Manual Instalacion ROD4-3x

rotoScan ROD4-30 / ROD4-36 / ROD4-38
Area Scanning Distance Sensor

DE/GB 00-09/08 50110396
TECHNICAL DESCRIPTION
Leuze electronic GmbH + Co. KG
P.O. Box 1111, D- 73277 Owen / Teck
Tel. +49(0) 7021/ 573-0,
Fax +49(0)7021/ 573-199
info@leuze.de • www.leuze.com
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07/2008
© All rights reserved, especially the right of reproduction, distribution and translation. Copying or
reproductions in any form require the written consent of the manufacturer.
Changes due to technical improvement may be made.
Table of contents
1 General information ........................................................................................................... 4

1.1 Explanation of symbols ........................................................................................................ 4
1.2 Declaration of conformity ..................................................................................................... 4
2 Safety notices..................................................................................................................... 5
2.1 Safety standards .................................................................................................................. 5
2.2 Application conditions and intended use.............................................................................. 6
2.3 Restrictions with regards to use ........................................................................................... 7
2.4 Working safely ..................................................................................................................... 8
2.5 Organisational measures ..................................................................................................... 9
3 Description ....................................................................................................................... 10
3.1 Technical overview ............................................................................................................ 10
3.2 Operating principle ............................................................................................................. 11
3.3 Special features of the ROD4-3… ..................................................................................... 12
3.4 Detection fields / detection field pairs ................................................................................ 12
3.4.1 Changing over between detection field pairs............................................................................... 12
3.4.2 4-field mode ................................................................................................................................. 15
3.5 Application examples ......................................................................................................... 16
3.5.1 Object detection........................................................................................................................... 16
3.5.2 Object measurement: .................................................................................................................. 18
4 Mounting ........................................................................................................................... 19
5 Electrical connection ....................................................................................................... 20

5.1 Connecting the rotoScan ROD4-3….................................................................................. 20
5.1.1 Pin assignments X1 and X2......................................................................................................... 21
5.1.2 Connector assignments for connection X1 .................................................................................. 22
5.1.3 Connector assignments for connection X2 (RS 232)................................................................... 24
5.1.4 Connector assignments for connection X2 (RS 422)................................................................... 24
5.2 Functions of connection X1................................................................................................ 25
5.2.1 Input circuit .................................................................................................................................. 25
5.2.2 Output circuit................................................................................................................................ 27
5.2.3 RESTART / resetting the data transmission rate to 57600 baud................................................. 28
5.3 Functions of connection X2................................................................................................ 29
5.4 Connection ......................................................................................................................... 29
5.4.1 Electrical supply........................................................................................................................... 29
5.4.2 Fabricating the cable on the sensor side ..................................................................................... 29
5.4.3 Structure of the connector ........................................................................................................... 30
5.4.4 Points to be observed when fabricating and laying the cable...................................................... 31
5.5 Integration in the control system ........................................................................................ 32
5.5.1 Connection example 1: without detection field pair switch .......................................................... 32
5.5.2 Connection example 2: with detection field pair switch ............................................................... 33
Leuze electronic rotoScan ROD4-3… 1

Table of contents
6 Commissioning ................................................................................................................ 34
6.1 Hardware and software requirements................................................................................ 34
6.2 Device configuration .......................................................................................................... 34
6.3 Device configuration with ext. configuration memory / device exchange........................... 36
6.4 Screwing down and aligning the device............................................................................. 37
6.5 Switching on the device ..................................................................................................... 37
7 Testing and maintenance................................................................................................ 38

7.1 Testing ............................................................................................................................... 38
7.2 Cleaning............................................................................................................................. 38
8 Delivery contents and accessories ................................................................................ 39

8.1 Scope of delivery ............................................................................................................... 39
8.2 Accessories........................................................................................................................ 39
8.2.1 Pin assignment for connection cables KB-ROD4-5000 and KB-ROD4-10000 ............................40
8.2.2 BT ROD4 mounting system..........................................................................................................41
9 Technical data .................................................................................................................. 42

9.1 Detection field data ............................................................................................................ 42
9.2 Electrical data .................................................................................................................... 43
9.3 Software............................................................................................................................. 43
9.4 Optical data........................................................................................................................ 44
9.5 Environmental data ............................................................................................................ 46
9.6 Dimensioned drawing ROD4-3…....................................................................................... 47
10 Status messages, errors and error rectification ........................................................... 48

10.1 LED indicators.................................................................................................................... 48
10.2 Status displays................................................................................................................... 50
10.3 Diagnostic codes and causes ............................................................................................ 51
11 Appendix........................................................................................................................... 56
11.1 Terms and abbreviations used with ROD4-3… and the RODsoft software ....................... 56
2 rotoScan ROD4-3… Leuze electronic

Figures and tables
Table 2.1: Standards and directives.............................................................................................. 5

Figure 2.1: Attachment of the stick-on label with warning notices.................................................. 8
Table 3.1: Device types............................................................................................................... 10
Figure 3.1: Measurement ranges and detection fields ................................................................. 10
Figure 3.2: Working range and angular resolution ....................................................................... 11
Figure 3.3: Operating principle ..................................................................................................... 11
Figure 3.4: Configuring detection field pairs 1 through 4 only ...................................................... 13
Table 3.2: Changeover of the detection field pairs via the control inputs.................................... 13
Figure 3.5: Also configuring detection field pairs 5 through 8....................................................... 14
Table 3.3: Changeover of the detection field pairs via the control inputs.................................... 14
Table 3.4: Assignment of detection field to switching output in 4-field mode .............................. 15
Figure 3.6: Application example - height/position detection ......................................................... 16
Figure 3.7: Application example - Protusion detection in high-bay warehouses .......................... 16
Figure 3.8: Application example - automatic parking system ....................................................... 17
Figure 3.9: Application example - 4-field mode ............................................................................ 17
Figure 3.10: Application example - measurement of pallets........................................................... 18
Figure 3.11: Application example - gripping system....................................................................... 18
Figure 5.1: Connecting the rotoScan ROD4-3… .......................................................................... 20
Table 5.1: Connections of the ROD4-3… – X1 and X2............................................................... 21
Table 5.2: SUB-D 15-pin – pin assignments for connection X1 .................................................. 22
Table 5.3: SUB-D 9-pin – pin assignments for connection X2 as RS 232 port ........................... 24
Table 5.4: SUB-D 9-pin – pin assignments for connection X2 as RS 422 port ........................... 24
Figure 5.2: Inputs of interface X1 ................................................................................................. 25
Figure 5.3: Example: Detection field pair switch for a DTS application ........................................ 26
Figure 5.4: Outputs of interface X1............................................................................................... 27
Figure 5.5: Plug wiring.................................................................................................................. 30
Figure 5.6: Connection example without detection field pair switch ............................................. 32
Figure 5.7: Connection example with detection field pair switch .................................................. 33
Figure 6.1: User interface of the configuration software............................................................... 35
Figure 6.2: Switch in the config. connector................................................................................... 36
Figure 6.3: LEDs........................................................................................................................... 37
Figure 8.1: Dimensioned drawing BT ROD4…............................................................................. 41
Table 9.1: Technical data - detection fields................................................................................. 42
Table 9.2: Technical data - electrical data................................................................................... 43
Table 9.3: Technical data - software ........................................................................................... 43
Table 9.4: Technical data - optical data ...................................................................................... 44
Figure 9.1: Object size/diffuse reflection as a function of distance for the ROD4-30/ROD4-36 ... 44
Figure 9.2: Typical beam dimensions for the ROD4-3….............................................................. 45
Table 9.5: Technical data - environmental data .......................................................................... 46
Figure 9.3: Dimensioned drawing ROD4-3… ............................................................................... 47
Figure 10.1: ROD4-3… LED indicators .......................................................................................... 48
Table 10.1: Status displays on the rotoScan ROD4-3................................................................... 50
Table 10.2: ROD4-3… – diagnostic codes, causes and measures............................................... 51
Figure 11.1: Components of the object speed................................................................................ 59
Leuze electronic rotoScan ROD4-3… 3

General information
1 General information
1.1 Explanation of symbols

The symbols used in this technical description are explained below.
Attention!
This symbol appears before text passages which must absolutely be observed. Failure to
heed this information may lead to injuries to personnel or damage to the equipment.
Attention Laser!
This symbol warns of possible danger through hazardous laser radiation.
The laser used in the rotoScan ROD4-3… is an infrared laser device of laser class 1 acc. to
DIN EN 60825-1. Observe the legal and local regulations applicable to the operation of laser
units.
Notice!
This symbol indicates text passages containing important information.
1.2 Declaration of conformity

The rotoScan ROD4-30, rotoScan ROD4-36 and rotoScan ROD4-38 distance sensors have
been developed and produced in accordance with the applicable European standards and
directives.
The rotoScan ROD4-3… distance sensors also fulfil the UL requirements (Underwriters
Laboratory Inc.) for the USA and Canada.
Notice!
The corresponding declaration of conformity can be requested from the manufacturer.
The manufacturer of the product, Leuze electronic GmbH + Co. KG in D-73277 Owen/Teck,
possesses a certified quality assurance system in accordance with ISO 9001.
C UL US
LISTED
4 rotoScan ROD4-3... Leuze electronic

Safety notices
2 Safety notices
2.1 Safety standards

The rotoScan ROD4-30/rotoScan ROD4-36/rotoScan ROD4-38 distance sensor (abbrevi-
ated as ROD4-3… in the following) has been developed, produced and tested subject to the
applicable safety standards. It represents the state of the art.
Standards and directives

The standards and directives which apply in Europe and which are to be observed during
the use and installation of the rotoScan ROD4-3… are listed below:
Standard or EC directive Designation

98/37/EC 1) Machine directive
2006/95/EU, Low voltage directive
2004/108/EU EMC - directive
1) Beginning December 29, 2009, the new edition of machine directive 2006/42/EC is to be
applied.
Table 2.1: Standards and directives
Laser
If the functionality is not ensured, the error output is immediately activated. The laser output
power and the rotational speed of the mirror are continuously monitored by the built-in
control system to ensure that the requirements of laser class I are satisfied.
Reference measurement
TNT 35/7-24V
A reference measurement cyclically controls the measurement function. The following func-
tions are checked on each rotation of the mirror by means of a test object located inside of
the device:
• optical systems (e.g. transmitter and receiver)
• hardware, software, etc.
Window monitoring
A total of six light axes monitor the degree of soiling of the window. During this procedure,
the results are compared with two reference sensors. Moreover, these reference sensors
are used for temperature compensation and ageing monitoring.
Software test
The system is tested when first switched on and during operation.
Leuze electronic rotoScan ROD4-3... 5

Safety notices
2.2 Application conditions and intended use
Attention!
The protection of personnel and the device cannot be guaranteed if the device is operated
in a manner not corresponding to its intended use.
The relevant regulations for machine safety apply to the use of the ROD4-3… The respon-
sible authorities (e.g. the employer's liability insurance association, OSHA) are available for
questions related to issues of safety. In general, the following application conditions are to
be maintained:
• If a protective housing is provided for the sensor, the detection must not occur through
additional window material (plastic, glass, etc.).
• Physical contact with the front cover of the sensor and the six diffused-light windows
is to be avoided.
• The electrical integration of the ROD4-3… in the control must only be performed by
electricians.
• The ROD4-3-… is designed in accordance with safety class III for supply by PELV
(protective extra-low voltage with reliable disconnection).
For UL applications: only for use in class 2 circuits according to NEC.
• The 24VDC power supply must be fed into the sensor via a separate branch by
means of a 2.5A fuse (without heating) or a 4A fuse (with heating), semi time-lag,
installed in the switch cabinet.
• Operation is permitted only with screwed-on control cable (X1) and PC cable (X2) or
dummy connector (X2). This also applies for transport and storage.
• Alarm output 1 (pin 5 at X1) must not be used to switch safety-relevant signals.
• The system (sensor, machine, control and switching components) must only be
tested if no persons are placed at risk by the test.
• Access to or changes on the ROD4-3… could result in the loss of proper device func-
tion.
• Commissioning, maintenance, parameter settings and detection-field configurations
are only to be performed by trained personnel. Knowledge of the safety notices in
these connection and operating instructions and the operating manual for the
RODsoft program is a part of the required skills.
• If the start disable/manual restart is provided, a test of all detection fields should be
performed prior to release - there must not be any objects in the detection fields.

Safety notices
2.3 Restrictions with regards to use

• Glass, highly reflective materials such as mirrors (luminosity coefficient > 10,000%)
as well as objects which do not reflect any light back to the sensor could falsify the
measurement value. Additional notices can be found in chapter 9.4.
• Do not expose the ROD4-3… to flying sparks (e.g. welding sparks); the front cover,
among other parts of the system, will be damaged.
• Vapours, smoke, dust and all particles visible in the air could affect the measurement
values and cause the semiconductor outputs to switch off.
• Avoid large temperature fluctuations.
TNT 35/7-24V

Safety notices
2.4 Working safely

Attention: Invisible laser radiation!
The ROD4-3… distance sensor operates with an invisible infrared laser of class 1 acc.
to EN 60825-1.
The maximum output power of the laser is 15W at a pulse duration of 3ns. The aver-
age laser power is less than 0.39mW in accordance with laser class 1 acc. to EN
60825-1.
The ROD4-3… complies with US rules 21 CFR 1040.10 except for deviations pursuant
to Laser Notice No. 50, dated July 2001.
The use of operating and adjusting devices other than those specified in this techni-
cal description, carrying out of differing procedures, or improper use of the distance
sensor may lead to dangerous exposure to radiation!
The use of optical instruments or devices in combination with the device can increase
the danger of eye damage!
Adhere to the applicable legal and local regulations regarding protection from laser
beams acc. to EN 60825-1 in its latest version. Avoid mounting the distance sensor at
eye level.
The front cover is the only opening through which the laser radiation can escape from
the device. The housing of the ROD4-3… distance sensor is sealed and has no parts
that need to be adjusted or maintained by the user. The device must not be tampered
with and must not be changed in any way!
Figure 2.1: Attachment of the stick-on label with warning notices
Attention!
Access and changes to the device, except where expressly described in this operating man-
ual, are not authorised.

Safety notices
2.5 Organisational measures

Documentation
All entries in this technical description must be observed, in particular those in chapter 2.
Keep this technical description in a safe place. It should be accessible at all times.
Safety regulations
Observe the locally applicable legal regulations and the rules of the employer's liability insur-
ance association.
Qualified personnel
Mounting, commissioning and maintenance of the device may only be carried out by quali-
fied personnel.
Electrical work must be carried out by a certified electrician.
Attention!
Adjustment and change of the detection fields by means of the RODSoft configuration soft-
ware may only be carried out by an authorised person. The password required is to be
stored under lock and key by the designated person.
Repair
Repairs must only be carried out by the manufacturer or an authorised representative.
TNT 35/7-24V

Description
3 Description
3.1 Technical overview
Designation Type Part No.

rotoScan ROD4-30 without heater 501 10238
rotoScan ROD4-36 with integrated heater 501 10666
with integrated heating,
rotoScan ROD4-38 501 10667
dust-insensitive version
Table 3.1: Device types
The ROD4-3… is an optical, two-dimensional measuring distance sensor. It could also be
referred to as an optical, area radar unit. The device periodically transmits light pulses within
an angular range of 190° via a rotating deflector unit.
If the pulses are incident upon objects or obstacles, the light is reflected and then received
and analysed by the ROD4-3…. From the propagation time of the radiated light and the
current angle of the deflector unit, the ROD4-3… unit calculates the exact coordinates of the
object. If the object or obstacle is located within defined detection fields, a stop function is
executed. In this case, the semiconductor switch outputs are switched off within the system
reaction time. The stop function is automatically reset once the detection field is clear or
upon acknowledgement, depending on the operating mode (software configuration: manual/
automatic).
The ROD4-3… can detect objects with diameters greater than 20mm at a distance of up to
4.0m, even if the surface of the given object is dark. Larger objects are detected in the far
detection field at a distance of up to 50m.
Eight reversible detection field pairs (7 configurable + 1 permanently defined) enable optimal
adaptation to the applications.
Measurement range ROD4-30/ROD4-36: max. 65m

Measurement range ROD4-38: max. 25m
Radius of far detection field: max. 50m
Radius of near detection field: max. 30m
Figure 3.1: Measurement ranges and detection fields
The ROD4-3… can be used both on vehicles (mobile object detection for vehicles) as well
as in stationary applications on systems and machines (object detection/measurement). The
long-range and contact-less measurement principle makes the ROD4-3… unit a universally
applicable monitoring device.

Description
3.2 Operating principle

The working range of the ROD4-3… (190°) is divided into 0.36° angular segments (corre-
sponds to 529 measurement values).
0.36°
Working range
Figure 3.2: Working range and angular resolution

Bundled light pulses are generated by a laser diode with coupled transmission optics. These
light pulses are reflected by a rotating mirror in such a way that a light pulse is emitted every
40ms in all angular segments (scanning rate: 25scans/s). If the light pulse is incident upon
an object, it is reflected and subsequently detected and analysed by the ROD4-3….
TNT 35/7-24V
Figure 3.3: Operating principle
The ROD4-3… works on the principle of pulse propagation time measurement. The light
pulse propagation time is a direct measurement of the distance to the object.
Combination of hardware and software

You can configure the ROD4-3… yourself using the supplied RODsoft software. In addition
to the device configuration, the software can also be used to adapt the field pairs to the given
application and to save them in the ROD4-3…
The image of the surroundings generated during the scan process is compared with the
specified detection field contours. If an object violates a detection field for a least one scan
(40ms), a corresponding, user-specific reaction is triggered.

Description
3.3 Special features of the ROD4-3…

• Seven freely configurable near detection fields (up to maximum 30m)
• Seven freely configurable far detection fields (up to maximum 50m)
• Monitoring range up to 190°
• Small construction size (W x D x H: 140mm x 135mm x 155mm)
• Low weight (2kg)
• Low current consumption (ROD4-30 without heating)
• Two interface types on the X2 SUB-D socket (RS 232 and RS 422)
• Easy-to-use RODsoft configuration software
• Measurement value transmission from distances of up to 65m
• Device plug with configuration memory facilitates simple exchange of devices
3.4 Detection fields / detection field pairs

Eight reversible detection field pairs (7 configurable + 1 permanently defined) enable optimal
adaptation to the applications. A detection field pair is considered to be the combination of
both a near and far detection field. The following designations are used in the RODsoft
configuration software:
Detection field pair x consists of detection_field_near x and detection_field_far x.
The near and far detection fields are represented by different colours in the RODsoft config-
uration software: near = red, far = green.
Detection field pairs 1 … 7 can be freely defined by the user. Detection field pair 8 is perma-
nently defined: both detection_field_near 8 as well as detection_field_far 8 are set to zero
here. This means that no area monitoring takes place upon activation of detection field
pair 8.
3.4.1 Changing over between detection field pairs
Attention!
1 or 2 detection field pairs may be simultaneously active and simultaneously moni-
tored!
Only detection field pairs 1 through 4 are configured

If only detection field pairs 1 through 4 are configured in the RODsoft configuration software,
i.e. it is only possible to start with a field pair between 1 and 4 and it is only possible to
changeover between a field pair between 1 and 4, then a maximum of 2 detection field pairs
may be simultaneously active and monitored.

Description
Figure 3.4: Configuring detection field pairs 1 through 4 only

The four control inputs FPS1 … FPS4 can be used to change over between the detection
field pairs. The following table shows the admissible control options.
Control input
Meaning
FPS1 FPS2 FPS3 FPS4
0 0 0 0 Detection field pair 1 is active
1 1 0 0 Detection field pairs 1 and 2 are active
TNT 35/7-24V
1 1 1 0 Not permitted
Table 3.2: Changeover of the detection field pairs via the control inputs
If an inadmissible state exists at the control inputs for more than 80ms, the sensor switches
to the error state.

Description
One of detection field pairs 5 through 8 is also configured

If, in addition detection field pairs 1 through 4, at least one of detection field pairs 5 through
8 is also configured in the RODsoft configuration software, i.e. it is possible to start with a
field pair between 1 and 7 and it is possible to changeover between a field pair between
1 and 8, then only 1 detection field pair may be simultaneously active and monitored.
Figure 3.5: Also configuring detection field pairs 5 through 8
In this case, the four control inputs can be used to change over between the detection field
pairs as follows.
Control input
Meaning
FPS1 FPS2 FPS3 FPS4
Table 3.3: Changeover of the detection field pairs via the control inputs

Description
While changing over between 2 detection field pairs, inadmissible states at the control inputs
are tolerated for a duration of 40ms; after this period the sensor switches to the error state.
The changeover between 2 detection field pairs occurs within a system reaction time of
80ms.
3.4.2 4-field mode

In 4-field mode (configuration via RODsoft), all 4 detection fields of detection field
pairs 1 and 2 are simultaneously activated and evaluated. In this case, a separate output is
assigned to each detection field pair.
Switching output
Detection field
Fn1 Fn2 ALARM1 ALARM2
Detection_field_near 1 X
Detection_field_near 2 X
Detection_field_far 1 (X)
Detection_field_far 2 X
Table 3.4: Assignment of detection field to switching output in 4-field mode
Inputs FPS1 … FPS4 are not evaluated in 4-field mode. Detection field changeover is not
possible in 4-field mode.
Attention!
Depending on the configuration, output ALARM1, in some cases, also signals device warn-
ings. This means that a violation of detection_field_far 1 is not uniquely signalled under cer-
tain circumstances.
All outputs are switched off during start-up. Outputs ALARM1 and ALARM2 are activated
during configuration.
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Notice!
Operation with 3 detection fields
If only three detection fields are to act on three outputs, only use detection_field_near 1,
detection_field_near 2 and detection_field_far 2 and set the alarm signal type for ALARM1
to "Device warning". The output will then only signal device warnings and is, as a result,
unique.
Operation with 2 detection fields
If only two or fewer independent outputs are needed, 4-field mode is not required and should
be deactivated with the appropriate RODsoft parameter.

Description
3.5 Application examples

The following examples can be considered typical areas of application for the ROD4-3….
3.5.1 Object detection
Height/position detection
Height and position detection of objects for collision prevention.
Figure 3.6: Application example - height/position detection
Protusion detection in high-bay warehouses

Overshoot detection for collision prevention with high-bay storage devices.
Figure 3.7: Application example - Protusion detection in high-bay warehouses

Description
Automatic parking system

Protrusion detection in parking systems under changing environmental conditions.
Figure 3.8: Application example - automatic parking system
4-field mode
Presence detection on the transport system with 4 independent detection fields.
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Figure 3.9: Application example - 4-field mode

Description
3.5.2 Object measurement:
Measurement of pallets
Contour measurement, determination of X, Y coordinates.
Figure 3.10: Application example - measurement of pallets
Manipulator positioning
Compact construction and low weight enable use on gripping head.
Figure 3.11: Application example - gripping system
Other applications
• Buffing protection (e.g. for telpher lines)
• Overshoot detection (e.g. in fully automatic parking systems)
• Detection / counting of persons
• Room security / façade monitoring
• Access control
• Contour measurement
• Packet measurement / volume measurement
• etc.

Mounting
4 Mounting
The ROD4-3… should be mounted so that the area which is to be monitored is covered by
the corresponding detection field.
Attention!
Because of the optical scanning principle, only objects with good reflective properties are
detected directly in front of the sensor window.
Physical damage to the sensor (e.g. due to collision or climbing on) should be prevented by
using a protective enclosure. If using an enclosure, the entire front cover of the device must,
however, remain unobstructed.
In order for the ROD4-3… to function optimally, it must be mounted in a favourable position.
You should make every effort to observe the following points:
• Position the ROD4-3… in a protected location.
• The mounting location and the electrical supply should be located as close as possi-
ble to one another.
• The ROD4-3… is to be mounted so that the area which is to be monitored is com-
pletely covered by the detection field.
• The mounting position of the sensor must offer protection from humidity, soiling, as
well as temperatures below 0°C (ROD4-30) or -20°C (ROD4-36, ROD4-38) and
above 50°C.
• The mounting location is to be selected such that the possibilities for mechanical
damage are minimised. Exposed locations are to be equipped with additional protec-
tive guards or loop guards.
• Reinforcements, enclosures, mounting alcoves and other machine elements must not
result in an obstruction in the sensor's field of vision.
• Retro-reflectors or very reflective surfaces, such as certain metals or ceramics, are to
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be avoided near the detection fields and at the height of the scanning plane as these
may result in measurement errors.
• To ensure a constant detection height at every point in the detection field, the sensor,
and thus the beam plane, is to be mounted parallel to the reference plane.
• If the sensor is used without start disable or start test with automatic start/restart, a
start warning (optical/acoustic) is to be provided.
• The sensor must not be used as a climbing aid. If there is a risk of this, a suitable,
inclined (45°) protector is to be mounted.
• If two sensors are used, they should be angled slightly with respect to one another or
be mounted at different heights.
The device dimensions and the reference of the scanning plane to the device edges can be
found in the dimensioned drawing (see figure 9.3 on page 47). Here, the zero point for the
distance measurement is the axis of rotation of the rotating mirror (a in figure 9.3).
BT ROD4… mounting system see chapter 8.2.2.
Notice!
Under certain circumstances, a larger measurement inaccuracy may occur with strongly re-
flective backgrounds (e.g. retro-reflectors, polished metal, etc.).

Electrical connection
5 Electrical connection
5.1 Connecting the rotoScan ROD4-3…

To configure the sensor, connect the control cable (KB-ROD4-…, socket X1) to the power
supply and the interface cable (KB-ROD4PC-…, socket X2) to the PC or laptop. Before
commissioning the system, please check the pin assignments, the wiring, the supply voltage
and the safeguarding. In spite of the sensor's robust housing and fittings, which include
various internal safety mechanisms, damages resulting from misconnection cannot be
excluded.
b
c
STOP ok.
ok.
ele ctronic
Leuze
a Connection for configuration only

b Dummy connector
c Connector X1 (15-pin, SUB-D)
d Connector X2 (9-pin, SUB-D)
Figure 5.1: Connecting the rotoScan ROD4-3…
Attention!
In normal operation, you must permanently connect the two Sub-D connectors to the
ROD4-3…. If one of the two connectors is missing, the ROD4-3… no longer has protection
class IP 65.

5.1.1 Pin assignments X1 and X2
Connection Connector Signals

• Power supply
• Switching outputs/alarm output
X1 SUB-D 15-pin • Inputs for field pair switch
• Restart/reset input
• Configuration connector
rotoScan ROD4-3… <–> PC interface
• Parameter configuration
X2 SUB-D 9-pin • Detection field definition
• Measurement data transmission
• Diagnostics
Table 5.1: Connections of the ROD4-3… – X1 and X2
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5.1.2 Connector assignments for connection X1
PIN Signal Description Wire colour

KB-ROD4-…
1 GND Supply voltage ground black
Safe input "restart-disable", reset the
2 Restart sensor and connection of the restart blue
button
3 UB Supply voltage +24VDC red
4 FPS1 Changeover of detection field pairs orange
Output for object detection in the far
detection field and for warning mes-
sages such as "Window lightly soiled"
5 ALARM1 or "Window heavily soiled" (configura- yellow
ble).
4-field mode: Output for object detec-
8 tion in detection_field_far 1
15
7 6 FPS2 Changeover of detection field pairs green
14
6 7 FPS3 Changeover of detection field pairs violet
13
5 8 FPS4 Changeover of detection field pairs grey
12
4 9 NC Do not use! –
11
3 10 NC Do not use! –
10
2 Semiconductor output, shutdown on
9
1 object detection in the near detection
11 Fn1 field, channel 1. white
tion in detection_field_near 1
Semiconductor output, shutdown on
object detection in the near detection
12 Fn2 field, channel 2. white/black
tion in detection_field_near 2
13 NC Do not use! –
14 NC Do not use! white/brown
Warning and error output
15 ALARM2 4-field mode: Output for object detec- brown
tion in detection_field_far 2
Table 5.2: SUB-D 15-pin – pin assignments for connection X1

Attention!
Any additionally used switching components (e.g. button for restarting) must be permanently
mounted.
• Loosely position the button at the intended position.

• Switch on the voltage supply of the ROD4-3… which has been configured for the
application.
• Violate the active near detection field, e.g. by entering it. The violation is indicated by
the following status display (see also chapter 10.1):
Red LED illuminated: Yellow LED with continuous light:

outputs Fn1 and Fn2 disabled restart-disable active
• Now actuate the restart button and observe the left, green LED. If this LED illumi-
nates, you are no longer in the near detection field and the location of the button is
suitable. If the LED does not illuminate, there are still objects located within the near
detection field. In this case, change the location of the button and perform the test
again.
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5.1.3 Connector assignments for connection X2 (RS 232)
PIN Signal Description

1 NC Do not use!
2 TxD Data communication, transmission
3 RxD Data communication, reception
1
6 4 NC Do not use!
2
7 Ground/shielding (to be connected only on the cabinet
3 5 GND/shield
8 side with PE)
4 Selection RS 232/RS 422,
9
5
6 RS 232
selection as RS 232 interface: do not use!
7 NC Do not use!
8 NC Do not use!
9 Reserved Reserved for test purposes, not wired
Table 5.3: SUB-D 9-pin – pin assignments for connection X2 as RS 232 port
5.1.4 Connector assignments for connection X2 (RS 422)
Notice!
If you would like to work with an RS 422 interface, you must connect PIN 6 with PIN 5 (GND)
by means of a bridge.
PIN Signal Description

1 TxD+
RS 422 transmitted data
2 TxD-
1
6 3 RxD-
2 RS 422 received data
7 4 RxD+
3
8 Ground/shielding (to be connected only on the cabinet
4 5 GND/shield
9 side with PE)
5
Selection RS 232/RS 422,
6 RS 422
selection as RS 422 interface: bridge to PIN 5!
7 NC Do not use!
Connection 8 NC Do not use!
PIN 5 to PIN 6
9 Reserved Reserved for test purposes, not wired
Table 5.4: SUB-D 9-pin – pin assignments for connection X2 as RS 422 port

5.2 Functions of connection X1
5.2.1 Input circuit

There are two Sub-D connections on the top of the device. At connection X1 with the 15-pin
Sub-D connector, a ready-made cable (KB-ROD4-…) or a cable self-made by the customer
is attached to the solder connections of the connector (connector set KD-ROD4-X1) by
means of soldered connections (see figure 5.5).
3,3k
X1-...
1k 0,1uF
X1-3
Figure 5.2: Inputs of interface X1
Inputs FPS1 … FPS4

With the ROD4-3…, it is possible to work with up to eight detection field pairs. Use inputs
X1-4 (FPS1), X1-6 (FPS2), X1-7 (FPS3) and X1-8 (FPS4) to switch between the detection
field pairs.
Detection field pairs are activated by applying +24VDC (logic: 1) to the appropriate inputs.
If no input is wired, detection field pair 1 is activated.
Notice!
The configuration-dependent changeover of detection field pairs is described in chapter
3.4.1 on page 12.
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Attention!
If an inadmissible signal combination (e.g. 1-1-1-1) is applied at inputs FPS1 …FPS4, a
warning is output at output ALARM2 and outputs Fn1/Fn2 are switched off. In addition,
an error is transmitted via the serial interface and stored in the error memory.

The following situation would be possible with a DTS application (see figure 5.3):
The vehicle enters an intersection area while detection field pair 1 (I) is activated (c). To
prevent objects from colliding, detection field pair 2 (II) is switched on as well before the
curve ("). Both detection fields (I + II) are now active. Detection field pair 1 (I) is switched
off. The vehicle travels around the curve with detection field pair 2 (II) active ("). Afterward,
detection field pair 1 (I) is switched back on as well ("). Both detection fields (I + II) are
active.
Detection field pair 2 (II) is switched off. The vehicle continues to travel with detection field
pair 1 (I) active (").
" "
"
DT
DT
I I + II II
T
D
Direction of movement
I + II
"
DT
c
DT
Movement path
Figure 5.3: Example: Detection field pair switch for a DTS application

5.2.2 Output circuit

The signal outputs are used to control indicator lamps or relays which indicate the device
status. This is switched by a transistor output with open collector set to "active high" (oper-
ating voltage).
20 - 30 VDC
X1-2
100 mA (max. 250 mA)

X1-...
10 k
GND
X1-1
Figure 5.4: Outputs of interface X1
"Fn1" (X1-11) and "Fn2" (X1-12)

These two semiconductor outputs report violation of the near detection field. X1-11 and
X1-12 = "active high" signals that no object is located in the near detection field. The "low"
state signals the detection of an object in the near detection field (see chapter 3.4 "Detection
fields / detection field pairs").
Attention!
Outputs "Fn1" and "Fn2" are tested alternately. For this purpose, the output signals are re-
moved alternately every 20ms for a duration of 100µs. For this reason, the load must dem-
onstrate lowpass characteristics, limit frequency fg ≤ 1kHz.
The outputs must not be short-circuited. It is not permissible to connect together the
outputs of two sensors.
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"ALARM1" (X1-5)
This output is configured via the RODsoft configuration software.
X1-5 = "active high" signals that the device is ready for operation. The "low" output state
signals one of the following states:
1. Possibility: Object detection in the far detection field.
2. Possibility: Device warning, e.g light window contamination, etc.
3. Possibility: Object detection in the far detection field or device warning, e.g. light win-
dow contamination, etc.
4. Possibility: No signalling.
5. Possibility: Device error, e.g. faulty reference measurement.
Notice!
A device error output at alarm output "ALARM2" is also always output at alarm output
"ALARM1", independent of how alarm output "ALARM1" was configured.

Notice!
In 4-field mode, output "ALARM1" (X1-5) signals object detection in detection_field_far 1. To
ensure the uniqueness of the signal, you should configure alarm output "ALARM1" so that
only "object detection in the far detection field" is signalled.
"ALARM2" (X1-15)
The "low" output state always signals a device warning or device error, independent of how
output "ALARM1" (X1-5) is configured.
Notice!
A device error output at alarm output "ALARM2" is also always output at alarm output
"ALARM1", independent of how alarm output "ALARM1" was configured.
In 4-field mode, output "ALARM2" (X1-15) signals object detection in detection_field_far 2.
5.2.3 RESTART / resetting the data transmission rate to 57600 baud

The RESTART input X1-2 has, depending on operating status, several functions:
• Release of the restart-disable following object detection in the detection field.
• Release of the start disable following a system start.
The functions are activated by applying +24VDC to input X1-2 of an operationally ready
ROD4-3…. Outputs Fn1 and Fn2 are switched off in the meantime; the display on the sensor
(LED No. 3) illuminates red. A voltage of +24VDC must be applied to the RESTART input
for between 0.12s and 3s.
Restart input X1-2 must be connected to an external, permanently mounted button. X1-2
must not be connected to the rest of the control as, under certain conditions, the application
of a restart pulse could result in an unintended release.
Hardware reset/resetting the data transmission rate to 57600 baud

For this purpose, the ROD4-3… must first be de-energised. By applying +24VDC for a
duration of 2 … 4s at input X1-2 during the power-on procedure, the data transmission
rate of the RS 232/RS 422 is reset to 57600 baud.
Attention!
Do not interrupt the supply voltage during this reset procedure under any circumstances!
Prematurely interrupting the reset procedure for resetting the data transmission rate can put
the ROD4-3… in an irreversible error state which can only be corrected by the manufacturer!

5.3 Functions of connection X2

At connection X2 (9-pin Sub-D socket), either an RS 232 or 422 interface is available. It is
used to
• configure the ROD4-3…,
• transfer measurement data during scanner operation.
• analyse the coordinates during the configuration
(e.g. for DTS applications).
• diagnose errors and perform troubleshooting.
By default, the connector housing for the X2 9-pin Sub-D connection is delivered with a PG
dummy cable gland. If the connection is not used, this connector housing ensures protection
class IP 65.
We recommend using the prefabricated cable KB-ROD4PC-… (accessory) for configuring
the ROD4-3… For information on fabricating cables yourself, please proceed according to
chapter 5.4.2. After configuring, remount the connector housing with the PG dummy cable
gland.
5.4 Connection
5.4.1 Electrical supply

The ROD4-3… requires a DC voltage of +24VDC for its electrical supply. The power
consumption is
• for the ROD4-30 (without heating) max. 8W
• for the ROD4-36 and ROD4-38(with heating) max. 50W
plus the load at the outputs (max. 20W).
The power supply must be fed in via an external fuse (e.g. in a switch cabinet) 2.5A semi
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time-lag (ROD4-30) or 4A semi time-lag (ROD4-36, ROD4-38). Furthermore, upstream of
the safeguarding, a constant current of 2.5A or 4A, respectively, is to be provided to ensure
that the fuse can be tripped in the event of failure.
5.4.2 Fabricating the cable on the sensor side

The delivery contents include three connector housings with screwed cable gland. Two are
required for holding the 9-pin SUB-D-connector and the 15-pin SUB-D-socket (PC and
control cable). One housing serves to protect interface X2 if no data communication is
desired with the PC.
The cable screw fittings can be used with cable diameters from 6.5mm to 10.5mm.

X1
3
35
X2
3
35
Figure 5.5: Plug wiring
Attention!
Please note that the connector housing of the control cable must be securely screwed to in-
terface X1, and the connector housing of cable X2, or the X2 dummy cap (without cable),
must be securely screwed to the ROD4-3… Corresponding threaded pins can be found on
the top side of the sensor housing.
If one of the two connector housings is missing, the ROD4-3… no longer meets protection
class IP 65. The connector assignments can be found in chapter 5.1.
5.4.3 Structure of the connector

Each connector housing consists of the following individual parts:
• Housing with sealing ring and locating pins.
• Cable screw fittings (M16) with dummy plugs.
• Sub-D 9-pin plug or Sub-D 15-pin socket, each with solder connection
Notice!
Information on using the config. connector at connection X1 can be found in chapter 6.3.

5.4.4 Points to be observed when fabricating and laying the cable

• The core cross section of the individual cable strands for connection X1 must be
at least 0.5 mm2.
• Select a cable outer diameter between 6.5mm and 10mm.
• Maximum length of the cable for connection X1: 50m.
• Maximum length of the cable for connection X2: 10m (for RS 232).
• Maximum length of the cable for connection X2: 50m (for RS 422, twisted pair).
• Use shielded cable.
• On the switching cabinet side of the system, the cable shielding must only be
connected to PE.
• The cables must not be laid unsecured.
Sensor control cables must not be laid bunched together parallel to the power supply lines
for machines. Inductive interference factors related to high-current-carrying motors are
reduced in this way. Furthermore, the cables are to be routed in such a way that no damage
(e.g. due to crushing) can occur.
As an option, sensor-side prefabricated cables are available in various lengths and for both
interfaces.
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5.5 Integration in the control system

The two following examples illustrate possibilities for connection to a control system.
After connecting the operating voltage PIN X1-3 (+UB) to PIN X1-1 (GND) and activating at
least one of the detection field pairs (X1-4, X1-6, X1-7 or X1-8, see chapter 5.2.1), the device
is ready for operation.
5.5.1 Connection example 1: without detection field pair switch
Integrating the ROD4-3… with discrete external wiring with relay or contactor
without detection field pair switch:
rotoScan ROD4-3…
RESTART
X1 Y1
ALARM1
ALARM2
FPS1
FPS2
FPS3
FPS4
GND
VCC
Fn1
Fn2
k1 k2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
WA
k1 k2 k1 k2
Z1
K1 K2
k1
Sl 2
k2
0V 24VDC
+20% / -30%
Figure 5.6: Connection example without detection field pair switch
With this connection example, the restart-disable is realised by means of the command
device "WA" connected at the RESTART input (X1-2). The device must, in this case, be
configured with the software in such a way that the operating mode "with restart-disable" is
active.
In this example, no detection field changeover is provided; only detection field pair 1 is
active. For this purpose, directly connect FPS1 (X1-4) to the operating voltage VCC. The
relays K1 and K2 used here have overlapping contacts (make before break) and are oper-
ated directly at the two semiconductor outputs Fn1 (X1-11) and Fn2 (X1-12).
The two semiconductor outputs possess an internal electronic current limit and are
protected in the event of errors by fuse SI 2.

5.5.2 Connection example 2: with detection field pair switch
Integrating the ROD4-3… with discrete external wiring with relay or contactor
with detection field pair switch:
rotoScan ROD4-3…
RESTART
X1 Y1
ALARM1
ALARM2
FPS1
FPS2
FPS3
FPS4
GND
VCC
Fn1
Fn2
k1 k2
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
WA S1 S2 S3 S4
k1 k2 k1 k2
Z1
K1 K2
k1
SI 2
k2
0V 24VDC
+20% / -30%
Figure 5.7: Connection example with detection field pair switch
In this example, a detection field changeover between up to 8 detection field contours is

possible via inputs X1-4 (FPS1), X1-6 (FPS2), X1-7 (FPS3) and X1-8 (FPS4) (one near and
one far contour for each). The restart-disable and contactor monitoring are realised via the
RESTART input.
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The ROD4-3… is operated in this case in the operating mode "with restart-disable". The
currently active, violated detection field is released by the command device "WA". The relays
K1 and K2 used here have overlapping contacts (make before break) and are operated
directly at the two secure semiconductor outputs Fn1 (X1-11) and Fn2 (X1-12).

Commissioning
6 Commissioning
By means of appropriate configuration with the aid of the RODsoft configuration software,
the ROD4-3… can be adapted to the given application conditions.
Notice!
The ROD4-3… models can only be configured with version 1.16 of the RODsoft config-
uration software and higher.
6.1 Hardware and software requirements

First steps with the device require the basis ROD4-3… unit, an interface cable and a PC.
For the voltage supply, a power supply unit possessing the characteristics described in
chapter "Technical data" on page 42 is required.
The PC used should meet the following requirements:

• Intel® processor at Pentium® level or faster (or compatible models, e.g. AMD®)
• At least 16 MB RAM
• CD-ROM drive
• Hard disk with at least 20 MB available memory.
• Free RS 232 interface (serial) or alternatively RS 422
• Microsoft® Windows 95/98/NT/2000/XP
The supplied installation CD-ROM is required for installing the RODsoft configuration soft-
ware. The setup program is located on the CD-ROM. This program launches a self-explan-
atory installation routine. After the installation, the program is ready to be started.
6.2 Device configuration

For the device configuration, you require the configuration software "ROD-Soft", which is
included in the delivery contents.
Notice!
The description of the program can be found in the user manual, which is also included in
the delivery contents.
Attention!
We assume here, that you perform the user-specific configuration of the ROD4-3… using
this user manual.
Commissioning procedure:
• Install the configuration software on the PC (setup.exe)
• Connect the ROD4-3… to the PC using a standard 9-pin sub-D cable
• Enter password "ROD4LE" in level "authorised customer"

Commissioning
Short description:
The current measurement values and detection fields can be displayed under "Display
measurement diagram". Under "Configuration" the response times, the detection field
switches and other parameters are defined. To configure the detection fields, select the
"Define detection fields" field. Error codes and other information are contained in the
"system data".
A detailed description can be found in the user manual for the RODsoft configuration soft-
ware.
Current measurement
values (yellow line)
Far detection field

(green line)
Near detection field

(red line)
Figure 6.1: User interface of the configuration software
Attention!
Before commissioning the device, you must adjust the device parameters and the detection
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fields for your application. To do this, configure the ROD4-3… using the software user man-
ual so that the detection fields are optimised for the monitoring task.

Commissioning
6.3 Device configuration with ext. configuration memory / device

exchange
The optional connection cable with configuration memory is used for supplemental, perma-
nent storage (backup) of the ROD4-3… device configuration in a memory module
(EEPROM) which is integrated in the connector housing.
The ROD4-3… can be connected via the standard X1 connection cable or the connection
cable with integrated configuration memory (see chapter 8.2 "Accessories"). The cable with
configuration memory has the same assignments as the standard connection cable.
If the cable with configuration memory is used, note the position of the slide switch which is
integrated in the connector.
L R
1 X
Figure 6.2: Switch in the config. connector
The switch position (see figure 6.2) defines how the configuration memory functions:
• Position "1" - left: the ROD4-3… loads the configuration stored in the configura-
tion memory of the cable when the device is switched on
(standard setting).
• Position "X" - right: the configuration memory of the cable loads the configuration
stored in the ROD4-3… when the device is switched on.
Notice!
The default position of the slide switch is position "1". Position "X" is only necessary in ex-
ceptional cases; this is used to copy the sensor configuration to the cable.
When the device is switched on, a check is performed to determine whether the configura-
tion in the sensor matches that in the configuration memory. If this is the case, the sensor
starts up as usual.
If the configurations do not match, then, depending on the position of the switch in the
connector, the configuration is either transferred from the configuration memory to the
ROD4-3… or vice versa.
Successful transfer is signalled by brief flashing of the two yellow LEDs 2 and 5 on the
ROD4-3…. The configurations stored in the configuration memory and in the ROD4-3… now
match. Afterward, the sensor starts up again as usual.

Commissioning
Notice!
The configuration memory of a ROD4-3… is incompatible with that of a ROD4…/ROD4-2…
and, after used once, cannot be used in the respective device of the other type.
Using the external configuration memory / exchanging devices

If you configure the ROD4-3… with the RODsoft software and save the configuration in the
ROD4-3…, the old configuration in the configuration memory is set to "invalid" and the new
configuration is automatically loaded in the configuration memory of the connection cable
the next time the sensor is started.
In the event of a device failure, disconnect the defective ROD4-3… from power, install the
replacement device and switch the operating voltage back on. The configuration saved in
the configuration memory is now transferred to the new device as described above.
Notice!
You can also use the connection cable with configuration memory to load the same config-
uration in several ROD4-3… devices without having to connect a PC/notebook.
6.4 Screwing down and aligning the device

The ROD4-3… is to be mounted and aligned as described in chapter 4.
6.5 Switching on the device

Once the device is installed, the required device parameters set and the detection fields
TNT 35/7-24V
defined, the ROD4-3… can be put into operation.
After you have switched on the voltage supply for the ROD4-3…, the red LED illuminates at
first. After the red LED switches off (for free near detection field only), the ROD4-3… is
ready.
Figure 6.3: LEDs

Testing and maintenance
7 Testing and maintenance
7.1 Testing
The response of the detection field should be checked annually to ensure availability.
7.2 Cleaning
The front cover and the aperture plates of the window-monitoring photoelectric sensors
should be cleaned at regular intervals (application dependent) with a soft cloth and commer-
cially available, non-aggressive glass cleaner.
Attention!
Do not use solvents or cleaning agents containing acetone. Use of improper cleaning agents
can damage the optical window.
If window monitoring continues to report a soiled cover even after cleaning the front cover
and the aperture plates of the window-monitoring photoelectric sensors, the front cover must
be replaced. In this case, please contact the Leuze electronic service department.
Attention!
When replacing the front cover, the ROD4-3… must always be disconnected from the volt-
age supply. The replacement must only be performed by trained personnel in a clean envi-
ronment.

Delivery contents and accessories
8 Delivery contents and accessories
8.1 Scope of delivery

The basic unit consists of:
• rotoScan ROD4-3…
• 2 hoods with integrated connectors with dummy plugs, including plugs for solder con-
nection
• RODsoft configuration software
• rotoScan ROD4-3… technical description
• user manual for RODsoft configuration software
8.2 Accessories
The following accessories are available:
Part No. Type designationRemark

Connection cable for ROD4-3x, Sub-D socket on one end, 15-pin,
501 08138 KB-ROD4-CP-5000
with configuration memory, cable length 5m
Connection cable for ROD4-3x, Sub-D socket on one end, 15-pin,
501 08139 KB-ROD4-CP-10000
with configuration memory, cable length 10m
Configuration cable for ROD4-3, Sub-D socket/Sub-D connector,
500 38069 KB-ROD4PC-3000
9-pin, cable length 3m
Configuration cable for ROD4-3, Sub-D socket/Sub-D connector,
500 38070 KB-ROD4PC-10000
9-pin, cable length 10m
Connection cable for ROD4-…, Sub-D socket on one end, 15-pin,
500 38067 KB-ROD4-5000
cable length 5m
Connection cable for ROD4-…, Sub-D socket on one end, 15-pin,
500 38068 KB-ROD4-10000
cable length 10m
500 38072 KD-ROD4-X1 Sub-D socket with housing, 15-pin, for connection X1
500 38073 KD-ROD4-X2 Sub-D socket with housing, 9-pin, for connection X2
TNT 35/7-24V
500 38066 BT ROD4 Mounting system for ROD4-3…
RODsoft configuration software for ROD4-3…,
– RODsoft
free download from www.leuze.de

8.2.1 Pin assignment for connection cables KB-ROD4-5000 and KB-ROD4-10000
12-wire connection cable (15-pin Sub-D socket, one end)
PIN Signal Core colour

1 GND black
2 Restart blue
3 UB red
8
15 4 FPS1 orange
7
14 5 ALARM1 yellow
6 6 FPS2 green
13
5 7 FPS3 violet
12
4 8 FPS4 grey
11
3 9 NC –
10
2 10 NC –
9 11 Fn1 white
1
12 Fn2 white-black
13 NC –
14 NC white-brown
15 ALARM2 brown

8.2.2 BT ROD4 mounting system

The ROD4-3… can be fastened using the holes on the rear of the device. No mounting kit
is necessary in this case.
It is, however, recommended that the ROD4-3… be mounted with the aid of the
BT ROD4 mounting system. The advantage of this mounting variant lies in the exchangea-
bility of the device. The device can, in this way, be removed from the mounting system and
returned at a later time without readjusting the device.
With the aid of the BT-ROD4 mounting system, pitches of maximum 8° downward or upward
are possible. In addition, the mounting kit allows lateral inclinations of up to ±4°.
Lateral view
Sensor mounting surface Part overview
TNT 35/7-24V
All dimensions in mm
Figure 8.1: Dimensioned drawing BT ROD4…

Technical data
9 Technical data
9.1 Detection field data

Radius of near detection field 0 … 30m 1)
ROD4-30/ROD4-36: from min. 1.8% (matte black)
Reflectivity
ROD4-38: from min. 6%
Object size see figure 9.1
Response time at least 40ms (corresponds to 1 scan)
Number of detection field pairs 8 (selectable via switching inputs)
Output two PNP transistor outputs, 24V/250mA
the start-up testing and start disable are configured
Start-up
separately.
Far detection field

Radius of far detection field 0 … 50m1)
ROD4-30/ROD4-36: from min. 1.8% (matte black)
Reflectivity
ROD4-38: from min. 6%
Response time at least 40ms (corresponds to 1 scan)
Number of detection field pairs 8 (selectable via switching inputs)
max. 2 PNP transistor outputs, max. 100mA
Output
(configurable)
1) Particularly in the far range, the ROD4-38 only detects large objects and objects with high
diffuse reflection
Object measurement
ROD4-30/ROD4-36: 0 … 65m
Measurement range
ROD4-38: 0 … 25m
Luminosity coefficient see figure 9.1
Output serial interface RS 232, RS 422
Distance resolution 5mm
Angular resolution 0.36°
Repeatability ± 15mm
Table 9.1: Technical data - detection fields

Technical data
9.2 Electrical data

Power supply
Voltage supply1) +24VDC +20% / -30%, safety class III
via fuse 2.5A (4A with heating) semi time-lag in the
Overcurrent protection
switch cabinet
Current consumption approx. 400mA (approx. 2.5A with heating)
Power consumption 10 … 50W at 24VDC
Overvoltage protection overvoltage protection with protected limit stop
Voltage dips acc. to EN 61496-1 (VDE 0113, part 201)
1) Protective Extra Low Voltage (PELV) - protective extra-low voltage with reliable disconnec-
tion.
For UL applications: only for use in class 2 circuits according to NEC.
Inputs
Release of the restart-disable following object detec-
tion in the detection field or release of the start disable
Restart/Reset
following a system start or reset of the data transmis-
sion rate to 57600 baud. See chapter 5.2.3.
selection between max. 8 detection field pairs via four
Detection field pair switch control lines with internal monitoring, 24VDC opto-
decoupled
Outputs
2x semiconductor output, PNP max. 250mA short-circuit
For near detection field
monitored, overcurrent protected, load must demonstrate
TNT 35/7-24V
(Fn1, Fn2)
lowpass characteristics, limit frequency fg ≤ 1kHz
For far detection field / PNP transistor output, max. 100mA,
soiling (ALARM1) configurable
For far detection field /
PNP transistor output, max. 100mA,
warning and error output
configurable
(ALARM2)
Table 9.2: Technical data - electrical data
9.3 Software
Configuration
"RODsoft" configuration software under Windows 9x/NT/
Configuration software
2000/XP
Interfaces
RS 232, RS 422 device configuration and measurement data transmission
Table 9.3: Technical data - software

Technical data
9.4 Optical data
Optical properties
Angular range max. 190°
Angular resolution 0.36°
Scanning rate 25scans/s or 40ms/scan
1 acc. to EN 60825-1, infrared laser diode,
Laser class wavelength: 905nm, Pmax: 15W, pulse duration: 3ns,
average output power: 12µW
approx. 15mm diameter, distance dependent,
Laser beam
see figure 9.2
Table 9.4: Technical data - optical data
Object size [mm]

10000
1000
100
50
25
12,5
10
1 2 4 8 10 15 20 100
Distance [m]
Remission [%]
10000
Reflector
1000
White plaster, writing paper 100
Grey cardboard (18%)

10
Black cord 1.8
1 2 4 8 10 15 20 100
Distance [m]
Figure 9.1: Object size/diffuse reflection as a function of distance for the ROD4-30/
ROD4-36

Technical data
Beam dimensions in mm
140
120
Y
Light spot height Y 100
80
60
Light spot width X 40

X
20
0
0 5 10 15 20 25 30
Distance [m]
Figure 9.2: Typical beam dimensions for the ROD4-3…
TNT 35/7-24V

Technical data
9.5 Environmental data
Environmental and material data

Protection class IP 65 acc. to IEC 60529
Contact protection all-insulated, safety class III
Operating temperature 0°C … +50°C, with heating -20°C … +50°C
Storage temperature -20°C … +60°C
Dimensions 140x155x135 (WxHxD) in mm
Distance from scanning plane to
48.75mm
bottom edge of housing
2 connectors (can be plugged from above, solder con-
Connection
nection)
max. 50m with conductor cross-section 0.5mm2
Cable length
(valid for X1 and X2 as RS 422)
Transmitter infrared laser diode (λ = 905nm)
Housing diecast aluminium, plastic
Weight approx. 2kg
acc. to IEC 60068 part 2 - 6,
Vibrating stress
10 … 55Hz max. 5G
Continuous shock acc. to IEC 60068 part 2 - 29, 10G, 16ms
as per DIN EN 61496-3 (in accordance with the
requirements for type 4) as well as per DIN 40839-1/3
Interference rejection
test impulse 1, 2, 3a, 3b and 5 (no application for vehi-
cles with combustion motors)
Rotating mirror drive brushless DC motor
Rotating mirror bearings maintenance-free ball bearing
Table 9.5: Technical data - environmental data

Technical data
9.6 Dimensioned drawing ROD4-3…
a Zero point for measuring
TNT 35/7-24V
b Scanning plane
R Smallest bending radius = 50mm
All dimensions in mm
Figure 9.3: Dimensioned drawing ROD4-3…

Status messages, errors and error rectification
10 Status messages, errors and error rectification
10.1 LED indicators

The status of the ROD4-3… can be read using the five LEDs located on the front side. A
transparent cover protects the LEDs from contamination and guarantees protection class
IP 65. When in a voltage-free state, the LEDs are hidden from view by this cover.
1 2 3 4 5
(green) (yellow) (red) (green) (yellow)
1 2 3 4 5
Figure 10.1: ROD4-3… LED indicators

Overview of LED indicators
LED Colour Function / Meaning

1 green Sensor functions active, near detection field is free
• Continuous light (CL): far detection field is occupied
• Flashing fast (FF) at approx. 4Hz Configuration from config.
2 yellow
for a duration of 1s: connector successfully loaded
(together with LED 5).
3 red Near detection field is occupied, Fn outputs are switched off
4 green Near detection field is free, Fn outputs are active
• Slowly flashing (SF) at approx. 1Hz: warning message
• Flashing fast (FF) at approx. 4Hz: error message
• Flashing fast (FF) at approx. 4Hz Configuration from config.
5 yellow
for a duration of 1s: connector successfully loaded
(together with LED 2).
• Continuous light (CL): restart-disable locked
TNT 35/7-24V

10.2 Status displays
Notice!
The rotoScan ROD4-3… outputs two different types of messages at output "ALARM1":
Warning message - Information for the user indicating that a non-critical danger area (e.g.
window contamination) has been detected in the device.
Error message - System has detected a critical device error and switches off all outputs.
LED indicators Status

• Near detection field is free,
• Fn outputs (X1-11, X1-12) are enabled.
• Fn outputs (X1-11, X1-12) are enabled,
• Far detection field is occupied,
(output X1-5 "ALARM1" is enabled)
• Fn outputs (X1-11, X1-12) are enabled,
SF • Warning message due to e.g. soiled front cover
• Near detection field is occupied,

• Fn outputs (X1-11, X1-12) are disabled,
CL • Restart-disable is active
CL • Restart-disable is switched on
• Near detection field is occupied,
FF • Output "ALARM1" (X1-5) is enabled

• Output "ALARM1" (X1-5) is enabled
FF FF • for a duration of 1s, configuration successfully transferred
from the config. connector,
Table 10.1: Status displays on the rotoScan ROD4-3

10.3 Diagnostic codes and causes

All errors which occur in the ROD4-3… during operation are stored in a diagnostic list in the
device. You can call up this list with the RODsoft software. On the toolbar, click or select
System data → Load diagnostic data from sensor on the menu bar.
The messages from the last 8 events are documented. This first memory slot always
contains the most recent error message.
Listed in the following table are all errors together with corresponding troubleshooting
notices:
Code No Meaning Measure

.
ª Check the interface parameters and start
102 2 Data transfer error on interface X2.
the transfer again.
the transfer again.
the transfer again.
Function, access, command not per- ª Change the access level and start the
105 6 mitted at currently selected access transfer again.
level.
Interface X2 time specifications not ª Check the interface parameters and start
201 4 complied with, last message overwrit- the transfer again.
ten.
Interface X2 time specifications not ª Check the interface parameters and start
302 2 complied with, send data not acknowl- the transfer again.
edged.
Previous message not completely ª Check the interface parameters and start
TNT 35/7-24V
306 5 issued, interface X2 time specifica- the transfer again.
tions not complied with.
Error memory cannot be read, internal ª If reset is not successful, contact customer
801 2
defect service.
Error memory cannot be transferred, ª Check the interface parameters and start
805 6
transmission error at interface X2 the transfer again.
Motor does not reach nominal rota- ª If reset is not successful, contact customer
1002 1 tional speed after start-up; internal service.
defect.
Motor speed not constant after start- ª If reset is not successful, contact customer
1002 2
up; internal defect. service.
Motor does not reach nominal rota- ª If reset is not successful, contact customer
1003 1 tional speed after start-up; internal service.
defect.
1003 2
up; internal defect. service.
Table 10.2: ROD4-3… – diagnostic codes, causes and measures


.
1003 3
up; time-out. service.
Switching outputs Fn1/Fn2 cannot be ª Check the connection/wiring of Fn1/Fn2.
1110 4 switched, short-circuit with 0 V DC or
+24 V DC.
1110 5 switched, short-circuit between Fn1
and Fn2.
1110 6 switched, short-circuit with 0 V DC or
+24 V DC.
Short-circuit between switching out- ª Check the connection/wiring of Fn1/Fn2.
1111 7
puts Fn1/Fn2.
Short-circuit of one switching output ª Check the connection/wiring of Fn1/Fn2.
1111 8
(Fn1 or FN2) with 0 V DC.
Short-circuit of one switching output ª Check the connection/wiring of Fn1/Fn2.
1111 9
(Fn1 or FN2) with +24 V DC.
Angle error detected, poss. rotation of ª If reset is not successful, contact customer
1606 4 the sensor housing; switch-off and service.
reset followed.
reset followed.
Motor speed not constant during ª If reset is not successful, contact customer
1608 8 operation, poss. rotation of the sensor service.
housing.
housing.
housing.
Signal of a photoelectric sensor of the ª Clean the front cover according to instruc-
1705 1 window monitoring below the bottom tions (see chapter 7.2 "Cleaning" on
limit, dirty front cover. page 38).
Signal from a photoelectric sensor of ª Clean the front cover according to instruc-
the window monitoring above the tions (see chapter 7.2 "Cleaning" on
1705 2
upper limit, oil/grease on the front page 38).
cover.


.
Switching outputs Fn1/Fn2 cannot be ª Check the connection/wiring of Fn1/Fn2. If
1906 1 switched, internal or external short- reset is not successful, contact customer
circuit. service.
Switching outputs Fn1/Fn2 cannot be ª Check the connection/wiring of Fn1/Fn2. If
1906 2 switched, internal or external short- reset is not successful, contact customer
circuit. service.
Read back error on switching outputs ª Check the connection/wiring of Fn1/Fn2. If
1906 5 Fn1/Fn2, internal or external short-cir- reset is not successful, contact customer
cuit. service.
Error on the laser's switch-off path, ª If reset is not successful, contact customer
1906 6 switch-off because of eye safety, inter- service.
nal defect.
reset followed.
reset followed.
Configuration data displayed for ª Start the transfer again.
2002 12 inspection not acknowledged quickly
enough
Date of the currently transmitted ª Update the PC's date and time setting.
detection field is older than the date
2007 18
of the detection field stored in the
sensor.
TNT 35/7-24V
ª Replace the ConfigPlug or the complete
2017 19 Data transfer error with ConfigPlug.
cable with plug.
The connected sensor does not sup- ª Change the sensor, observe the device
2017 23 port the configuration file in the Con- type.
figPlug.
The connected sensor does not sup- ª Change the sensor, observe the device
2017 24 port the configuration file in the Con- type.
figPlug.
Date of the currently transmitted con- ª Update the PC's date and time setting.
2017 26 figuration is older than the date of the
configuration stored in the sensor.
Number of measurements in the scan ª If reset is not successful, contact customer
too small due to rotational speed error service.
2201 5
in the motor or because internal fuse
was blown.
2302 1 Error occurred during sensor start-up. Sequential error.


.
Reference measurement failed; glare Sensor performed reset.
2401 10 from another light source (905 nm) or
rotation speed error.
Reference measurement failed, dust ª Screw the plugs of interfaces X1 and X2.
2401 13 in the device, due to the plug housing
or dummy cap not being screwed on.
Invalid diagnostic command received, ª Use a newer version of the configuration
2701 1
software incompatible with firmware. software.
Invalid diagnostic value requested, ª Use a newer version of the configuration
2702 3
software incompatible with firmware. software.
2 field pair control inputs activated ª Check the switchover times of the control
2800 2
longer than 1s. inputs FPS1 - FPS4.
The detection field changeover which ª Check the activation of the detection fields
2800 3 occurred does not match the preset in the program wizard.
which was programmed in the sensor.
More than 2 detection fields activated ª Check the activation of the control inputs
2800 4
during operation. FPS1 - FPS4.
Unusable or defective control voltage ª Check the activation of the control inputs
2800 6
for the detection field activation. FPS1 - FPS4.
No detection field activated. Can ª If detected during running operation, check
2800 8 occur during operation and switching the activation of the control inputs FPS1 -
off the device. FPS4.
Error while testing the inputs for ª Contact the customer service.
2801 1 detection field changeover; internal
defect.
The detection field activation which ª Check the activation of the detection fields
More than 2 detection fields selected ª Only activate one of the control inputs
2802 4
when starting the sensor. FPS1 - FPS4.
Unusable or defective control voltage ª Check the activation of the control inputs
2802 6
for the detection field activation. FPS1 - FPS4.


.
No detection field activated during ª Activate one of the control inputs FPS1 -
2802 8
start-up of the sensor. FPS4.
The detection field activation which ª Check the activation of the detection fields
ª Check the activation of the control inputs
2804 4 No detection field clearly selected.
FPS1 - FPS4.
Unusable or defective control voltage ª Check the switchover times of the control
2804 6
for the detection field activation. inputs FPS1 - FPS4.
Confirmed single password entered ª Repeat the password entry.
3016 11
wrong.
Sensor has optical glare caused by ª Switch off the supply voltage and start the
3203 6
another device. sensor again.
Sensor has optical glare caused by ª Switch off the supply voltage and start the
3203 7
another device. sensor again.
TNT 35/7-24V

Appendix
11 Appendix
11.1 Terms and abbreviations used with ROD4-3… and the RODsoft soft-
ware
Alarm output ALARM1
Semiconductor output which signals a device warning and error and/or occupancy of
a detection field. The function can be selected in RODsoft via the "alarm signal type".
The output is at pin 5 of interface X1 and is designated in the ROD4 handbook as
ALARM.
Alarm output ALARM2
Semiconductor output which signals a device warning and error.
The output is at pin 15 of interface X1 and is designated in the ROD4 handbook as
WARN.
Start disable
Following device start-up, the restart button must be actuated in order to activate the
outputs.
Start-up test
Following device start-up, the near detection fields must be clear after the start-up
delay period has passed; the outputs are switched off. To activate the outputs, at least
one near detection field must be occupied and then again be cleared.
Start-up delay
Configurable time which must pass before a permanently clear near detection field
activates the corresponding switching output. The start-up delay for far detection
fields is permanently set to 80ms.
Response time
Time which must pass before a permanent detection field occupancy switches off the
corresponding switching output (separately configurable for near and far detection
fields).
Output start-stop segment, output resolution
Used to configure the measurement value transmission at serial interface X2. The
configuration is made in multiples of 0.36°. A detection range of 180° corresponds to
a start segment of 14*0.36° and a stop segment of 514*0.36°. If the output resolution
is > 1*0.36°, the minimum value within the resolution interval is transferred/displayed.
Notice: Monitoring of the detection fields also occurs outside of the configured trans-
mission range.
F
Field
Detection field
Long version of the term field.

Appendix

Max. detection range 30m, object detection within the near detection field affects out-
puts Fn1 (pin X1-11) and Fn2 (pin X1-12). The near detection field is represented in
the user interface of the RODsoft configuration software by the colour red.
Fn
Short version of the term near detection field.
Far detection field
max. detection range 50m, object detection within the far detection field affects out-
put ALARM1 (pin X1-5, depending on the configuration). The far detection field is
represented in the user interface of the RODsoft configuration software by the colour
green.
Ff
Short version of the term far detection field.
FP
Field pair, detection field pair;
the configuration software can be used to configure up to 7 field pairs in the ROD4-
3…, each with two detection fields (near and far).
FP1
Field pair 1.
FPS
Field pair switch.
Minimum object size
This parameter is permanently stored and is calculated from the maximum radius of
the detection field. Objects are detected if at least the minimum number of consecu-
tive scanning beams (multiple of 0.36°) is incident on an object.
Scanning rate
TNT 35/7-24V
Rotational frequency of the scanner deflection mirror = 25Hz.
Sector size
This parameter can be changed. If the value for the sector size is > 1, objects are
detected if the minimum number of consecutive scanning beams (multiple of 0.36°) is
incident on an object. If the sector size is > 1, the entry for minimum object size is
immaterial.

Appendix
Serial interface baud rate

Used to configure the transmission rate (9.6 … 687.5 kBit/s) at serial interface X2 of
the sensor. The baud rate is continuously changed in the sensor.
Important notice:
If the baud rate is changed, a PC cannot initially be connected to the sensor via ROD-
soft. This must first be adjusted in RODsoft with the Settings –> PC configuration –
> Interface menu command (max. 115200Baud at RS 232). We recommend working
with the factory setting of 57600 Bd.
If the baud rate at X2 is set to a value higher than 115200Baud, a connection is no

longer possible with RODsoft via the RS 232. Resetting to 57600 Bd can then only be
performed via an external connection at pin X1-2 (see chapter 5.2.3 "RESTART /
resetting the data transmission rate to 57600 baud").
Dust suppression
With the introduction of the new ROD4-3… models, considerably more effective dust
suppression was implemented in the devices. With activated dust suppression (rec-
ommended), sensor availability is significantly increased in the event of small parti-
cles in the air, such as insects. This also maximises the time which may pass before
cleaning of the front cover becomes necessary.
Dust suppression is implemented globally, i.e. it is used in all detection fields. In the
RODsoft configuration software, 3 parameters determine the function of the dust sup-
pression (factory setting: activated):
• the object size (factory setting: 70mm)
• the object speed (factory setting: 1600mm/s)
• the response time (factory setting: 80ms)
Object size
This dust suppression parameter defines the maximum size up to which interfering
objects (e.g. particles in the air) should not be detected. Values that are too large pre-
vent object detection. Values that are too small increase the sensitivity to interfering
objects. The 'Automatic' setting results in less efficient dust suppression.
Object speed
The object speed specifies the maximum speed of the objects that are to be detected;
if necessary, the speed of the sensor itself is to be taken into account. Values that are
too small prevent object detection. Values that are too large and the value '0 mm/s'
increase the sensitivity to interfering objects.

Appendix
Comment:
Speed refers not only to the speed at which an object moves toward the sensor
(speed component vx in figure 11.1); it generally refers to the maximum speed with
which objects may move in the detection field (speed components vx and vy in
figure 11.1). As area scanning occurs in the XY plane, speed component vz cannot
be detected and evaluated. The maximum object speed can be best optimised
through testing.
vz
vy
vx
Figure 11.1:Components of the object speed
Response time
Another important parameter is the response time. The longer the selected response
time, the more calculating time is available for the dust-suppression algorithm and,
thus, the more powerful the dust suppression. With a response time < 80ms, only the
object size is evaluated.
Dust suppression is more efficient the:

• greater the selected object size
• lower the selected object speed
TNT 35/7-24V
• longer the response time
It is a good idea to optimise the values preset ex works (object size: 70mm, object
speed: 1600mm/s, response time: 80ms) for the respective application through prac-
tical tests.
Notice!
Compatibility mode for old ROD4/ROD4-2… models:
• Object size ’automatic’
• Object speed: 0mm/s
Config. connector:If a ConfigPlug with ROD4-3x configuration (with new dust sup-
pression) is plugged into a ROD4/4-2x, the configuration is accept-
ed, but the old dust suppression used!

Appendix
RODsoft: If a ROD4-3x configuration with new dust suppression is loaded

from a file while a ROD4 or ROD4-2x is plugged in, the new dust
suppression parameters are not displayed. The sensor uses the old
dust suppression following the transfer. The ROD4-3x configuration
becomes a ROD4-2x compatible configuration.
A ROD4-3x configuration can also be loaded if a ROD4/4-2x was
selected. The new dust suppression parameters are not displayed
in this case. The scanner uses the old dust suppression following
the transfer.
Restart
Determines how switching outputs are switched following object detection in a near
detection field in the event of subsequent non-occupancy.
• Manual restart: The restart button must be actuated and start disable must be
active.
• Automatic restart: Following a start-up delay, the outputs are activated.
Angular resolution
Smallest technically possible resolution of the sensor in angular degrees.

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rotoScan ROD4-30 / ROD4-36 / ROD4-38

Area Scanning Distance Sensor

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1 General information ........................................................................................................... 4

5 Electrical connection ....................................................................................................... 20

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7 Testing and maintenance................................................................................................ 38

8 Delivery contents and accessories ................................................................................ 39

9 Technical data .................................................................................................................. 42

10 Status messages, errors and error rectification ........................................................... 48

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Table 2.1: Standards and directives.............................................................................................. 5

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1.1 Explanation of symbols

1.2 Declaration of conformity

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2.1 Safety standards

Standards and directives

Standard or EC directive Designation

Table 2.1: Standards and directives

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2.2 Application conditions and intended use

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2.3 Restrictions with regards to use

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2.4 Working safely

Figure 2.1: Attachment of the stick-on label with warning notices

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2.5 Organisational measures

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3.1 Technical overview

Designation Type Part No.

Measurement range ROD4-30/ROD4-36: max. 65m

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3.2 Operating principle

Figure 3.2: Working range and angular resolution

Figure 3.3: Operating principle

Combination of hardware and software

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3.3 Special features of the ROD4-3…

3.4 Detection fields / detection field pairs

3.4.1 Changing over between detection field pairs

Only detection field pairs 1 through 4 are configured

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Figure 3.4: Configuring detection field pairs 1 through 4 only

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One of detection field pairs 5 through 8 is also configured

Figure 3.5: Also configuring detection field pairs 5 through 8

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3.4.2 4-field mode

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3.5 Application examples

3.5.1 Object detection

Figure 3.6: Application example - height/position detection

Protusion detection in high-bay warehouses

Figure 3.7: Application example - Protusion detection in high-bay warehouses