SICK NAV245 2D laser scanners Operating instructions

OPERATING INSTRUCTIONS

NAV245

2D Laser scanner

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Described product

Product family: NAV245

Manufacturer

SICK AG

Erwin-Sick-Str. 1 · 79183 Waldkirch · Germany

Phone: +49 7641 469-0

Fax: +49 7641 469-1149

E-mail: [email protected]

Production location

SICK AG

Merkurring·20 22143 Hamburg · Germany

Legal information

This work is protected by copyright. The associated rights are reserved by SICK AG.

Reproduction of this document or parts of this document is only permissible within the

limits of the legal determination of copyright law.

Any modification, expurgation or translation of this document is prohibited without the

express written permission of SICK AG.

The trademarks stated in this document are the property of their respective owner.

Original document

This document is an original document of SICK AG.

CONTENTS

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Contents

1 About this document................................................................................. 7

1.1 Purpose of this document............................................................................... 7

1.2 Target group ....................................................................................................7

1.3 Information depth ........................................................................................... 7

1.4 Symbols used .................................................................................................. 8

2 Safety information..................................................................................... 9

2.1 Authorized personnel...................................................................................... 9

2.2 Intended use ................................................................................................... 9

2.3 General safety notes and protective measures...........................................10

2.3.1 Electrical installation work ...........................................................10

2.3.2 Laser radiation from the laser positioning sensor ......................11

2.4 Quick stop and quick restart ........................................................................12

2.4.1 Switching off the NAV245 ............................................................12

2.4.2 Switching on the NAV245 again...................................................12

2.5 Protection of the environment......................................................................12

2.5.1 Power consumption ......................................................................12

2.5.2 Disposal after final decommissioning .........................................12

3 Product description .................................................................................13

3.1 Scope of delivery...........................................................................................13

3.2 Structure of the NAV245 ..............................................................................14

3.3 Operating and status indicators ...................................................................15

3.3.1 Operator interface ........................................................................15

3.3.2 Status indicators...........................................................................15

3.4 Operating principle of the NAV245 ..............................................................17

3.4.1 Landmark detection operating mode ..........................................18

3.4.2 Impact of objects on the measurement ......................................19

3.4.3 Sensing range of the NAV245......................................................20

3.4.4 Beam diameter and measuring point distance...........................21

3.4.5 Sensing range of the NAV245......................................................22

3.5 Measuring mode ...........................................................................................23

3.5.1 Measurement accuracy................................................................23

3.6 Reflector detection........................................................................................24

3.6.1 How the NAV245 deals with source of error ...............................25

3.6.2 Contamination measurement ......................................................27

3.7 Output of measured values ..........................................................................28

3.8 Integrating the NAV245 into the control system of an automated guided

CONTENTS

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vehicle ........................................................................................................... 28

3.8.1 Data interfaces............................................................................. 28

3.8.2 Communicating data via telegrams............................................. 29

3.8.3 Output of measured values of a second reflective pulse........... 30

3.8.4 Relative positioning system and absolute positioning system... 32

3.8.5 Digital output ................................................................................ 33

3.8.6 Synchronizing the clock in the automated guided vehicle and the

NAV245......................................................................................... 33

3.8.7 Result Port .................................................................................... 34

3.8.8 Detection mode ............................................................................ 35

3.9 Digital switching outputs .............................................................................. 36

3.10 Project planning............................................................................................ 36

3.10.1 System requirements of the NAV245.......................................... 36

3.10.2 Mounting requirements ............................................................... 37

3.10.3 Distance between the NAV245 and the object/surface to be

measured...................................................................................... 38

3.10.4 Beam diameter and measuring point distance .......................... 39

3.10.5 Reflectors ..................................................................................... 40

3.10.6 Heating ......................................................................................... 42

4 Alignment of the scan level....................................................................43

4.1 Introduction and Preparation ....................................................................... 43

4.2 Preparation ................................................................................................... 44

4.3 Alignment of the NAV245 by SOPAS............................................................ 46

4.4 Search and check for the target boards...................................................... 47

4.5 Alignment of the NAV245............................................................................. 48

4.5.1 Alignment of the rolling angle...................................................... 49

4.5.2 Alignment of the pitch angle........................................................ 50

5 Mounting ................................................................................................... 51

5.1 Overview of the mounting steps .................................................................. 51

5.2 Preparation for mounting ............................................................................. 51

5.2.1 Getting the components to be mounted ready ........................... 51

5.2.2 Getting the accessories and material ready ............................... 51

5.2.3 Getting the tools ready................................................................. 51

5.2.4 Selecting the mounting location.................................................. 52

5.3 Steps for mounting ....................................................................................... 52

5.3.1 Direct mounting............................................................................ 53

5.3.2 Mounting with mounting kit 1a.................................................... 53

5.3.3 Mounting with mounting kit 1b.................................................... 54

5.3.4 Mounting with mounting kit 2 and 3 ........................................... 55

5.4 Dismantling the NAV245.............................................................................. 55

6 Electrical installation............................................................................... 56

6.1 Overview of the installation steps................................................................ 56

6.2 NAV245 connections.................................................................................... 56

CONTENTS

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6.3 Preparation for electrical installation...........................................................59

6.3.1 Supply voltage...............................................................................59

6.3.2 Wire cross-section ........................................................................59

6.3.3 General requirements of the data interfaces..............................59

6.4 Carrying out the electrical installation on the NAV245 ...............................60

6.4.1 Auxiliary means.............................................................................60

6.4.2 Connecting to the auxiliary and Ethernet interface of the NAV245

60

6.4.3 Wiring the M12 round connector on the NAV245.......................60

6.4.4 Wiring inputs and outputs on the NAV245..................................62

7 Commissioning and configuration ........................................................64

7.1 Overview of the commissioning steps..........................................................64

7.2 SOPAS ET configuration software.................................................................64

7.2.1 Installing SOPAS ET ......................................................................64

7.2.2 SOPAS ET default settings............................................................65

7.3 Establishing communication with the NAV245 ...........................................65

7.3.1 Connecting data interfaces ..........................................................65

7.3.2 Configuring the Ethernet connection ...........................................65

7.4 Initial commissioning ....................................................................................66

7.4.1 NAV245 configuration ..................................................................66

7.5 Connecting and performing a test measurement........................................67

8 Maintenance.............................................................................................68

8.1 Maintenance during operation .....................................................................68

8.1.1 Cleaning the optical cover ............................................................68

8.2 Replacing a NAV245 .....................................................................................68

9 Troubleshooting .......................................................................................69

9.1 Response to faults ........................................................................................69

9.2 Monitoring error and fault signals................................................................69

9.3 Troubleshooting ............................................................................................70

9.4 Detailed fault analysis ..................................................................................70

9.5 SICK support .................................................................................................71

10 Technical data..........................................................................................72

10.1 NAV245 data sheet.......................................................................................72

10.2 Dimensional drawings...................................................................................74

10.2.1 NAV245 dimensional drawing......................................................74

10.2.2 NAV245-10100S01 dimensional drawing .................................75

10.2.3 Mounting kit dimensional drawings.............................................76

10.3 Accessories ...................................................................................................78

11 Appendix ...................................................................................................79

11.1 Overview of the appendices .........................................................................79

CONTENTS

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11.2 Ordering information .................................................................................... 79

11.2.1 Consumables................................................................................ 79

11.3 Glossary......................................................................................................... 79

11.4 EU declaration of conformity........................................................................ 80

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ABOUT THIS DOCUMENT 1

1About this document

Please read this chapter carefully before you begin working with this documentation and

the NAV245 laser positioning sensor.

1.1 Purpose of this document

These operating instructions are intended to allow the technical personnel to perform

assembly, electrical installation work, configuration, commissioning, and maintenance on

the laser positioning system in the following variants:

Important For simplicity in this document, the variants are referred to as the “NAV245” for short,

unless a clear distinction needs to be made.

1.2 Target group

The target group for this document consists of people in the following roles:

Table 1: Target group

1.3 Information depth

These operating instructions contain the following information about the NAV245:

• Product description

• Mounting

• Electrical installation

• Commissioning and configuration

• Maintenance

• Troubleshooting

• Ordering information

• Conformity and approval

In addition, online support on operating the user interface and configuring the NAV245 is

included with the supplied SOPAS ET configuration software.

Additional information on the NAV245 is available from the SICK AG Identification &

Measuring Division and online at www.sick.com.

A detailed description of the different telegrams can be found in the document “Telegram

listing LMS1xx”, part no.: 8014631 with the accompanying “Supplement telegram listing

NAV245”, part no.: 8018823, English versions.

Activities Target group

Mounting, electrical

installation, maintenance,

replacement

Qualified personnel, such as service technicians or industrial

electricians

Commissioning,

configuration

Qualified personnel, such as technicians or engineers

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1 ABOUT THIS DOCUMENT

1.4 Symbols used

Recommendation Recommendations are designed to assist you in the decision-making process with respect

to the use of a certain function or a technical measure.

Important Passages marked with “Important” inform you about special aspects of the device.

Explanation Explanations convey background knowledge about technical concepts.

Menu option

This font indicates a term in the SOPAS ET user interface.

Terminal output

This font indicates messages that the NAV245 outputs via its interfaces.

▸ Take action…

This indicates that action needs to be taken. This symbol indicates an instruction which only

contains one step, or steps in warnings where you do not have to adhere to a certain order.

Instructions which have several steps that follow on from one another are numbered.

This symbol includes a reference to additional documentation available.

Software notes show where you can make the appropriate settings in the SOPAS ET

configuration software.

NOTE:

A note refers to a potential risk of damage or functional impairment to the NAV245 or

other devices.

WARNING:

A warning indicates a specific or potential hazard. It is designed to protect you against

accidents.

The safety mark next to the warning refers to the type of accident risk, e.g., electricity-

related. The warning level (DANGER, WARNING, CAUTION) refers to the severity of the

danger.

▸ Carefully read and follow the warnings.

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SAFETY INFORMATION 2

2 Safety information

This chapter concerns your own safety and the safety of the system operator.

▸ Please read this chapter carefully before you begin working with the NAV245.

2.1 Authorized personnel

The NAV245 laser positioning sensor must only be mounted, commissioned, and

maintained by adequately qualified personnel.

The following qualifications are necessary for the various tasks:

Table 2: Authorized personnel

2.2 Intended use

The NAV245 is used to determine reflector landmarks. The NAV245 is attached to the

automated guided vehicle and continuously measures the positions of identified reflectors

as well as the surrounding contour. Depending on the selected operating mode, the

NAV245 outputs the position of the reflectors as well as the distance, the angle, and the

reflectance of the visible surrounding contour on the automated guided vehicle's computer.

The vehicle computer can use this information to correct the course of the automated

guided vehicle accordingly to keep it on track.

NOTE:

Repair work on the NAV245 may only be performed by qualified and authorized service

personnel from SICK AG.

Activities Qualification

Mounting and maintenance

• Basic practical technical training

• Knowledge of the current safety regulations in the workplace

Electrical installation and

replacement

• Practical electrical training

• Knowledge of current electrical safety regulations

• Knowledge of the operation and control of the devices in their

particular application (e.g., crane, mounting system)

Commissioning, operation,

and configuration

• Knowledge of the operation and control of the devices in their

particular application (e.g., crane, mounting system)

• Knowledge of the software and hardware environment in their

particular application (e.g., crane, mounting system, forklift truck)

• Basic knowledge of the Windows operating system used

• Basic knowledge of data transmission

NOTE:

The NAV245 laser positioning sensor is intended for use in industrial environments.

Radio interference may result when used in residential areas.

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2 SAFETY INFORMATION

The NAV245 is a sensor designed for use in industrial environments and also for uses

within the permitted ambient temperature range in outdoor areas (also see “NAV245 data

sheet” on page 72).

Important In the event of any other usage or modification to the NAV245, e.g., due to opening the

housing during mounting and electrical installation, or to the SICK software, any claims

against SICK AG under the warranty will be rendered void.

2.3 General safety notes and protective measures

2.3.1 Electrical installation work

NOTE:

The NAV245 must only be operated in the permitted ambient temperature range

(see “NAV245 data sheet” on page 72).

WARNING:

Safety notes

Observe the following to ensure the safe use of the

NAV245 as intended.

• The notes in these operating instructions (e.g., regarding the use, mounting,

installation, or integration into the machine controller) must be observed.

• All official and statutory regulations governing operation of the NAV245 must be

complied with.

• The national and international legal specifications apply to the installation and use of

the laser positioning sensor, to its commissioning, and to recurring technical

inspections, in particular:

– The accident prevention regulations and work safety regulations

– Any other relevant safety regulations

• The manufacturer and operator of the system in which the NAV245 is installed are

responsible for coordinating and complying with all applicable safety specifications

and regulations, in cooperation with the relevant authorities.

• Through checks must be carried out by qualified safety personnel or specially

authorized and instructed personnel and must be documented such that they can be

replicated and traced at any time.

• These operating instructions must be made available to the operator of the system in

which the NAV245 is used. The system operator must be instructed by qualified

safety personnel and must read the operating instructions.

• The NAV245 does not constitute personal protection equipment in accordance with

the respective applicable safety standards for machines.

NOTE:

• Only authorized personnel are allowed to perform electrical installation work.

• The power supply must be disconnected when attaching and detaching electrical

connections.

• Select and implement wire cross-sections and their correct fuse protection in

accordance with the applicable standards.

• An external fuse and an external switch to separate the supply voltage must be

provided for the electrical connection.

!▸

Do not open the housing.

▸ Observe the current safety regulations when working on electrical systems.

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SAFETY INFORMATION 2

2.3.2 Laser radiation from the laser positioning sensor

Important No maintenance is required to ensure compliance with laser class 1.

Laser output aperture

The laser output aperture is the window in the scanner head of the NAV245.

Laser power

The laser operates at a wavelength λ = 905 nm (invisible infrared light). The radiation

emitted in normal operation is harmless to human skin and eyes.

Fig. 1: Laser output aperture

WARNING:

Laser radiation!

The NAV245 corresponds to laser class 1 (eye-safe) according to

EN/IEC 60825-1:2014. Identical laser class for issue EN/IEC 60825-1:2007.

Complies with 21 CFR 1040.10 and 1040.11 except for deviations pursuant to

Laser Notice No. 50. The laser beam is not visible to the human eye.

• Improper use can lead to hazardous radiation exposure.

▸ Do not open the housing (opening the housing does not prevent the laser

from switching on).

▸ Pay attention to the laser safety regulations as per IEC 60825-1 (2007)

(valid version).

Window of the optical

cover

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2 SAFETY INFORMATION

2.4 Quick stop and quick restart

2.4.1 Switching off the NAV245

▸ Switch off the power supply to the NAV245.

The NAV245 retains parameters permanently stored in the internal memory. Measured values

at the interface are lost.

2.4.2 Switching on the NAV245 again

▸ Switch on the power supply to the NAV245.

The NAV245 restarts operation with the last saved parameters.

2.5 Protection of the environment

The NAV245 has been designed to minimize its impact on the environment. It consumes

only a minimum of energy.

Always act in an environmentally responsible manner at work. For this reason, please note

the following information regarding disposal.

2.5.1 Power consumption

• The NAV245 consumes a maximum of 20 W in operation.

• The NAV245 also consumes a maximum of 40 W cyclically for heating.

2.5.2 Disposal after final decommissioning

▸ Always dispose of unusable or irreparable devices in accordance with the applicable

waste disposal regulations specific to your country.

▸ Dispose of all electronic assemblies as hazardous waste. The electronic assemblies are

easy to dismantle.

Important SICK AG does not currently take back devices that are unusable or irreparable.

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PRODUCT DESCRIPTION 3

3 Product description

This chapter provides information on the special properties of the NAV245 laser

positioning sensor. It describes the construction and operating principle of the device,

in particular the various operating modes.

Always read this chapter before you mount, install and commission the device.

3.1 Scope of delivery

The NAV245 delivery includes the following components:

Table 3: Scope of delivery

Sources for obtaining more information

Additional information about the NAV245 and its optional accessories can be found in the

following places:

Product web page for the NAV245

(www.sick.com/NAV2xx)

• Detailed technical specifications (online data sheet)

• Technical information (additional information, e.g., for telegrams for NAV245,

part. no.: 8018823)

• These operating instructions are available in German, English, and other languages

if required.

• Dimensional drawing and 3D CAD dimension models in various electronic formats

• EU declaration of conformity

Updates for the SOPAS configuration software: Support is also available from your

sales partner: www.sick.com/worldwide.

Piece Component

1 NAV245 laser positioning sensor

1

Safety note with electrical connection

diagram for initial information

1Lens cloth

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3 PRODUCT DESCRIPTION

3.2 Structure of the NAV245

Fig. 2: View of the NAV245

LEDs and 7-segment display

NAV245

M12 round connector

System plug with PG connector, the number and

position (bottom/back) of the connectors may vary.

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PRODUCT DESCRIPTION 3

3.3 Operating and status indicators

3.3.1 Operator interface

The laser positioning sensor is fully automatic in normal operation and requires no

operator intervention.

The SOPAS ET configuration software supplied makes interactive configuration possible.

For this, the software runs on a PC which is connected to one of the interfaces with the

NAV245.

Use the graphic scan view in SOPAS ET to verify the generated measured values and the

measuring range online. Please note that the field evaluation monitor cannot display the

data in real time and therefore not all measured values are visualized.

3.3.2 Status indicators

The LEDs and 7-segment display signal the operational status of the NAV245.

Fig. 3: Status indicators

Important As well as the standard indicators described below, the indicator functions of the LEDs and

the 7-segment display can be configured in SOPAS ET for the NAV245.

Project tree, NAV245, Parameters, Network/Interfaces/IOs, Indicator.



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LEDs

Table 4: Meaning of the LEDs

7-segment display

Table 5: Indicators in the 7-segment display

Indicator Possible cause

NAV245 in operation, no evaluation cases report an event

Red: Motor failure, configuration error

Off: OK, measurement

Optical cover is dirty

Switching output is on

Not assigned

OK

STOP

Q1

Q2

Indicator Possible cause Remedy

- No error Device is in measuring mode



IDLE mode, outputs are in OFF

state, laser is switched off.

No fault. If the criteria for IDLE mode are

withdrawn, operational readiness is restored.



Motor starts No fault.

-

No error

Indicator in service level: Number of visible

reflectors



NAV245 is defective

Send the NAV245 to the manufacturer for

repair.

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PRODUCT DESCRIPTION 3

3.4 Operating principle of the NAV245

The NAV245 has an opto-electronic laser scanner that uses laser beams to scan the

outline of its surroundings on a plane without contact. The NAV245 measures its

surroundings in two-dimensional polar coordinates. If a measuring beam strikes an object,

the position of that object is determined in terms of distance, direction, and remission.

Fig. 4: Measurement principle of the NAV245

The NAV245 calculates the distance from the object using the elapsed time that the light

requires between sending and receiving the reflection in the sensor.

The scanning sector is 270°. The scanner head rotates with a frequency of 25 Hz.

A laser pulse and thus a distance measurement is triggered continuously after each angle

increment of 0.25°.

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3.4.1 Landmark detection operating mode

The NAV245 has integrated application software which detects reflectors continuously.

The relative position can be displayed on the connected vehicle computer using the

detected reflectors.

Fig. 5: Principle of operation of the NAV245

In addition to landmark detection, the NAV245 can also display the measured surrounding

contour on the connected vehicle computer (mixed mode).

x = 1000

y = 2500

= 70°α

x = 2500

y = 2500

=45°α

Reflectors

Landmark detection

(reflector position display)

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PRODUCT DESCRIPTION 3

3.4.2 Impact of objects on the measurement

Most surfaces produce a diffuse reflection of the laser beam in all directions. The structure

and color of the surface determine how well the laser beam is reflected. Bright surfaces

reflect the laser beam better than dark surfaces and can be detected by the NAV245 over

greater distances. Brilliant white plaster reflects approx. 100 % of the light, while black

foam rubber reflects approx. 2.4 %. On very rough surfaces, part of the energy is lost due

to shadowing. The sensing range of the NAV245 is therefore reduced.

Fig. 6: Diffuse reflection of objects

The angle of reflection corresponds to the angle of incidence. If the laser beam hits a

surface at right angles, the energy is optimally reflected (left). If the laser beam hits a

surface at an oblique angle, energy, and range are lost accordingly (right).

Fig. 7: Targeted reflection of reflectors

The beam is not reflected diffusely in all directions; instead it is reflected in a targeted way.

Thus a large part of the emitted energy can be received by the NAV245. The NAV245 utilizes

this in order to be able to measure the positions of the reflectors extremely precisely.

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Possible sources of error

Fig. 8: Possible sources of error when measuring

The laser beam is almost completely deflected on reflective surfaces (fig. 9, left). This means

that an object hit by the deflected beam may be detected instead of the reflective surface.

Objects that are smaller than the diameter of the laser beam (fig. 9, right) cannot reflect

the laser light's full energy. The energy of the non-reflected part of the laser light is lost. This

means the range is less than would theoretically be possible due to the reflective property

of the object's surface.

3.4.3 Sensing range of the NAV245

The sensing range of the NAV245 depends on the remission of the object to be detected.

The better a surface reflects the beams it is hit by, the greater the range of the NAV245 is.

Table 6: Typical remissions

Material Remission

Black car paint, matte 5 %

Black photo mounting board, matte 10 %

Gray concrete 18 %

White cardboard 90 %

White plaster 100 %

Reflective tape 3000 %

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SICK NAV245 2D laser scanners Operating instructions

SICK NAV245 2D laser scanners Operating instructions

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