Banner AG4 Series, User Manual

Page 1: ... 65 1 131 moreseru ors moresolutions AG4 Series Safety Laser Scanner User Manual Original Instructions 02 2010 P N 144924 rev A Buy www ValinOnline com Phone 844 385 3099 Email CustomerService valin com ...

Page 2: ...r use of the Scanner to the factory applications department at the telephone number or addresses shown on the back cover In addition to OSHA regulations several other organizations provide information about the use of safeguarding devices Refer to the American National Standards Institute ANSI the Robotics Industries Association RIA the Association for Manufacturing Technology AMT and others Banne...

Page 3: ...figuration and diagnostic software AG4soft included with the product on CD ROM AG4 Series Safety Laser Scanner User Manual this document AG4 operation capabilities functions and applications for the machine designer installer and end user P N 144924 included with the product on CD ROM AG4 Software Manual How to configure operational settings access diagnostic information and manage configuration f...

Page 4: ...words 11 1 7 2 Providing Information for Use 11 1 8 Laser 11 1 9 High Voltage 11 1 10 Handling the Scanner 12 1 11 Scanner Limitations 12 1 12 Basic Operation Functions 12 1 12 1 Start Restart Reset Interlock 13 1 12 2 Start Test 14 1 12 3 Dust Suppression 14 1 12 4 Field Pairs Independently Activated Protective and Warning Fields 14 1 12 5 Reference Contour Surface Monitoring 17 1 12 6 Alarm Auxi...

Page 5: ...7 3 5 2 Initial Electrical Connections 48 3 6 Scanner Initial Checkout 48 3 6 1 Initial Power Up and Configuration of the Scanner 49 3 6 2 Initial Optical Field Verification 49 3 6 3 Trip Test Protective and Warning Field Verification 50 3 7 Electrical Interface to the Guarded Machine 51 3 7 1 Permanent Hookup 51 3 7 2 OSSD Output Connections 51 3 7 2 FSD Interfacing Connections 52 3 7 3 Machine P...

Page 6: ...op up Error Messages 82 5 3 Electrical and Optical Noise 83 5 4 Servicing and Maintenance 83 5 4 1 Removing the Scanner from the Machine 83 5 4 2 Cleaning the Front Screen Window and Scatter Screens 83 5 4 3 Cleaning the Scatter Screens 84 5 4 4 Changing the Front Screen Window 85 5 4 5 Calibrating the Front Screen Window 86 5 4 6 Scanner Replacement Procedure 87 5 5 Repairs and Warranty Service 8...

Page 7: ...start reset signal depending on the operating mode 1 Configured Warning Field WF User defines shapes and ranges 2 Configured Protective Field PF User defines shapes and ranges 3 Object person in the Protective Field Example 4 AG4 Scanner a Maximum Monitored Area 50 meters d Configurable Protective Field and Warning Field field of view extension 5 e Configurable Protective Field and Warning Field f...

Page 8: ...nterlock is active reset required Flashes 2 Hz Front screen is dirty Flashes 4 Hz Fault Figure 1 3 Status LEDs 1 2 Mounting System Optional The AG4 MBK1 mounting system simplifies Scanner installation and alignment The mounting system is available as an accessory see Section 2 Figure 1 4 AG4 Scanner with AG4 MBK1 mounting system in place 1 3 Machine Interface X1 ConfigPlug The ConfigPlug included ...

Page 9: ...ision avoidance on mobile vehicles The user is responsible for satisfying all local state and national laws rules codes or regulations relating to the installation and use of this control system in any particular application Take extreme care to meet all legal requirements and follow all installation and maintenance instructions contained in this manual The user has the sole responsibility to ensu...

Page 10: ... password to access the Scanner s configuration program Access and change the Scanner s configuration settings Reset the system following a lockout condition Perform maintenance and repairs as described in Section 5 1 7 Responsibility for Safety The responsibility for the proper use of the Scanner and compliance with the regulations and directives that apply in the country of use lies with the mac...

Page 11: ...ng devices and methods are appropriate for any given machine or application The Qualified Person who configures installs and or maintains it must be aware of the power up behavior of the Scanner and instruct the machine operator on the operation of the Scanner At a minimum the machine manufacturer must provide information to the user to inform the operator of the requirements for the safe operatio...

Page 12: ...d Where changes are made to the Scanner all guarantee claims against the manufacturer of the Scanner shall no longer apply Service life TM in accordance with DIN ISO 13849 The Scanner s PL and PFHd specifications refer to the TM service life of 20 years Repairs or replacement of wear and tear parts do not extend the service life Protective function limits The Scanner does not protect against inclu...

Page 13: ...tion Using Start Restart Reset Interlock Install an appropriate start restart switch see Specifications which causes the Scanner outputs to turn ON when the switch is actuated Position the start restart switch outside the hazardous area so that it cannot be activated from within the hazardous areas The operator must be able to see all hazardous areas from this position Label the start restart swit...

Page 14: ...e the safeguarded area in an application in which a hazard is not continually present or in mobile applications in which direction speed and stopping distance varies After the Scanner is configured switching over or a ctivating an individual Field Pair is controlled by the four FP inputs on the Machine Interface X1 plug see Table 1 and Figures 3 18 3 19 and 3 20 WARNING PROTECTIVE FIELD PAIR SWITC...

Page 15: ...s not occur In higher risk applications it is highly recommended to use redundant sensors or switches to initiate or enable a Field Pair change Diverse technology can minimize the possibility of common cause or common mode failures Ensure that selecting deselecting Field Pairs does not expose any individual to a hazard Supplemental safeguarding may be required Field Pair 8 Field pair 8 is pre conf...

Page 16: ...0 0 1 0 Field pair 3 is active 4 0 0 0 1 Field pair 4 is active 5 1 1 1 0 Field pair 5 is active 6 1 1 0 1 Field pair 6 is active 7 1 0 1 1 Field pair 7 is active 8 0 1 1 1 All fields are deactivated WARNING Scanner outputs remain ON Key Logic 1 30V dc max 16V min Logic 0 3V dc Figure 1 9 Example Field Pair Switchover timing diagrams Buy www ValinOnline com Phone 844 385 3099 Email CustomerService...

Page 17: ...ot be assigned as a reference contour When one of the following is selected in the configuration software the software will automatically define the boundary of the Protective Field as the reference contour shown as blue segments This can be manually adjusted in the configuration software Passage Control access guarding Access Perimeter Guarding Arm Protection point of operation Vertical Guarding ...

Page 18: ...5 is flashing Warning Field interrupted automatic reset only default Device Warning or Warning Field interrupted Alarm 2 Auxiliary 2 output X1 15 provides the Device Warning function which signals a lockout condition or dirty window indication i e LED 5 is flashing by turning OFF the output See Figures 3 18 3 19 and 3 20 for hookup wiring information Important Note The alarm auxiliary outputs are ...

Page 19: ...B9 Serial to USB converter cordset NOTE Do not use with 10 meter AG4 PCD9 10 1 m 2 1 2 Accessories AG4 CLN1 AG4 cleaning kit includes approved fluid for cleaning plastic soft lint free cleaning cloths 150 ml fluid 25 cloths AG4 CLN2 1000 ml fluid 100 cloths AG4 MBK1 Mounting system swivel bracket AG4 TB1 Test box to test the Scanner for proper output behavior prior to connecting to the machine It ...

Page 20: ...e Section 4 9 for more information Wavelength 905 nm Protection Field Radius Sensing Range Model AG4 4E 150 mm resolution 200 mm to 4 0 m 70 mm resolution 200 mm to 4 0 m 50 mm resolution 200 mm to 2 8 m 40 mm resolution 200 mm to 2 2 m 30 mm resolution 200 mm to 1 6 m Sensing object reflectance Minimum 1 8 Model AG4 6E 150 mm resolution 200 mm to 6 25 m 70 mm resolution 200 mm to 6 25 m 50 mm res...

Page 21: ...h logical 1 16 30V Low logical 0 3V Laser Protection Class Class 1 IEC 60825 1 Number of Field Pair Configurations 8 Field Pairs in combination of Protective Field and Warning Field can be switched overby external inputs Field Pair 8 is not user configurable see Section 1 12 Environmental Rating IP65 per IEC 60529 Housing Material Die cast aluminum with a thermoplastic resin window Weight 2 1 kg O...

Page 22: ...CPD15 minimum bend radius 25 mm 1 static 89 mm 3 5 flexible a Rotary mirror axis b Beam level A Interface X1 for connection with control system B Interface X2 for connection with PC or laptop All dimensions in mm Figure 2 1 AG4 dimensions Buy www ValinOnline com Phone 844 385 3099 Email CustomerService valin com ...

Page 23: ...Banner AG4 Series Safety Laser Scanner All dimensions in mm Figure 2 2 AG4 MBK 1 Mounting system optional accessory dimensions Buy www ValinOnline com Phone 844 385 3099 Email CustomerService valin com ...

Page 24: ... Section 1 12 6 6 yellow FP 2 Input for activating Field Pair 2 7 red FP 3 Input for activating Field Pair 3 8 gray FP 4 Input for activating Field Pair 4 9 Not connected 10 Not connected 11 black OSSD 1 Semiconductor safety output channel 1 turn OFF with Protective Field interruption 12 white OSSD 2 Semiconductor safety output channel 2 turn OFF with Protective Field interruption 13 Not connected...

Page 25: ...ses Figure 2 4 Plug X2 interface assignment as RS 232 port Plug X2 as RS 422 port PIN Signal Description 1 Tx Data communication send 2 Tx Data communication send 3 Rx Data communication receive 4 Rx Data communication receive 5 GND shield Ground shield 6 RS 422 Selection as interface RS 422 via jumper to pin 5 7 Not connected 8 Not connected 9 Reserved Reserved for test purposes Figure 2 5 Plug X...

Page 26: ...med by a Qualified Person as defined in Section 4 1 See Warning below WARNING READ THIS SECTION CAREFULLY BEFORE INSTALLING THE SYSTEM The user is responsible for satisfying all local state and national codes and regulations relating to the installation and use of this control system in any particular application Take extreme care to meet all legal requirements and follow all technical installatio...

Page 27: ...m 7 26 Start Restart Interlock selectable Manual or Auto reset Default Start Restart Interlock enabled Manual Vertical Guarding Hand Detection Hand protection point of operation Vertical Protective Field stationary Resolution 30 mm Maximum Protective Field range 1 6 m 5 28 Start Restart Interlock selectable Manual or Auto reset Default Start Restart Interlock enabled Manual Vertical Guarding Body ...

Page 28: ...elds with a range of less than 200 mm are not permitted Ensure that safety distance and stopping distance calculations incorporate all factors that can effect response time including The additive effect of all device response times such as the Scanner UM FA safety module and all control elements FSDs and or MPCEs Add the appropriate response time values to account for any reasonably foreseeable ma...

Page 29: ...The area behind and on either side the Scanner is not monitored see Figure 3 1 3 It must not be possible to walk in unmonitored areas or otherwise access them This can be accomplished by recessing the Scanner into the machine using supplemental safeguarding or using mechanical barriers to prevent access If there is a possibility that the Scanner could be used as a climbing aid or standing surface ...

Page 30: ...ght emitted by the Scanner cannot bend around or penetrate through solid objects The shadow effect can be caused by both opaque and transparent objects Any unmonitored areas resulting from the shadow effect must not allow unprotected access routes to the hazard This can be prevented by repositioning the Scanner installing additional Scanners or by adding supplemental safeguarding If the object is ...

Page 31: ...sing points to detect the full 70 mm resolution size Inward Needle and Cone Shaped Field Contours The effect of an inward cone shape is to increase the effective resolution immediately adjacent to the shape For the Scanner to identify that an object is equal to or greater than the stated resolution e g 70 mm the entire object must be within the Protective Field to turn OFF the OSSDs e g Object 4 W...

Page 32: ... stationary applications both horizontal and vertical Protective Fields For scanners mounted side by side this shielding must be at least at the height of the front screen window and flush with the front of the housing see Figure 3 5 Ensure that the means of shielding does not create any unmonitored areas see Section 3 3 1 Install scanners at an off set height of at least 100 mm see Figure 3 6 Ins...

Page 33: ...le Mounting Height Detection Capability Resolution d Minimum Height H 50 mm 2 0 70 mm 2 8 300 mm 12 90 mm 3 5 600 mm 24 117 mm 4 6 1000 mm 39 H should not be greater than 1000 mm This ensures detection of a given body part e g thigh leg ankle for a given resolution For example a Protective Field with 70 mm resolution may not reliably detect an ankle which requires a 50 mm resolution Thus the 70 mm...

Page 34: ...K 1600 mm per second 63 inches per second see note 1 below TS maximum stopping time sec of the machine see note 2 below TR maximum response time sec of the Scanner see note 3 below Dpf Depth penetration factor The additional distance required by U S standards such as ANSI B11 19 to prevent a person from encroaching towards the hazard without being detected ZSM the additional distance needed to acc...

Page 35: ...ance could result in serious bodily injury or death Table 4 Vertical Protective Field Applications Normal Approach Detection Capability Resolution d Dpf 30 mm 1 2 78 mm 3 1 40 mm 1 6 112 mm 4 5 50 mm 2 146 mm 5 9 70 mm 2 75 900 mm 36 150 mm 5 9 900 mm 36 Horizontal Protective Field Applications parallel approach Dpf 1200 mm 48 Note See Section 3 3 3 for information on allowable Protective Field he...

Page 36: ...d result in serious bodily injury or death WARNING DETERMINE CORRECT STOP TIME Stop time T must include the response time of all devices or controls that react to stop the machine If all devices are not included the calculated Safety distance S will be too short This can lead to serious bodily injury or death Be sure to include the stop time of all relevant devices and controls in the calculations...

Page 37: ...evices are not included the calculated safety distance Ds will be too short and serious injury could result 3 Consideration for Adjacent Scanners When adjacent Scanners share the same detection plane and have an unobstructed view of each other an additional 40 ms must be added to the response times of both Scanners If the adjacent scanners detection planes are shielded therefore no clear line of s...

Page 38: ...d area and the machine frame or hard guarding Reducing or Eliminating Pass Through Hazards Eliminate or reduce pass through hazards whenever possible While it is recommended to eliminate the pass through hazard altogether this may not be possible due to machine layout machine capabilities or other application considerations One solution is to ensure that personnel are continually sensed while with...

Page 39: ...rea To accomplish this supplemental guarding mechanical barriers such as screens or bars as described by ANSI B11 safety requirements or other appropriate standards must be installed Access will then be possible only through the defined area of the Scanner or through other safeguarding that prevents access to the hazard see Figure 3 11 The mechanical barriers used for this purpose are typically ca...

Page 40: ... occur If it is not possible to completely safeguard the vehicle including trailers protruding or overhanging loads etc during the full length of travel including curves additional safeguarding such as additional Scanners or bumper edge switches must be used see 3 2 3 The following instructions are general in nature and are intended to provide guidance to safely install the Scanner on mobile vehic...

Page 41: ...tion of 70 mm be as near as possible to the floor but no greater than 200 mm 7 9 above the floor see Figure 3 12 In general a height of 150 mm 5 9 has been recognized by industry to be the most advantageous height above the floor Figure 3 12 Determining mounting height Unmonitored Areas Mounting the Scanner on the mobile vehicle must not create unmonitored areas between the Protective Field and th...

Page 42: ...ensure that the sides of the vehicle or a protruding load do not create a hazard It is highly recommended that an oversized Warning Field in comparison to the Protective Field be used The Warning Field and its associated output signal the approach of the mobile vehicle e g by sounding a horn or illuminating lights beacons and reduce the speed of the mobile vehicle This can reduce the need or the a...

Page 43: ...idual will recognize and will avoid the hazard or at a minimum stop their movement If this cannot be reasonably expected such as if the Warning Field is not used to signal the approach of the vehicle the factor ZA should incorporate the expected speed of an individual see below When all factors that influence a mobile vehicle stopping performance are considered the formula is D DSD ZSM Zrefl ZF ZA...

Page 44: ...aking such as loose dirt gravel wet moisture icing etc which can add 10 or more to the manufacturer s stated distance It should be noted that braking distance is not a linear function it increases by a square function as velocity increases Additional Distance Factors Z Specific for Mobile Applications For mobile applications two additional factors must be considered ZSM and Zrefl ZSM Measurement T...

Page 45: ...icles or trailers resulting in large lateral travel Multiple factors may or may not result in a cumulative effect ZA ZA1 ZA2 ZAn Evaluate each factor to determine its impact on all Additional Distance Factors Z Additional Side Distance Z Protective Field Width The width of the Protective Field is determined by the width of the mobile vehicle and the Additional Distance Factors Z as described above...

Page 46: ...ner should be configured with a resolution of at least 150 mm to detect the torso of an individual i e Body protection danger zone guarding The risk assessment should determine if a smaller resolution is necessary Table 7 Vertical Guarding Application Application Configuration Description Vertical Guarding Body Detection Body protection danger zone guarding Vertical Protective Field stationary Res...

Page 47: ...ts of the control system are located This must be done per local wiring code for low voltage dc control cables and may require installation of electrical conduit See Sections 2 1 1 and 2 4 for information about Banner supplied cables Do the same with the PC interface cable if it is to be permanently installed if this connection is only to be used during configuration or troubleshooting route the c...

Page 48: ...set switch must be a normally open switch that is held closed for approximately 1 4 second but no longer than 5 seconds and then re opened to accomplish the reset The switch must be capable of switching 10 to 30V dc at 30 mA 3 6 Scanner Initial Checkout The initial checkout procedure must be performed by a Qualified Person see Section 4 1 It must be performed only after configuring the System and ...

Page 49: ...D9USB 1 Serial to USB adaptor Apply power to the Scanner Status information can now be uploaded and the configuration can be downloaded to the Scanner See Section 4 3 6 2 Initial Optical Field Verification Table 8 Typical LED indications shown below assumed Warning Field controls Alarm 1 a Protective and Warning Fields clear OSSD and Alarm 1 Auxiliary outputs ON b Protective Field clear Warning Fi...

Page 50: ...t piece and verify that LED 2 turns OFF Repeat this along the entire Warning Field perimeter as shown in Figure 3 16 Pay special attention at needle and cone shaped areas see Section 3 3 1 3 With the appropriate test piece that matches the configured expected resolution interrupt the perimeter of the Protected Field and verify LED 1 Green turns OFF Remove the test piece and verify that LED 1 turns...

Page 51: ...EC 60204 1 See the warning in Section 3 5 The connections for supply power and the external reset switch should already be connected The Scanner must also have been configured mounted and passed the initial checkout as described in Section 3 6 The final connections to be made are OSSD outputs FSD interfacing MPCE EDM connections Alarm Auxiliary Outputs 3 7 2 OSSD Output Connections Both the output...

Page 52: ...the machine s safety related control system that includes the Scanner The normally open safety outputs from a safety module provide a series connection of redundant contacts that form safety stop circuits for use in either single channel or dual channel control See Figure 3 20 Dual Channel Control Dual channel control provides the ability to electrically extend the safe switching point beyond the ...

Page 53: ...ime performance of the machine Ts used to calculate the safety distance see Sections 3 3 4 and 3 3 5 must take into account the slower of the two channels Refer to Figure 3 20 or consult the machine manufacturer for additional information To ensure that an accumulation of failures does not compromise the redundant control scheme i e cause a failure to danger a method to verify the normal functioni...

Page 54: ...a PNP current sourcing output 100 mA max that switches OFF to indicate the following conditions Alarm 1 X1 5 If the Warning Field has been interrupted default if the AG4 has locked out or both conditions configurable via the software Alarm 2 X1 15 If the AG4 has locked out 3 8 Preparing for System Operation After the initial trip test has been accomplished Section 3 4 and the OSSD safety output co...

Page 55: ...Banner AG4 Series Safety Laser Scanner Figure 3 18 Hookup with FSD inputs Buy www ValinOnline com Phone 844 385 3099 Email CustomerService valin com ...

Page 56: ...Banner AG4 Series Safety Laser Scanner Figure 3 19 Hookup using UM module Buy www ValinOnline com Phone 844 385 3099 Email CustomerService valin com ...

Page 57: ...Banner AG4 Series Safety Laser Scanner Figure 3 20 Hookup to the SC22 3 Safety Controller Buy www ValinOnline com Phone 844 385 3099 Email CustomerService valin com ...

Page 58: ...the AG4Soft Software Manual for information on changing and resetting the passwords 4 2 System Configuration Settings The AG4Soft configuration software is used to establish the Scanner operating parameters for complete information see the AG4Soft Software Manual AG4Soft is included on the CD that was included with the Scanner and is also available on line at Banner website The Scanner is configur...

Page 59: ...ided in the Select a file to open box After the file is successfully loaded click OK The Configuration Wizard opens with a dialog box that allows naming of the Scanner and a note or description of the location of the Scanner that the configuration will eventually be loaded into No entry is required for the purposes of the walk through Click on NEXT Note Navigation can move forward or backward thro...

Page 60: ...2000 ms Click NEXT when complete The next dialog box allows setting of the Protective Field and Warning Field response times individually Care must be taken because all fields are affected by these settings After clicking NEXT the dialog box allows activating default or deactivating the dust suppression algorithm It is recommended to keep the algorithm activated Click NEXT The fifth page of the wi...

Page 61: ...nistrative Parameters and allow configuration of the functionality of Alarm Output 1 see Section 1 12 6 the amount of measurement data that is communicated see Section 1 12 5 and the baud rate of the X2 PC serial interface Buy www ValinOnline com Phone 844 385 3099 Email CustomerService valin com ...

Page 62: ...ccessed by clicking on Help on the Menu Bar Note The display can be manipulated via the menu bar path Settings PC configuration Change diagram color or Rotate contour display by 180 Position cursor small blue ring Navigation Tool Bar Work Space Warning Field Protective Field Position of the Scanner Menu Bar Operating Mode Tabs active mode highlighted yellow Operating Mode Icons Information Area St...

Page 63: ...omplete descriptions 1 Zoom out 2 Zoom in 3 Show all full 70 meter x 70 meter display 4 Change authorization level 5 Exit configuration program 6 Load configuration data from file 7 Save configuration data as a file 8 Print configuration data 9 Load configuration data from a file and transfer to Scanner 10 Retrieve configuration data from Scanner 11 Transfer configuration data from PC to Scanner 1...

Page 64: ... 21 Define elliptical Protective Warning Field 22 Define rectangular Protective Warning Field 23 Define polygonal Protective Warning Field 24 Change Protective Warning Field segment 25 Change Protective Warning Field segment on all fields 26 Reduce Protective Warning Field limits 27 Blank out Protective Warning Field segment 28 Define Protective Field segment as reference contour 29 Reset referenc...

Page 65: ...Section 3 3 1 This setting is found in menu bar path Settings PC Configuration 190º Protective Warning Fields option default is checked enabled Unchecking this option results in a 180º field and is effective after the field shape has been changed Zoom in or out of an area by using minus 1 and plus 2 icons and the directional arrows on the Navigation Tool Bar or by drawing a box around the area of ...

Page 66: ...ield that is displayed in the Select Protective Warning Field window 19 can be saved by clicking on File Save Protective Warning Field as a file or by clicking on the Save Protective Warning Field as a file 17 icon The Protective Warning Fields definition operating mode tab must be highlighted yellow to access this save function 4 3 Connecting the PC to the Scanner Note Ensure power is removed fro...

Page 67: ...Highlight the Configuration Operating Mode tab then on the Menu Bar click on Settings PC configuration Interface and baud rate to access the PC Configuration window Ensure that The Serial Interface is set to the same port as that assigned to the Scanner interface by the PC Device Manager Ports COM LPT e g CO M 18 the actual port will vary and The Baud Rate matches the PC Baud rate e g 57600 If thi...

Page 68: ...ick on Po rt Settings to verify both these settings If PC Hardware Installation Wizard appears follow its instructions to install the device drivers When using the model AG4 PC9USB 1 USB to serial adaptor keep total cable length to a minimum Do not use the AG4 PCD9USB 1 with the 10 meter AG4 PCD9 10 cordset Do not exceed 5 m USB cable length if a USB extension cable is used with the AG4 PCD9USB 1 ...

Page 69: ...edure as described in Section 6 or return to Section 3 6 2 Initial Optical Field Verification 4 6 Start Restart Interlock Reset Procedures 4 6 1 Resetting the System System resets are typically performed using an external reset switch This switch must be located as discussed in Section 3 3 7 If supervisory control of the reset switch is required a key switch may be used with the key kept in the po...

Page 70: ...ct equal to or greater than the configured resolution e g a test piece Then after the field is clear the OSSD outputs turn ON The Protective Field must be clear before the test is performed or all obstructions must be removed and then the test can be performed No manual reset operation is required 4 8 2 During Run Mode The Scanner can be configured for two output configurations Restart Interlock M...

Page 71: ...rements To ensure continued reliable operation the System must be checked out periodically See Section 6 for more information At every shift change power up and machine setup change the Daily checkout should be performed this checkout may be performed by a Designated or Qualified Person see Section 6 3 and the Daily Checkout Card for the procedure Semi annually the Scanner and its interface to the...

Page 72: ...ction 5 1 1 and 5 1 2 for diagnostic information and resolution of error fault conditions See Section 5 2 for communication errors and loss of communication Recovery Procedures To recover from a Lockout condition all errors must be corrected and a reset routine must be performed as described below or power must be cycled power the Scanner down wait a second or two then power it up NOTE See Section...

Page 73: ...rning Field is interrupted Flashes 2 Hz Front screen is dirty Flashes 4 Hz ConfigPlug configuration is not compatible with the Scanner 3 red ON Safety outputs or switching function OSSD 1 and 2 are switched off 4 green ON Safety outputs or switching function OSSD 1 and 2 are switched on 5 yellow ON Start restart interlock is active Flashes 2 Hz Front screen is dirty Flashes 4 Hz Fault Figure 5 1 S...

Page 74: ...d Protective Field definition if required 1 1 0 1 The sensor function is active the active Protective Field is free Safety outputs or switching function are switched off Start restart interlock is active Actuate the start restart switch 1 0 0 1 0 The sensor function is active the active Protective Field is free The active Warning Field is free Safety outputs or switching function are switched on 1...

Page 75: ...must correspond with the ConfigPlug s configuration 1 0 1 0 1 Device fault Safety outputs or switching function are switched off Errors on the Field Pair control inputs Check the Field Pair switchover switchover sequences and switchover times At least one Field Pair must always be active For the precise error cause read the diagnostics list with the software 1 0 1 0 1 Device fault Safety outputs o...

Page 76: ...written Check the interface parameters and start the transfer again 302 2 Interface X2 time specifications not complied with send data not acknowledged Check the interface parameters and start the transfer again 306 5 Previous message not completely issued interface X2 time specifications not complied with Check the interface parameters and start the transfer again 801 2 Error memory cannot be rea...

Page 77: ...llowed If reset is not successful contact customer service 1607 5 Angle error detected poss rotation of the sensor housing switch off and reset followed If reset is not successful contact customer service 1608 8 Motor speed not constant during operation poss rotation of the sensor housing If reset is not successful contact customer service 1608 9 Motor speed not constant during operation poss rota...

Page 78: ...d for too long Start the transfer again 2007 18 Date of the Protective Field currently being transferred is older than the date saved in the Scanner Update the PC s date and time setting 2017 19 Data transfer error with ConfigPlug Replace the ConfigPlug or the complete cable with plug 2017 23 The connected Scanner does not support the configuration file in the ConfigPlug Change the Scanner observe...

Page 79: ...al error 2401 13 Reference measurement failed dust in the device as the plug housing or dummy cap not screwed Screw the plugs of interfaces X1 and X2 2401 10 Reference measurement failed glare from another light source 905 nm or rotation speed error Scanner performs reset 2401 41 Reference measurement failed glare from another light source 905 nm or rotation speed error Scanner performs reset 2402...

Page 80: ...canner Check the activation of the Protective Fields in the program wizard 2802 4 More than 2 Protective Fields selected when starting the Scanner Only activate one of the control inputs FP1 FP4 2802 6 Unusable or defective control voltage for the Protective Field activation Check the activation of the control inputs FP1 FP4 2802 8 No Protective Field activated during the Scanner start Activate on...

Page 81: ...t 3402 10 Motion Monitor maximum speed exceeded or wrong Field Pair activation Cannot be corrected Check the activation of the Protective Fields in the speed matrix and the speed the vehicle moved at 3403 7 Motion Monitor activated Field Pair was not released in the configuration Check the activation of the Protective Fields in the speed matrix and the program wizard 3403 12 Motion Monitor error o...

Page 82: ... to the AG4 X2 PC Interface connector Do not exceed 10 meters 30 of cable length or communication errors may occur When using a USB to serial adaptor keep total cable length to a minimum Do not use the AG4 PCD9USB 1 with the 10 meter AG4 PCD9 10 cordset Do not exceed 5 m USB cable length if an USB extension cable is used with a USB to serial adaptor See Belkin website for further information on th...

Page 83: ...r sources of optical noise Turn off the Scanner Then use a Banner BT 1 Beam Tracker to check for light at the AG4 front screen window by press the RC V button on the BT 1 and moving across the full length of the window with the BT 1 lenses facing away from the AG4 If the BT 1 s indicator lights check for light from other sources e g other safety laser scanners by t racking down the emitted light u...

Page 84: ...th cleaning cloth Scratches Replace front screen If the cleaning takes longer than four seconds removing fingerprints for example the Scanner displays a front screen monitoring fault If this occurs reset the Scanner using the Start restart switch Soak cloth with cleanser Wipe front screen free in one swipe Figure 5 3 Front screen cleaning procedure 5 4 3 Cleaning the Scatter Screens Soak cloth wit...

Page 85: ...w front screen especially fingerprints before re using the Scanner 1 Remove the Scanner from the machine 2 Place the Scanner on an even base 3 Loosen the four Allen screws on the rear of the housing and carefully pull the two housing parts apart 4 Loosen the screws of the fixing plates 5 Remove the fixing plates 6 Push the old front screen backwards out of the housing 7 Hold the new front screen o...

Page 86: ...the rubber sleeves provided for this 13 Carefully tighten the Allen screws on the housing rear by alternating between them 1 Retaining bolts 2 Rubber sleeves 14 Remove any fingerprints on the front screen Figure 5 5 Scanner front screen replacement procedure 5 4 5 Calibrating the Front Screen Window Requirements The new front screen is correctly mounted Front screen is clean and scratch free Ambie...

Page 87: ...ropriate configuration from a saved file or create a new configuration see Section 4 or the AG4Soft Software Instruction Manual 6 Apply power to only the Scanner not the machine and perform the Commissioning Checkout Section 6 2 Figure 5 6 ConfigPlug configuration 5 5 Repairs and Warranty Service Scanner components are designed for reliability Do not attempt any repairs to the Scanner other than r...

Page 88: ...part of the application is installed or altered The procedure must be performed by a Qualified Person Commissioning Checkout Perform the procedure described in Section 6 2 at installation or whenever changes are made to the Scanner configuration or to the machine being guarded The procedure must be performed by a Qualified Person Shift Daily Checkout Perform the Daily Checkout procedure described ...

Page 89: ...tion 3 or Supplemental safeguarding and hard guarding as described by the appropriate safety standards are in place and functioning properly in any space between the Protective Field s and any hazard which is large enough to allow a person to be undetected by the Scanner see Sections 3 3 1 and 3 3 3 5 Verify that all reset switches are mounted outside and in full view of the guarded area out of re...

Page 90: ...cle While it is moving use the appropriate test piece to interrupt the Protective Field Do not attempt to insert the test piece into the dangerous parts of the machine or directly in the path of the moving vehicle Upon interrupting the Protective Field at any point verify that For stationary applications The dangerous parts of the machine come to a stop with no apparent delay Remove the test piece...

Page 91: ...e installation guarded machine for easy reference 6 4 Semi Annual Six Month Checkout Perform the Semi Annual Checkout procedure every six months following system installation or whenever changes are made to the Scanner configuration or to the machine A copy of checkout results should be recorded and kept in the appropriate place e g near or on the machine in the machine s technical file Tester Qua...

Page 92: ...the System Latch Condition The response of the OSSD outputs they turn OFF when an object blocks interrupts a light beam of the System operating in Latch mode A manual Reset must be performed after all objects are removed beam s clear to Reset the output latch and allow the outputs to turn ON Lockout Condition A condition of the System that is automatically attained when it detects internal or cert...

Page 93: ...ility to solve problems relating to the subject matter and work Response Time The time between the physical initiation of the safety device and the machine coming to a stop or the risk being removed Trip Condition In trip output models the response of the FSD relays when an object equal to or greater than the diameter of the specified test piece enters the Protective Field In a trip condition FSD ...

Page 94: ...irective valid until 29 December 2009 and 2006 42 EC Machinery Directive and all essential Health and Safety Requirements have been met 3 17 2010 3 17 2010 R Eagle Engineering Manager Date Peter Mertens Managing Director Date Banner Engineering Corp Banner Engineering Europe 9714 Tenth Avenue North Park Lane Culliganlaan 2F Minneapolis MN 55441 5019 USA 1831 Diegem Belgium Download the complete EC...