SICK Laser Scanner Interface LSI 101 Operating instructions

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FIN

GB

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NL

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PERATING

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NSTRUCTIONS

Laser Scanner Interface

LSI 101

D

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9. Konformitätserklärung

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9. Overensstemmelsesattest

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LSI E

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9. Declaración de conformidad

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9. Certificat de conformité CE

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9. Vaatimustenmukaisuusvakuus

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Contents

1. General......................................................................... 136

2. System description........................................................ 137

3. Safety regulations and instructions................................ 137

4. Mounting....................................................................... 139

4.1 Mechanical mounting ............................................. 139

4.2 Electrical installation .............................................. 139

4.3 Cabling requirements ............................................. 140

5. Notes on commissioning ............................................... 142

6. Tests............................................................................. 142

6.1 Test of PLS with LSI .............................................. 142

6.2 Checklist ................................................................ 145

7. Diagnosis...................................................................... 148

7.1 Diagnostic elements............................................... 148

7.2 Service .................................................................. 150

8. Accessories .................................................................. 150

9. Declaration of Conformity ............................................. 151

10. Technical Data, LSI..................................................... 152

11. Appendix: Key to diagrams ......................................... 160

This document is protected by the law of copyright, whereby all

rights established therein remain with the company SICK AG.

Reproduction of this document or parts of this document is only

permissible within the limits of the legal determination of Copyright

Law. Alteration or abridgement of the document is not permitted

without the explicit written approval of the company SICK AG.

GB LSI

8 008 308/M848/06-05-02 Operating Instructions · LSI

1. General

This manual contains information on commissioning,

diagnosis, servicing and technical data, as well as certification

of conformity. For more detailed information, such as

ordering, system use and programming, refer to the LSI

Technical Description.

For information on the PLS laser scanner refer to the PLS

documentation.

This instruction manual refers only to the following device:

LSI 101 - 11X

The last digit of the type designation (X: 1 to 4) represents the

maximum number of connectable sensors.

This device is certified for use as a personal protection unit

and, when used correctly, conforms to the relevant standards.

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137

2. System description

The LSI Laser Scanner Interface together with the PLS laser

scanner forms a sensor system unit for personal protection on

vehicles and industrial plant in enclosed areas. The LSI offers

the possibility of operating up to four PLS units

simultaneously. The connected laser scanners communicate

online via serial interfaces with the LSI. Up to eight protective

and warning fields – subsequently referred to as monitoring

areas – can be stored in the non-volatile memory of the

interface. The various areas are selected by way of binary

inputs or speed transducers and are assigned to various

output channels.

The LSI is used in conjunction with PLS units in driverless

transport systems and in manufacturing plant. It significantly

enhances the applications of the laser scanner in those areas.

Registering the running speed makes it possible to adapt

monitoring areas dependent on speed and direction of travel.

Likewise, in stationary area protection applications protective

fields can be controlled dependent on machine position and

status.

By the use of two independent 2-channel outputs (OSSD),

simultaneous monitoring cases can be implemented. Each

OSSD pair has a separate reset/restart and external device

monitoring input.

3. Safety regulations and instructions

Before mounting and wiring up the LSI, please observe the

instructions set out in the Technical Descriptions of the LSI

and the PLS. Mounting and connection work must only be

carried out only by qualified personnel.

Prior to initial commissioning, a test must be carried out by

the operating company’s line manager. Tests of such kind

may be carried out only by qualified personnel.

1. The use and installation of the non-contact safety device,

both for commissioning and for routine technical inspections,

GB LSI

8 008 308/M848/06-05-02 Operating Instructions · LSI

is subject to the relevant national and international legal

requirements, in particular

the Machinery Safety Regulations derived from the

Machinery Directive 98/37 EC,

the Word Equipment Regulations derived from the

Provision and Use of Work Equipment Directive 89/655

EEC,

the applicable safety directives and

the rules governing accident prevention and safety at

work.

The manufacturers and users of the machinery on which our

safety devices are used are solely responsible for ascertaining

all applicable safety rules and regulations from the competent

authorities and for compliance with the said rules and

regulations.

2. Furthermore, the instructions given by us - and in

particular the test regulations (see section “Tests”) set out

in the Technical Description and in the Operating Instructions

(including instructions relating to use, mounting, installation

and integration into the machine control system) - must be

followed.

3. The tests must be performed by qualified experts or by

specially authorised and instructed personnel and must

be documented in such a way as to be verifiable at any time.

4. Our Operating Instructions must be made available to the

employee (operator) of the machine on which our safety

device is used. The employee must be instructed by qualified

experts.

5. The appendix to this brochure includes a checklist for

testing by the manufacturer and equipment supplier.

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4. Mounting

4.1 Mechanical mounting

The housing of the LSI can be DIN rail mounted in the switch

cabinet rails (top-hat TS 35) or by means of the supplied

brackets (min. protection IP54). For correct mounting of the

PLS unit(s) refer to the PLS Technical Description.

4.2 Electrical installation

When wiring up the system you are advised to unfold the pin

assignment diagram presented in the appendix to this

document.

With regard to the power supply to the LSI, it should be noted

that the overall current consumption is dependent on the

number of sensors in use and the connected load at the

outputs. For relevant data refer to the PLS and LSI Technical

Descriptions. Also ensure that the cable cross-section is

sufficiently dimensioned. To wire the WAGO connectors use

the supplied plastic U-clamp.

If the incremental encoder inputs C and D are used, the static

inputs C1, C2 and D1, D2 are no longer available!

Mark the connectors to prevent inadvertent swapping.

Notes on installation of the PLS units on the LSI

The safety outputs (OSSD) of the connected PLS unit(s) must

not be used in conjunction with the LSI. Also refer to the

complete connection diagram in the appendix.

Lay all cables and wires such that they are protected against

damage.

If you pre-assemble the connectors and cables yourself, make

sure you do not confuse the power supply and interface

connectors.

Close off exposed tapped holes using the supplied blanking

plugs and make sure the seals are correctly positioned.

Do not drop the connectors. The Sub-D connector may be

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8 008 308/M848/06-05-02 Operating Instructions · LSI

pushed into its housing as a result, and so be rendered

unusable.

Check that that the seal on the connection boxes fits tight.

Insert the connectors in the pre-assigned mountings on the

correct sides in the PLS housing. Push the connectors into the

PLS housing by exerting a small amount of pressure. You will

identify that a correct connection has been made when the

connection boxes with the connectors terminate flush with the

PLS housing.

Only then you should secure the connection boxes by the

hexagon socket screws.

Only when both connection boxes with their seals are inserted

and secured in the way specified does the housing conform to

enclosure rating IP65.

4.3 Cabling requirements

Communication cable from LSI to PLS:

The communication cable to the PLS must be a shielded

twisted pair data cable. On the LSI end be sure to use the

accessory 9-pin metallised Sub-D connectors, because they

are provided with a special shield. Connect the data cable

shield to the strain relief on the LSI end only. The shield is not

connected on the PLS end. Pay attention to the pin

assignment.

Use a low-capacitance twisted pair data cable of type Li2YCY

(TP) with a cross-section of at least 2 x 2 x 0.25 mm

2

.

Max. cable length: 30 m

Power supply cable to LSI:

Use a copper cable with a maximum cross-section of 2.5

mm

2

. Max. cable length: 50 m

Signal cables to and from the LSI:

Use a copper cable with a maximum cross-section of 2.5

mm

2

. Max. cable length: 50 m

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Power supply cable to PLS:

Use a copper cable with a maximum cross-section of

0.5 mm

2

. Max. cable length: 30 m

Notes:

When dimensioning the cable cross-sections dependent on

line length and power pack tolerance, make sure the system is

not operated outside its permitted voltage ranges (see

technical data of LSI and PLS).

The spring clamp female connector strips can hold cables

(single-wire, multi-wire, fine-wire or fine-wire with ferrule) with

cross-sections from 0.08 to 2.5 mm

2

.

Example table - Power supply cables:

Power supply cable length

System Power pack – LSI LSI – PLS

LSI with two PLS 50 m (2.5 mm

2

) 10 m (0.5 mm

2

)

Power pack 24 V DC ± 3 % 40 m (2.5 mm

2

) 20 m (0.5 mm

2

)

24 m (1.5 mm

2

) 20 m (0.5 mm

2

)

LSI with four PLS 40 m (2.5 mm

2

) 4 m (0.5 mm

2

)

Power pack 24 V DC ± 3 % 28 m (2.5 mm

2

) 20 m (0.5 mm

2

)

17 m (1.5 mm

2

) 20 m (0.5 mm

2

)

LSI with two PLS 50 m (2.5 mm

2

) 20 m (0.5 mm

2

)

Power pack 24 V DC ± 1 % 30 m (1.5 mm

2

) 20 m (0.5 mm

2

)

LSI with two PLS 4 m (1.0 mm

2

) 4 m (0.5 mm

2

)

Power pack

24 V DC +20 %/-25 %

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8 008 308/M848/06-05-02 Operating Instructions · LSI

5. Notes on commissioning

Commissioning is subject to special safety precautions. Be

sure to refer to the relevant sections of the Technical

Description in this regard.

The device is programmed in a basic configuration. Changes

to monitoring areas or to the parameter settings may be made

only by authorised (qualified) personnel.

6. Tests

6.1 Test of PLS with LSI

These tests are required in order to check that the safety

devices are functioning correctly and are properly integrated

into the machine/plant control, as well as to reveal any

alterations or manipulations in the system.

The following instructions must be observed to ensure

regulation use:

The units must be installed and connected only by qualified

personnel. “Qualified” means personnel trained and

experienced in operation of the power-driven machinery being

checked, and familiar with the relevant statutory work safety

and accident prevention regulations, standards and generally

accepted technical rules (e.g. DIN standards, VDE rules,

technical standards and regulations of other EU states) such

that they are able to assess the operational safety of the

power-driven machinery concerned. Such personnel are

usually qualified employees of the manufacturers of non-

contact protective devices, or personnel who have undergone

training by the manufacturers of such devices, are primarily

engaged in testing of non-contact protective devices and have

been commissioned to carry out the work by the company

operating the devices.

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1. Pre-commissioning test of the machine protective

device by qualified personnel:

- The pre-commissioning test confirms compliance with the

safety requirements laid down in the national and

international regulations, in particular machinery and

equipment use directives (EC Declaration of Conformity).

- Test of the effectiveness of the protective device on the

machine in all modes in which the machine is capable of

operating, based on the enclosed checklist.

- The operating personnel of the machine protected by the

protective device must be instructed by specialist

personnel of the machine operating company before

beginning work. The said instruction is the responsibility of

the machine operating company.

Test your LSI system using the checklist reproduced in

section 6.2.

2. Routine testing of the protective device by qualified

personnel:

- Test based on national regulations, at the intervals they

stipulate. These tests serve to reveal modification or

manipulations of the protective device relative to the initial

commissioning stage.

- The tests must be conducted any time major modifications

are made to the machine or the protective device, as well

as whenever resetting or repair work is carried out in the

event of damage to the housing, front screen, connecting

cables, etc.

Test your LSI system using the checklist reproduced in

section 6.2.

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8 008 308/M848/06-05-02 Operating Instructions · LSI

3. Daily testing of the protective device by authorised and

instructed personnel:

To test your LSI system correctly:

1. The test must be carried out for the relevant preset

monitoring case.

2. Check the mechanical installation to ensure that all

mounting screws are secure and that the PLS is properly

aligned.

3. Check each PLS unit for visible changes, such as damage,

manipulation etc.

4. Switch on the machine/plant.

5. Watch the LEDs on each PLS (red, green, yellow).

6. If at least one LED is not permanently lit when the

machine/plant is switched on, it is to be assumed that there

is a fault in the machine or plant. In this case the machine

must be shut down immediately and checked by a

specialist.

7. Deliberately obstruct the protective field without risk to any

personnel while the machine is running in order to test the

effectiveness of the entire system. The LEDs of each

tested PLS unit must change from green to red and the

hazardous movement must stop immediately. Repeat this

test at different points in the danger area and on all PLS

units. If you discover any non-conformance of this function,

the machine/plant must be shut down immediately and

checked by a specialist.

8. For stationary applications, check that the danger area

marked out on the floor matches the shape of the

protective field stored in the PLS

and that any gaps are

protected by additional safety measures. In the case of

mobile applications, check that the moving vehicle actually

stops at the field limits which are set in the LSI and listed

on the data plate in the vehicle or in the configuration

protocol. If you discover any non-conformance of this

function, the machine/plant/vehicle must be stopped

immediately and checked by a specialist.

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9. This test replaces the test specified in the PLS Technical

Description / Operating Instructions.

Note for the operator

The instructions concerning daily checking are also

provided in the form of a self-adhesive label. Please affix

the label in an easily readable location near the safety

device in order to facilitate the daily checking procedure.

6.2 Checklist

Checklist for machine manufacturer/installer for the

installation of Electro Sensitive Protective Equipment

(ESPE)

.

Dependent upon the application, the below listed checks are a

minimum when placing an ESPE in operation for the first

time.

For reference purposes the list should be retained or stored

with the machine documents.

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1. Are the relevant safety standards incorporated into the

machine build? Will they satisfy the Regulations

?

Yes o No o

2. Are the standards listed in the Declaration of Conformity?

Yes o No o

3. Is the ESPE the correct Type and interfaced to the correct

Category

? Yes o No o

4. Is access to the danger zone / point of danger only possible

through the ESPE

? Yes o No o

5.

Are measures in place to prevent standing between the

ESPE and the danger zone? If so, are these measures

secured against removal

?Yes o No o

6. Are all monitoring cases, which can be selected by way of the

LSI designed such, that the measures in place as set out

under item 5 remain effective

?Yes o No o

7.

Are the mechanical means positioned to avoid reaching over,

under or around? (see EN294)

?

Yes o No o

8.

Has the overall machine stopping time been checked and

documented

? Yes o No o

9.

Is the resultant safety distance observed between the danger

point and the ESPE

?Yes o No o

10. Is the ESPE correctly fixed and secured against movement

after setting in its fixed position

?

Yes o No o

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11. Are the required protection measures against electric shock

in place

? Yes o No o

12. Are the signals for switching monitoring cases for inputs A, B,

C, D of the LSI two-channel (for more details see section 8.2,

LSI Technical Description)

? Yes o No o

13. Is the re-set / re-start switch for the ESPE installed and fitted

to the correct standard

?Yes o No o

14.

Are the OSSDs of the ESPE connected in accordance with

the machine circuit diagram

? Yes o No o

15. Have the protective functions been inspected in accordance

with the inspection instructions of this document

?

Yes o No o

16. Are the switching elements controlled by the ESPE, e. g.

contactors, valves monitored

?Yes o No o

17. Is the ESPE effective during the entire hazardous state?

Yes o No o

18. Is the Daily Check Requirement sign positioned in a place

visible to the operator

?Yes o No o

This checklist does not replace the initial commissioning or

regular inspections by qualified personnel

.

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