modified. This applies in particular
to the opening of the housing, also within the scope of assembly and
electrical installation.
2.6 Safety precautions and potential hazards
To reduce the risk of injury and to avoid dangerous situations, the warnings
given here and in the other chapters must be strictly observed.
WARNING
Electrocution
Electrical voltage can cause severe or lethal injury.
»The device must not be modified.
»If the device is connected to a power source, the
enclosure must be completely closed.
»If the housing of the sensor is damaged, the device
must be disconnected from the power supply and
may only be put back into operation after repair and
inspection by the manufacturer.

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WARNING
Electrical Voltage
Electrical voltage can cause serious or fatal injuries as
well as property damage.
»Work on electrical installations may only be carried
out by qualified personnel.
»Before making or disconnecting electrical
connections, the power supply must be completely
shut down. Residual charges must be dissipated.
»Observe the national and local regulations.
»Observe the safety requirements for working on
electrical installations.
WARNING
Risk of bodily injury and property damage from potential
equalizing currents.
Improper grounding can result in dangerous equipotential
bonding currents, which in turn can cause dangerous
voltages on metal surfaces, such as connector housings.
Electrical voltage can cause serious or fatal injuries.
»Work on electrical equipment may only be carried out
by qualified personnel.
»Follow the instructions.
»Ensure correct grounding.

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3PRODUCT DESCRIPTION
3.1 Product Overview
The ECHO ONE® 3D ultrasonic echolocation and distance sensor operates
according to the time-of-flight (ToF) principle and, as a sensor system,
enables machines and mobile robots to determine the position of objects
in three-dimensional space. Due to the large aperture angle (depending on
configuration, geometry and position of the reflective object) and the
integrated near-field detection, the sensor has no blind zone. This enables
reliable avoidance of collisions with objects and thus leads to increased
availability and productivity of your machine.
3.2 Device Description
1
Ultrasonic emitter “Transducer”
2
Microphone array
3
Acoustic axis
4
M5 thread, 5mm depth
5
M12 A-coded 8-pin plug and socket

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4SPECIFICATIONS
4.1 Dimensions
1
Ultrasonic emitter “Transducer”
2
Microphone array
3
M5 thread, 5mm depth
4
M12 A-coded 8-pin plug
5
M12 A-coded 8-pin socket

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4.2 Interfaces
Interfaces
CAN
ISO 11898-2:2016/CAN 2.0A
Connector In
M12 A-coded, 8 Pin, plug
Connector Out
M12 A-coded, 8 Pin, socket
Termination
120 Ohms, pluggable Terminator*
*See section 13, Accessories list

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4.3 Connection cable requirements
Toposens recommends only using cables listed in the accessory list
available on the website. If other cables are used these minimum
requirements need to be observed:
4.3.1 TPU to Sensor connection
Wire gauge
≥ 0.22 mm² (AWG 24)
Number of conductors
8
Shielding
Yes, Cu-Mesh
Permissible operating voltage
≥30 V DC
Current carrying capacity (all conductors)
≥2 A
Flammability
UL 2556 VW-1
The used connectors must fulfill the following specifications:
Connector type
M12 A-coded
Number of contacts
8
Shielding
Yes, cable shield and connector housing
Permissible operating voltage
≥30 V DC
Current carrying capacity per contact
≥2 A
Termination requirements
Shrouded ferrules or solid wire, max. 0.5 mm²
(AWG20)