S3000 in a Narrow Aisle and S3000 Anti Collision

Transcription

1 OPERATING INSTRUCTIONS S3000 in a Narrow Aisle and Safety laser scanners en

2 Operating instructions This document is protected by the law of copyright, whereby all rights established therein remain with the company SICK AG. Any duplication of this document or of parts thereof is only permitted within the bounds of the statutory provisions of the German Copyright Law. Alteration or abridgement of the document is not permitted without the explicit written approval of the company SICK AG. 2 SICK AG Industrial Safety Systems Germany All rights reserved /

3 Operating instructions Contents Contents 1 About this document Scope of the document Scope of the individual chapters For your safety Regulations to be observed Correct use Product description S Planning the protective fields for the detection of persons Example for determining the permissible play on the industrial truck Dimensioning of the protective field Required protective field length Required protective field width Example for protective field configuration Example for usable protective field length and stopping distance Example for protective field configuration for single-sided narrow aisle situation Product description Product identification Product features of the Field types Field modes Interfaces, inputs and outputs Application examples Example of usage of monitoring case switching Two collision protection fields in combination with the Drive Monitor Entrance and exit from the narrow aisle Planning the collision protection Position of the on the vehicle Using the as a reference target Using the reflectors as a reference target Attaching the reference targets Dimensioning of the collision protection field Necessary collision protection field length Required collision protection field width Integrating in the electrical control Installation and mounting Scope of delivery Installing the Mounting the reflectors Preparing for mounting Bonding the reflector Preliminary tests on the adhesive strength / SICK AG Industrial Safety Systems Germany All rights reserved 3

4 Contents Operating instructions 8 Electrical installation Pin assignment for the I/O module of the Configuration Configuration of all S3000 variants in the narrow aisle Application variant Restart Protective fields Configuration of the Application variant Resolution Angular resolution/basic response time Field mode Drawing collision protection fields Commissioning Protective field Test object Driving trials to test the protective field Collision protection field Checking the system Operation Maintenance Maintenance of all S3000 variants Maintenance of the Reference targets Scan plane of the Technical specifications Ordering information Available systems of the Accessories/spare parts for the S3000 in a narrow aisle Mounting kits System plug Service cables Self assembly connecting cables Network solutions Miscellaneous Expanded system solution with Flexi Soft Annex List of tables List of illustrations SICK AG Industrial Safety Systems Germany All rights reserved /

5 Operating instructions Chapter 1 About this document 1 About this document This document is an original document. 1.1 Scope of the document Note These operating instructions apply to all S3000 safety laser scanners in narrow aisle applications as per section 2.2 Correct use on page 6. These operating instructions are also applicable to the safety laser scanner with the following entry on the type label in the field Operating Instructions: This document is the English edition of the operating instructions Sicherheits-Laserscanner S3000 im Schmalgang und with SICK part number This document describes only the boundary conditions to be observed on the usage of the S3000 in a narrow aisle as well as on the usage of the in a narrow aisle with collision protection field. These operating instructions do not describe the properties of the S3000. These operating instructions only apply in conjunction with the original operating instructions S3000 Safety Laser Scanner (SICK part number , S3000 Safety Laser Scanner operating instructions in all available languages). For the configuration and diagnostics of these devices you require CDS (Configuration & Diagnostic Software) version or higher. 1.2 Scope of the individual chapters Some of the chapters in these operating instructions are applicable to all S3000 in narrow aisle applications, some only to the. Tab. 1: Scope of the individual chapters No. Chapter Valid for all S3000 variants Valid for S3000 Anti Collision 1 About this document 5 2 For your safety 6 3 Product description S Planning the protective fields for the detection of persons 9 5 Product description S3000 Anti Collision 6 Planning the collision protection Page Installation and mounting 38 8 Electrical installation S3000 Anti Collision 40 9 Configuration Commissioning Operation Maintenance Technical specifications Ordering information / SICK AG Industrial Safety Systems Germany All rights reserved 5

6 Chapter 2 For your safety Operating instructions 2 For your safety 2.1 Regulations to be observed Along with the requirements stated in these operating instructions and the operating instructions for the S3000, the following documents from the responsible trade association for retail and goods logistics (Berufsgenossenschaft Handel und Warenlogistik, BGHW) are to be followed: 1. Empfehlungen für die Prüfung von Personenschutzsystemen an Flurförderzeugen für die Regalbedienung in Schmalgängen (Recommendations for the testing of personnel protection systems on conveyor equipment employed for rack service work in narrow aisles) 2. Check list for the protection of personnel in narrow aisles 3. Personenschutz beim Einsatz von Flurförderzeugen in Schmalgängen (Protection of persons on the usage of industrial vehicles in narrow aisles) Can be obtained from Document 1 can be downloaded from the Internet at The documents 2 and 3 can be obtained from the BGHW: BGHW Direktion Mannheim M5, Mannheim phone: 0621/183-0 fax: 0621/ info@bghw.de Correct use The is an item of protective equipment for the protection of persons: type 3 according to IEC SIL2 according to IEC category 3 as well as PL d according to EN ISO SILCL2 according to EN The is also used to prevent collisions between vehicles. The S3000 safety laser scanner is suitable for use on industrial trucks in narrow aisles. Taking into account document 3 in section 2.1 Regulations to be observed on page 6, usage is also possible on the correct simultaneous presence in a narrow aisle of pedestrians and industrial trucks for accessing shelving. 6 SICK AG Industrial Safety Systems Germany All rights reserved /

7 For your safety Operating instructions Chapter 2 Miscellaneous The following notes relate to the mounting and the operation of the S3000, as per the work safety regulations Flurförderzeuge (Industrial trucks) (BGV D27) as well as DIN 15185, part 2. These regulations include, among other aspects: DIN defines that if the S3000 is shut down as the industrial truck leaves the narrow aisle, this end of aisle shutdown must correspond as a minimum to category 2 as per EN ISO The point for the shut down must be selected such that the path covered with the S3000 deactivated is as short as possible. The application-specific boundary conditions such as aisle width, aisle length, speed (maximum 2.5 km/h) and if necessary other criteria must be taken into account. After the vehicle has reentered a narrow aisle, the S3000 must be switched back on automatically. There must not be any crossing aisles in the narrow aisles. Crossing aisles that are only provided as an emergency exit route for the operators are excluded from this requirement. The speed of the industrial truck must be reduced to creep speed (maximum 2.5 km/h) before leaving the narrow aisle, or the industrial truck must be stopped without intervention by the operator. This statement also applies on approaching the end of an aisle. If the S3000 is bypassed by the driver, only creep speed is allowed. For operation with high availability, goods must not protrude beyond the front of the shelf in the narrow aisle after storage. Otherwise operation with acceptable availability of the industrial truck is not possible with the stipulated distance for the protective field and front of the shelf. In addition, at these heights retroreflectors are not permitted. If the end of aisle detection is triggered using photoelectric switches with reflectors, the reflectors that are necessary on the entrances and exits to the narrow aisle are exempted from this rule. The protective field dimensions allowed for the protection of narrow aisles as given in section in Fig. 4 on page 11 and in section in Tab. 2 on page 13. The guide play on the industrial truck as well as the vertical play on the scan plane of the S3000 have a crucial impact on the reliability of detection and availability of the overall system. The maximum permissible angular error relative to the symmetrical middle position for the industrial truck defines the guide play in the narrow aisle and is ±0.3. This aspect is to be taken into account on dimensioning the protective fields (see section 4.2 on page 10). The related value pairs for the distance between the guide elements for the industrial truck and maximum play per guide element are given in section 4.1, Fig. 1 on page / SICK AG Industrial Safety Systems Germany All rights reserved 7

8 Chapter 3 Product description S3000 Operating instructions 3 Product description S3000 You will find the product description for S3000 variants in the underlying operating instructions S3000 Safety Laser Scanner (SICK part number ). You will find the product description for the in chapter 5 on page SICK AG Industrial Safety Systems Germany All rights reserved /

9 Planning the protective fields for the detection of persons Operating instructions Chapter 4 4 Planning the protective fields for the detection of persons Note In principle all S3000 variants can fulfill the function of the detection of persons in a narrow aisle application using a protective field. It is a prerequisite that they achieve the protective field range calculated in this chapter. If you use the, you must also undertake the planning steps described in this chapter. Fig. 1: Maximum permissible play per guide element. Magnitude as a function of the distance between the guide elements on the stacker in the direction of travel for the maximum permissible angular error of ± Example for determining the permissible play on the industrial truck At a distance between the guide elements on the industrial truck of 1.8 m, the maximum permissible play per guide element is ±0.5 cm (see Fig. 1). The calculation is based on the maximum angular error for the guide play of = ±0.3. Determination of the guide play at the vehicle: for mechanical guides: If the guide elements on the left are in contact with the guide rail (0 cm play) the distance between the elements on the right and the rail is allowed to be a maximum of cm = 1 cm. for inductive guides: The industrial truck is allowed to diverge from the guide line by a maximum of ±0.5 cm. Max. play per guide element [cm] Distance between the guide elements on the stacker in the direction of travel [cm] / SICK AG Industrial Safety Systems Germany All rights reserved 9

10 Chapter 4 Fig. 2: Dimensioning of the protective field Planning the protective fields for the detection of persons 4.2 Dimensioning of the protective field Operating instructions The size of the protective field is defined by means of: the length of the protective field at which the industrial truck comes to a standstill under all conditions before the load or the vehicle contour come into contact with people. The maximum protective field radii of up to 4.0 m (S3000 with short-range sensor head), up to 5.5 m (S3000 with medium-range sensor head), or up to 7.0 m (S3000 with longrange sensor head) can be programmed. the protective field width at which people or the test object in accordance with Fig. 3 are reliably detected in the boundary area in front of the shelf. The unmonitored area of width D PF Shelf (see Fig. 2) between the protective field and the front of the shelf is necessary due to the angular error on the industrial truck and the measuring accuracy of the S3000 and should be as small as possible (see section on page 13). Definitive for the dimensions of the protective field is the final test on the reliability of detection in accordance with section 10 Commissioning on page 45. D PF Shelf Max. protective field radius W PFleft Protective field length L PF X S3000 Shelf S3000 Shelf Vehicle Shelf Guide rail Y X Guide rail 10 SICK AG Industrial Safety Systems Germany All rights reserved /

11 Operating instructions Chapter 4 Planning the protective fields for the detection of persons Fig. 3: Test object and positioning X TO Shelf 120 mm Front of shelf 70 mm 700 mm 400 mm Z X Guide rail Notes During the design of the protective field ensure the field is adequate to prevent a hazard. Note that the CDS function Protective field suggestion is unsuitable due to the random actual position of the vehicle in the aisle and the yaw motion of the vehicle as it moves along the aisle. All S3000 variants provide the required resolution of 70 mm at the maximum protective field radius. In this way the detection capability is also ensured for the bottom part of the test object Required protective field length During the determination of the necessary protective field length by driving trials, the parameters are to be set in the vehicle to produce the longest stopping distance. As a rule these are: the maximum speed that can be achieved the maximum load to be expected and the maximum load dimensions to be expected unevenness on the floor that could affect the stopping distance Carry out the driving trials as per section Driving trials to test the protective field on page 45. The stopping distance L Stop comprises the distance covered during the response time of the S3000 as per the operating instructions, the response time of the controller and the braking distance. Determine the stopping distance with action of the protective field only / SICK AG Industrial Safety Systems Germany All rights reserved 11

12 Chapter 4 Planning the protective fields for the detection of persons Operating instructions The length of the protective field to be programmed L PF is to be calculated as follows: L PF = L Stop L Fork + V PFL Where: L Stop = Maximum stopping distance 1.1 = Supplement R 10% of the stopping distance for wear on the brakes L Fork = Fork length or maximum distance from the mounting position for the S3000 to the front edge of the load V PFL = Value for the supplement to the protective field length from Tab. 2 This value takes into account: the measurement error on the S3000 compensation for greater distance between the middle of the test object and the front of the shelf X TO Shelf with increasing aisle width, see Fig. 3, to suit the supplement rule. The supplement rule states that for each centimeter that the test object is displaced from its original position (X TO Shelf = 12.5 cm) in the direction of the middle of the narrow aisle, a supplement of 20 cm must be applied to the protective field length. The maximum distance from the middle of the test object to the front of the shelf that can be assumed is 20 cm (X TO Shelf = maximum 20 cm). The maximum permissible protective field lengths as a function of the distance from the middle of the S3000 to the front of the empty shelf (X S3000 Shelf, see Fig. 2) are defined in Tab. 2 on page 14 and shown in Fig. 4. The usable protective field length L PFuse is defined by the maximum protective field length L PFmax after deducting the value for the supplement to the protective field length V PFL. L PFuse = L PFmax V PFL 12 SICK AG Industrial Safety Systems Germany All rights reserved /

13 Planning the protective fields for the detection of persons Operating instructions Chapter 4 Fig. 4: Maximum and usable protective field length as a function of the position of the safety laser scanner X S3000 Shelf U L PFmax = Maximum protective field length V< L PFuse = Usable protective field length It is shown in gray in Fig. 4 (cf. Tab. 2): L PFmax (white), L PFuse (gray) 800 (cm) Narrow aisle protection Restart Without time delay Narrow aisle protection Restart Time delayed after 2 s Single-sided narrow aisle protection: Restart Without time delay 0 E < X < X < X < X < X < X 400 Position of the safety laser scanner X S3000 Shelf (cm) Required protective field width The distance D PF Shelf between the protective field and the front of the shelf to be programmed is given in Tab. 2 as a function of distance X S3000 Shelf from the middle of the S3000 to the front of the empty shelf. The distances X S3000 Shelf are to be calculated or measured for an industrial truck in the middle of the narrow aisle with an angular error of 0 for the left and right protective field width. The necessary supplements for the value determined can be read in Tab. 2. If the S3000 is mounted off center on the industrial truck the larger supplements V PFW for the wider half of the protective field are to be used. The protective field distances D PF Shelf are to be used correspondingly for the left and right width. The left or right protective field width, W PFleft or W PFright, is defined from Tab. 2 using the following formula: W PFleft or W PFright = X S3000 Shelf D PF Shelf (see Fig. 2) / SICK AG Industrial Safety Systems Germany All rights reserved 13

14 Chapter 4 Planning the protective fields for the detection of persons Operating instructions Tab. 2: Distance between protective field and front of shelf Distance middle of S3000 to front of shelf X S3000 Shelf [cm] < < < 250 Type of restart Without time delay Time delayed after 2 s Distance test object X TO Shelf [cm] Maximum protective field length L PFmax [cm] Value for the supplement to the protective field length V PFL [cm] Usable protective field length L PFuse [cm] Protective field length L PF [cm] Protective field distance to front of shelf D PF Shelf [cm] W L PFmax Example for protective field configuration stopping distance L Stop = 350 cm, fork length L Fork = 120 cm off-center mounting of the S3000 on the industrial truck: distance on left from S3000 front of shelf X S3000 Shelf = 100 cm distance on right from S3000 front of shelf X S3000 Shelf = 120 cm The test object must be detected at the following distance from the front of the shelf: in front of the shelf on the left at a distance X TO Shelf = 15 cm in front of the shelf on the right at a distance X TO Shelf = 16 cm required protective field width W PF : Depending on the protective field length L PF, 4 to 8 corner points must be programmed, see Tab. 3. For examples for protective field lengths 0 cm and 100 cm, see Tab. 4 and Tab. 5: left protective field width: W PFleft = X S3000 Shelf D PF Shelf = = 90.5 cm right protective field width: W PFright = X S3000 Shelf D PF Shelf = = cm required protective field length L PF : left half of the protective field: L PFleft = L Stop L Fork + V PFL(100 cm) = = 575 cm right half of the protective field: L PFright = L Stop L Fork + V PFL(150 cm) = = 595 cm The larger value is to be used for the right half of the protective field L PF = 595 cm. The maximum permissible protective field length for the right half of the protective field is L PFmax = 680 cm, see Tab SICK AG Industrial Safety Systems Germany All rights reserved /

15 Planning the protective fields for the detection of persons Operating instructions Chapter 4 Fig. 5: Corner points During the configuration of the S3000 using the user software CDS (see section 9.1 Configuration of all S3000 variants in the narrow aisle on page 42), the application variant Mobile is to be set. If it is not possible to program a permissible corner point because the maximum permissible protective field length L PFmax or the maximum measuring radius of 700 cm is exceeded, then with a constant X value, reduce the Y position until a permissible value W L PFmax is achieved. The programmed protective field length and width must always be larger or equal to that required. The protective field width on the right or left can, if necessary, be changed by slightly moving the S3000 transverse to the direction of travel of the industrial truck and as a result the necessary protective field length then programmed. On the entry of corner points (X/Y) in CDS the values must be rounded to the next largest safety-related value. For the left corner point close to the vehicle this rounding produces X = 91 cm instead of 90.5 cm as well as Y = 0 cm. For the left corner point away from the vehicle this rounding produces X = 92 cm, instead of 91.5 cm and Y = 595 cm. Corner point away from the vehicle Corner point close to the vehicle Y X For this example the permissible and programmable co-ordinates for the protective field corner points are summarized in Tab. 3 and Tab / SICK AG Industrial Safety Systems Germany All rights reserved 15

16 Chapter 4 Planning the protective fields for the detection of persons Operating instructions Tab. 3: Example values for the left half of the protective field Entries in CDS Values realized by CDS Protective field length [cm] X S3000 Shelf + D PF Shelf [cm] Position X [cm] Position Y [cm] = = = = Tab. 4: Examples values for the right half of the protective field Protective field length [cm] Entries in CDS X S3000 Shelf D PF Shelf [cm] Position X [cm] Values realized by CDS Position Y = [cm] = = = Example for usable protective field length and stopping distance fork length L Fork = 200 cm distance S3000 front of shelf X S3000 Shelf = 150 cm As per Tab. 2 the useable protective field length is: L PFuse =L PFmax V PFL = 680 cm 90 cm = 590 cm From the usable protective field length L PFuse, after the deduction of the fork length and based on the maximum stopping distance of the industrial truck for the narrow aisle width given, including the response time of the safety laser scanner and controller and the factor for brake wear of 1.1, the following is found: L Stop W (L PFuse L Fork ) : 1.1 W (590 cm 200 cm) : 1.1 W cm 16 SICK AG Industrial Safety Systems Germany All rights reserved /

17 Planning the protective fields for the detection of persons Operating instructions Chapter 4 Tab. 5: Maximum protective field length for single-sided narrow aisle situation Example for protective field configuration for single-sided narrow aisle situation In applications with a single-sided narrow aisle situation (see Fig. 6), the S3000 can be programmed on the open side to have a half protective field width of W 7 m. The maximum protective field lengths allowed outside a narrow aisle reduce to values defined in Tab. 5 and shown in Fig. 4 due to the resolution of the S3000. Maximum protective field length [cm] Half protective field width W [cm] 690 B W < B W < B W < B W < B W < B W < B < 400 Fig. 6: Industrial truck with single sided narrow aisle situation Depending on the distance from the S3000 to the front of the shelf, the supplement V PFL is to be added to the necessary protective field length as per Tab. 2. A supplement of V PFW = 10.0 cm is to be added to the necessary protective field width on the open side. This supplement takes into account the maximum measurement error on the S3000 and is independent of the protective field length. D PF Shelf away from vehicle Protective field width < 700 cm Supplement to the protective field width V PFW = 10.0 cm Protective field length L PF < 700 cm D PF Shelf close to vehicle Max. protective field radius Shelf Vehicle Guide rail Y X / SICK AG Industrial Safety Systems Germany All rights reserved 17

18 Chapter 4 Planning the protective fields for the detection of persons Example width of the industrial truck = 320 cm stopping distance L Stop = 200 cm off-center mounting of the S3000 on the industrial truck distance on left from S3000 front of shelf X S3000 Shelf = 60 cm right distance S3000 right vehicle contour X S3000 VCright = 270 cm required protective field width W PF left protective field width, as per section and Tab. 2 on page 14: W PFleft =X S3000 Shelf D PF Shelf = 60 cm 9.5 cm = 50.5 cm for protective field length 0 cm and 100 cm Operating instructions W PFleft =X S3000 Shelf D PF Shelf = 60 cm 8.5 cm = 51.5 cm for protective field length 200 cm and L PFmax right protective field width: W PFright =X S3000 VCright + V PFW = 270 cm cm = 280 cm required protective field length L PF left half of the protective field: L PF =L Stop V PFL(100 cm) = 200 cm cm = 290 cm For V PFL refer to Tab. 2. right half of the protective field: In a one-sided narrow aisle situation the protective field length on the side of the vehicle facing the shelf is to be used. In this case the value for the left half of the protective field is to be used. checking the protective field dimensions left half of the protective field: The maximum permissible protective field length for the left half of the protective field is L PFmax = 690 cm in accordance with Tab. 5 and is therefore larger than the example value required of 290 cm. right half of the protective field: The maximum permissible protective field length for a width on the right of 280 cm is L PFmax = 630 cm in accordance with Tab. 5 and is therefore larger than the example value required of 290 cm. 18 SICK AG Industrial Safety Systems Germany All rights reserved /

19 Product description S3000 Anti Collision Operating instructions Chapter 5 5 Product description The content of this chapter is exclusively for the with the type identifier S30A-7021EK. The also has safe collision protection fields in addition to the protective field. With these collision protection fields the safely detects vehicles that are equipped with a reference target. Fig. 7: Position of the type label 5.1 Product identification You can identify the using its type label. Type label Label Fig. 8: Type label of the The following points identify the : type code: S30A-7021EK ident no.: label: ANTI COLLISION by SICK / SICK AG Industrial Safety Systems Germany All rights reserved 19

20 Chapter 5 Product description S3000 Anti Collision 5.2 Product features of the Operating instructions protective field range 7 m collision protection field range 15 m dual field mode with field sets consisting of protective field and collision protection field (optional simultaneous monitoring of two field sets) triple field mode with field sets consisting of one protective field and two collision protection fields 16 field sets in dual field mode 10 field sets in triple field mode 32 monitoring cases for switching the field sets. In this way, for example protection fields and collision protection fields can be activated to suit the speed, the load state, the position of the center of gravity etc. Limitations There is no compatibility with other S3000 variants. (The cannot be replaced with a different variant.) There is no interoperability with other S3000 variants. (The can form a host-guest group only with other S3000 Anti Collision, however not with other S3000 variants or with the safety laser scanners S300 or S300 Mini.) Usage only with EFI partners, e.g. the Flexi Soft safety controller The must be used in conjunction with an EFI partner, for example the Flexi Soft safety controller. The status of the collision protection fields must be output via EFI and must, e.g., be forwarded via a Flexi Soft safety controller to the vehicle controller for safe shutdown. As the Flexi Soft safety controller provides several safe outputs, up to four fields can be evaluated independently per. The also receives input information for switching the monitoring cases from the Flexi Soft safety controller. 20 SICK AG Industrial Safety Systems Germany All rights reserved /

21 Operating instructions Chapter Field types Product description S3000 Anti Collision WARNING Never use the collision protection field to detect people! The collision protection field prevents collisions between vehicles. The detection of people is only ensured by the protective field on the safety laser scanner. The safety laser scanner has the field types protective field and collision protection field. Warning fields are not available. Fig. 9: Protective field and collision protection field Collision protection field With the aid of the collision protection field the safely detects other industrial trucks that are equipped with corresponding reference targets. The reference target is used to establish defined optical conditions in an otherwise variable environment. If the collision protection field is infringed, the speed of the vehicles can be reduced or the vehicles can be stopped. In this way a collision between two vehicles in the narrow aisle can be prevented. A hazard for the operating personnel is prevented in this way. Shelf Oncoming vehicle (fields not drawn completely) Reference target Collision protection field Protective field Vehicle / SICK AG Industrial Safety Systems Germany All rights reserved 21

22 Chapter 5 Fig. 10: Field modes of the (example arrangement of the field geometries) Product description S3000 Anti Collision Field modes Operating instructions The safety laser scanner has the following field modes: dual field mode consisting of protective field and collision protection field triple field mode consisting of a protective field and two collision protection fields Collision protection field Collision protection field 2 Collision protection field 1 Protective field Protective field Dual field mode Triple field mode Fig. 11: Simultaneous monitoring on the S3000 Anti Collision (example arrangement of the field geometries) Simultaneous monitoring Simultaneous monitoring is only possible in the dual field mode. With simultaneous monitoring the monitors two field sets each with a protective field and a collision protection field. Simultaneous collision protection field Collision protection field Simultaneous protective field Protective field Dual field mode with simultaneous monitoring Field set Simultaneous field set 22 SICK AG Industrial Safety Systems Germany All rights reserved /

23 Product description S3000 Anti Collision Operating instructions Chapter Interfaces, inputs and outputs The has the following interfaces (see also operating instructions of the S3000 safety laser scanner, part no ): safe bus interface via enhanced function interface (EFI) for transferring the status of the protective field and collision protection field to the Flexi Soft safety controller for switching the monitoring cases OSSDs (can only be used for protective fields) external device monitoring (EDM) input reset input 3 universal outputs RS-422 interface for output of measured data incl. CMS reflector detection (see Telegram Listing CMS, part no ). Note 5.3 Application examples You will find a detailed description of the monitoring case switching in the underlying operating instructions S3000 Safety Laser Scanner (SICK part number ) Example of usage of monitoring case switching Fig. 12: Speed-dependent monitoring case switching Using speed-dependent monitoring case switching the protective fields and collision protection fields are activated to suit the stopping distance of the vehicle. The stopping distance is defined by, among other aspects, the speed and the height of the load (risk of tipping). The vehicle controller safely recognizes these parameters and forwards the actual operational situation to the Flexi Soft safety controller. The Flexi Soft safety controller forwards the switching information to the S3000 Anti Collision. This activates the monitoring case for the actual speed. Given a corresponding collision protection field configuration, only the hazardous area monitored that corresponds to the actual stopping distance is monitored. Fast movement with large fields Slow movement with smaller fields / SICK AG Industrial Safety Systems Germany All rights reserved 23

24 Chapter 5 Fig. 13: Usage of two collision protection fields Product description S3000 Anti Collision Operating instructions Two collision protection fields in combination with the Drive Monitor If two collision protection fields are used (e.g. in the triple field mode), then monitoring case switching in combination with the Drive Monitor in the Flexi Soft safety controller makes it possible to prevent vehicle wear. If the collision protection field is infringed, the speed can be reduced in steps. If the front collision protection field is infringed, the related signal is used in the vehicle controller to reduce the speed. The speed is recognized safely and continuously by the Drive Monitor in the Flexi Soft safety controller. Due to the low speed the switches to a monitoring case with shorter field lengths. If the collision protection field is then clear, the vehicle can continue to move. If the collision protection field is still infringed, the speed can be reduced even further. If the reduction of the speed is not sufficient, the collision protection field close to the vehicle is infringed and an emergency stop initiated. Front collision protection field infringed Reducing the speed results in a clear collision protection field 24 SICK AG Industrial Safety Systems Germany All rights reserved /

25 Product description S3000 Anti Collision Operating instructions Chapter 5 Fig. 14: Driving out of the narrow aisle Entrance and exit from the narrow aisle On driving out of the aisle a 15 m long collision protection field or a 7 m long protective field can result in unintentional field infringements and as a consequence in the loss of availability. The same applies on approaching a wall. As per DIN the vehicle must automatically detect the approach of the end of the aisle and automatically reduce the speed to creep speed (maximum 2.5 km/h). The speed change is safely recognized by the Drive Monitor in the Flexi Soft modular safety controller and forwarded to the. Due to the low speed, the switches to a monitoring case with shorter field lengths. On driving into the narrow aisle a monitoring case with correspondingly dimensioned protective and collision protection fields must be activated by the controller. Fast movement with large fields Slow movement with smaller fields / SICK AG Industrial Safety Systems Germany All rights reserved 25

26 Chapter 6 Planning the collision protection Operating instructions 6 Planning the collision protection Note WARNING The content of this chapter only applies to the safety laser scanner with type identifier S30A-7021EK. Only use the collision protection field on the in narrow aisle applications! Only if the following prerequisites are met is the correct function of the collision protection field ensured: The vehicles always approach each other head-on (the collision protection field function is not designed for one-sided narrow aisle operation, as described in section from page 17). A is correctly mounted on all vehicles in both directions of movement (see section 6.1 on page 27). If the reference target is not recognized by the, detection of the vehicle may be delayed and as a result a collision may occur! Make sure the following prerequisites are met: The reference targets are correctly mounted on all vehicles in both directions of movement. If all safety laser scanners are on the same scan plane, the can be used as a reference target (see section 6.2 on page 28). If this is not the case, then use the reflectors supplied as the reference target (see section 6.3 on page 28). The collision protection fields are adequately dimensioned (see section 6.4 on page 31). Notes When driving forwards the lifting device (fork) must be raised sufficiently such that the protective field of the is unoccupied. Please observe the work safety regulations BGV D27 12, sections 2 and 3. The characteristics of the floor (in particular the unevenness and the inclinations) in the narrow aisle area must satisfy the requirements of the VDMA guideline Floors for use with VNA Trucks (Sept. 2010). In this way the overlap between the scan plane of the safety laser scanner and the reference targets is ensured independent of the position and direction of movement of the vehicles. 26 SICK AG Industrial Safety Systems Germany All rights reserved /

27 Operating instructions Chapter 6 Fig. 15: Scan plane Planning the collision protection 6.1 Position of the on the vehicle Max. ±0.1 Max. 200 mm J 50 mm To ensure the detection of the oncoming vehicle, the scan plane must be at the same height as the reference target on the other vehicles (see Fig. 17 on page 29). This must be the case independent of the distance between the vehicles. For this purpose the following prerequisites must be met: During the mounting and alignment of the the scan plane must be parallel to the floor surface. A maximum divergence of ±0.1 is allowed. The scan plane is allowed to be at a maximum height of 200 mm, as the S3000 Anti Collision is also used for the detection of people. In this way persons lying down will be reliably detected. We recommend aligning the scan plane at 150 mm. On each vehicle there must be at least one reference target mounted in both directions of movement at the height of the scan plane of the mounted on the other vehicles. The itself can also be used as a reference target (see section 6.2 on page 28). How to position the : If possible use a common mounting height for all. If this is not possible, fit a separate reference target for each scan plane in the application. Mount the bottom edge of the housing at least 50 mm above the floor. In this way you will increase the availability if there is pitching motion on the industrial truck (see section 7.2 on page 38) / SICK AG Industrial Safety Systems Germany All rights reserved 27

28 Chapter 6 Fig. 16: Front screen of the safety laser scanner Planning the collision protection Operating instructions 6.2 Using the as a reference target The S3000 safety laser scanner 1) can be used as a reference target due to its optical reflectance properties. For this purpose the following prerequisites must be met: All safety laser scanners are mounted at the same height on all vehicles. The front screen on the safety laser scanner is completely clear and not partially covered, for example by a mask. Mask Front screen unoccupied Front screen partially covered Note If these prerequisites are not met, a reflector must be used as the reference target (see section 6.3 on page 28)! 6.3 Using the reflectors as a reference target WARNING Only use the reflectors supplied by SICK! To achieve the required reflected values it must be ensured that the reflector supplied by SICK is used. With different reflectors the reflection behavior may be inadequate and therefore the collision protection function rendered ineffective! The reflectors must be fitted in the correct position. The reflectors must be correctly fastened. If the collision protection function is active, the reflectors must not be covered. The reflectors are not allowed to be cut, folded or reduced in size by any other means. The reflectors must be undamaged and must not be dirty. 1) Only an S3000 safety laser scanner can be used as a reference target. The safety laser scanners S300 and S300 Mini are not suitable! 28 SICK AG Industrial Safety Systems Germany All rights reserved /

29 Planning the collision protection Operating instructions Chapter 6 Fig. 17: Reflectors at the height of the laser output Attaching the reference targets As the scan planes are aligned parallel to the floor (see Fig. 15 on page 27), you must mount the reflectors at the height of the laser output on the safety laser scanner. Height of the laser output Reflector Attach the reference targets as follows: perpendicular to the direction of travel of the vehicle as far forward as possible on the vehicle. In this way you will avoid large supplements to the necessary collision protection field. The middle of the reflector must be at the height of the laser output on the safety laser scanner. The reflector is not allowed to be attached rotated in steps of less than 90 (Fig. 17). Fig. 18: Reference target mounted further to the rear Reference targets mounted further to the rear With reference targets mounted further to the rear there is a risk that parts of the vehicle or protruding parts of the load will cover the reference target. If reference targets are mounted further to the rear, it must be ensured that a reference target still remains visible for the oncoming. Fig. 18 shows as an example the covered area and the areas in which there is no covering. Area with no covering Covered area Max. length of the collision protection field If it is not possible to avoid covering, then if necessary attach additional reference targets outside the covered area / SICK AG Industrial Safety Systems Germany All rights reserved 29

30 Chapter 6 Planning the collision protection Second reference target Operating instructions In certain cases additional reference targets must be attached to ensure that at least one reference target is visible in every situation. Possible cases are: Note If the reference target can only be attached on a surface of the vehicle that is to the rear of the safety laser scanner (see Fig. 18 on page 29) and the reference target may be covered. If safety laser scanners are used at different heights in a narrow aisle application, then reference targets must be attached for each of these heights. If it is possible to attach two reference targets, then in general we recommend fitting more than one reflector on the front of each vehicle. Position of the reference targets on the front of a vehicle The position of the reference targets on industrial trucks must be selected centrally such that despite a reduced collision protection field width and the yaw motions of the vehicle (± ), the target is always detected at the front of the collision protection field. Fig. 19: Attachment area W CPF = Width of the collision protection field D CPF Shelf D CPF Shelf W CPF MX RT MX RT L CPF tan X VEmiddle Z X L CPF tan Using the following formula you can determine the area in which the reference target must be attached: [X RT = (½ W Aisle ) D CPF Shelf + (L CPF tan ) (½ W RT ) X VEmiddle Where [X RT = The outer boundary of the area in which the reference targets must be attached W Aisle = Aisle width D CPF Shelf = Distance between the edge of the collision protection field and the front of the shelf L CPF = Length of the collision protection field tan = Angular error (see section 4.1 on page 9) W RT = Reference target width = Middle of the vehicle relative to the middle of the aisle X VEmiddle 30 SICK AG Industrial Safety Systems Germany All rights reserved /

31 Planning the collision protection Operating instructions Chapter 6 Fig. 20: Size of the collision protection field 6.4 Dimensioning of the collision protection field The collision protection field must be designed such that two vehicles approaching each other head-on are braked in good time. The size of the collision protection field is defined by the following properties: the collision protection field length at which the industrial truck comes to a standstill in all conditions before the load or the vehicle comes into contact with the oncoming vehicle or its load. the collision protection field width at which the reference targets on the oncoming vehicle are safely detected. W CPF Max. scanning range of the collision protection field D CPF Shelf L CPF Shelf Shelf Y X The unmonitored area of the width D CPF Shelf between the collision protection field and the front of shelf in Fig. 20 is necessary due to the angular error on the industrial truck as well as the measuring accuracy of the and should be as small as possible / SICK AG Industrial Safety Systems Germany All rights reserved 31

32 Chapter 6 Planning the collision protection Necessary collision protection field length Operating instructions WARNING Determination of the stopping distance by means of driving trials The results of the driving trials in section page 11 can be used to determine the stopping distance for the collision protection field. This is the case if the same braking reaction is triggered independent of the triggering field (protective field/collision protection field). During the determination of the stopping distance by means of driving trials, set the parameters on the vehicle that produce the longest stopping distance. As a rule these will be the following parameters: the maximum achievable speed on both vehicles the maximum load to be expected the maximum dimension to be expected for the load Carry out the following driving trials: at least 5 : driving forward at least 5 : driving backward Calculating the stopping distance Take into account the longest stopping distance over all vehicles! During the calculation of the stopping distance, the longest stopping distance of all the vehicles in use is to be selected. The design of the collision protection field depends on the stopping distance of the oncoming vehicle. If vehicles are added to the facility at a later date, their stopping distance is to be checked. If this stopping distance is greater than the previous longest stopping distance, the collision protection fields on all vehicles are to be modified appropriately. Fig. 21: Dimensioning the length of the collision protection field The stopping distance L Stop comprises the following distances: the distance covered during the response time of the S3000 as per the operating instructions the distance covered during the response time of the control the braking distance L CPF X Y L Fork L RT 32 SICK AG Industrial Safety Systems Germany All rights reserved /

33 Planning the collision protection Operating instructions Chapter 6 Calculate the length of the collision protection field as follows: L CPF = 2 (L Stop 1.1) + L RT + L Fork + V CPF Note Where L CPF = Length of the collision protection field L Stop = Maximum stopping distance for the braking mechanism triggered by the collision protection field (for each of the vehicles involved) 1.1 = Supplement R 10% of the stopping distance for wear on the brakes L RT = Maximum distance from the reference target to the front edge of the load 2) L Fork = Fork length or maximum distance from the mounting position for the S3000 to the front edge of the load 2) V CPF = Value for the supplement to the collision protection field length due to the measuring error of the S3000 (100 mm) Further supplements, as would be necessary for the detection of people, are not required. Example for the collision protection field length stopping distance L Stop = 3500 mm fork length L Fork = 1200 mm reference target mounted further to the rear L RT = 1400 mm Required collision protection field length L CPF L CPF = 2 (L Stop 1.1) + L RT + L Fork + V CPF = 2 (3500 mm 1,1) mm mm mm = 10,400 mm 2) The maximum value for all vehicles operating in the application must be used / SICK AG Industrial Safety Systems Germany All rights reserved 33

34 Chapter 6 Fig. 22: Dimensioning the width of the collision protection field Planning the collision protection Required collision protection field width Operating instructions To ensure the high availability of the systems, along with the protective fields the collision protection fields should also not fill the entire width of the aisle. In this way it is avoided that adjacent shelf structures are recognized by the collision protection field due to the yaw motion of the vehicle. The minimum width of the collision protection field must be selected such that even in the event of yaw motion due to the angular error the reference target on the oncoming vehicle is recognized by the front of the collision protection field. D CPF Shelf W CPF W CPFleft W CPFright L CPF X S3000 Shelf X RT Shelf Y X 34 SICK AG Industrial Safety Systems Germany All rights reserved /

35 Planning the collision protection Operating instructions Chapter 6 From the minimum distance that occurs between the reference target and shelf (in the entire application) X RT Shelf and the maximum lateral offset on the collision protection field in the event of yaw motion L CPF tan the maximum distance between the outer edge of the collision protection field and the D CPF Shelf can be derived (see Fig. 19 on page 30): D CPF Shelf = X RT Shelf L CPF tan The collision protection field must be dimensioned such that on the exact alignment of the vehicle along the axis of the aisle, the distance from the collision protection field to the shelf does not exceed this value (A CPF Shelf ). The left or right part of the collision protection field width W CPFleft or W CPFright is given by the following formula: W CPFleft or W CPFright = X S3000 Shelf D CPF Shelf Where W CPFleft or W CPFright = Left or right part of the collision protection field width 3) X S3000 Shelf D CPF Shelf X RT Shelf = Distance from the central axis of the 4) to the shelf = Distance of the collision protection field from the shelf = Distance middle of reference target to front of shelf Example for collision protection field width Off-center mounting of the S3000 on the industrial truck: distance on left from S3000 front of shelf X S3000 Shelf = 1000 mm distance on right from S3000 front of shelf X S3000 Shelf = 1200 mm mounting position of the reference target in relation to the shelf X RT Shelf = 400 mm (symmetrical attachment of two reference targets) required collision protection field length from section = 10,400 mm tan = tan(0.3 ) Required collision protection field width W CPF W CPFleft = (X S3000 Shelf X RT Shelf + L CPF tan ) = (1000 mm 400 mm + 10,400 mm tan(0,3 )) = (1000 mm 400 mm + 55 mm) = 655 mm 5) W CPFright = X S3000 Shelf X RT Shelf + L CPF tan = 1200 mm 400 mm + 10,400 mm tan(0,3 ) = 1200 mm 400 mm + 55 mm = 855 mm 5) 3) 4) 5) As seen from the safety laser scanner, in the direction of travel. With vehicle in the middle of the aisle. With these values the distance between the collision protection field and the shelf is 345 mm on both sides / SICK AG Industrial Safety Systems Germany All rights reserved 35

36 Chapter 6 Fig. 23: in combination with a Flexi Soft safety controller Planning the collision protection 6.5 Integrating in the electrical control Operating instructions To integrate the in the control you will need, in addition to the information in these operating instructions, information from the following documents: Flexi Soft Modular Safety Controller Hardware operating instructions Flexi Soft Designer Software operating instructions operating instructions of the vehicle controller The status of the protective fields and the collision protection fields must be output via EFI and forwarded by a Flexi Soft safety controller to the vehicle controller for safe shutdown. As the Flexi Soft safety controller provides several safe outputs, up to four fields can be evaluated independently per. The also receives input information for switching the monitoring cases from the Flexi Soft safety controller. 36 SICK AG Industrial Safety Systems Germany All rights reserved /

37 Planning the collision protection Operating instructions Chapter 6 Fig. 24: in combination with a Flexi Soft safety controller with Drive Monitor Note The cut-off path for the protective field can also be connected to the local OSSD pair on the safety laser scanner / SICK AG Industrial Safety Systems Germany All rights reserved 37

38 Chapter 7 Installation and mounting Operating instructions 7 Installation and mounting 7.1 Scope of delivery The is supplied as follows: sensor head with I/O module mounted operating instructions and CDS (Configuration & Diagnostic Software) on DVD adhesive label with note on the daily check 6 reflectors for collision protection 7.2 Installing the The following points are to be noted when mounting the S3000: For reasons of availability (pitching movements of the industrial truck) the bottom edge of the S3000 housing should be at least H S3000 = 50 mm above the floor. The scan plane must also be parallel to the floor surface. The scan plane is allowed to be maximum 200 mm high. In this way persons lying down will be reliably detected. We recommend aligning the scan plane at 150 mm. 7.3 Mounting the reflectors WARNING Only use the reflectors supplied by SICK! To achieve the required reflected values it must be ensured that the reflector supplied by SICK is used. If you use different reflectors, the reflection behavior may be inadequate and therefore the collision protection function rendered ineffective! Reference targets must always be fully bonded and visible. Cutting the reflector or partial covering is not allowed and can cause loss of detection capability. Only new reflectors are allowed to be used! The renewed usage of a reflector already bonded once can result in the reflector falling off during operation and as a consequence in the loss of the detection capability. Prevent damage, loss or covering! Damage, loss or covering the reflector can result in the loss of the detection capability. Bond the reflectors to a flat surface perpendicular to the direction of travel and so they are straight! Attaching at an angle can cause the loss of detection capability. 38 SICK AG Industrial Safety Systems Germany All rights reserved /

39 Installation and mounting Operating instructions Chapter Preparing for mounting Only bond the reflector if the temperature of the mounting surface and the ambient air is in range from 15 to 38 C. Clean the surface to be bonded. If necessary, remove any residual dust, oil or grease using isopropanol, acetone or other cleaning agents that do not leave any residue on the surface. The surface must be dry before bonding Bonding the reflector Bond the reflector on a firm surface as flat as possible, preferably an unpainted aluminum surface or a stainless steel surface. Do not bond the reflector over rivets, beading or seams. As far as possible chose a protected position on the vehicle where the reflectors cannot be damaged, lost or covered. If you bond a reflector to a painted surface, make sure that the surface structure is as smooth as possible and the paint used is free of silicone. Ideally, carry out preliminary tests (see section on page 39). If you bond reflectors to a surface already painted, then we recommend using two reflectors on the front of each vehicle for safety reasons. How to bond the reflectors in place: The reflector is self-adhesive. After removing the protective film, quickly bond the reflector to the surface and press on hard and so there are no air bubbles (use squeegee or hand roller, contact pressure > 20 N/cm 2 ) Preliminary tests on the adhesive strength On poor backgrounds or on unknown paints, we recommend undertaking preliminary tests to determine the adhesion of the reference target. For this purpose bond a reference target as a sample and wait at least 24 hours. Then test the adhesive strength on this sample. If the reference target can be removed undamaged from the surface, the adhesive strength is inadequate. Using a carrier plate If the adhesive strength is inadequate, use an unpainted carrier plate made of aluminum or stainless steel. Bond reference target to the carrier plate. Screw carrier plate to the vehicle / SICK AG Industrial Safety Systems Germany All rights reserved 39

40 Chapter 8 Electrical installation S3000 Anti Collision Operating instructions 8 Electrical installation WARNING Switch the entire machine/system off line! The machine/system could unintentionally start up while you are connecting the devices. Ensure that the entire machine/system is disconnected during the electrical installation. Tab. 6: Pin assignment for the I/O module of the S3000 Anti Collision 8.1 Pin assignment for the I/O module of the S3000 Anti Collision Pin Signal Function V DC Supply voltage 2 0 V DC Supply voltage 3 OSSD1 Output signal switching device 4 OSSD2 Output signal switching device 5 RESET Input, Reset 6 EDM Input, external device monitoring 7 UNI-O1/ERR Universal output resp. application diagnostic output or connection for a jumper for addressing as guest 6) 8 UNI-O2/RES_REQ Universal output, Reset required output 9 UNI-O3 Universal output 10 A1 Connection for a jumper for addressing as guest 6) n.c. Not assigned 14 EFI A Enhanced function interface = safe SICK device 15 EFI B communication n.c. Not assigned 25 RxD 26 RxD+ 27 TxD+ RS-422 interface for output of measured data 28 TxD 29 n.c. Not assigned 30 n.c. Not assigned 6) In an EFI system, a device must be defined as a guest using a jumper between pin 7 and pin 10. This is also necessary if several safety laser scanners are connected to one EFI string on a Flexi Soft safety controller. 40 SICK AG Industrial Safety Systems Germany All rights reserved /

41 Electrical installation S3000 Anti Collision Operating instructions Chapter 8 Notes WARNING Connect EFI A on the first device with EFI A on the second device and EFI B on the first device with EFI B on the second device. Always use screened twisted pair cables for EFI! If the length of the cable to the safety laser scanner is more than 30 m, the shield is to be connected as close as possible to the device. In an EFI system with two safety laser scanners, set the address of one of the scanners to guest! To differentiate unambiguously between the host and guest device in an EFI system, one must be configured as the guest. For this purpose a jumper is wired between the connection terminals 7 (ERR) and 10 (A1). The jumper always defines the guest device. This jumper is never allowed to be fitted on the host device / SICK AG Industrial Safety Systems Germany All rights reserved 41

42 Chapter 9 Configuration Operating instructions 9 Configuration Configure the S3000 with the aid of Flexi Soft Designer and CDS. Only the configuration steps specifically tailored to the narrow aisle application are described in this chapter. You will find a general description of the configuration in the underlying operating instructions S3000 Safety Laser Scanner (SICK part number ). 9.1 Configuration of all S3000 variants in the narrow aisle Application variant The usage in the narrow aisle must be configured in a mobile application. Choose application variant Mobile Restart Note In addition to the design of the restart as per the operating instructions S3000 Safety Laser Scanner the following is to be observed. If complete monitoring of the area in front of the industrial truck is available (see Tab. 2 on page 14), configure the type of restart as follows: Without a time delay if the maximum distance from the middle of the S3000 to the front of the shelf on the left or right is X S3000 Shelf W 150 cm. Time delayed by 2 s if the maximum distance from the middle of the S3000 to the front of the shelf on the left or right is 150 < X S3000 Shelf W 250 cm. With restart interlock if it is possible to stand behind the protective field in front of the industrial truck due to the mounting position of the S3000. Note that setting multiple sampling will have an effect on the response time of the safety laser scanner and therefore on the stopping distance of the industrial truck Protective fields Fig. 25: Protective field in the field set editor Draw protective fields in CDS in the field set editor. Change to the drawing mode for the protective field. The maximum protective field range is displayed. Change to the drawing mode for the protective field Protective field Protective field range Draw the protective field as per the results of the planning (see section 4.2 Dimensioning of the protective field on page 10). 42 SICK AG Industrial Safety Systems Germany All rights reserved /

43 Operating instructions Chapter 9 Configuration 9.2 Configuration of the Application variant For the the application variant Mobile is set and cannot be changed Resolution For usage in a narrow aisle the resolution Leg detection 70 mm should be selected Angular resolution/basic response time The angular resolution is set to The resulting basic response time of the is 120 ms Field mode Select Dual. You can draw field sets that comprise one protective field and one collision protection field. If necessary, activate Simultaneous monitoring. The monitors two field sets at the same time. Select Triple. You can draw field sets that comprise one protective field and two collision protection fields / SICK AG Industrial Safety Systems Germany All rights reserved 43

44 Chapter 9 Fig. 26: Collision protection field in the field set editor Configuration Drawing collision protection fields Operating instructions Draw the collision protection fields in CDS or in Flexi Soft Designer in the field set editor. Change to the drawing mode for the collision protection field. The maximum collision protection field range is displayed. Change to the drawing mode for the collision protection field Collision protection field Collision protection field range Draw the collision protection field as per the results of the planning (see section 6.4 Dimensioning of the collision protection field on page 31). The configured length and width of the collision protection field must always be greater than or equal to the size calculated during the planning. If it is not possible to configure a permissible corner point because the maximum permissible collision protection field length L CPFmax or the maximum collision protection field radius of 15 m is exceeded, then in the field editor reduce the Y position while the X value remains unchanged until a permissible value L CPFmax is achieved. The width on the right or left of the collision protection field can, if necessary, be changed by slightly moving the S3000 transverse to the direction of travel of the industrial truck and as a result the necessary length of the collision protection field then programmed. 44 SICK AG Industrial Safety Systems Germany All rights reserved /

45 Operating instructions Chapter Commissioning Commissioning 10.1 Protective field Test object Note The test object available as an accessory must be set up as per Fig. 3 and Tab. 2 for the driving trials on the detection reliability. The top edge of the test object must always be at a height of 70 cm above the floor. All S3000 variants provide the required resolution of 70 mm at the maximum protective field radius. As a result only the bottom cylindrical part of the test object is relevant Driving trials to test the protective field Before commissioning the industrial truck, ensure by means of driving trials that the test object is detected in the distance from the middle of the test object to the front of the shelf in accordance with Tab. 2 and an industrial truck stops in time under the conditions that result in the longest stopping distance. As a rule these are: the maximum speed that can be achieved the maximum load to be expected the maximum dimensions to be expected for the load Carry out the following driving trials: at least 5 : left front of shelf, driving forward at least 5 : left front of shelf, driving backward at least 5 : right front of shelf, driving forward at least 5 : right front of shelf, driving backward Documentation of the driving trials and settings is to be included in the test certificate required in accordance with the work safety regulations BGV D / SICK AG Industrial Safety Systems Germany All rights reserved 45

46 Chapter 10 Fig. 27: Checking the parallel alignment with the aid of the test object Commissioning 10.2 Collision protection field Operating instructions Prior to commissioning and at least once a year check the geometrical overlap on the collision protection fields. If wear occurs on the vehicle due to operation and this wear affects the alignment of the position of the scan plane (e.g. due to abrasion on the drive wheel), the intervals for the check must be reduced to suit the wear behavior. Check the correct alignment of the scan planes on all related safety laser scanners with collision protection function. The scan planes must meet the following prerequisites: The scan planes must be parallel to the floor. The scan planes must be at the same height as the reference targets attached (middle of the front screen = middle of the reference target, see section on page 29). Test equipment Reflector Checking using the test object for the collision protection For the test on the correct alignment of the the following prerequisites must be met: The area for the collision protection field in front of the vehicle must be clear. The 7-segment display on the must signal an unoccupied collision protection field (see Tab. 8 on page 48). Apart from the test object there must not be any other object (e.g. the person who is carrying out the test) in the collision protection field. How to carry out the check: Adjust the test object such that its reflector is at exactly the same height as the reference targets on the vehicles. Place the test object at the point furthest away in the collision protection field. Align the reflector on the test object perpendicular to the safety laser scanner. The safety laser scanner is correctly aligned if the status of the collision protection field changes and signals the presence of the test object. After removing the test object the collision protection field must return to the unoccupied status. Note Scan finder For the coarse localization of the scan plane the scan finder LS70b (part no ) can be used. 46 SICK AG Industrial Safety Systems Germany All rights reserved /

47 Commissioning Operating instructions Chapter 10 Fig. 28: Checking the reflector in the data recorder Data recorder in the CDS or in the Flexi Soft Designer Using the data recorder you can check in the measured scan contour whether the test object is recognized by the scan plane. You can identify the test object in the scan contour displayed by the turquoise color (in this way the data recorder indicates the particularly high signal received from the reflector material). Carry out the test over a distance as large as possible. In this way you will achieve a high level of accuracy during the check Checking the system To ensure reliable detection, check the following points at regular intervals: the mounting of the S3000 the guide play of the industrial truck the braking action of the industrial truck the inclination of the industrial truck (changes may be caused, e.g., by wheel wear) the presence and integrity of the reference targets on all vehicles / SICK AG Industrial Safety Systems Germany All rights reserved 47