10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230 40 250 260 270 280 290 300 310 320 330 340 350 360 370 380 390 400 410 420 430 40 450 460 470 480 490 500 510 520 530 540 550 560 570 580 590 600 610 620 630 640 650 660 670 680 690 700 710 720 730 740 750 760 770 780 790 800 810 820 830 8 40 850 860 870 880 890 900 910 920 930 940 950 960 970 980 990 1000 1010 1020 030 1040 1050 1060 1070 1X080 1090 1100 1110 1120 1130 1140 1150 1160 1170 1180 1190 1200 1210 1220 1230 1240 1250 1260 1270 1280 1290 1300 1310 1320 1330 1340 1350 1360 1370 1380 1390 1400 1410 1420 2430 1440 1450 1460 Installation and Operation Manual POLARIS D I G I TA L L A S E R S E N S O R S Please read and observe! Keep this manual for future reference © LAP GmbH, MAN-1104 Rev 2.6-en-GB, 2015-01 Translation of the original POLARIS Laser sensor 10 400 All brand names and product names are trademarks or registered trademarks of the respective title holder © LAP GmbH Laser Applikationen,1999 The reproduction, distribution and utilisation of this document as well as the communication of its contents to others without express authorisation are prohibited Offenders will be held liable for the payment of damages All rights reserved in the event of the grant of a patent, utility model or design This document is intended to be used by the owner of the LAP product, its users and contractual partners of LAP It must not be handed to other persons or made available to third parties This document is subject to a document content service and subject to change without prior notice LAP GmbH can assume no liability for the correctness, completeness or up-to-dateness of any laws, regulations or guidelines (e.g DIN, VDE, ) referenced directly or indirectly or quotes taken from such sources in this publication We recommend that the complete regulation or guideline in the latest valid version be consulted for work to be carried out, where applicable Subject to technical changes This product complies with European statutory regulations and the requirements of the European directives These directives are listed in the accompanying EC declaration of conformity © LAP GmbH, MAN-1104 Rev 2.6-en-GB, 2015-01 POLARIS Laser sensor 10 400 Table of contents General information 1.1 About this document 1.2 Validity 1.3 Styles and conventions 1.4 1.3.1 Safety instructions 1.3.2 Warning and information symbols 1.3.3 Markups Intended use Safety instructions 10 2.1 General safety instructions 10 2.2 Safety instructions on the mechanical system 11 2.3 Safety instructions on electrical equipment 11 2.4 Safety instructions on lasers 11 2.4.1 Safety instructions on Laser Class 12 2.4.2 Safety instructions for Laser Class 3R 12 2.4.3 Safety instructions for Laser Class 3B 13 2.5 Notes on the EMC Directive 14 2.6 Employer's liability insurance association regulations 15 2.7 Underlying regulations 15 Goods receipt, transport, storage 16 3.1 Goods receipt 16 3.2 Transport .16 3.3 Storage 17 3.3.1 Devices 17 3.3.2 Data medium 18 Technical description 19 4.1 4.2 4.3 The laser system in use .19 4.1.1 Operating principle .19 4.1.2 Thickness measurement using two laser sensors .21 4.1.3 Converting the sensor value to a measured value .22 4.1.4 Dimensions 23 4.1.5 Technical data 24 4.1.6 Model overview 25 Outputs 25 4.2.1 Description of the outputs 25 4.2.2 Data output format 26 4.2.3 Cable/Connector pin assignment 27 4.2.4 Function of LEDs 28 Operating modes 29 © LAP GmbH, MAN-1104 Rev.2.6-en-GB, 2015-01 POLARIS Laser sensor 10 400 4.3.1 Single mode 29 4.3.2 Master-slave mode .29 4.3.3 Multiplex mode .30 Installation 31 5.1 General information .31 5.2 Cabling 31 Initial start-up 33 6.1 Use of the diagnostic and parametrisation tool 33 6.1.1 Scaling the measured values .33 Adjustment and calibration 35 7.1 Laser sensor holder of the laser system .35 7.1.1 View and structure 35 7.1.2 Operating principle .36 Operation 37 Care and maintenance 38 10 9.1 Care and maintenance of the system 38 9.2 Care and maintenance of the windows .38 9.3 Maintenance by LAP 38 Troubleshooting 40 10.1 Remedying of faults .41 11 Repair 42 12 Packaging/intermediate storage 43 13 Dismounting/disposal 44 14 Optional accessories .45 14.1 14.2 Parametrisation set of the laser system 45 14.1.1 DP-SOFT 45 14.1.2 Power supply unit for the laser sensor 45 14.1.3 RS485-USB converter 45 Interface modules 45 Annex A: Labelling of the POLARIS laser sensors .46 Annex B: Declaration of conformity .47 Annex C: Return sheet 49 Annex D: Addresses .51 Annex E: Glossary 52 List of figures 57 Index 58 © LAP GmbH, MAN-1104 Rev 2.6-en-GB, 2015-01 POLARIS Laser sensor 10 400 General information 1.1 About this document Dear customer, This document is designed to help you put your new LAP product to the best possible use By observing the information in this document you can avoid potential dangers and extend your product's service life The product has been designed and constructed according to the state of the art, and prior to delivery it has been checked thoroughly for proper functionality It may be used only as intended Improper use of the system will terminate all warranty claims The owner alone is responsible for the risk and any damage or injury This document is a component of the product Keep the document in a designated location close to the product for easy reference If the equipment is moved to a different operating location make sure the document is transferred as well Read this document carefully prior to installing and using this product! Keep this document in a designated location close to the product for easy reference All persons working on or with this product must have read and understood the relevant sections of the manual, and in particular the chapter "Safety instructions" The instructions must be observed The owner must also inform his/her staff about potential dangers The owner must ensure that the document has been understood This is the best way to ensure that the user is as safe as possible This document is intended for use by persons with the following knowledge: • Qualified technician, mechatronics engineer or similar qualification • Instruction in laser technology If you not have the requisite knowledge, you should ask qualified persons or persons who have received appropriate instruction for assistance The most important terms used in this document are explained in the glossary To effectively use the device, refer to the accompanying software and the functional description of the DP-SOFT © LAP GmbH, MAN-1104 Rev.2.6-en-GB, 2015-01 POLARIS Laser sensor 10 400 diagnostic and parametrisation tool, hereinafter "diagnostic and parametrisation tool" Ensure that the version of the parametrisation tool is at least equal to or higher than the firmware version of the laser sensor used The version number is defined as follows: Example: 2.3.1.26 Firmware version (see laser sensor documentation) = mechanics revision, = electronics revision If you have advanced questions about the content of this operation manual or handling of the device, please contact your dealer or the regional partner of LAP The addresses and contact data of the regional LAP partners are listed in the annex Possible modifications to this product made by users are not subject to the manufacturer's control Therefore, always check whether the information in this documentation matches the actual product technology before operating or using the device In case of deviations or unclear issues, please contact us immediately This is in your own interest as well The instructions given to you by LAP service staff take precedence over this document We aim to continuously improve the quality of our documentation If you have any questions or requirements with regard to this document, please contact us at techdoc@lap-laser.com 1.2 Validity This document is valid for: • POLARIS Laser sensor 10 400 © LAP GmbH, MAN-1104 Rev 2.6-en-GB, 2015-01 POLARIS Laser sensor 10 400 1.3 Styles and conventions This chapter describes conventions as used in this operation manual Read this chapter to make it easier for you to use this operation manual 1.3.1 Safety instructions This operation manual uses a multi-level system to notify the reader of different degrees of hazards DANGER Cause of the danger Signals that death or severe physical harm will result if the specified precautions are not observed WARNING Cause of the danger Signals that death or severe physical harm may result if the specified precautions are not observed CAUTION Cause of the danger Signals, that minor physical injury may result if the specified precautions are not observed Notice Signals that property damage can occur or indicates important information on handling the product or important sections of the document © LAP GmbH, MAN-1104 Rev.2.6-en-GB, 2015-01 POLARIS Laser sensor 10 400 1.3.2 Warning and information symbols In addition to the general danger symbols, we also use the following pictograms in this operation manual in order to point out specific hazards DANGER Electric voltage Signals danger to life or limb with permanent physical damage due to electric voltage WARNING Laser beams Signals physical harm with permanent physical damage due to laser beams Please also note the following information symbols: Manufacturer Fragile, handle with care! Serial number of the devices Keep dry! Do not dispose of the device with regular domestic waste We offer a return service Please refer to the return sheet in the annex 1.3.3 Markups We use the following markups in this operation manual: Markup ● Bulleted list General list or instruction in no particular order Numbered list Operating steps which need to be performed in the order listed Tab 1-1: Usage Markups © LAP GmbH, MAN-1104 Rev 2.6-en-GB, 2015-01 POLARIS Laser sensor 10 400 1.4 Intended use POLARIS laser sensors are used to measure the distance or the thickness of standing or moving objects They can be installed permanently in or on a machine or building structures directly using the bracket provided Any other use is not permitted The owner bears sole responsibility for the consequences of improper use Intended use also includes adhering to our instructions regarding installation, removal, commissioning, operation, maintenance and disposal of the system The operating staff must immediately notify the owner or his/her representative of any safety-relevant changes to the system As a basic rule, any intended changes to the device must be approved in writing by LAP © LAP GmbH, MAN-1104 Rev.2.6-en-GB, 2015-01 POLARIS Laser sensor 10 400 Safety instructions 2.1 General safety instructions Safety instructions are intended to ensure occupational health and safety and the prevention of accidents They must be heeded In order to protect you and your colleagues against injury, we need your co-operation, too Therefore be careful at work all the times Always be aware that dangers are usually "not obvious" In order to ensure safe operation, the owner must make sure that the persons working on or with the device are informed about the possible dangers of laser radiation Only qualified authorised personnel who have received appropriate instruction may work with/on the laser system described in this manual The person who operates this laser system must have read and understood the relevant sections of the operation manual A copy of this operation manual must always be kept in a designated location close to where the laser system is used Safety-relevant changes to the laser system must be reported immediately to the persons responsible The user must make sure that unauthorised persons remain outside the work area of the laser system Users, fitters and maintenance technicians must be given instruction on all safety-relevant aspects of the laser system by the owner on a regular basis The same applies to safety regulations that are to be observed at the user's premises and are not included in this operation manual The applicable national and local safety regulations as well as the safety regulations of the user must be strictly observed when operating or making interventions in the system If a malfunction occurs, the laser beam may stray outside the designated zone Use only accessories approved by LAP Steps have been taken at the development stage to ensure maximum protection of the user through the design of the laser and integrated safety devices However, this does not relieve the user of the obligation to observe his/her general duty of care 10 © LAP GmbH, MAN-1104 Rev 2.6-en-GB, 2015-01 POLARIS Laser sensor 10 400 14 Optional accessories 14.1 Parametrisation set of the laser system Besides the power supply unit for the power supply of the laser sensor, the parametrisation set includes a converter which is looped in between the laser sensor and the computer via a 9-pin D-Sub extension cable 14.1.1 DP-SOFT This software is used to set the parameters 14.1.2 Power supply unit for the laser sensor Fig 14-1: 14.1.3 Power supply unit for the laser sensor RS485-USB converter The converter can be utilised up to 921.6 kBd Higher baud rates are possible if interface cards (PCI or PCMCIA) are used (see also chapter 14.2) Fig 14-2: Converter The cable from the laser sensor is connected on the RS485 side The USB side goes to the computer The two LEDs in the converter indicate data traffic 14.2 Interface modules Interface modules available from LAP are used to easily integrate the POLARIS laser sensors into the respective application environment For detailed information, please refer to the respective operation manuals © LAP GmbH, MAN-1104 Rev.2.6-en-GB, 2015-01 45 POLARIS Laser sensor 10 400 Annex A: Labelling of the POLARIS laser sensors CAUTION Risk of injury due to illegible symbols As time passes, stickers and signs may become soiled or unrecognisable for other reasons with the result that the user will not be aware of potential dangers and will not be able follow the necessary instructions for operation This poses a risk of injury Make sure all safety, warning and operating instructions are clearly legible at all times Replace damaged signs or stickers immediately You can obtain replacements from LAP GmbH Technical Service; see Annex D: on page 51 46 Fig A-1: Type plate (example) Fig A-2: Warning label for laser radiation (example) © LAP GmbH, MAN-1104 Rev 2.6-en-GB, 2015-01 POLARIS Laser sensor 10 400 Annex B: Declaration of conformity © LAP GmbH, MAN-1104 Rev.2.6-en-GB, 2015-01 47 POLARIS Laser sensor 10 400 Annex C: Return sheet Return sheet for free disposal of electric and electronic equipment within the meaning of Directive 2002/96/EC (WEEE) You want to dispose of your electric or electronic equipment manufactured by LAP? LAP GmbH takes back and disposes of electric and electronic equipment within the meaning of Directive 2002/96/EC within the European Union and bears the resulting costs The following requirements must be met for returning a device: Inform LAP GmbH about your disposal request You can notify LAP GmbH about your disposal request by phone +49 (0)4131/951195, by fax +49 (0) 4131/951196 or by e-mail to info@lap-laser.com Discuss with LAP GmbH how and when you wish to return your device Unannounced returns cannot be accepted The old device must be returned to LAP GmbH in complete condition If this is not the case, consult LAP GmbH regarding further action to be taken When returning a product, you must attach the completed return sheet Please send the return to the following address: LAP GmbH Laser Applikationen Rücknahme WEEE Zeppelinstrasse 23 21337 Lüneburg Germany Please provide us with the following data: Serial number of the product Address of the returner Company name Street and number Postal code and city Tab C-1: Return information _ Date, signature and company stamp of the sender of the return © LAP GmbH, MAN-1104 Rev.2.6-en-GB, 2015-01 49 POLARIS Laser sensor 10 400 50 © LAP GmbH, MAN-1104 Rev 2.6-en-GB, 2015-01 POLARIS Laser sensor 10 400 Annex D: Addresses Headquarters, support for Europe, Russia, South America and Africa: LAP GmbH Laser Applikationen Zeppelinstr 23 21337 Lüneburg Germany Phone: +49 (0)4131 9511-95 Fax: +49 (0)4131 9511-96 Fax Technical Service: +49 (0)4131 9511-396 E-mail: info@lap-laser.com E-mail Technical Service: service@lap-laser.com Website: www.lap-laser.com Support for North America: LAP Laser LLC 1830 Airport Exchange Blvd Suite 110 Erlanger, KY 41018 USA Phone: +1 (513) 271-4529 Fax: +1 (513) 271-3821 E-mail: info-us@lap-laser.com Support for Asia and Australia: LAP Laser Applications Asia Pacific Pte Ltd Block 750 A Chai Chee Road # 07-07 Technopark @ Chai Chee Singapore 469001 Phone: +65 6536 9990 Fax: +65 6533 6697 E-mail: info-asia@lap-laser.com © LAP GmbH, MAN-1104 Rev.2.6-en-GB, 2015-01 51 POLARIS Laser sensor 10 400 Annex E: Glossary Adjustment An adjustment is carried out to achieve the greatest possible agreement between an actual value and the corresponding target value The objective is to reduce the measured deviation using the test equipment ASCII Abbreviation for "American Standard Code for Information Interchange" Widely used character encoding, originally bit ASCII-coded files are an extremely convenient way in which to exchange data as a large number of programmes can process this code A disadvantage of this code is that it does not support all special symbols for specific languages Calibration Determination of systematic deviation between the test equipment and the target value With LAP products, calibration also involves adjustment in most cases CE The manufacturer documents its full conformity with legal regulations with the CE label COM port COM port is the designation for the serial interface of a PC This RSUSB/V.24 interface is usually accessible via a 9-pole D-Sub plug Decoder A decoder receives a digital data stream from an encoder The decoder uses this data stream to generate the original signal Device A device is an individual component of a larger system There may be only one device DSP Abbreviation for "digital signal processor" Hardware module that serves the continuous processing of digital data flows (e.g audio and video signals) 52 © LAP GmbH, MAN-1104 Rev 2.6-en-GB, 2015-01 POLARIS Laser sensor 10 400 EMC Abbreviation for "electromagnetic compatibility" EMC tests are performed to ensure that the electromagnetic waves emitted by different devices not cause them to interfere with one another To this end, both the stray radiation transmitted by a device and the device's own susceptibility to foreign stray radiation are minimised Emitted interference Many electronic devices internally use clock signals and other signals changing over time Because all alternating currents generate electromagnetic waves, this can cause disturbances for other devices During the design phase of a device, it is therefore an issue to generate as little disturbance as possible Encoder An encoder converts the signal of a data source in a digital data stream into a defined format This digital data stream is transferred to a decoder Ethernet Ethernet is a common network technology standardised in IEEE 802.3 Ethernet supports different cabling technologies and speeds Firmware Firmware consists of digital data loaded in hardware (mainly special modules such as FPGAs or DSPs) The firmware defines the hardware's range of functions Hardware Hardware refers to the physical mechanical components of a device as opposed to the 'non-physical' firmware and software stored in the memory components Hardware is defined as the existing mechanical components of a device, as opposed to firmware and software which are integrated in the memory chips but are not visible Interference resistance Electromagnetic waves from very different sources can generate interference in the electrical conductors of devices This interference can trigger malfunctions When a device is developed, it is therefore important that shielding and other means be provided to prevent the interference from triggering a malfunction Interlock © LAP GmbH, MAN-1104 Rev.2.6-en-GB, 2015-01 53 POLARIS Laser sensor 10 400 An interlock is a switching device that automatically renders a device harmless when it is opened This could involve the stopping of engines or the deactivation of radiation sources, for example International Protection Rating Classification of devices as defined in the EN 60529 standard which states the protection rating against the ingress of solid objects and water The "IPxx" classification indicates the protection with two digits The first digit states the degree of protection against solid objects, the second states the degree of protection against water The higher the number, the higher the protection rating IP Abbreviation for "Internet Protocol" The Internet Protocol serves as switchboard layer of the OSI model in the TCP/IP protocol LED Abbreviation for "light-emitting diode" In LEDs light is generated in the semiconductor junction LEDs produce the light substantially more efficiently than incandescent lamps and are very robust Maintenance technician Maintenance providers are persons appointed by the owner of the device to maintain the same Offset An offset is a fixed default value by which a zero position is displaced Operating personnel Operating personnel are persons appointed by the owner of the device to operate the same Owner The owner is any natural or legal person who uses the device either himself/herself or on whose behalf the device is used The owner can appoint another person who exercises his/her rights and responsibilities Qualified staff Qualified staff are persons who, due to specialised training and their experience, have sufficient knowledge of a spe54 © LAP GmbH, MAN-1104 Rev 2.6-en-GB, 2015-01 POLARIS Laser sensor 10 400 cific subject field and are familiar with the relevant regulations on industrial safety and accident prevention as well as with the generally accepted technical rules RS485 The RS485 standard defines a data bus system with one or two core pairs on which serial data can be exchanged between different devices A RS485 bus must be terminated at both ends Software Software consists of digital data, which, as opposed to firmware, are not an integral part of the hardware SynchroNet Data transmission method developed by LAP The method uses an RS485 bus on which data can be exchanged via a token-based protocol System A larger installation consisting of multiple devices is referred to as a system in the document TCP Abbreviation for "Transmission Control Protocol" This is one of the protocols used for data transfer on the Internet In contrast to UDP, TCP establishes a fixed logical connection in order to secure the transfer of data Top hat rail A top hat rail is a U-shaped mounting rail Devices can be mounted by sliding on or engagement to a top hat rail Top hat rails are often used in control cabinets and support relays and other electromechanical parts there UDP Abbreviation for "User Datagram Protocol" This is one of the protocols used for data transfer on the Internet In contrast to TCP, UDP does not establish a fixed logical connection The transfer of data must be secured by the application, as a result very little bandwidth is required by UDP for the management data USB USB is a serial bus system for connection of a computer with external components USB supports "hot plugging", © LAP GmbH, MAN-1104 Rev.2.6-en-GB, 2015-01 55 POLARIS Laser sensor 10 400 i.e devices can be connected or disconnected while the computer is in operation User Users are persons authorised by the owner to operate the device 56 © LAP GmbH, MAN-1104 Rev 2.6-en-GB, 2015-01 POLARIS Laser sensor 10 400 List of figures Fig 2-1: Laser warning sign class (example) 12 Fig 4-1: Measuring principle (diagram) 20 Fig 7-1: Laser sensor holder 35 Fig 7-2: Dimensioned drawing for laser sensor holder 36 Fig 9-1: Inspection sticker 39 Fig 14-1: Power supply unit for the laser sensor 45 Fig 14-2: Converter 45 Fig A-1: Type plate (example) 46 Fig A-2: Warning label for laser radiation (example) 46 © LAP GmbH, MAN-1104 Rev.2.6-en-GB, 2015-01 57 POLARIS Laser sensor 10 400 Index A F Addresses 51 Firmware 53 Adjustment 35, 52 Function of LEDs 28, 31 ASCII 52 G C Glossary 52 Cable/Connector pin assignment 27 Goods receipt 16 Calibration 35, 52 H Care 38 Hardware 53 System 38 I Care and maintenance 38 Information symbols CE 52 Initial start-up 33 COM port 52 Installation 31 Converting the sensor value into a measured value 22 Cabling 31 General information 31 D Intended use Data output format 26 Interface modules 45 Declaration of conformity 47 Interference resistance 53 Decoder 52 Interlock 53 Description of the outputs 25 Intermediate storage 43 Device 52 International Protection Rating 54 Dimensions 23 IP 54 Dismounting 44 L Disposal 44 Labelling 46 packaging 16 Documentation, validity DP-SOFT 45 DSP 52 E Laser class Safety instructions 12 Laser class 3B Safety instructions 13 Laser class 3R EMC 14, 53 Safety instructions 12 Emitted interference 53 Laser sensor holder 35 Employer's liability insurance association regulations 15 Laser system Encoder 53 Ethernet 53 technical data 24 Use 19 LED 54 58 © LAP GmbH, MAN-1104 Rev 2.6-en-GB, 2015-01 POLARIS Laser sensor 10 400 List of figures 57 RS485 55 M RS485-USB converter 45 Maintenance 38 S System 38 Safety instructions 7, 10 Maintenance by LAP 38 Single mode 29 Maintenance technician 54 Software 55 Markups Standards 15 Master-slave mode 29 Storage 17 Model overview 25 Structure 35 Multiplex mode 30 SynchroNet 55 O System 55 Offset 54 T Operating modes 29 Target group Operating personnel 54 TCP 55 Operating principle 19, 36 Technical description 19 Operation 37 Temperature equalisation 16 Optional accessories 45 Outputs 25 Thickness measurement using two laser sensors 21 Owner 54 Top hat rail 55 P Transport 16 Packaging 43 Troubleshooting 40 Parametrisation set 45 U Power supply unit 45 UDP 55 Q USB 55 Qualifications of user Use of the diagnostic and parametrisation tool 33 Qualified staff 54 R Remedying of faults 41 Repair 42 Requirements 15 User 56 V View 35 W Warning symbols Return sheet 49 © LAP GmbH, MAN-1104 Rev.2.6-en-GB, 2015-01 59