User Manual

Original Instructions

SafeZone Mini Safety Laser Scanner

Catalog Number 442L-SFZNMN
Important User Information
Read this document and the documents listed in the additional resources section about installation, configuration, and
operation of this equipment before you install, configure, operate, or maintain this product. Users are required to
familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws,
and standards.

Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are
required to be carried out by suitably trained personnel in accordance with applicable code of practice.

If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may
be impaired.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from
the use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or
software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,
Inc., is prohibited

Throughout this manual, when necessary, we use notes to make you aware of safety considerations.

WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous
environment, which may lead to personal injury or death, property damage, or economic loss.

ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.

IMPORTANT Identifies information that is critical for successful application and understanding of the product.

Labels may also be on or inside the equipment to provide specific precautions.

SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.

BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.

ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).
 Table of Contents

Preface
Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Who Should Use This Manual? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Scope of Publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Depth of Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Chapter 1
Safety Qualified Safety Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Applications of the Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Correct Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
General Safety Notes and Protective Measures . . . . . . . . . . . . . . . . . . . 13
Environmental Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Separation of Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Applicable Directives and Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Application and Installation of Protective Devices. . . . . . . . . . . . 15

Chapter 2
Product Description Special Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Principle of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Field Set Comprising Protective and Warning Fields . . . . . . . . . 19
Contour Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Device Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Chapter 3
Configurable Functions System Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Application Name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Name of the Scanner. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
User Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Display Direction of the Seven-segment Display. . . . . . . . . . . . . . 26
Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Basic Response Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Maximum Protective Field Range . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Universal I/O Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Stand-by . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
OSSDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Internal OSSDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
External Device Monitoring (EDM) . . . . . . . . . . . . . . . . . . . . . . . . 29

Rockwell Automation Publication 442L-UM005B-EN-P - April 2017 3

Table of Contents

Restart of the SafeZone Mini Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Configuration without Restart Interlock . . . . . . . . . . . . . . . . . . . . 30
Restart Delay for Mobile Applications. . . . . . . . . . . . . . . . . . . . . . . 30
Configuration with Restart Interlock. . . . . . . . . . . . . . . . . . . . . . . . 31
Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Reset Signals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Field Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Configure the Protective and Warning Field . . . . . . . . . . . . . . . . . 33
Protective or Warning Field Suggested by the
Safety Laser Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Use the Contour as a Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Vertical Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Monitoring Cases . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Multiple Sampling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Stand-by Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Chapter 4
Mounting Mounting Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Stationary Application in Horizontal Operation . . . . . . . . . . . . . . . . . 40
Protective Field Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Stationary Application in Vertical Operation for
Access Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Minimum Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Stationary Application in Vertical Operation for
Hazardous Point Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Minimum Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Mobile Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Application Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Protective Field Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Protective Field Width. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Methods to Prevent Unprotected Areas . . . . . . . . . . . . . . . . . . . . . . . . . 53
Near Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Mounting Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Direct Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Mounting with Mounting Kit 1or 2. . . . . . . . . . . . . . . . . . . . . . . . . 57
Mounting with Mounting Kit 3 and 4. . . . . . . . . . . . . . . . . . . . . . . 58
Information Label Important Information. . . . . . . . . . . . . . . . . . . 58
Using Multiple Safety Laser Scanners. . . . . . . . . . . . . . . . . . . . . . . . 59

Chapter 5
Electrical Installation Electrical Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
System Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Wiring in Accordance with EMC Regulations . . . . . . . . . . . . . . . 63
Functional Earth . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Round Plug Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Configuration Connection M8 × 4 (Serial Interface). . . . . . . . . . . . . 64

4 Rockwell Automation Publication 442L-UM005B-EN-P - April 2017

 Table of Contents

Chapter 6
Application Examples and Stationary Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
Connection Diagrams Mobile Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Connection Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Restart Interlock and External Device Monitoring . . . . . . . . . . . 67
SI Guardmaster Safety Relay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Two SafeZone Mini Devices with DI Guardmaster
Safety Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Chapter 7
Configuration Default Delivery Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Prepare the Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Configuration with the SCD Software . . . . . . . . . . . . . . . . . . . . . . 69

Chapter 8
Commissioning Initial Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Power-up Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Test Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Inspection of the Protective Device . . . . . . . . . . . . . . . . . . . . . . . . . 73
Daily Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

Chapter 9
Maintenance and Care Clean Optics Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Optics Cover Cleaning Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Replace Optics Cover. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Optics Cover Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . 76
Recommission the SafeZone Mini Device. . . . . . . . . . . . . . . . . . . . 77

Chapter 10
Diagnostics Faults or Errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Rockwell Automation Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Error and Status Indication — Status Indicators . . . . . . . . . . . . . . . . . 80
Error and Status Indication — Seven-segment Display . . . . . . . . . . . 81
Lockout Operational Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Extended Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

Rockwell Automation Publication 442L-UM005B-EN-P - April 2017 5

Table of Contents

Chapter 11
Technical Specifications Scanning Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
OSSD Response Times . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Calculate the Total Response Time TS: . . . . . . . . . . . . . . . . . . . . . 84
Multiple Sampling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
OSSD Timing Behavior . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
General Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Functional Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Electrical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Dimension Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
SafeZone Mini Safety Laser Scanner. . . . . . . . . . . . . . . . . . . . . . . . . 91
Mounting Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Scan Plane Origin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Appendix A
Ordering Information Items Supplied with SafeZone Mini Device. . . . . . . . . . . . . . . . . . . . . . 95

Appendix B
Checklist to Install Electro- Checklist for the Manufacturer and Installer. . . . . . . . . . . . . . . . . . . . . 97
sensitive Protective Equipment
(ESPE)
Appendix C
EU Declaration of Conformity Certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

6 Rockwell Automation Publication 442L-UM005B-EN-P - April 2017

 Preface

IMPORTANT Read this Preface carefully before working with this documentation and the
SafeZone™ Mini safety laser scanner.

This user manual shows you how to mount, install, commission, operate, and
maintain your SafeZone Mini safety laser scanner correctly.

This user manual does not provide instructions for operating the machine,
system, or vehicle on which the safety laser scanner is, or will be, integrated.
This information can be found in the user manual for the machine, system, or
vehicle.

Summary of Changes This manual contains new and updated information as indicated in the
following table.

Topic Page
Updated Applications of the Device section. 12
Added Safe state in case of error to Table 23. 90
Added Safe state in case of error to Glossary. 101

Who Should Use This This user manual is intended for planning engineers, machine designers, and
the operators of machines and systems that are to be protected by one or several
Manual? SafeZone Mini devices. It is also for people that integrate SafeZone Mini
devices into a machine, system, or vehicle, initialize its use, or who are in charge
of servicing and maintaining the device.

Scope of Publication This user manual is only applicable to the SafeZone Mini device with the
following entry on the type label in the field Operating Instructions (Part
Number 10000337275).

For the configuration and diagnostics of these devices, you require the Safety
Configuration and Diagnostic (SCD) software (version 3.0 or higher)
programming software. To determine the software version, select the Module
Info… option in the Help menu.

Depth of Information

This user manual contains information on the SafeZone Mini device in the
following parts:

• Mounting • Fault diagnosis and troubleshooting

• Electrical installation • Catalog numbers
• Commissioning and configuration • Accessories
• Care and maintenance • Conformity and approval

Rockwell Automation Publication 442L-UM005B-EN-P - April 2017 7

Preface

Planning and using protective devices such as the SafeZone Mini device also
require specific technical skills that are not detailed in this documentation.

General information on accident prevention using optoelectronic protective

devices can be found in the competence brochure “Guidelines Safe Machinery.”

When operating the SafeZone Mini device, the national, local, and statutory
rules and regulations must be observed.

TIP Also refer to the Safety Laser Scanner product page at http://
ab.rockwellautomation.com/Sensors-Switches/Operator-Safety/SafeZone-
Mini-Laser-Scanners.
Here you can find information on:
• Application examples
• This user manual in different languages for viewing and printing

Symbols Display indicators show the status of the seven-segment display on the
SafeZone Mini device:

Symbol Description

. Constant indication of characters

. Flashing indication of characters

Alternating indication of characters

Symbols describe the status of an status indicator:

Symbol Description

The “OSSDs in the OFF state” status indicator is illuminated continuously.

The “Error/contamination” status indicator is flashing.

The “Warning field interrupted” status indicator is off.

Information is displayed in the software indicating to you which settings you can make in the Safety
Configuration and Diagnostic (SCD) software.

8 Rockwell Automation Publication 442L-UM005B-EN-P - April 2017

 Preface

Additional Resources These documents contain additional information concerning related products
from Rockwell Automation.
Resource Description
Industrial Automation Wiring and Grounding Guidelines, Provides general guidelines for installing a Rockwell
publication 1770-4.1 Automation industrial system.
Product Certifications website, http:// Provides declarations of conformity, certificates, and
www.rockwellautomation.com/global/certification/ other certification details.
overview.page

You can view or download publications at

http://www.rockwellautomation.com/global/literature-library/overview.page.
To order paper copies of technical documentation, contact your local
Allen-Bradley distributor or Rockwell Automation sales representative.

Rockwell Automation Publication 442L-UM005B-EN-P - April 2017 9

Preface

Notes:

10 Rockwell Automation Publication 442L-UM005B-EN-P - April 2017

 Chapter 1

Safety

This chapter deals with your safety and the safety of the system operators.

IMPORTANT Read this chapter carefully before working with the SafeZone™ Mini device
or with the machine that is protected by a SafeZone Mini device.

Qualified Safety Personnel Only qualified safety personnel must install, connect, commission, and service
the SafeZone Mini safety laser scanner. Qualified safety personnel meet the
following criteria:
• They have adequate knowledge of the power-driven equipment to be
checked due to their specialist training and experience.
• The responsible machine owner has instructed them in the operation of
the machine and the current valid safety guidelines.
• They are sufficiently familiar with the applicable official health and
safety regulations, directives, and recognized engineering practice (for
example, DIN standards, VDE stipulations, engineering regulations
from other EU member states), so they can assess the work safety aspects
of the power-driven equipment.
• They have access to this user manual and have read them.

As a rule, these qualified safety personnel are from the electro-sensitive

protective equipment (ESPE) manufacturer or also those persons who have
been appropriately trained at the ESPE manufacturer, are primarily involved in
checking ESPE and are allocated the task by the organization operating the
ESPE.

Rockwell Automation Publication 442L-UM005B-EN-P - April 2017 11

Chapter 1 Safety

Applications of the Device The SafeZone Mini device is used to help protect persons and systems. It is
intended to be used to monitor hazardous areas indoors.
• It is not allowed to use the SafeZone Mini device outdoors.
• The SafeZone Mini device cannot provide protection from parts that
are thrown out of the machine or emitted radiation.
• The SafeZone Mini device complies with the requirements in the
standard on the radiated emissions as defined for class A (industrial
application); the SafeZone Mini device is therefore only suitable for use
in an industrial environment.
• The device is a type 3 ESPE as defined by IEC 61496-1 and
IEC 61496-3 and is therefore allowed for use with category 3 PLd
controls as per EN ISO 13849-1 or SIL 2 as per IEC 61508.
• The SafeZone Mini device is suitable for:
– Hazardous area protection
– Hazardous point protection
– Access protection
– Vehicle protection (electrically powered industrial trucks)

IMPORTANT Depending on the application, you may require other protective devices and
measures in addition to the safety laser scanner.

Correct Use • Only use the SafeZone Mini device as defined in Applications of the
Device on page 12.
• Only qualified personnel can use the SafeZone Mini device.
• Only use the SafeZone Mini device on the machine where the
installation and initialization was done by qualified safety personnel in
accordance with this user manual.
• Only use on machines where the SafeZone Mini device can stop the
dangerous state immediately and/or it is possible to prevent the machine
being placed in operation.

ATTENTION: If the device is used for any other purposes or modified in any
way — also during mounting and installation — any warranty claim
against Rockwell Automation becomes void.

12 Rockwell Automation Publication 442L-UM005B-EN-P - April 2017

 Safety Chapter 1

General Safety Notes and ATTENTION:

Protective Measures • Pay attention to the safety notes.
Observe the following items to verify the correct use of the SafeZone Mini
device.
• Repair only by authorized persons.
The improper repair of the protective device can result in the loss of the
protective function. Only the manufacturer or persons authorized by the
manufacturer can repair the protective device.

The SafeZone Mini device is of laser safety class 1. Additional measures for
screening the laser radiation are not necessary (eye-safe).

• This device meets the norms: IEC 60825-1, CDRH 21 CFR 1040.10
and 1040.11; excluded are deviations due to Laser Notice No. 50, dated
24.06.2007. In the standards CDRH 21 CFR 1040.10 and 1040.11 the
following note is required: “Caution – use of controls, adjustments or
performance of procedures other than those herein specified may result
in hazardous radiation exposure!”
• During the mounting, installation and usage of the SafeZone Mini
device, observe the standards and directives applicable in your country.
An overview of the most important regulations can be found in
Applicable Directives and Standards on page 15.
• The national/international rules and regulations apply to the
installation, commission, use, and periodic technical inspections of the
SafeZone Mini device, including:
– Machinery Directive
– Work Equipment Directive
– The work safety regulations/safety rules
– Other relevant health and safety regulations
• Manufacturers and operators of the machine on which the SafeZone
Mini device is used are responsible for obtaining and observing all
applicable safety regulations and rules.
• The notes, in particular the test notes (see Commissioning on page 71)
in these operating instructions (for example, on use, mounting,
installation, or integration into the machine control) must be observed.
• Changes to the configuration of the devices can degrade the protective
function. After every change to the configuration, you must check the
effectiveness of the protective device. The person who makes the change
is also responsible for the correct protective function of the device.
When making configuration changes, always use the password hierarchy
that is provided by Rockwell Automation to verify that only authorized
persons change the configuration.

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Chapter 1 Safety

• Qualified safety personnel or specially qualified and authorized

personnel must conduct the tests and must record and document the
test to allow for tests to be reconstructed and retraced at any time.
• The user manual must be made available to the operator of the machine
where the SafeZone Mini device is used. The machine operator is to be
instructed in the use of the device by qualified safety personnel and must
be instructed to read the operating instructions.
• To meet the requirements of the relevant product standards (for
example, EN 61496-1), the external voltage supply for the devices must
be able to bridge a brief mains failure of 20 ms. Power supplies according
to EN 60204-1 satisfy this requirement. Suitable power supplies are
available as accessories from Rockwell Automation.

TIP Enclosed with these operating instructions is a checklist for checking by the
manufacturer and OEM (see Checklist to Install Electro-sensitive Protective
Equipment (ESPE) on page 97). Use this checklist when checking the system
that the SafeZone Mini device helps to protect.

Environmental Protection The SafeZone Mini device is constructed in such a way that it adversely affects
the environment as little as possible and uses only a minimum of power and
natural resources.

TIP At work, always act in an environmentally responsible manner.

Disposal

Unusable or irreparable devices must be disposed of per the applicable national

regulations on waste disposal (for example, European waste code 16 02 14).

TIP Information on the individual materials in the SafeZone Mini device is given
in Table 18 on page 87.

Separation of Materials

ATTENTION: Only qualified safety personnel are allowed to separate

materials. Caution is required when devices are dismantled. There is a risk of
injuries.

Before you send the devices for appropriate recycling, it is necessary to separate
the different materials in the SafeZone Mini device.
• Separate the housing from the rest of the parts (in particular the
circuit boards).
• Send the separated parts for recycling as appropriate (see Table 1).

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 Safety Chapter 1

Table 1 - Overview of Disposal by Components

Components Disposal
Product
Housing Metal recycling (aluminum)
Motor bracket Metal recycling (zinc die-cast housing)
Optics cover Plastic recycling
Circuit boards, cables, connectors, and electrical Electronic recycling
connection pieces
Packaging
Cardboard, paper Paper/cardboard recycling
Polyethylene packaging Plastic recycling

Applicable Directives and The most important directives and standards, valid for the use of
optoelectronic protective devices in Europe, are listed in Application and
Standards Installation of Protective Devices. Further regulations may be of importance to
you, depending on the application. You can obtain further information of
machine-specific standards from national institutions (for example, DIN, BSI,
AFNOR), the authorities, or your trade association.

If you operate the machine or vehicle in a country outside the European Union,
contact the manufacturer of the system and the local authorities to obtain
information on the regulations and standards applicable there.

Application and Installation of Protective Devices

Machinery Directive:
• Safety of machinery – Basic concepts, general principles for design
(EN ISO 12100)
• Industrial automation systems – Safety of integrated manufacturing
systems – Basic requirements (ISO 11161)
• Safety of machinery – Electrical equipment of machines – Part 1:
General requirements (EN 60204-1)
• Safety of machinery – safety distances to help prevent reaching hazard
zones with the upper and lower limbs (EN ISO 13857)
• Safety requirements for robots (EN ISO 10218-1)
• Safety of industrial trucks. Driverless trucks and their systems
(EN 1525)
• Safety of machinery – The positioning of protective equipment in
respect of approach speeds of parts of the human body (EN ISO 13855)
• Safety of machinery – Principles for risk assessment (EN ISO 14121-1)
• Safety of machinery – Safety-related parts of control systems – Part 1:
General principles for design (EN ISO 13849-1) and part 2: Validation
(EN ISO 13849-2)

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Chapter 1 Safety

• Safety of machinery – electro-sensitive protective equipment – Part 1:

General requirements (EN 61496-1) and part 3: Special requirements
for AOPDDR (CLC/TS 61496-3)
• Safety of machinery – Application of protective equipment to detect the
presence of persons (IEC/TS 62046)

Regional standards, for example:

• Performance Criteria for Safeguarding (ANSI B11.19)
• Machine tools for manufacturing systems/cells (ANSI B11.20)
• Safety requirements for Industrial Robots and Robot Systems (ANSI/
RIA R15.06)
• Safety Standard for guided industrial vehicles and automated functions
of named industrial vehicles (ANSI B56.5)

IMPORTANT To some extent, these standards require the protective device to have the
safety level “Control reliable.” The SafeZone Mini device meets this
requirement.

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 Chapter 2

Product Description

This chapter provides information on the special features and properties of the
SafeZone™ Mini safety laser scanner. It describes the construction and the
operating principle of the device.

Special Features • Small design

• 270° scan area
• Increased dust and particle tolerance due to light saturation and particle
algorithms
• With scanning ranges of 2 m (6.6 ft) or 3 m (9.8 ft) maximum protective
field radii
• Configuration using computer with Rockwell Automation® SCD
software
• Field sets comprising of one protective field and up to two warning fields
• Contour monitoring of the protective field if only one warning field is
used
• Only standalone operation
• One field set
• One monitoring case
• Integrated external device monitoring (EDM)
• Integrated restart interlock/restart interlock delay for which the
parameters can be set
• Two universal I/O connections

Function The SafeZone Mini device operates correctly as a protective device only if the
following conditions are met:
• The control of the machine, system, or vehicle must be electrical.
• It must be possible to transfer the dangerous machine, system, or vehicle
state to a safe state with the OSSDs on the SafeZone Mini device at any
time, that is before a person has reached the hazardous point or
hazardous area.

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Chapter 2 Product Description

Or, it must be possible to transfer the dangerous state of the machine, system,
or vehicle to a safe state at any time with the OSSDs on a safety controller
connected to the SafeZone Mini device.
• The SafeZone Mini device must be mounted and configured such that it
detects objects as they enter the hazardous area (see Mounting on
page 39 and Commissioning on page 71).
• The optical path of the safety laser scanner must always remain clear. Do
not cover the optical path with transparent objects such as protective
windows, Plexiglas, and lenses. To maintain the protective function of
the safety laser scanner do not bypass the contamination measurement
function by such measures.

Principle of Operation

The SafeZone Mini device is an optical sensor that scans its surroundings in
two dimensions with infrared laser beams. It is used to monitor hazardous areas
on machines or vehicles.

The SafeZone Mini device works on the principle of time-of-flight

measurement (Figure 1). It sends out short pulses of infrared light (send
pulses). Simultaneously, an “electronic stopwatch” is started. When the light
hits an object, it is reflected and the safety laser scanner receives it (receive
pulses). From the time between sending and reception (∆t), the SafeZone Mini
device calculates the distance to the object.

Figure 1 - Time-of-flight Measurement

Send pulses

Receive pulses

SafeZone Mini

Send pulses

Receive pulses

In the SafeZone Mini device, there is also a mirror that rotates at constant
speed and deflects the light pulses such that they cover an arc of 270°
(Figure 2). In this way, an object can be detected in the protective field within
270°. The first beam of a scan starts at -45° relative to the back of the safety
laser scanner.

The SafeZone Mini device sends a pulse of light with an angular resolution of
0.5° (A). As a result resolutions between 30…70 mm (1.18…2.76 in.) can be
achieved (B).

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 Product Description Chapter 2

Figure 2 - Rotation of the SafeZone Mini Device

225°

180°

-45°

0° 90°

Due to its active scanning principle, the SafeZone Mini device does not require
receivers or reflectors, which has the following advantages:
• Your installation effort is lower.
• You can easily adapt the monitored area to the hazardous area on a
machine.
• In comparison with contact sensors, electro-sensitive scanning is nearly
wear-free.

Field Set Comprising Protective and Warning Fields

Protective fields and warning fields form the field set. You can configure these
field sets with the aid of the SCD software. The fields can be configured as
circular, rectangular or of arbitrary shape. If the monitored area changes, then
you can reconfigure the SafeZone Mini device in software without additional
mounting effort.

You can configure field sets as one protective field and one or two warning
fields.

The SafeZone Mini device secures the hazardous area on a machine or vehicle.
As soon as the safety laser scanner detects an object in the protective field, it
switches the OSSDs to the OFF state. This action initiates the shutdown of the
machine or stop of the vehicle.

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Chapter 2 Product Description

Figure 3 - Field Set with One Protective Field and Two Warning Fields

Protective field

Warning field 1

Warning field 2

You can define the warning fields such that the safety laser scanner detects an
object before the actual hazardous area.

Warning field 1 can be used in particular for vehicle protection to detect an

object even before the actual hazardous area and to slow the movement of the
vehicle or bring it to a standstill. In this way, the wear on the brakes on an AGV
can be reduced. Warning field 2 can also be used to trigger a warning signal.

ATTENTION: A warning field on the SafeZone Mini device is not allowed to

be used for tasks that are related to the protection of people.

Contour Monitoring

In addition to the protective field, the SafeZone Mini device can also monitor a
contour (for example, the floor in vertical applications).

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 Product Description Chapter 2

Device Components The SafeZone Mini device comprises following components:

• The sensor with the optoelectronic detection system, the status
indicators, the seven-segment display, and the connecting cable with the
electrical connections
• The optics cover with the window for the light output

Figure 4 - Device Components

Window for light output Optics cover
Round plug
connector

Connecting cable

Status indicators
and seven- Sensor
segment display

Figure 5 - Maximum Protective Field Range [m (ft)]

2 (6.6)
3 (9.84)

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Chapter 2 Product Description

Applications Table 2 - Possible Applications for the SafeZone Mini Device

Application Representation
Hazardous area protection on an insertion station

Hazardous point protection on an insertion station

Presence detection for a safety light curtain

Protection of an automated guided vehicle (AGV) for

one velocity

Access protection for high areas of access

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 Product Description Chapter 2

Status Indicators The status indicators and the seven-segment display indicate the operational
status of the SafeZone Mini device. They are on the front face of the safety laser
scanner.

Figure 6 - Status Indicators

The symbols have the following meaning:

Table 3 - Status Indicator Meaning

Symbol Meaning
OSSDs in the OFF state (for example, object in the protective field, monitored contour is changed, reset
required, lockout)
Warning field is interrupted (object in one of the warning fields)

OSSDs in the ON state (no object in protective field)

Reset required

Optics cover contaminated

Seven-segment display for the indication of the status and errors

.

TIP Detailed information can be found in Table 14 on page 80 and in

Table 15 on page 81).

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Chapter 2 Product Description

Notes:

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 Chapter 3

Configurable Functions

System Parameters A name can be assigned to the application configured and to safety laser
scanners. The names are saved in the devices after the configuration is
transferred. The name that is chosen can be, for example, the identifier for the
vehicle, system or the machine.

You enter the application name and the names of the safety laser scanners that are used in the SCD
software.

Application Name

Enter a name for your application. You can enter a name with a maximum of
16 characters.

If you assign unique application names, you can reserve the devices for certain
duties. When a machine maintenance person compares exchanged devices with
the configuration data that is saved in the SCD software they are notified that
the application name does not match. They can then exchange these devices for
devices with the correct application name.

Name of the Scanner

Enter a device name for each of the safety laser scanners in the system. You can
enter names with a maximum of eight characters.

IMPORTANT Use meaningful names (example: “front” and “rear”) for vehicle monitoring.
Unique device names make the subsequent configuration steps easier (for
example, on control inputs allocation or the OSSDs).

User Data

You can enter your name in the field Name of the user. You can enter a name
with a maximum of 22 characters. The name is added to the configuration
protocol and in the diagnostics report.

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Chapter 3 Configurable Functions

Display Direction of the Seven-segment Display

The numbers on the seven-segment display can rotate 180° with the aid of the
SCD software. Rotation is useful, for example, when the SafeZone™ Mini is
rotated 180° due to the specific application.

If you rotate the numbers of the seven-segment display, the point in the seven-
segment display goes out.

Determine the Display Direction of the Seven-segment Display

Under seven-segment display, activate the Rotated by 180° option. After the
configuration draft has been transferred to the SafeZone Mini device, the
numbers of the seven-segment display rotate by 180°.

Application With the help of the SCD software, you can configure the SafeZone Mini
device for the required application. Depending on whether you select a
stationary or a mobile application, different configuration options are
available:

Table 4 - Comparison of Mobile and Stationary Applications

Mobile Applications [mm (in.)] Stationary Applications [mm (in.)]

Resolution
Hand Detection: Hand Detection:
• 30 (1.2) (with smaller protective field size) • 30 (1.2) (with smaller protective field size)
• 40 (1.6) (with larger protective field size) • 40 (1.6) (with larger protective field size)
Leg Detection: Leg Detection:
• 50 (2.0) (with smaller protective field size) • 50 (2.0) (with smaller protective field size)
• 70 (2.8) (with larger protective field size) (1) • 70 (2.8) (with larger protective field size)
Whole Body Detection:
• 150 (5.9)
Manipulation Prevention
The safety laser scanner checks whether in any 90° segment all measured values correspond to the maximum
distance value that can be measured.
If so, the SafeZone Mini device shuts down after 2 hours If so, the SafeZone Mini device shuts down after
and signals . 5 seconds and signals .
(1) In mobile applications, a resolution of only 70 mm (2.8 in.) is required for leg detection.

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 Configurable Functions Chapter 3

Resolution

The maximum protective field range(1) depends on the configured resolution.

The following table shows the related maximum protective field range at the
resolutions that can be set:

Table 5 - Maximum Protective Field Range at Different Resolutions

Maximum Protective Field Range [m (ft)]

Configured Resolution
[mm (in.)] 2 m (6.6 ft) 3 m (9.8 ft)
30 (1.2) – (hand detection) 1.25 (4.1) 1.25 (4.1)
40 (1.6) – (hand detection) 1.60 (5.2) 1.60 (5.2)
50 (2.0) – (leg detection) 2.00 (6.6) 2.10 (6.89)
70 (2.8) – (leg detection) 2.00 (6.6) 3.00 (9.84)
150 (5.9) (whole body detection) 3.00 (9.84)

IMPORTANT The warning field can be configured to up to 8 m (26.25 ft) for all
resolutions. The detection capability within the warning field is dependent
on the remission of the objects to be detected (see Technical Specifications
on page 83).

Basic Response Time

The basic response time of the SafeZone Mini device is 80 ms.

TIP You may need to add supplements to the basic response time due to
multiple sampling (see OSSD Response Times on page 84).

Maximum Protective Field Range

Depending on the configured resolution that is used (see Resolution), the

maximum protective field range of the safety laser scanner is shown in the SCD
software.

ATTENTION: The maximum protective field range of the SafeZone Mini

device must be sufficient to cover the calculated protective field size
including the necessary supplements (see Protective Field Size on page 41).

(1) Radial distance to the safety scanner.

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Chapter 3 Configurable Functions

Universal I/O Connections ATTENTION: You are not allowed to use the universal I/O connections for
safety-relevant functions.
You are only allowed to use the universal I/O connections for signaling. You
must never use the signals for controlling the application or for
safety-relevant functions.

The SafeZone Mini device has two universal I/O connections (see Round Plug
Connector on page 63). You can configure these two connections for the
following functions:
• Inactive (factory default setting)

As inputs (it is only possible to select one function per universal I/O
connection):
• Stand-by
• External device monitoring (EDM) (see page 29)
• Resetting the restart interlock (see page 30)

As outputs (it is possible to select several functions per universal I/O

connection, these functions are linked together using an OR operator):
• Device error
• Contamination error
• Contamination warning
• Second warning field
• Reset required

TIP Other functions that can be configured are dependent on the configuration
of the universal I/O connections. For example, you can only realize a restart
interlock if you configure one of the universal I/Os as an input for resetting
the restart interlock.

The universal I/O connections are configured in the SCD software in the Universal I/O area. Figure 7
shows a configuration example.

Figure 7 - Configuration Example Universal I/O Connections

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 Configurable Functions Chapter 3

Stand-by

If, in mobile applications, vehicles are not moved for a time, the OSSDs can be
switched to the OFF state and the laser on the SafeZone Mini device can be
switched off. In this way, the power consumption of the device is reduced.

IMPORTANT Use this function if, for example, you use several vehicles and do not move
them for a time. The SafeZone Mini device remains in the stand-by mode as
long as the related input information is present.

OSSDs Internal OSSDs

If there is an object in the protective field, the internal OSSDs on the SafeZone
Mini device always switch. This response cannot be configured differently in
the SCD software.

External Device Monitoring (EDM)

The EDM checks if the contactors actually de-energize when the protective
device is tripped. If you activate external device monitoring, then the SafeZone
Mini device checks the contactors after each interruption of the protective
field and before the machine restart. The EDM can so identify if one of the
contactors has welded, for instance. In this case, the external device monitoring
places the system in a safe operational state and the OSSDs are not switched
back to the ON state.

Figure 6 shows how the SafeZone Mini device reacts if the external device
monitoring detects a contactor malfunction:

Table 6 - Behavior of the SafeZone Mini Device on a Contactor Malfunction

Without internal restart interlock or with restart delay • The system locks completely (lockout).
• The error message 8 appears in the seven-segment
display.
With restart interlock • The SafeZone Mini device switches its OSSDs to the
OFF state.
• The status indicator is illuminated.
• The error message . appears in the seven-
segment display.

You can configure the external device monitoring in the SCD software.

TIP Examples of the connection of external device monitoring can be found in

Connection Diagrams on page 66.

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Chapter 3 Configurable Functions

Restart of the SafeZone Mini You can configure the restart behavior of the SafeZone Mini device as follows:
Device • Without restart interlock
• With restart delay
• With restart interlock

You can configure the type of restart in the SCD software.

ATTENTION: It is imperative that you configure the SafeZone Mini device or

the application with restart interlock if the protective field can be left to
approach the hazardous point or if a person cannot be detected by the
SafeZone Mini device at every point in the hazardous area.
During the assessment, pay attention to whether the protective field can be
left in the direction of the hazardous point, to areas that are unprotected due
to the mounting and the unprotected near range of the SafeZone Mini device
(see Methods to Prevent Unprotected Areas on page 53).

Configuration without Restart Interlock

After the OSSDs on the SafeZone Mini device have been switched to the OFF
state due to an object in the protective field, the OSSDs are re-enabled again
immediately when there is no longer an object in the active protective field.

This configuration is only allowed in the following cases:

• An external restart interlock is realized on the machine controller.
• The protective field cannot be left in the direction of the hazardous
point and the SafeZone Mini device detects people at every point in the
hazardous area.

Restart Delay for Mobile Applications

In mobile applications, you can configure a restart delay from 2…60 seconds on
the SafeZone Mini device. The OSSDs on the SafeZone Mini device change to
the ON state if there is no object in the protective field for the duration given.

This configuration is only allowed if the protective field cannot be left in the
direction of the hazardous point and if a person can be detected at every point
in the hazardous area by the SafeZone Mini device.

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 Configurable Functions Chapter 3

Configuration with Restart Interlock

The OSSDs on the SafeZone Mini device change to the OFF state to initiate a
machine (1 in Figure 8) or vehicle stop as soon as there is an object in the
protective field (2 in Figure 8). They do not change to the ON state (3 in
Figure 8), even if there is no longer an object in the protective field. The
OSSDs only change to the ON state if the operator operates the control switch
for restart or reset.

ATTENTION: Place the control switch for restart or reset outside the
hazardous area in a place where it can clearly be seen from the hazardous
area.
Place the control switch for restart or reset outside the hazardous area such
that it cannot be operated by a person in the hazardous area. Confirm that
the person who operates the control switch has a full view of the hazardous
area.

Figure 8 - Schematic Outline of the Operation with Restart Interlock

IMPORTANT Do not confuse the restart interlock with the starting interlock on the
machine. The starting interlock prevents the machine starting after
switching on. The restart interlock prevents the machine starting again after
an error or a protective field infringement.

TIP Examples of the connection of internal restart interlocks can be found in

Connection Diagrams on page 66.
If you do not use the internal restart interlock, then do not configure any of
the universal I/Os as an input for resetting (see Universal I/O Connections on
page 28).

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Chapter 3 Configurable Functions

Reset

IMPORTANT The reset function is often also called “preparation for restart.” In this user
manual, the term Reset is used.

If you want to activate the restart interlock on the SafeZone Mini device
(internal) and also a restart interlock on the machine (external), then each
restart interlock has its own control switch.

After operating the control switch for the internal restart interlock (with
protective field unoccupied) the following occurs:
• The SafeZone Mini device switches its OSSDs to the ON state.
• The status indicator ( ) on the SafeZone Mini device illuminates
green.

The external restart interlock helps prevent the machine from restarting. After
resetting the SafeZone Mini device, the operator must press the control switch
to restart the machine controller.

ATTENTION: Verify that the correct sequence is followed.

The controller must be realized such that the machine only restarts if the
SafeZone Mini device is first reset and then the control switch for restarting
the machine controller is operated.

Reset Signals

If the SafeZone Mini device is operated using the ¡§With restart interlock¡¨
function, then after a protective field infringement and the subsequent clearing
of the protective field, it requests a reset signal from the control system (reset
required).

ATTENTION: The reset signal must be safety-related (single failure proof).

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 Configurable Functions Chapter 3

Field Sets Fields sets can be configured manually or suggested by the laser scanner and
your SCD software.

Configure the Protective and Warning Field

With the aid of the SCD software, you can configure the field set, which comprises a protective field (1)
and two warning fields (2). During this process, you configure the shape and size of the protective and
warning fields. You can realize any field shape required.

Figure 9 - Create a Field Set in the SCD Software

The SafeZone Mini device radially scans the area to be monitored. The
SafeZone Mini device cannot see through objects during this process.
Therefore, the area behind objects that are in the area to be monitored (pillars,
grilles, and so on) cannot be monitored.

Protective fields and warning field can cover up an angle of up to 270° and have
different radial scanning ranges depending on the resolution configured (see
Resolution on page 27).

ATTENTION: Check the protective fields configured.

Before commissioning the machine or vehicle, check the configuration of the
protective fields using the instructions in Commissioning on page 71 and
using the Checklist to Install Electro-sensitive Protective Equipment (ESPE)
on page 97.

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Chapter 3 Configurable Functions

In Figure 10, if the protective field (3) or the warning fields (2) stretch as far as
a wall or another object (pillar, neighboring machine, shelf ), there must be a
distance of 100 mm (3.94 in.) between the protective field or warning field and
the object to help prevent false triggering (1).

Figure 10 - Configure Protective and Warning Fields

ATTENTION: Secure unprotected areas.

If it is possible to access a narrow strip between the protective field and a
wall or another object, you must protect this strip with additional measures
(for example, fence or floor protection).

Protective or Warning Field Suggested by the Safety Laser Scanner

The SCD software can suggest the protective or warning field in the field set editor. The safety laser
scanner scans the visible surrounding contour several times. From the data that is obtained, the SCD
software suggests the contour and size of the field. Figure 11 shows an example for the reading of a
protective field.

Figure 11 - Reading the Protective Field

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 Configurable Functions Chapter 3

In those places at which the surrounding contour is smaller than the maximum
protective field range (for example, at 1 in Figure 11), the protective field (4 in
Figure 11) corresponds to the surrounding contour.

TIP The measuring error tolerances for the SafeZone Mini device are
automatically subtracted from the protective field size. As a result the
protective field is slightly smaller than the surface covered (2 in Figure 11).

In those places where the surrounding contour is larger than the protective
field range (3 in Figure 11) the protective field corresponds to the possible
scanning range.

ATTENTION: Check the protective field suggested by the SCD software

The protective field suggested by the SCD software is not a replacement for
the calculation of the minimum distance. Calculate the minimum distance
and check the effectiveness of the protective fields before commissioning the
application.
Pay attention to the descriptions in Mounting on page 39, the notes in
Commissioning on page 71, and the Checklist to Install Electro-sensitive
Protective Equipment (ESPE) on page 97.

Use the Contour as a Reference

In addition to the protective field, the SafeZone Mini device can also monitor a
contour (for example, the floor in vertical applications).

Figure 12 - Schematic Diagram of Contour as Reference

For contour monitoring, you define a contour segment (1 in Figure 12). The
contour segment comprises a positive (2 in Figure 12) and a negative (3 in
Figure 12) tolerance band.

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Chapter 3 Configurable Functions

The OSSDs on the SafeZone Mini device change to the OFF state or the
SafeZone Mini Remote signals in the following situations:
• There is an object in the protective field.
• The monitored surrounding contour is no longer in the tolerance band
(for example, if the position of the SafeZone Mini device is changed).

TIP • You can define any number of contour segments.

• The contour segments must not be narrower than the configured
resolution.
• At the points where a contour has been configured as a reference you
cannot define warning fields. If, for example, you use the floor as a
reference for access protection, you cannot configure a warning field
there. However, you can, for example, configure a warning field to the
left and right of the contour segment to control a warning signal on
approach from the side.
• The contour as reference function and the warning field 2 function are
mutually exclusive.

You define the contour as a reference in the SCD software field set editor.

Vertical Operation

In vertical operation (for access protection and hazardous point protection),

according to CLC/TS 61496-3 you must always configure the protective fields
that are used with the contour as reference function.

Figure 13 - Contour as Reference for Vertical Operation

Item Description
1 Protective field
2 Contours of the machine opening
3 Contour segment

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 Configurable Functions Chapter 3

IMPORTANT Use lateral and vertical boundaries of the opening (for example, door frame)
and the floor as reference. In this case, if the position of the SafeZone Mini
device is changed in one or more planes, the distance to the reference
changes and the SafeZone Mini device switches its OSSDs to the OFF state.

Monitoring Cases The SafeZone Mini device supports a configuration with monitoring cases.

ATTENTION: Confirm for each monitoring case that the minimum distance
to the hazardous area is maintained.
See Mounting on page 39.

You can configure the monitoring cases in the SCD software.

Each monitoring case includes:

• The input conditions (or control signals) that control the activation of
the monitoring case.
• A field set, including a protective field and warning field or fields.
• The multiple sampling for the field set.

Monitoring cases can be switched with the following input information:

• Static information

Multiple Sampling

If multiple sampling is set, an object must be scanned several times before the
SafeZone Mini device switches its OSSDs to the OFF state. This setting helps
reduce the probability that insects, welding sparks, or other particles result in
the shutdown of the system.

If a multiple sampling of three is configured, for instance, an object must be

detected in the protective field three times in succession before the SafeZone
Mini device switches the OSSDs to the OFF state.

ATTENTION: The total response time increases by the multiple sampling.

With a multiple sampling greater than two, you must add a supplement to
the basic response time (see OSSD Response Times on page 84).

On the SafeZone Mini device, a multiple sampling of two is the minimum

setting. You can set the multiple sampling to up to 16 with the aid of the SCD
software. The supplement to the basic response time that results from your
setting is displayed in the SCD software.

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Chapter 3 Configurable Functions

Table 7 - Recommended Multiple Sampling

Application Recommended Multiple Sampling

Stationary under clean ambient conditions 2 times
Vertical applications 2 times
Mobile 4 times
Stationary under dusty ambient conditions 8 times

TIP With multiple sampling, you can increase the availability of a system.

You can configure the multiple sampling in the SCD software. You can set individual multiple sampling
for each monitoring case.

Stand-by Mode

If, in mobile applications, vehicles are not moved for a time (for example, for
battery charging), the OSSDs can be switched to the OFF state and the laser
on the SafeZone Mini device can be switched off. In this way, the power
consumption of the device is reduced.

In this way, you also help prevent the safety laser scanners from optically
interfering with each other and entering an error condition.

The function can be realized with the aid of the stand-by mode.

To switch to the stand-by mode, one universal I/O connection must be

configured as standby input on the SafeZone Mini device. (see Universal I/O
Connections on page 28).

IMPORTANT The stand-by mode does not occupy a monitoring case.

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 Chapter 4

Mounting

This chapter describes the preparation and completion of the mounting of the
SafeZone™ Mini safety laser scanner.

Mounting requires four steps:

• Definition of the application and the necessary mounting location for
the safety laser scanner.
• Calculation of the protective field sizes and minimum distances (see
EN ISO 13855)
• Mounting the safety laser scanner with or without mounting kits

ATTENTION: No protective function without sufficient minimum distance.

Only if you configure the protective field such that there is an adequate
minimum distance to the hazardous area, is protection by the SafeZone Mini
device achieved.

Mounting Notes • Mount the SafeZone Mini device in a dry place and protect the device
from dirt and damage.
• Avoid the installation of the SafeZone Mini device in the vicinity of
strong electric fields. Welding cables, induction cables in the immediate
vicinity, and mobile telephones operated nearby can produce these
electrical fields.
• Verify that there are no obstacles in the area to be monitored in the field
of view of the SafeZone Mini device that could cause interference or
shadowing. The SafeZone Mini device cannot monitor shadowed areas.
If there are unavoidable shadowed areas, check whether there is a risk.
Take additional safety precautions as necessary.
• Keep the area to be monitored free of smoke, fog, steam, or other forms
of air impurities. There must not be any condensation on the optics
cover. Otherwise, the function of the SafeZone Mini device can be
impaired and incorrect switching can occur.
• Avoid placing highly reflective objects in the scan plane of the SafeZone
Mini device. Examples: Retroreflectors can affect the measurement
results of the SafeZone Mini device. Highly reflective objects within the
protective field can blank a part of the area to be monitored in certain
circumstances.

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Chapter 4 Mounting

• Mount the SafeZone Mini device such that it is not saturated by

incident sunlight. Do not position stroboscopic and fluorescent lights or
other strong light sources directly in the scan plane as these light sources
can affect the SafeZone Mini device in specific circumstances.
• If reasonable for the application, mark the protective field on the floor
(see EN 61496-1).

The following steps are necessary after mounting:

• Completing the electrical connections (Electrical Installation on
page 61)
• Configuration of the protective field (Configuration on page 69)
• Commissioning and checking of the installation (Commissioning on
page 71)
• Checking the function and safe shutdown (Test Notes on page 72)

Stationary Application in This type of protective device is suitable for machines and systems on which,
for example, a guard does not enclose a hazardous area entirely.
Horizontal Operation
Figure 14 - Horizontal Stationary Application

For a horizontal stationary application determine the following:

• The protective field size to observe the necessary minimum distance.
• The height of the scan plane.
• The restart behavior.
• Measures to protect any areas that are not covered by the SafeZone Mini
device.

IMPORTANT Once you have defined the protective field size, mark the boundaries of the
protective field on the floor. In this way, you make the protective field
boundaries visible for the operator and ease subsequent testing of the
protective function.

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 Mounting Chapter 4

Protective Field Size

The protective field must be configured so the minimum distance (S) to the
hazardous area is maintained. This safety distance helps ensure that the
hazardous point can only be reached after the dangerous state of the machine
has been stopped completely.

IMPORTANT You can operate the SafeZone Mini device in stationary horizontal operation
with 30, 40, 50, or 70 mm (1.2, 1.6, 2.0, or 2.8 in.) resolution. The resolution
gives the maximum protective field range for the SafeZone Mini device.

ATTENTION: Verify that a human leg can be detected with 70 mm (2.8 in.)
resolution.
As per EN ISO 13855, mount the scan planes for horizontal stationary
applications with 70 mm (2.8 in.) resolution at least 300 mm (11.8 in.) above
the floor (see Height of Scan Plane on page 52).

Figure 15 - Minimum Distance S

Dangerous state K x (1M + 1s) 2G + 2R + O

The minimum distance S (Figure 15) depends on the following:

• Approach speed of the body or parts of the body
• Stopping/run-down time of the machine or system
(The stopping/run-down time is shown in the machine documentation
or must be determined by taking a measurement.)
• Response time of the SafeZone Mini device
• Supplements for general measurement errors and any measurement
errors that are related to reflection
• Supplement for prevention of reaching over
• Height of the scan plane
• Possibly the time for switching between the monitoring cases

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Chapter 4 Mounting

Calculate Minimum Distance S

See EN ISO 13855. Calculate S with the following formula:

S = (K × (TM + TS)) + ZG + ZR + C

Variable Description
K Approach speed (1600 mm/s (63 in./s), defined in EN ISO 13855)
TM Stopping/run-down time of the machine or system
TS Response time of the SafeZone Mini device and the downstream controller
ZG General safety supplement of the SafeZone Mini device = 100 mm (3.94 in.)
ZR Supplement for measurement error that is related to reflection
C Supplement for prevention of reaching over

Response Time TS of the SafeZone Mini Device

The response time TS of the SafeZone Mini device depends on the following:
• The basic response time of the SafeZone Mini device.
• The multiple sampling set.

See OSSD Response Times on page 84.

Supplement ZR for Measurement Errors Caused by Reflection

ATTENTION: Avoid mounting retroreflectors at a distance of less than one

meter from the boundary of the protective field.
With retroreflectors that are positioned at a distance of less than 1 m (3.28 ft)
from the boundary of the protective field a supplement ZR of 200 mm
(7.87 in.) must be added to the protective field.

Supplement C for Protection Against Reaching Over

With a protective field installed horizontally, there is a risk that people may
reach over the protective field and in this way reach the hazardous area before
the SafeZone Mini device shuts down the dangerous state. For this reason, the
calculation of the minimum distance must take into account a supplement to
help prevent persons from finding themselves in a hazardous situation by
reaching over (see EN ISO 13857) before the SafeZone Mini device triggers.

The necessary supplement for the minimum distance is dependent on the

height of the scan plane for the protective field. In Figure 16, At low heights (1)
the supplement is larger than at greater heights (2 and 3).

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 Mounting Chapter 4

Figure 16 - Mounting Variations for the Scan Plane [mm (in.)]

1 2 3

hs hD = 875 (34.4) hD = 875 (34.4)

hD = 0 hs
hs
C = 1200 (47.2) C = 850 (33.5) C = 850 (33.5)

In summary, there are three usual variations of mounting the scan plane for the
SafeZone Mini device. The optimal variation depends on the related
application. Table 8 helps make the selection.

Table 8 - Advantages and Disadvantages of Mounting Variations [mm (in.)]

Mounting Orientation (1) Advantage Disadvantage

Safety laser scanner low (HS < 300 Low external effects due to ambient Higher supplement C.
(11.81 in.)) light interference, crawling beneath
Low inclination of the scan plane not possible.
(HD ≈ HS)
Safety laser scanner high (HS > 300 Lower protective field supplement Danger of crawling beneath (at the
(11.81 in.)) C. front and side).
Low inclination of the scan plane
(HD ≈ HS)
Safety laser scanner low (HS < 3300 Lower protective field supplement Danger of crawling beneath (at the
(11.81 in.)) C. front), external effect due to
High inclination of the scan plane ambient light interference possible.
(HD > HS)
(1) HD = detection height; HS = scanner mounting height.

ATTENTION: If scan planes are at a height of more than 300 mm (11.81 in.)
verify that people cannot reach the hazardous area by crawling underneath
the scan plane.
If you mount the protective device higher than 300 mm (11.81 in.), you must
help prevent crawling beneath with additional measures. For applications
that are accessible to the public, the mounting height must be reduced to
200 mm (7.87 in.)(1).
(1) See the appropriate regulations.

Calculate the Supplement C

• If there is enough empty space in front of your machine or system, use
1200 mm (47.2 in.) for the supplement C.
• If the minimum distance is to be kept as small as possible, calculate C
with the following formula:
C = 1200 mm – (0.4 × HD)
Here HD is the height at which the protective field is mounted.

IMPORTANT The minimum supplement C to help prevent reaching over is 850 mm

(33.5 in.) (arm length).

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Chapter 4 Mounting

Scan Plane Height (70 mm [2.8 in.] Resolution)

Due to the radial sampling of the protective field, the optical resolution is
lower the further away you get from the safety laser scanner.

Figure 17 - Relationship between Resolution and Protective Field Mounting Height

A B

If you choose a resolution of 70 mm (2.8 in.) in the SCD software for

hazardous area protection, a human leg may, in certain circumstances, not be
detected (for example, scan to left and right of the bone - A in Figure 17).

If you mount the SafeZone Mini device higher, the scan plane is at calf height
and the leg is also detected with an object resolution of 70 mm (2.8 in.) (B in
Figure 17).

Stationary Application in Access protection can be used when the access to the machine can be defined
by physical means. For access protection, the SafeZone Mini device detects the
Vertical Operation for Access entry of an entire body.
Protection • To achieve adequate access protection, a response time of ≤90 ms and a
resolution of 150 mm (5.91 in.) or finer are required.
• To help protect the protective device against inadvertent adjustment or
manipulation, you must use the contour of the surroundings as a
reference for the SafeZone Mini device (see Use the Contour as a
Reference on page 35).

Minimum Distance
For access protection, a minimum distance (S) must be maintained between
protective field and hazardous area. This safety distance helps ensure that the
hazardous point can only be reached after the dangerous state of the machine
has been stopped completely.

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 Mounting Chapter 4

Figure 18 - Access Protection

Protective field

Contour of the
floor as reference

The minimum distance S as defined in EN ISO 13855 and EN ISO 13857

depends on the following:
• Reach or approach speed
• Stopping/run-down time of the machine or system
(The stopping/run-down time is shown in the machine documentation
or must be determined by taking a measurement.)
• Response time of the SafeZone Mini device
• Supplement C against reaching through

Calculate Minimum Distance S

See EN ISO 13855. Calculate S with the following formula:

S = (K × (TM + TS)) + C

Variable Description
K Approach speed (1600 mm/s (63 in./s), defined in EN ISO 13855)
TM Stopping/run-down time of the machine or system
TS Response time of the SafeZone Mini device and the downstream controller
C Supplement for prevention of reaching over (850 mm (33.5 in.))

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Chapter 4 Mounting

Response Time TS of the SafeZone Mini Device

ATTENTION: The total response time of the SafeZone Mini device must not
be more than 80 ms for access protection.
If a critical response time is exceeded, a person may no longer be detected
under certain circumstances.
In specific cases agreed with the responsible authorities higher response
times may be allowed (for example by increasing the detection time
available by positioning the safety laser scanner at an angle). In this case,
verify that the areas the safety laser scanner cannot see are protected by
additional measures.

The response time TS of the SafeZone Mini device depends on the following:
• The basic response time of the SafeZone Mini device.
• The multiple sampling set.

See OSSD Response Times on page 84.

Stationary Application in Hazardous point protection is necessary if the operator must remain near the
dangerous state of the machine. Hand protection is required for hazardous
Vertical Operation for point protection.
Hazardous Point Protection
IMPORTANT The SafeZone Mini device must be configured with a resolution of at least
40 mm (1.6 in.)

ATTENTION: Never use the SafeZone Mini device for safety applications in
which finger protection is required.
Due to the finest possible resolution of 30 mm (1.2 in.), the SafeZone Mini
device is not suitable for finger protection.

To help protect the protective device against inadvertent adjustment or

manipulation, you must use the contour of the surroundings as a reference for
the SafeZone Mini device (see Use the Contour as a Reference on page 35).

Minimum Distance

For hazardous point protection, a minimum distance must be observed

between protective field and hazardous point. This safety distance helps ensure
that the hazardous point can only be reached after the dangerous state of the
machine has been stopped completely.

ATTENTION: Prevent reaching around or behind the protective field.

Always mount the safety laser scanner such that reaching around and behind
is impossible. Provide suitable additional precautions as necessary.

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 Mounting Chapter 4

Figure 19 - Minimum Distance to the Hazardous Area

S
Contour as
reference

The minimum distance S as defined in EN ISO 13855 and EN ISO 13857

depends on the following:
• Stopping/run-down time of the machine or system
(The stopping/run-down time is shown in the machine documentation
or must be determined by taking a measurement.)
• Response time of the SafeZone Mini device
• Reach or approach speed
• Resolution of the SafeZone Mini device

Calculate Minimum Distance S

See EN ISO 13855. Calculate S with the following formula:

S = 2000 × (TM + TS) + 8 × (d - 14) [mm]

Variable Description
TM Stopping/run-down time of the machine or system
TS Response time of the SafeZone Mini device
d Resolution of the SafeZone Mini device [mm]

The reach/approach speed is already included in the formula.

• If the result S is ≤ 500 mm (19.7 in.), then use the determined value as
the minimum distance.
• If the result S is > 500 mm (19.7 in.), you may be able to reduce the
minimum distance with the following calculation:
S = 1600 × (TM + TS) + 8 × (d – 14) [mm]
• If the new value S is > 500 mm (19.7 in.), then use the newly calculated
value as the minimum distance.
• If the new value S is ≤ 500 mm (19.7 in.), then use 500 mm (19.7 in.) as
the minimum distance.

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Chapter 4 Mounting

Response Time TS of the SafeZone Mini Device

The response time TS of the SafeZone Mini device depends on the following:
• The basic response time of the SafeZone Mini device.
• The multiple sampling set.

See OSSD Response Times on page 84.

Mobile Applications If a vehicle (for example, AGV or fork lift) produces the dangerous state, the
hazardous area that the movement of the vehicle produces is protected by the
SafeZone Mini device.

Application Notes
• The SafeZone Mini device may only be used to help protect vehicles that
are powered by an electric motor.
• In the following calculations, only consider the velocity of the vehicle,
not the speed of the person walking. This is based on the assumption
that the person recognizes the danger and stands still.
• For vehicle protection, observe EN 1525 “Safety of industrial trucks.
Driverless trucks and their systems.”
• If the application is to help protect vehicles from collisions, then you
need to use different assumptions.

For a horizontally mounted mobile application, determine:

• Protective field length
• Protective field width
• Height of the scan plane
• Restart behavior
• Methods of preventing unprotected areas

Protective Field Length

You must configure the protective field such that a minimum distance to the
vehicle is maintained. This distance helps ensure that a vehicle that is
monitored by the SafeZone Mini device comes to a stop before a person or
object is reached.

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 Mounting Chapter 4

Calculate the Protective Field Length SL

See EN ISO 13855. Calculate the necessary protective field length SL with the
formula:

S L = SA + Z G + Z R + Z F + Z B

Variable Description
SA Stopping distance
ZG General safety supplement of the SafeZone Mini device = 100 mm (3.94 in.)
ZR Supplement for any reflection-related measurement error of the SafeZone Mini device
ZF Supplement for any lack of ground clearance of the vehicle
ZB Supplement for the reduction in the braking performance of the vehicle to be found in the related
vehicle documentation

Calculate the Stopping Distance SA

The stopping distance comprises the braking distance for the vehicle, the
distance covered during the response time of the safety laser scanner, and the
response time of the vehicle controller.

Figure 20 - Stopping Distance

SafeZone Mini

SAnF SAnS SBr

IMPORTANT Consider that the braking distance for a vehicle is not linear with increasing
velocity, but increases in a square function.

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Chapter 4 Mounting

Figure 21 - Stopping Distance as a Function of the Vehicle Velocity

Stopping distance

Stopping distance +
safety supplements
Necessary protective
field length

Speed

Calculate the stopping distance SA with the formula:

SA = SBr + SAnF + SAnS

Variable Description
SBr Braking distance, to be found in the vehicle documentation
SAnF Distance that is covered during the response time of the vehicle controller, to be found in the vehicle
documentation
SAnS Distance that is covered during the response time of the safety laser scanner

The distance that is covered during the response time of the safety laser scanner
depends on the following:
• The response time of the safety laser scanner.
• The maximum velocity of the vehicle in your mobile application.

The response time TS of the SafeZone Mini device depends on the following:
• The basic response time of the SafeZone Mini device.
• The multiple sampling set.

See OSSD Response Times on page 84.

Calculate the Distance SAnS

This distance is covered during the response time of the safety laser scanner.
Calculate the distance SAnS with the formula:

SAnS = TS × Vmax

Variable Description
TS Response time of the safety laser scanner
Vmax Maximum velocity of the vehicle from the related vehicle documentation

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 Mounting Chapter 4

Supplement ZR

Supplement ZR is used for measurement errors that are caused by reflection.

With retroreflectors in the background at a distance of less than 1 m (3.28 ft)
from the boundary of the protective field, the supplement ZR is 200 mm (7.87
in.).

Supplement ZF

Supplement ZF is due to lack of ground clearance. This supplement is necessary

because a person is detected above the foot and the braking action therefore
cannot consider the length of the foot in front of the detection point. If a
vehicle has no ground clearance, a person can receive foot injuries.

Figure 22 - Supplement Due to Lack of Ground Clearance

SafeZone Mini

Protective field length 2F

Ground clearance

The flat rate supplement for ground clearance below 120 mm (4.7 in.) is
150 mm (5.91 in.). This supplement can be further reduced in specific cases.
For this purpose, read off the actual supplement necessary for the ground
clearance of your vehicle from Figure 23.

Figure 23 - Diagram of Ground Clearance of the Vehicle

120
Ground clearance of the
vehicle in mm

60

50

0 50 100 150
Supplement 2F in mm

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Chapter 4 Mounting

Protective Field Width

The width of the protective field must cover the width of the vehicle and the
supplements for the measurement error and the lack of ground clearance.

Calculate the Protective Field Width SB

See EN ISO 13855. Calculate the protective field width SB with the formula:

SB = FB + 2 × (ZG + ZR + ZF)

Variable Description
FB Vehicle width
ZG General safety supplement of the SafeZone Mini device = 100 mm (3.94 in.)
ZR Supplement for any reflection-related measurement error of the SafeZone Mini device
ZF Supplement for any lack of ground clearance of the vehicle

Height of Scan Plane

ATTENTION: Mount the SafeZone Mini device such that the scan plane is at a
maximum height of 200 mm (7.87 in.).
In this way, persons lying down are reliably detected. Tilting the protective
field so objects with a diameter of 200 mm (7.87 in.) are not detected, is not
allowed. We recommend aligning the scan plane horizontally at 70 mm
(2.76 in.).

Figure 24 - Mounting Height [mm (in.)]

Set protective
field length

190 (7.48) 150 (5.91)

Set protective
field length

110 (4.33) 150 (5.91)

TIP To produce the optimal scan plane, you can also mount the SafeZone Mini
device reversed.

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 Mounting Chapter 4

Methods to Prevent During mounting the SafeZone Mini device, areas may be found that are not
covered by the safety laser scanner (A in Figure 25).
Unprotected Areas
Figure 25 - Unprotected Areas

ATTENTION: Prevent or secure unprotected areas.

• Mount the SafeZone Mini device such that there are no unprotected areas.
• For mobile applications, if the vehicle is accelerated to a maximum velocity
of 0.3 m/s (0.98 ft/s) in less than 3 seconds when in operation, you must
help prevent personnel from entering the unprotected areas with
mechanical trim panels, switch strips, or fitting the SafeZone Mini device in
the vehicle trim panels.

Mount the SafeZone Mini device, for example, on a corner to help prevent
unprotected areas.

Figure 26 - Preventing Unprotected Areas

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Chapter 4 Mounting

With two SafeZone Mini devices mounted at an angle of 45° on the front
corners of a vehicle, you can configure the protective fields so that there are no
unprotected areas and the hazardous areas in narrow aisles can also be
protected.

Figure 27 - Mounting Example for Front and Side Protection in a Direction of Travel

Protective field and

warning field safety
laser scanner 1

Protective field and

warning field safety
laser scanner 2

With two SafeZone Mini devices mounted diagonally opposite, you can
implement protective fields on the vehicle for all-round protection in all
directions of travel.

Figure 28 - Mounting Example for All-around Protection in All Directions of Travel

Protective field and

warning field safety
laser scanner 2
Protective field and
warning field safety
laser scanner 1

Near Range

Make the near range impassible using a bar or a recess, or additionally protect
the near range (50 mm (2.0 in.)) wide area in front of the optics cover using a
proximity switch with 50 mm (2.0 in.) acquisition range. The vehicle can then
be accelerated as required.

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 Mounting Chapter 4

Mounting Steps ATTENTION: Only qualified safety personnel are allowed to separate
materials.
Caution is required when devices are dismantled. There is a risk of injuries.

Special features to note during mounting:

• Mount the SafeZone Mini device such that it is protected from
moisture, dirt, and damage.
• Verify that the entire field of view of the SafeZone Mini device is not
restricted.
• Mount the safety laser scanner such that the indicators are easy to see.
• Avoid excessive shock and vibration loading on the safety laser scanner.
• On systems that suffer from heavy vibration, help prevent the fixing
screws from coming loose by using screw-locking devices.
• Regularly check the tightness of the fixing screws.
• Prevent personnel from being able to crawl beneath, stand behind or
climb over the protective field with appropriate mounting of the
SafeZone Mini device.

Figure 29 - Prevent Crawling Beneath, Standing Behind, and Climbing Over

The origin of the scan plane is 80 mm (3.15 in.) above the bottom edge of the
SafeZone Mini device (see Figure 54 on page 91).

There are three possible ways of mounting the SafeZone Mini device:
• Direct mount without mounting kit
• Mount with mounting kit 1 or 2
• Mount with mounting kit 3 and 4 (only with mounting kit 1 or 2)

The mounting kit part numbers are found in Table 25 on page 95.

IMPORTANT Pay attention to the maximum torque of the M5 fixing screws on the
SafeZone Mini device (5.9 N•m [4.4 ft•lb], max).

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Chapter 4 Mounting

Direct Mounting

The SafeZone Mini device has two threaded holes M5×8 on the rear. Using
them you can mount the SafeZone Mini device directly on the intended
mounting surface. To avoid a possible tendency to vibrate, if necessary the
reference surface on the rear can be used as the third mounting point (A in
Figure 30).

Figure 30 - Direct Mounting

M5 x 8

IMPORTANT During mounting, review the Dimension Drawings on page 91.

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Mounting with Mounting Kit 1or 2

With the aid of mounting kit 1 or 2, you can mount the SafeZone Mini device
indirectly on the mounting surface. Mounting kit 1 is available as a mounting
kit without protection device for the optics cover and as mounting kit 2 with
protection device for the optics cover.

1. Mount mounting kit 1 or 2 on the mounting surface.

2. Then, mount the SafeZone Mini device on the mounting kit 1 or 2.

Figure 31 - Mounting with Mounting Kit 2 (Including Protection for the Optics Cover)
Mounting screws
Mounting kit 2

Mounting screws

Threaded holes M5 x 8

IMPORTANT During mounting, review the Dimension Drawings on page 91.

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Chapter 4 Mounting

Mounting with Mounting Kit 3 and 4

With the aid of mounting kits 3 and 4 (only with mounting kit 1 or 2), you can
align the SafeZone Mini device in two planes. The maximum adjustment angle
is ±11° in both planes.

1. Mount mounting kit 1 or 2 to the SafeZone Mini device.

2. Mount the mounting kit 4 on the mounting surface.
3. Fit the centering pin [4 mm (0.16 in.)] in the central hole on mounting
bracket 4.
4. Fit mounting kit 3 to mounting kit 4 and mount it using two fixing
screws M4 × 10.
5. Then, mount the SafeZone Mini device on mounting kit 3 with the aid
of the threaded holes in mounting kit 1.
6. Adjust the SafeZone Mini device longitudinally and transversely and
then tighten the six fixing screws on the mounting kits.

Figure 32 - Mounting with Mounting Kit 2

Mounting kit 1 Mounting kit 3 Mounting kit 4
Mounting screws

Centering pin

Mounting screws

Threaded holes M4

IMPORTANT During mounting, review the Dimension Drawings on page 91.

Information Label Important Information

On completion of mounting, you must affix the self-adhesive information label

Important information supplied:
• Use only the information label in the language that the operators of the
machine can read and understand.
• Place the information label such that it is clearly visible for the operators
during operation. The information label must not be covered even after
additional items have been mounted.

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 Mounting Chapter 4

Using Multiple Safety Laser Scanners

The SafeZone Mini device is designed so that mutual interference between

several safety laser scanners is unlikely. To exclude erroneous switching, you
must mount the safety laser scanners as shown in the following examples.

IMPORTANT In any circumstance, observe EN ISO 13855 when calculating the minimum
distance.

Use mounting kits 1 or 2 and 3 to adjust the safety laser scanners to different
angles (see Table 25 on page 95).

Figure 33 - Opposite Mounting

Min. 3°

Figure 34 - Offset Parallel Mounting

Min. 100 mm
(3.94 in.)

Figure 35 - Mounting on a Cross

Min. 3°

Figure 36 - Reverse Mounting, Parallel Offset

Min. 100 mm
(3.94 in.)

Figure 37 - Reverse Mounting of Two SafeZone Mini Devices, with Parallel Offset

Min. 100 mm
(3.94 in.)

Rockwell Automation Publication 442L-UM005B-EN-P - April 2017 59

Chapter 4 Mounting

Notes:

60 Rockwell Automation Publication 442L-UM005B-EN-P - April 2017

 Chapter 5

Electrical Installation

ATTENTION: Switch the entire machine/system offline.

The machine/system could unintentionally start up while you are connecting
the devices. Verify that the entire machine/system is disconnected during
the electrical installation.

ATTENTION: Connect OSSD1 and OSSD2 separately.

You are not allowed to connect OSSD1 and OSSD2 together, otherwise signal
safety is not maintained.
Confirm that the machine controller processes the two signals separately.
Downstream contactors must be positively guided and monitored.
OSSD1

OSSD2

OSSD1

OSSD2

ATTENTION: Only connect one downstream switching element to an OSSD.

Each output signal switching device (OSSD) is only allowed to be connected
to one switching element (for example, relay or contactor). If several
switching elements are required, you must choose a suitable form of contact
duplication.

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Chapter 5 Electrical Installation

ATTENTION: Help prevent the occurrence of a potential difference between

the load and the protective device.
If you connect loads that are not reverse-polarity protected to the OSSDs or
the safety outputs, you must connect the 0V connections of these loads and
of the corresponding protective device individually and directly to the same
0V terminal strip. This is the only way to verify that, if there is an anomaly,
there is no potential difference between the 0V connections of the loads and
of the corresponding protective device.

Safety output 1

Safety output 2

Safety output 1

Safety output 2
OSSD1

OSSD2

OSSD1

OSSD2
Electrical Notes • Route all cables and connection cables such that they are protected from
damage.
• Verify that the controller that is connected and all devices that are
related to safety have the required category as per EN ISO 13849-1 or
the required Performance Level as per EN ISO 13849-1.
• If you use screened cables, lay the screen evenly around the connection
terminal.
• Verify that the SafeZone™ Mini device is adequately protected
electrically. See Electrical Specifications on page 89 for the electrical data
necessary for determining the correct fuse.

System Connection All inputs and outputs on the SafeZone Mini device are on the round plug
connector on the connecting cable. Connect the SafeZone Mini device with
pre-assembled extension cables (see Table 10 on page 64).

All inputs and outputs on the SafeZone Mini device are to be used only in the
context specified.

The round plug connectors are coded. If you use plug connectors other than
the connectors intended, any claim against Rockwell Automation under the
warranty is rendered void.

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 Electrical Installation Chapter 5

Wiring in Accordance with EMC Regulations

The quality of the shield is dependent on the quality of the connection of the
screen. In principle, the best screening action can only be achieved with the
connection of the shield at both ends with large area connections.

If it is not possible to connect the screen via threaded fittings, connect the
screen physically close, for example, to a control cabinet chassis with a metal
clamp.

IMPORTANT If there is a PE in an installation, it can be used for the connection of the

functional earth connection (FE). However, an FE is never allowed to be used
as a PE.

Functional Earth

To achieve the specified EMC safety, the functional earth FE must be

connected (for example, to the central earth star point of the vehicle or system).

Round Plug Connector

Figure 38 - Round Plug Connector

6 4
7 3
2
1

Table 9 - Pin Assignment (1)

Pin Signal Function

1 WF Output for warning field 1
2 +24V DC Supply voltage
3 I/O1 Universal I/O
4 I/O2 Universal I/O
5 OSSD1 Output signal switching device
6 OSSD2 Output signal switching device
7 0V DC Supply voltage
8 FE/shield Functional earth/shield
Housing FE/shield Functional earth/shield

(1) Use the cordsets that are listed in Table 25 on page 95 to connect the SafeZone Mini device.

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Chapter 5 Electrical Installation

Table 10 - Core Assignment of the SafeZone Mini Device Cable

Core Color Function

1 White Output for warning field 1
2 Brown Supply voltage 24V DC
3 Green Universal I/O connection 1
4 Yellow Universal I/O connection 2
5 Gray Output signal switching device OSSD1
6 Pink Output signal switching device OSSD2
7 Blue Supply voltage 0V DC
8 FE/shield Functional earth/shield

Universal I/O Connections

ATTENTION: Do not use the universal I/O connection outputs for safety-
related tasks. The universal I/O connection outputs are purely application
diagnostics outputs, for example, for the transfer of information to
controllers.

Configuration Connection Figure 39 - Pin Assignment

3
M8 × 4 (Serial Interface) 4

1 2

Table 11 - Pin Assignment Configuration Connection M8 × 4

Pin SafeZone Mini Device PC-side RS-232-D-Sub

1 Reserved Not assigned
2 RxD Pin 3
3 0V DC (voltage supply) Pin 5
4 TxD Pin 2

After configuration:
• Always remove the connecting cable from the configuration connection.
• Locate the attached protection cap to cover the configuration
connection.

64 Rockwell Automation Publication 442L-UM005B-EN-P - April 2017

 Chapter 6

Application Examples and Connection

Diagrams

The examples that are shown are provided as an aid for your planning. You may
need to consider additional protection measures for your application.

Stationary Applications Figure 40 shows coverage of one area that a SafeZone™ Mini safety laser scanner
monitors permanently.

Figure 40 - Hazardous Area Protection with SafeZone Mini Device (Horizontal Mounting)

SafeZone Mini with one protective

field and one warning field —
mounted horizontally

The access in Figure 41 is monitored permanently. For safety against

manipulation on the SafeZone Mini device, for example, the floor is used as a
reference. If the alignment of the SafeZone Mini device changes (for example,
due to changes to the bracket), it switches its OSSDs to the OFF state.

Figure 41 - Access Protection with SafeZone Mini Device (Vertical Mounting)

SafeZone Mini with one
protective field —
mounted vertically

Floor as reference

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Chapter 6 Application Examples and Connection Diagrams

Mobile Applications Figure 42 shows vehicle monitoring for unidirectional travel with a SafeZone
Mini device. The SafeZone Mini device monitors the area in the direction of
travel and switches its OSSDs to the OFF state to stop the vehicle as soon as
there is an object in the protective field.

Figure 42 - Vehicle Monitoring

SafeZone Mini with one protective

field and two warning fields

Connection Diagrams IMPORTANT • Only use relays/contacts with positively guided contacts. The protection
elements connected in parallel with the relays/contactors are used for
arc-suppression.
• Verify that there is adequate arc-suppression at the relays/contactors.
Consider that arc-suppressors can lengthen the response time.
• The arc-suppressors must be in parallel with the relays/contactors (not
across the contacts).

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 Application Examples and Connection Diagrams Chapter 6

Restart Interlock and External Device Monitoring

SafeZone Mini device with relays/contactors; operating mode: with restart

interlock (universal I/O 1 must be configured as reset) and external device
monitoring (universal I/O 2 must be configured as EDM).

Figure 43 - Connection Diagram with Restart Interlock and External Device Monitoring
+24V DC

Reset K1

SafeZone Mini K2

Wht* L1 L2 L3
Brn Grn** Yel***
K1
Shld Gry Pnk Blu K2
Color Pin Signal
wire
Wht 1 Output - Warning Field1*
Brn 2 +24V DC
Grn 3 Universal I/O1** (Reset) M
Yel 4 Universal I/O2*** (EDM)
Gry 5 OSSD 1
Pnk 6 OSSD 2
Blu 7 0V DC K1 K2
Shld 8 Earth Ground
* Not configured for this application
* No Connection
** Software Configu ed for Reset input
*** Software Configu ed for EDM

0V DC

SI Guardmaster Safety Relay

SafeZone Mini device in combination with a SI Guardmaster safety relay:

operating mode of SafeZone Mini device is ON/OFF and SI safety relays is
configured for monitored manual reset.

Figure 44 - Connection Diagram in Combination with a GSR SI Safety Relay

24V DC
SafeZone Mini
Color Pin Signal
Wht 1 Output-Warning Field1* Wht* Grn* Yel*
Brn 2 +24V DC
Grn 3 Universal I/O1*
Yel 4 Universal I/O2* Brn Reset
Gry 5 OSSD 1
Pnk 6 OSSD 2 Shld Gry Pnk Blu
Blu 7 0V DC wire L1 L2 L3
Shld 8 Earth Ground
K1
* not configured for this A1 A2 S11 S21 S12 S22
application + -
24VDC IN1 K2
no connection RESET 0
SI
AM
MM
M
13 14 23 24
L11 Y32 S34 13 14 23 24

K1 K2

0V DC
Monitored Manual Reset

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Chapter 6 Application Examples and Connection Diagrams

Two SafeZone Mini Devices with DI Guardmaster Safety Relay

Two SafeZone Mini devices that are connected to a DI Guardmaster safety

relay. The DI safety relay is configured for monitored manual reset. SafeZone
Mini scanners are configured for ON/OFF.

Figure 45 - Connection Diagram in Combination with a GSR DI Safety Relay

24V DC

Color Pin Signal SafeZone Mini

Wht 1 Output-Warning Field1*
Brn 2 +24V DC Wht* Grn* Yel*
Grn 3 Universal I/O1* Brn
Yel 4 Universal I/O2*
Gry 5 OSSD 1 Blu
Pnk 6 OSSD 2 Shld
Blu 7 0V DC wire Gry Pnk Reset

Shld 8 Earth Ground SafeZone Mini

* not configured for
this application
no connection Wht* Grn* Yel*
Brn L1 L2 L3

Shld Gry Pnk Blu K1

wire
K2

A1 A2 S11 S21 S12 S22 S32 S42

+
Power 24VDC
- Test Out
0
IN1 IN2 M
In1 DI LOGIC 1
2
In2 3
Out 8
76 54
Logic
L12 L11 Y32 S34 13 14 23 24

K1 K2

0V DC
Monitored Manual Reset

68 Rockwell Automation Publication 442L-UM005B-EN-P - April 2017

 Chapter 7

Configuration

Default Delivery Status The SafeZone™ Mini safety laser scanner is delivered in a non-configured
default state.
• The operational status is Waiting for configuration.
• The seven-segment display indicates . .
– The output signal switching devices (OSSDs) are in the OFF state,
the red status indicator is illuminated: .

Prepare the Configuration To prepare the configuration:

• Make sure that the safety laser scanner has been correctly mounted and
that the electrical connections are correct and in place.
• Have the necessary tools at hand.

To configure the safety laser scanner, you need:

• SCD software on CD-ROM or downloaded from http://
ab.rockwellautomation.com/sensors-switches/operator-safety/safezone-
mini-laser-scanners#software.
• Computer with Windows NT 4/2000 Professional/XP/Vista/7
(32-Bit) and a serial RS-232 interface (computer not included)
• Service cable for connecting computer and SafeZone Mini device

Configuration with the SCD Software

To configure and perform diagnostics on the SafeZone Mini device, directly

connect the computer to the configuration connection on the SafeZone Mini
device.

Figure 46 - Configuration Connection

Configuration connection

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Chapter 7 Configuration

Two service cables of different lengths are available for computer connection
(see Table 25 on page 95).

IMPORTANT • Verify that the service cable is not laid near high-power electrical drives
or cables that carry high power. In this way, you avoid EMC effects on the
service cable.
• The service cable is only allowed to be connected for configuration and
diagnostics. The service cable must be disconnected and the protective
cap is in place while in operation.

TIP Use the password function in the SCD software to help protect the
configuration settings from unauthorized access. Also, verify that the
passwords are stored to help protect against unauthorized access.

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 Chapter 8

Commissioning

Initial Commissioning ATTENTION: Commissioning requires a thorough check by qualified safety

personnel.
Before you operate a system that is monitored by the SafeZone™ Mini device
for the first time, make sure qualified safety personnel check and release the
system. The result of the test must be documented. Read the notes in
Chapter 1 on page 11.
• Before the machine is released, check whether the protective devices
entirely monitor the access to the hazardous area or the hazardous point.
• After approval of the machine, at regular intervals (for example, in the
morning before the start of work) check whether the OSSDs (on the
SafeZone Mini device, a safety laser scanner that is connected or on a safety
controller) switch correctly to the OFF state as soon as there is an object in
the protective field. This test must be performed along all protective field
boundaries as per the specific regulations for the application (see Test Notes
on page 72).

Power-up Sequence

After power up, the SafeZone Mini device runs through a power-up cycle.
During the power-up cycle, the seven-segment display indicates the device
status.

During the initial commissioning of an SafeZone Mini device, the following

indications are possible:

Table 12 - Seven-segment Display during and after the Power-up Sequence on Initial
Commissioning

Step Display Meaning

1 Power-up cycle, testing the seven-segment display. All segments are activated
sequentially.
.
2 .
Power up cycle, during initial commissioning: device in configuration mode

Other display Safety lock activated. Malfunction in external conditions or in the device itself. See
Error and Status Indication — Seven-segment Display on page 81.

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Chapter 8 Commissioning

Table 13 - Status Indication after the Power-up Sequence

Step Display Meaning

1 Device self-test

2 Device self-test

3 Device status: waiting for configuration or object in the protective field,

OSSDs in the OFF state
Other display Safety lock activated. Malfunction (see Error and Status Indication —
Status Indicators on page 80)

Test Notes ATTENTION: Confirm that you do not place anybody at risk during initial
commissioning of the machine.
Always expect that the machine, system, or the protective device does not
yet behave as planned.

• Verify that there are no persons in the hazardous area during initial
commissioning.
• Check the effectiveness of the protective device that is mounted to the
machine, using all selectable operating modes as specified in the
checklist in the annex (see Checklist to Install Electro-sensitive
Protective Equipment (ESPE) on page 97).
• Verify that the qualified safety personnel instructs the operating
personnel of the machine that is protected by the safety laser scanner
before being allowed to operate the machine. Instruction of the
operating personnel is the responsibility of the machine owner.
• Confirm that the information label Important information, which is
included with the safety laser scanner on delivery, is affixed to the
machine in a place where it is clearly visible for the operators. Confirm
that the operators have the possibility to perform this daily check
correctly.
• Appendix B on page 97 includes a checklist for review by the
manufacturer and OEM. Use this checklist as a reference before
commissioning the system for the first time.
• Document the adjustment of the safety laser scanner and the results of
the testing during initial commissioning in a traceable manner. For this
purpose, also print the complete configuration of the safety laser scanner
(including protective field shapes) and include these configurations with
the documentation.
• Contact your Rockwell Automation sales office or Allen-Bradley
distributor for questions regarding initial commissioning.

TIP Use the Create development dump... function in the SCD software
(right-click the COM interface to which the safety laser scanner is
connected). You can keep this data as a backup and in this way document
the state during initial commissioning at any time.

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 Commissioning Chapter 8

Inspection of the Protective Device

Your protective device must be inspected by qualified safety personnel

regularly.
• Check the system following the inspection intervals that are specified in
the national rules and regulations. This procedure verifies that any
changes on the machine or manipulations of the protective device after
the initial commissioning are detected.
• If major changes have been made to the machine or the protective
device, or if the safety laser scanner has been modified or repaired, check
the system again as per the checklist in the annex (see Checklist to
Install Electro-sensitive Protective Equipment (ESPE) on page 97).

Daily Testing
A specialist or authorized personnel must check the effectiveness of the
protective device daily. The test must also be performed if the operating mode
is changed.

ATTENTION: No further operation if errors occur during the test.

If any one of the following points is not met, it is not permitted to continue
to work on the machine or operate the vehicle. In this case, qualified safety
personnel must check the installation of the SafeZone Mini device (see
Inspection of the Protective Device).

• The test must be conducted for the relevant preset monitoring case.
• Check the mechanical installation to verify that all mounting screws are
secure and that the SafeZone Mini device is properly aligned.
• Check each SafeZone Mini device for visible changes such as damage
and manipulation.
• Switch on the machine/system.
• Watch the status indicators on each SafeZone Mini device.
• If not at least one status indicator of each SafeZone Mini device is
permanently lit when the machine/system is switched on, it is to be
assumed that there is a fault in the machine or system. In this case, the
machine must be shut down immediately and checked by qualified
safety personnel.
• Deliberately infringe the protective field while the machine is running to
test the protective function for the entire system. The status indicators
of the SafeZone Mini device must change from green to red and the
dangerous movement must stop immediately.
• Repeat this test at different points in the hazardous area and on all
SafeZone Mini devices. If you discover any non-conformance of this
function, the machine/system must be shut down immediately and
checked by qualified safety personnel.

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Chapter 8 Commissioning

• For stationary applications, check that the hazardous areas marked out
on the floor match the shapes of the protective fields that are stored in
the SafeZone Mini device and that any gaps are protected by additional
safety measures. For mobile applications, check that the moving vehicle
actually stops in a timely manner at the protective field boundaries that
are set in the SafeZone Mini device and listed on the information label
on the vehicle or in the configuration protocol. If you discover any non-
conformance of this function, the machine/system/vehicle must be
stopped immediately and checked by qualified safety personnel.

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 Chapter 9

Maintenance and Care

ATTENTION: Do not make any repairs to the device.

The SafeZone™ Mini device does not contain any repairable components. For
this reason, do not open the SafeZone Mini device and only replace the parts
that are described in the following chapters as replaceable.

ATTENTION: Switch the entire machine/system off line.

The system could inadvertently start up while you are replacing the optics
cover. As a matter of principle, always isolate the machine from the power
supply during all work on the machine and safety laser scanner.

Clean Optics Cover The SafeZone Mini device requires little maintenance. However, the optics
cover on the safety laser scanner must be cleaned on a regular basis and when it
becomes contaminated.
• Do not use aggressive cleaning agents.
• Do not use abrasive cleaning agents.
• Static charges cause dust particles to be attracted to the optics cover. You
can reduce this effect by using the anti-static plastic and the lens cloth.

Optics Cover Cleaning Procedure

1. Use a clean and soft brush to remove dust from the optics cover.
2. Moisten the optics cloth with the anti-static plastic cleaner and wipe off
the window for light output on the optics cover with the cloth.

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Chapter 9 Maintenance and Care

Replace Optics Cover ATTENTION: Perform an optics cover calibration with the aid of the SCD
software after the replacement of the optics cover.
The level of contamination is measured continuously during the operation of
the SafeZone Mini device. For this purpose, the optics cover calibration must
first be performed; this information serves as a reference for the
contamination measurement (status = not contaminated).
The optics cover calibration is only allowed to be performed with a new
optics cover. The new optics cover must be free of contamination at the time
of the optics cover calibration. The optics cover calibration must be
performed at room temperature [10…30 °C (50…86 ° F)].

If the optics cover is scratched or damaged, it must be replaced. Order the

replacement optics cover from Rockwell Automation (see Table 25 on
page 95).
• The optics cover on the SafeZone Mini device is an optical part that
must not be soiled or scratched on replacement.
• Only qualified safety personnel are allowed to replace the optics cover in
a dust and dirt-free environment.
• Never replace the optics cover during ongoing operation, as internal
parts can be irreparably damaged in certain circumstances and dust
particles can enter the device.
• It is imperative that you avoid contamination of the inside, for example,
with fingerprints.
• Do not use any additional sealant for sealing the optics cover, for
example, silicon, as these substances can affect the optics.
• Use a torque wrench (universal joint) with 2.5 mm (0.1 in.) hex socket
bit.
• Mount the optics cover per the following instructions to verify that the
housing is sealed to IP65.

Optics Cover Replacement Procedure

TIP • Only use a new optics cover (see Table 25 on page 95).
• When replacing the optics cover, take electrostatic discharge (ESD)
protection measures.
• Set your torque wrench to 1.2 N•m (10.6 lb•in) (hand-tight).

1. Disconnect the round plug connector on the end of the connecting

cable and remove the SafeZone Mini device.
2. Take the SafeZone Mini device to a clean place (office, repair shop, or
similar).
3. Clean the outside of the SafeZone Mini device. Cleaning keeps foreign
bodies from entering the device when it is opened.
4. Remove the optics cover mounting screws (Figure 47).

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 Maintenance and Care Chapter 9

Figure 47 - Optics Cover Mounting Screws

Screw
Screw

Screw

5. Remove the optics cover.

6. Check whether the mirror on the motor is clean and remove any
contamination with an optic brush.
7. Take the new optics cover out of the packaging and remove the
protection for the seal.
8. Remove any remnants of packaging.
9. Place the optics cover on the safety laser scanner and place the new
mounting screws.

IMPORTANT When fitting the new cover, verify that the arrow on the top of the cover
points to the front and that the optics cover is fully in contact without a gap.

10. Tighten the front screws with the torque wrench.

11. Make sure that the optics cover is free of dirt and that it is not damaged.

Recommission the SafeZone Mini Device

1. Correctly remount the SafeZone Mini device (see Mounting on
page 39).
2. Connect the round plug connector on the end of the connection cable
for the SafeZone Mini device.
3. Perform an optics cover calibration with the aid of the SCD software.

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Chapter 9 Maintenance and Care

Notes:

78 Rockwell Automation Publication 442L-UM005B-EN-P - April 2017

 Chapter 10

Diagnostics

This chapter describes how to identify and remedy errors and malfunctions
during the operation of the safety laser scanner.

Faults or Errors ATTENTION: Do not operate if behavior is unclear.

Stop the machine, system, or vehicle if you cannot clearly identify or allocate
an error and if you cannot safely remedy the malfunction.

ATTENTION: Repair only by authorized persons.

The improper repair of the protective device can result in the loss of the
protective function. Only the manufacturer, or persons who are authorized
by the manufacturer, are allowed to repair the protective device.

Rockwell Automation If you cannot rectify an error with the help of the information that is provided
in this chapter, contact your local Rockwell Automation representative.
Support

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Chapter 10 Diagnostics

Error and Status This section describes the meaning of the error and status indications of the
status indicators and how you can respond. You can find a description of the
Indication — indicators in Status Indicators on page 23, the connections for the outputs of
Status Indicators the SafeZone™ Mini device in System Connection on page 62.

Table 14 - Error and Status Indication

Display Output Level Possible Cause Corrective Action

At the OSSDs Object in the protective field, No error
OSSDs in the OFF state
At the OSSDs Protective field unoccupied, No error
OSSDs in ON state
At the warning field Object in one of the warning No error
output (1) fields

On the universal I/O (2)

At the OSSDs No operating voltage or voltage Check the voltage supply and
too low activate, if necessary.
On the universal I/Os

On the universal I/O (3) Reset required Operate the control switch for
restart.
No level change Restart delay is counting down. No action is required.

On the universal I/O (4) No error

On the universal I/O (5) Optics cover contaminated, no Clean the optics cover.
operation
On the universal I/O (6) Optics cover contaminated, still in Clean the optics cover.
operation
(1) If warning field 1 is infringed.
(2) If this is configured as the output for warning field 2 and warning field 2 is infringed.
(3) If this is configured as the output for “Reset required.”
(4) f this is configured as the output for a contamination error/warning.
(5) If this is configured as the output for a contamination error.
(6) If this is configured as the output for a contamination warning.

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 Diagnostics Chapter 10

Error and Status This section explains the meaning of the error indications on the
seven-segment display and how to respond to the messages. You can find a
Indication — description of the positions and symbols on the SafeZone Mini device in Status
Seven-segment Display Indicators on page 23.

Lockout Operational Status

In case of certain faults or an erroneous configuration, the device can go into
the lockout operational status. The seven-segment display on the safety laser
scanner then indicates . , . , , , , , , , , or . To place the device back in
operation, follow these steps:

1. Rectify the cause of the fault per Table 15 on page 81.

2. Switch off the power supply for the SafeZone Mini device, wait at least 3
seconds, and then switch back on the power supply.
Or, restart the safety laser scanner with the aid of the SCD software.
Table 15 - Error and Status Indication on the Seven-segment Display
Display Possible Cause Corrective Action
Power-up cycle — all segments are No error
activated sequentially.
.
Object in protective field No error

Object in warning field 1 No error

Object in warning field 2 No error

Initialization of the device The display goes out automatically when the SafeZone Mini device has been initialized and/or the connection to
.
the second device has been made.
If the display . does not go off:
• Check whether the partner device is in operation.
• Check the wiring.
If no partner device is connected:
Check the system configuration with the aid of the SCD software. Transfer the corrected configuration to the
SafeZone Mini device again.
Waiting for configuration or The display goes off automatically once the configuration has been successfully transferred.
.
configuration not completed If the display . does not go off:
Check the system configuration with the aid of the SCD software. Transfer the corrected configuration to the
SafeZone Mini device again.
Waiting for restart of the device Switch off the voltage supply for the SafeZone Mini device for at least 2 seconds and then switch it back on.
.
Error of the external device monitoring • Check whether the contactors are working correctly or if they are wired incorrectly and rectify any error.
.
(EDM) • If . is displayed: also switch off the voltage supply for the SafeZone Mini device for at least 2 seconds and
or switch it back on.
.
Error in the control switch for restart or • Check the functionality of the control switch. The button may be defective or permanently operated.
.
reset • Check the wiring of the control switch for short circuit to 24V.
SafeZone Mini device has a malfunction Switch off the voltage supply for the SafeZone Mini device for at least 2 seconds and then switch it back on.
or is faulty If the display does not go off:
Send the SafeZone Mini device to the manufacturer for repair.
Overcurrent on OSSD connection 1 • Check the switching element connected (contactor, relay). Replace, if necessary.
• Check the wiring for short circuit to 0V.
Short circuit to 24V at OSSD connection 1 Check the wiring for short circuit to 24V.

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Chapter 10 Diagnostics

Table 15 - Error and Status Indication on the Seven-segment Display

Display Possible Cause Corrective Action
Short circuit to 0V at OSSD connection 1 Check the wiring for short circuit to 0V.

Overcurrent on OSSD connection 2 • Check the switching element connected (contactor, relay). Replace, if necessary.
• Check the wiring for short circuit to 0V.
Short circuit to 24V at OSSD connection 2 Check the wiring for short circuit to 24V.

Short circuit to 0V at OSSD connection 2 Check the wiring for short circuit to 0V.

Short circuit between OSSD connection 1 Check the wiring and rectify the error.
and 2
General OSSD wiring error Check the complete wiring of the OSSDs.

The SafeZone Mini device is receiving no For the correct function of the safety laser scanner, always verify that measured values are received within a
measured values within a range of at range of 90°; this range can be moved as required within the scan range.
least 90° (measuring range maximum
29.9 m (98.1 ft), it is not detecting any
obstacles such as building walls.
Device is faulted. • Check whether an external light source, for example, headlight, infrared light sources, stroboscopic light, or
sun is affecting the SafeZone Mini device.
• If necessary, remount the device.
Temperature error. The operating Check whether the SafeZone Mini device is operated as per the permissible ambient conditions.
temperature of the SafeZone Mini device
has exceeded the permissible range.
Invalid configuration of the EDM. Verify that the machine-side EDM is connected correctly.

Undervoltage of the supply voltage Check the power supply or the connecting cables.

There is a short circuit between the input Check the wiring for cross-circuits.
for the control switch for restart or reset
and another input or output.
Park/stand-by mode, the OSSDs of the No error. If the criteria for the park mode or the stand-by mode are withdrawn, readiness for operation is
SafeZone Mini device are in the OFF state; reestablished.
the laser is deactivated. If the display does not go off:
Test the levels at the universal I/O and at the control inputs that switch to the monitoring case with park mode.
Optics cover calibration active. No error.

Window for light output on the optics Clean the window for the light output on the optics cover.
cover contaminated
Optical saturation of the contamination Check whether an external light source, for example, headlight, infrared light source, stroboscopic light, or sun is
measurement (there may not be an affecting the SafeZone Mini device.
and optics cover fitted) Or:
• Fit the new optics cover.
• Then, perform optics cover calibration.

IMPORTANT If you have problems during troubleshooting, contact Rockwell Automation

support. Keep a copy of the results of the diagnostics at hand.

Extended Diagnostics The SCD software is supplied with the devices. It allows you to narrow down
the problem if the error is non-specific or if you experience usage downtime
problems. Find detailed information in the online help for the SCD software.

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 Chapter 11

Technical Specifications

Scanning Range Figure 48 - Scanning Range Diagram (2 m [6.56 ft] SafeZone™ Mini Device)
500 Reflectors > 2000%

Remission (%)
Reflective films > 300%

200

100
White plaster
Writing paper
50

20 Gray cardboard

10

5 Matte black paint

2 Black shoe leather

1
0.1 0.2 0.5 1 2 5 10 20 50
Scanning range [m]
Protective field
Warning field

Figure 49 - Scanning Range Diagram (3 m [9.84 ft] SafeZone Mini Device)

500
Remission (%)

Reflectors > 2000%

Reflective films > 300%
200

100
White plaster
50 Writing paper

20
Gray cardboard
10

5
Matte black paint
2
Black shoe leather
1
0.1 0.2 0.5 1 2 5 10 20 50
Scanning range [m]
Protective field
Warning field

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Chapter 11 Technical Specifications

OSSD Response Times The total response time of your application is dependent on:
• The basic response time of the SafeZone Mini device.
• The multiple sampling set.
• The OSSDs that are used.

Calculate the Total Response Time TS:

TS = tB + TMFA

Variable Description
tB Basic response time = 80 ms
TMFA Supplement due to multiple sampling > 2

Multiple Sampling
On the SafeZone Mini device at least double multiple sampling is always set.
For a multiple sampling of three or higher, you must add a supplement of 80 ms
to the basic response time.

Table 16 - Multiple Sampling Supplements

Multiple Sampling Supplement Basic Response Time + Supplement

2 times (basic setting) 0 ms 80 ms
3 times 40 ms 120 ms
4 times 80 ms 160 ms
5 times 120 ms 200 ms
6 times 160 ms 240 ms
7 times 200 ms 280 ms
8 times 240 ms 320 ms
9 times 280 ms 360 ms
10 times 320 ms 400 ms
11 times 360 ms 440 ms
12 times 400 ms 480 ms
13 times 440 ms 520 ms
14 times 480 ms 560 ms
15 times 520 ms 600 ms
16 times 560 ms 640 ms

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 Technical Specifications Chapter 11

OSSD Timing Behavior The SafeZone Mini device tests the OSSDs immediately after switch-on and
then at regular intervals. For this purpose, the SafeZone Mini device briefly
switches off both OSSDs (for 300 µs) and checks whether the OSSDs switch
to the OFF state during this time.

ATTENTION: Verify that the safety inputs on the controller that is used do
not respond to these test pulses and as a result cause the machine or system
to unintentionally shut down.

Figure 50 - Diagram of OSSD Test Pulses

40 ms
120 ms 120 ms 120 ms

OSSD1

OSSD2

Approx. t
35 ms
A B C D C D

Approximately 35 ms after the switch-on of the OSSDs, the SafeZone Mini

device performs the first voltage test (A) and then after a half basic response
time (40 ms) it performs a second voltage test (B).

After another half basic response time of the SafeZone Mini device, there is a
shutdown test (C). 120 ms later another voltage test (D). Then, the SafeZone
Mini device performs a shutdown test (C) and a voltage test (D) alternately at
an interval of 120 ms. Figure 51, Figure 52, and Figure 53 show the pulse
duration for the individual tests.

Figure 51 - Voltage Test after Switching on the OSSDs

Approx. 650 s

<300 s <300 s
OSSD1

OSSD2

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Chapter 11 Technical Specifications

Figure 52 - Shutdown Test

Approx. 650 s

OSSD1 <300 s

OSSD2 <300 s

Figure 53 - Voltage Test

OSSD1 <300 s

OSSD2

86 Rockwell Automation Publication 442L-UM005B-EN-P - April 2017

 Technical Specifications Chapter 11

General Specifications Table 17 - General Specifications

Attribute 442L-SFZNMN
Type 3 (EN 61496-1)
(1)
Safety integrity level SIL 2 (IEC 61508)
(1)
SIL claim limit SILCL2 (EN 62061)
Category Category 3 (EN ISO 13849-1)
Performance Level (1) PLd (EN ISO 13849-1)
PFHd (Tamb = 25 °C) 8 × 10–8
(mean probability of a dangerous failure per hour)
TM (mission time) 20 years (EN ISO 13849)
Laser protection class Laser class 1
(according to IEC 60825-1, CDRH 21 CFR 1040.10 and
1040.11; excluded are deviations due to Laser Notice No.
50, dated 24.06.2007)
Enclosure rating IP65 (EN 60529)
Protection class III (EN 50178 and EN 60950)
Operating temperature range -10…+50 °C (14…122 °F)
Storage temperature range -25…+50 °C (-13…+122 °F)
-25…+70 °C (-13…+158 ° F) (≤24 h)
Humidity (considering the operating temperature EN 61496-1, CLC/TS 61496-3 (Protective Field Width on
range) page 52)
Vibration EN 61496-1 and CLC/TS 61496-3
Frequency range 10…150 Hz
Amplitude 0.35 mm (0.01 in.) or 5 g (0.18 oz)
Shock resistance EN 61496-1, Chapter 4 and CLC/TS 61496-3
Single shock 15 g (0.53 oz), 11 ms
Continuous shock 10 g (0.35 oz), 16 ms
Sender Pulsed laser diode
Wavelength 895…915 nm (905 nm, typical)
Divergence of the collimated beam (solid angle) 14 mrad
Pulse duration 5.0 ns (5.5 ns, max)
Average output power 3.42 mW
Light spot size at optics cover 8 mm (0.31 in.)
Size of light spot at 2.0 m (6.56 ft) scanning range 28 mm (1.1 in.)
(1) For detailed information on the safety design of your machine/system, contact your local Rockwell Automation sales office or
Allen-Bradley distributor.

Material Table 18 - Material

Attribute 442L-SFZNMN
Housing
Material Aluminum die-cast
Color RAL 1021 (rapeseed yellow) and RAL 9005 (black)
Optics Cover
Material Polycarbonate
Surface finish Outside with scratch-resistant coating

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Chapter 11 Technical Specifications

Dimensions Table 19 - Dimensions [mm (in.)]

Attribute 442L-SFZNMN
SafeZone Mini Safety Laser Scanner
Height 116 (4.57)
Width 102 (4.02)
Depth 105 (4.13)
Total weight (without connecting cables) 0.8 kg (1.76 lb)
Connecting Cable
Length 250 (9.84)
Diameter of round plug connector 15 (0.59)

Functional Data Table 20 - Functional Data

Attribute 442L-SFZNMN
Resolution of the 2 m (6.56 ft) SafeZone Mini Device 30, 40, 50, 70 mm (1.2, 1.6, 2.0, 2.8 in.)
Resolution of the 3 m (9.84 ft) SafeZone Mini Device 30, 40, 50, 70, 150 mm (1.2, 1.6, 2.0, 2.8, 5.9 in.)
Protective field of the 2 m (6.56 ft) SafeZone Mini Medium Range
At 30 mm (1.2 in.) resolution 1.25 m (4.10 ft)
At 40 mm (1.6 in.) resolution 1.60 m (5.25 ft)
At 50 mm (2.0 in.) resolution 2.00 m (6.56 ft)
At 70 mm (2.8 in.) resolution 2.00 m (6.56 ft)
Protective field of the 3 m (9.84 ft) SafeZone Mini Medium Range
At 30 mm (1.2 in.) resolution 1.25 m (4.10 ft)
At 40 mm (1.6 in.) resolution 1.60 m (5.25 ft)
At 50 mm (2.0 in.) resolution 2.10 m (6.89 ft)
At 70 mm (2.8 in.) resolution 3.00 m (9.84 ft)
At 150 mm (5.9 in.) resolution 3.00 m (9.84 ft)
Scan angle 270°
Remission 1.8% (min)
Several 1000% (reflectors) (max)(3)
Angular resolution 0.5°
Protective field supplement necessary 100 mm (3.94 in.)
Supplement for retroreflectors in scan plane at a 200 mm (7.87 in.)
distance of less than 1 m (39.4 in.) to the protective field
boundary
Evenness of the scan field at 2 m (6.56 ft) ±50 mm (2.0 in.)
Distance from mirror axis of rotation (zero point on the X 55 mm (2.17 in.)
and Y axis) to the rear of the device
Distance between center of the scan plane and the 80 mm (3.15 in.)
bottom edge of the housing
Warning field (1) 8 m (26.25 ft)
Distance measuring range 30 m (98.4 ft)
Number of multiple samplings 2…16
(configurable via SCD software)
Power-up delay of a configured device 18 s
Restart after (configurable) 2…60 s
Basic response time (2) 80 ms
(1) The detection capability of the warning field is dependent on the remission of the objects to be detected.
(2) The total response time of your application is dependent on further factors.
(3) Complies with Diamond Grade 3000X™ (approx. 1250 cd/lx × m²).

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 Technical Specifications Chapter 11

Electrical Specifications Table 21 - Electrical Specifications

Attribute 442L-SFZNMN
(1) (2)
Supply voltage (SELV) 16.8…30 V (24V, typical)
(3)
Permissible residual ripple ±5%
(4)
Switch on current 2.0 A
Operating 2 m (6.56 ft) SafeZone Mini Device 0.16 A (0.20 A, max) (5)
current without
output load 3 m (9.84 ft) SafeZone Mini Device 0.18 A (0.25 A, max) (5)

Operating 2 m (6.56 ft) SafeZone Mini Device 1.35 A (5)

current with
max output load 3 m (9.84 ft) SafeZone Mini Device 1.35 A (5)

Power 2 m (6.56 ft) SafeZone Mini Device 3.9 W (4.8 W, max) (5)
consumption
without output 3 m (9.84 ft) SafeZone Mini Device 4.4 W (6.0 W, max) (5)
load
Power 2 m (6.56 ft) SafeZone Mini Device 33 W
consumption
with max output 3 m (9.84 ft) SafeZone Mini Device 33 W
load
Power 2 m (6.56 ft) SafeZone Mini Device 3.6 W (4.8 W, max)
consumption in
the stand-by
mode or park 3 m (9.84 ft) SafeZone Mini Device 4.4 W (6.0 W, max)
mode without
output load
Electrical connection Connecting cable with round plug connector
Cable length for power supply tolerance ±10% 25 m (82.0 ft)
Cable length for power supply tolerance ±5% 34 m (111.5 ft)
Cable length for power supply tolerance ±1% 40 m (131.2 ft)
(1) To meet the requirements of the relevant product standards (for example, EN 61496-1), the external voltage supply for the
device must be able to bridge a brief mains failure of 20 ms. Power supplies according to EN 60204-1 satisfy this requirement.
Suitable power supplies are available as accessories from Rockwell Automation.
(2) Operation only in a short-circuit protected system with max. 8 A
(3) The absolute voltage level must not drop below the specified minimum voltage.
(4) The load currents for the input capacitors are not considered.
(5) With the typical supply voltage of 24V.

Table 22 - Universal I/O Specifications

Attribute 442L-SFZNMN
Input resistance when HIGH 2Ω
Voltage for HIGH 11…30V (24V, typical)
Voltage for LOW -3…+5V (0V, typical)
Input capacitance 15 nF
Static input current 6…15 mA
Actuating time of the control switch for restart 120…200 ms
HIGH switching voltage at 100 mA VS – 3.3 V…VS
Source switching current 100…200 mA
Current limiting (after 5 ms at 25 °C [77 °F]) 600…920 mA
Power up delay 1.4…2 ms
Switch off delay 0.7…2 ms
Response time with configuration as second warning Corresponds to the resulting response time of the OSSDs
field output plus 50 ms

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Chapter 11 Technical Specifications

Table 23 - OSSD Specifications

Attribute 442L-SFZNMN
Output signal switching device pair 2 PNP semiconductors, short-circuit protected (5),
cross-circuit monitored
Safe state in case of error At least one OSSD is in the OFF state.
HIGH switching voltage at 250 mA VS – 2.7 V…VS
Switching voltage LOW 0…2 V (0V, typical)
Source switching current (1) 6…250 mA
(2)
Leakage current 250 µA
Load inductance 2.2 H
Load capacity 2.2 µF at 50 Ω
Switching sequence (without switching 5 ¹/s
Permissible cable resistance (3) 2.5 Ω
(4)
Test pulse width 230…300 ms
Test frequency 120 ms
Power-up delay of the OSSDs from red to green 120 ms
Time offset on switching the OSSDs between OSSD2 and 2 ms
OSSD1
(1) Switching currents up to 500 mA are allowed briefly (≤100 ms).
(2) In the case of a fault (0V cable open circuit) maximally the leakage current flows in the OSSD cable. The downstream controller
must detect this status as LOW. An FPLC (fail-safe programmable logic controller) must be able to identify this status.
(3) Make sure to limit the individual line core resistance to the downstream controller to this value to confirm that a cross-circuit
between the outputs is safely detected. (Also note EN 60 204-1.)
(4) When active, the outputs are tested cyclically (brief LOW). When selecting the downstream controllers, make sure that the test
signals do not result in deactivation.
(5) Applies to the voltage range between VS and 0V.

Table 24 - Configuration and Diagnostics Interface Specifications

Attribute 442L-SFZNMN
Communication protocol RS-232 (proprietary)
Transmission speed 38400 Bauds
Cable length at 38400 Baud and 0.25 mm² cables 15 m (49 ft)
Galvanic isolation No
Output TxD HIGH 5…15 V
Output TxD LOW -15…-5 V
Voltage range RxD -15…+15 V
Switching threshold RxD LOW -15…+0.4 V
Switching threshold RxD HIGH 2.4…15 V
Short-circuit current at TxD -60…+60 mA
Max. voltage level at RxD -15…+15 V
Max. voltage level at TxD -11…+11 V

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 Technical Specifications Chapter 11

Dimension Drawings The measurements in the following drawings are in millimeters (inches).

SafeZone Mini Safety Laser Scanner

Figure 54 - SafeZone Mini Device [mm (in.)]
94 (3.7) dia.

116
(4.57)

79.7
(3.14)

43.3
(1.70)

36.5
(1.44)
73 (2.87) dia.
102 (4.02) dia.

200 (7.87) max.

104 (4.09)
54.5
(2.15)
23.8
(0.94)
Min. 15
Min. 15
36.4
(1.43)

10.5 (0.41) 43.3

M5 x 7.5 (1.70)

5
(0.20)
250 (9.84)

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Chapter 11 Technical Specifications

Mounting Kits
Figure 55 - Mounting Kit Dimensions [mm (in.)]
100 (3.94) dia

109.6 (4.31)
73
(2.87) 48 102.5 (4.03)
4 (0.16) (1.89)
4 DIN74-F5 73
(0.16) (2.87) 78
(3.07) 110 (4.33)
110 (4.33)
DIN74-F5
15.9 15.9
(0.63) (0.63)
16 37.9
(0.63) (1.49) 21.9
49 21.9 49 16
15.7 (0.63) (0.86)
(1.93) (0.86) (1.93)
21.9 (0.62)
74.7 (0.86) 74.7
(2.94) (2.94)
Mounting Kit 1 Mounting Kit 2
Cat. No. 442L-AMBSZMN1 Cat. No. 442L-AMBSZMN2

)
25
(6.
8.8
15 )
5 .91
0(
139.4 (5.49) 15 )
5.12 41
0( (1.57)
130 (5.12) 13
33.4 18
37.7(1.31) (0.71)
(1.48)
4
(0.16) 118.5 (4.67)
18
(0.71) 5
(0.20)

19.7 M4
40.7 (0.78)
78.2 20.5
(3.08)
(1.60) 19.7 (0.80) 5.5
(0.78) (0.22)
Mounting Kit 3 Mounting Kit 4
Cat. No. 442L-AMBSZMN3 Cat. No. 442L-AMBSZMN4

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 Technical Specifications Chapter 11

Scan Plane Origin

Figure 56 - Scan Plane with Mounting Kit 1, 3, and 4 [mm (in.)]

150
(5.91)

73 270°
(2.87)

130
(5.12)

23.8
(0.94)
36.4
(1.43) 43.3
(1.70)

74.7
(2.94)
69.7 54.5
(2.74) (2.15)
59.7 104
(2.35) (4.09)

109.6
(4.31)

74.7
(2.94)

Min. 15 Min. 15

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Chapter 11 Technical Specifications

Notes:

94 Rockwell Automation Publication 442L-UM005B-EN-P - April 2017

 Appendix A

Ordering Information

Items Supplied with • Safety laser scanner

SafeZone Mini Device • Operating instructions and SCD software on CD-ROM
• Adhesive label Important information

IMPORTANT Cordsets for the SafeZone™ Mini device are not included.

Table 25 - Product Selection

Cat. No. Product Description

SafeZone mini safety laser scanner,
442L-SFZNMN 2 m (6.56 ft) safety field

SafeZone mini safety laser scanner,

442L-SFZNMN3 3 m (9.84 ft) safety field

Cordsets
442L-ACABL2 2.5 m (8.2 ft) cordset
442L-ACABL10 10 m (32.8 ft) cordset
442L-ACABL20 20 m (65.6 ft) cordset
Accessories

442L-AMBSZMN1 Mounting bracket 1a

442L-AMBSZMN2 Mounting bracket 1b

442L-AMBSZMN3 Mounting bracket 2

442L-AMBSZMN4 Mounting bracket 3

442L-SZMNW Replacement window kit

442L-ACUSB-2 2 m (6.56 ft) USB programming cable

442L-ACUSB-10 10 m (32.8 ft) USB programming cable

Rockwell Automation Publication 442L-UM005B-EN-P - April 2017 95

Appendix A Ordering Information

Notes:

96 Rockwell Automation Publication 442L-UM005B-EN-P - April 2017

 Appendix B

Checklist to Install Electro-sensitive Protective

Equipment (ESPE)

Checklist for the Details about the points listed in the following checklist must be present at
least during initial commissioning. The points are dependent on the respective
Manufacturer and Installer application, the specification of which are to be controlled by the
manufacturer/installer.

IMPORTANT This checklist must be retained and kept with the machine documentation
to serve as reference during tests.

1. Have the safety rules and regulations been observed in compliance with the directives/standards applicable to the machine? Yes □ No □

2. Are the applied directives and standards listed in the declaration of conformity? Yes □ No □

3. Does the protective device fulfill the required PL/SILCL and PFHd according to EN ISO 13 849-1/EN 62 061 and the type according to Yes □ No □
EN 61496-1?

4. Is the access to the hazardous area/hazardous point only possible through the protective field of the ESPE? Yes □ No □

5. Have measures been taken to help prevent and monitor unauthorized presence in the hazardous area when hazardous area/ Yes □ No □
hazardous point protection (mechanical protection) and have these measures been secured against removal?

6. Are additional mechanical protective measures fitted and secured against manipulation, which help prevent reaching under, over, Yes □ No □
and around the ESPE?

7. Has the maximum stopping and/or stopping/run-down time of the machine been measured, specified, and documented (at the Yes □ No □
machine and/or in the machine documentation)?

8. Has the ESPE been mounted such that the required minimum distance from the nearest hazardous point has been achieved? Yes □ No □

9. Are the ESPE devices properly mounted and secured against manipulation after adjustment? Yes □ No □
10.Are the required protective measures against electric shock in effect (protection class)? Yes □ No □

11.Is the control switch for resetting the protective device (ESPE) or restarting the machine present and correctly installed? Yes □ No □

12.Are the outputs of the ESPE (OSSDs, ASInterface Safety at Work) integrated in compliance with the required PL/SILCL according to Yes □ No □
EN ISO 13 8491/EN 62 061 and does the integration comply with the circuit diagrams?

13.Has the protective function been checked in compliance with the test notes of this documentation? Yes □ No □

14.Are the given protective functions effective at every setting of the operating mode selector switch? Yes □ No □

15.Are the switching elements activated by the ESPE, for example, contactors, valves, monitored? Yes □ No □

16.Is the ESPE effective over the entire period of the dangerous state? Yes □ No □

17.Once initiated, will a dangerous state be stopped when switching the ESPE on or off and when changing the operating mode, or Yes □ No □
when switching to another protective device?

18.Has the information label for the daily check been attached so that it is easily visible for the operator? Yes □ No □

IMPORTANT This checklist does not replace the initial commissioning, nor the regular
inspection, by qualified safety personnel.

Rockwell Automation Publication 442L-UM005B-EN-P - April 2017 97

Appendix B Checklist to Install Electro-sensitive Protective Equipment (ESPE)

Notes:

98 Rockwell Automation Publication 442L-UM005B-EN-P - April 2017

 Appendix C

EU Declaration of Conformity

Certificate See our Product Certification site for Declarations of Conformity, certificates,
and other certification details.

Rockwell Automation Publication 442L-UM005B-EN-P - April 2017 99

Appendix C EU Declaration of Conformity

Notes:

100 Rockwell Automation Publication 442L-UM005B-EN-P - April 2017

 Glossary

The following terms and abbreviations are used throughout this manual. For
definitions of terms that are not listed here, refer to the Allen-Bradley
Industrial Automation Glossary, publication AG-7.1.

AGV Automated Guided Vehicle

ANSI American National Standards Institute

AWG American Wire Gauge. Standardization and classification of wires and cables
by type, diameter, and so on.

AOPDDR Active opto-electronic protective device responsive to diffuse reflection (for

example, SafeZone™ Mini device, see also CLC/TS 61496-3)

Dangerous state The dangerous state (standard term) of the machine is always shown in the
drawings and diagrams of this document as a movement of a machine part. In
practical operation, there can be a number of different dangerous states:
• Machine movements
• Vehicle movements
• Electrical conductors
• Visible or invisible radiation
• Combination of several risks and hazards

EDM External device monitoring

EMC Electromagnetic compatibility

ESD Electrostatic discharge

ESPE Electro-sensitive protective equipment

External device monitoring (EDM) A device that electronically monitors the relay or contactor that is operated by
the protective device before each new start.

Field set Protective fields and warning fields form the so-called field set.

FPLC Fail-safe programmable logic controller

GSP Guardmaster safety relay

Optics cover Plastic part with window for light output. The optics cover is available as a
spare part.

OSSD Output signal switching device. The OSSD output is the switching output on
the SafeZone Mini device that is used to stop the dangerous movement. This
output is a semiconductor output and is periodically tested for correct
function. The SafeZone Mini device has two OSSD outputs that operate in
parallel; for safety reasons these outputs must be evaluated using two channels.

Rockwell Automation Publication 442L-UM005B-EN-P - April 2017 101

Glossary

Protective field The protective field secures the hazardous area on a machine or vehicle. As
soon as the safety laser scanner detects an object in the protective field, it
switches the OSSDs to the OFF state and initiates the shutdown of the
machine or stop of the vehicle.

Remission Reflection of luminance. A measure of the remission is the level of remission

that is defined as the ratio of the luminance reflected from a surface in the
measuring direction and the luminance of a matte white surface
(white standard).

Resolution/object resolution The minimum size of an object the protective device acquires and the
manufacturer certifies.

Restart interlock The restart interlock is a protective device. In certain situations, it helps
prevent the machine from automatically restarting. It applies, for example, after
the scanner function has triggered during a dangerous machine state, after a
change to the operating mode or the method of activation of the machine, or
after the change to the start control device on the machine.

RIA Robotic Industries Association

Safe state in case of an error If the internal error detection detects an error that prevents the correct
operation of the safety component, the safety component adopts a defined safe
state. The safety component remains in this state until the error has been
rectified. Error cases in which the safety component adopts a safe state
includes:
• Safety-related internal errors
• Invalid input signal conditions
• Supply voltage loss
• Loss of the assured detection capability

SCD software Rockwell Automation® Safety Configuration and Diagnostic software (SCD
software). Software for configuration and diagnostics on the SafeZone Mini
device.

Universal I/O The SafeZone Mini device has two universal I/O connections. These two
connections can be configured as inputs (for example, for stand-by, EDM or
reset) or as outputs (for example, for device error, contamination or second
warning field).

Warning field The warning field is a field with a radius of up to 8 m (26.25 ft) (see Scanning
Range on page 83). Using this field, larger areas can be controlled and simple
switching functions (for example, warning functions) triggered. The warning
field is not allowed to be used for tasks that are related to personnel protection.

102 Rockwell Automation Publication 442L-UM005B-EN-P - April 2017

 Index

A D
access protection 44, 46 daily testing 73
application 22, 26 data
device 12 functional 88
example 65 user 25
mobile 48, 66 declaration of conformity
name 25 conformity 99
protective device 15 default delivery status 69
stationary 65 delivery status
horizontal operation 40
vertical operation 44, 46 default 69
audience 7 depth
information 7
description
C product 17
device
calculate
application 12
total response time 84 component 21
care 75 DI
case Guardmaster safety relay
monitoring 37 two SafeZone Mini devices 68
changes diagnostics 79
summary 7 extended 82
checklist interface
manufacturer 97 specification 90
clean diagram
optics cover 75 connection 65, 66
procedure 75 dimension 88
commissioning 71 drawing 91
initial 71 mounting kit 92
component SafeZone Mini 91
device 21 direct mounting 56
configurable direction
function 25 display 26
configuration 69 directives 15
connection display
M8 × 4 64 direction 26
prepare 69 seven-segment
SCD software 69 error 81
specification 90 status indication 81
with restart interlock 31 seven-segment 26
without restart interlock 30 disposal 14
configure distance
protective field 33 minimum 44, 46
warning field 33 drawing
connection
dimension 91
diagram 65, 66
system 62
universal I/O 28
connector
round plug 63
contour
monitoring 20
reference 35
correct use 12

Rockwell Automation Publication 442L-UM005B-EN-P - April 2017 103

Index

E I
EDM 29, 67 indicator
electrical status 23
installation 61 information
notes 62 depth 7
specification 89 label
EMC regulation important information 58
wiring 63 ordering 95
environmental initial commissioning 71
protection 14 inspection
error 79 protective device 73
LED 80 installation
seven-segment display 81 electrical 61
EU protective device 15
declaration of conformity 99 interface
example serial 64
application 65 interlock
external device restart 67
monitoring 29, 67 internal
OSSD 29
items supplied 95
F
fault 79
feature L
special 17 length
field protective field 48
protective 19 lockout operational status 81
warning 19
field set 19, 33
function 17 M
configurable 25 machinery directive 15
functional data 88 maintenance 75
functional earth 63 manufacturer
checklist 97
material 87
G separation 14
general minimum distance 44, 46
specification 87 mobile application 48, 66
glossary 101 notes 48
Guardmaster safety relay restart delay 30
DI mode
two SafeZone Mini devices 68 stand-by 38
SI 67 monitoring
case 37
contour 20
H external device 29, 67
hazardous point protection 46 mounting 39
horizontal operation direct 56
stationary application 40 kit
1or 2 57
3 and 4 58
dimension 92
mounting steps 55
multiple
safety laser scanners 59
sampling 37, 84

104 Rockwell Automation Publication 442L-UM005B-EN-P - April 2017

 Index

N protective measures 13
name publication
application 25 scope 7
scanner 25
near range 54 Q
notes
qualified safety personnel 11
electrical 62
mobile application 48
safety 13
test 72 R
range
near 54
O protective field 27
operation scanning 83
horizontal recommission 77
stationary application 40 reference
principle 18 contour 35
vertical 36 regional
stationary application 44, 46 standards 16
optics cover replace
clean 75 optics cover 76
cleaning procedure 75 procedure 76
replace 76 reset 32
replacement procedure 76
ordering information 95 signal 32
resolution 27
OSSD 29
resources 9
internal 29
response time 27
response time 84
specification 90 OSSD 84
timing behavior 85 total 84
restart
SafeZone Mini 30
P restart delay
parameter mobile application 30
restart interlock 67
system 25
personnel round plug connector 63
qualified safety 11
power-up sequence 71
prepare
S
configuration 69 safety 11
prevent notes 13
unprotected area 53 safety laser scanner
principle of operation 18 multiple 59
product SafeZone Mini
description 17 dimension 91
protection restart 30
sampling
access 44, 46
environmental 14 multiple 37, 84
hazardous point 46 scan plane origin 93
protective device scanner
application 15 name 25
inspection 73 scanning range 83
installation 15 SCD software
protective field 19 configuration 69
configure 33 scope
length 48 publication 7
range 27 separation
size 41
material 14
suggested 34
sequence
width 52
power-up 71
serial interface 64

Rockwell Automation Publication 442L-UM005B-EN-P - April 2017 105

Index

seven-segment display 26 U
error 81 universal I/O
status indication 81
SI connection 28
specification 89
Guardmaster safety relay 67
unprotected area
signal
prevent 53
reset 32 use
size
contour as a reference 35
protective field 41 correct 12
special feature 17
user
specification
data 25
configuration 90
diagnostics interface 90
electrical 89 V
general 87
OSSD 90 vertical operation 36
technical 83 stationary application 44, 46
universal I/O 89
standards 15
regional 16 W
stand-by 29 warning field 19
mode 38 configure 33
stationary application 65 suggested 34
horizontal operation 40 width
vertical operation 44, 46 protective field 52
status wiring
indication EMC regulation 63
LED 80
seven-segment display 81
indicator 23
lockout operational 81
steps
mounting 55
suggested
protective field 34
warning field 34
summary of changes 7
support 79
symbol 8
system
connection 62
parameter 25

T
technical specification 83
test notes 72
testing
daily 73
time
response 27
total response 84
timing behavior
OSSD 85
total response time
calculate 84

106 Rockwell Automation Publication 442L-UM005B-EN-P - April 2017

.

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Supersedes Publication 442L-UM005A-EN-P - October 2014 Copyright © 2017 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.