Inxpect LBK System Instruction Manual
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Inxpect LBK System Instruction Manual

Volumetric safety system
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LBK System
Volumetric Safety System
Instruction manual
v1.3 - EN
Instructions translated from the original
WARNING! Whoever uses this system must read the instruction manual for their safety. Read and
adhere to the "Safety information" chapter in its entirety before using the system for the first time.

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Summary of Contents for Inxpect LBK System

  • Page 1 LBK System Volumetric Safety System Instruction manual v1.3 - EN Instructions translated from the original WARNING! Whoever uses this system must read the instruction manual for their safety. Read and adhere to the "Safety information" chapter in its entirety before using the system for the first time.
  • Page 2 Transferring the document on websites or other electronic systems. Copying contents without any modification and stating Inxpect SpA as copyright owner. Inxpect SpA reserves the right to make modifications or improvements to the relative documentation without prior notice. Requests for authorization, additional copies of this manual or technical...

  • Page 3: Table Of Contents

    8.5 Updates 9. Technical references 9.1 Technical data 9.2 Terminal blocks and connectors pin-outs 9.3 Electrical connections 9.4 Default values 10. Appendix 10.1 Disposal 10.2 Service and warranty LBK System | Instruction manual v1.3 SEP 2019 | LBK-System_instructions_en v1.3 | © 2018-2019 Inxpect SpA...

  • Page 4: Glossary Of Terms

    If it does not correspond to the dangerous area defined in the risk assessment, the residual risk must be calculated and additional safety measures must be introduced. LBK System | Instruction manual v1.3 SEP 2019 | LBK-System_instructions_en v1.3 | © 2018-2019 Inxpect SpA...
  • Page 5 Portion of the monitored area where detection is not guaranteed. Uncertainty area Area of the field of vision where detection or not of an object depends on the characteristics of the same object. LBK System | Instruction manual v1.3 SEP 2019 | LBK-System_instructions_en v1.3 | © 2018-2019 Inxpect SpA...

  • Page 6: This Manual

    1.1 Information on this manual 1.1.1 Objectives of this instruction manual This manual explains how to integrate LBK System for safeguarding machinery operators and how to install it, use it and maintain it safely. These instructions do not pertain to the functioning of the machinery where LBK System is installed.
  • Page 7 1.1.5 Intended users of this instruction manual The recipients of the instruction manual are: The designer of the machinery onto which the system will be installed System installer Machinery maintenance technician LBK System | Instruction manual v1.3 SEP 2019 | LBK-System_instructions_en v1.3 | © 2018-2019 Inxpect SpA...

  • Page 8: Safety

    2.1.3 INTENDED USE LBK System is certified as SIL 2 according to IEC/EN 62061 and PL d in accordance with EN ISO 13849-1. Performs the following safety functions: access detection function: prevents access to a dangerous area. Access to the area de-energizes the safety relays to stop the machinery's moving parts.

  • Page 9: Conformity

    Note: no type of failure has been excluded during the system analysis and design phase. 2.2.2 CE The manufacturer, Inxpect SpA, states that the LBK System type of radio equipment complies with the LBK System | Instruction manual v1.3 SEP 2019 | LBK-System_instructions_en v1.3 | © 2018-2019 Inxpect SpA...
  • Page 10 At the same address all updated certifications are available for download. 2.2.3 FCC LBK System complies with FCC CFR title 47, part 15, subpart B. It contains FCC ID: UXS-SMR-3X4. Operation is subject to the following two conditions: this device may not cause harmful interference, and...

  • Page 11: National Restrictions

    2.3 National restrictions 2.3.1 FRANCE AND THE UNITED KINGDOM LBK System is a short range device in class 2 in accordance with the directive 2014/53/EU (RED - Radio equipment) and is subject to the following restrictions: Restrictions in France and the United Kingdom. The national frequency allocation in France and the United Kingdom prohibits free use of the entire 24-24.25 GHz band.
  • Page 12 2.3.4 ARGENTINA Restrictions in Argentina. In Argentina, the national allocation of frequencies does not allow the free use of the whole band 24-24.25 GHz. Set the authorized band correctly in the Inxpect Safety application. es-AR Restricciones en Argentina. La atribución de las bandas de frecuencia en la República Argentina no permite el uso libre de toda la banda de 24-24,25 GHz.

  • Page 13: Get To Know Lbk System

    3.1.4 Main components LBK System is composed of a controller and up to six sensors. The Inxpect Safety software application allows system operation configuration and checks. LBK System | Instruction manual v1.3 SEP 2019 | LBK-System_instructions_en v1.3 | © 2018-2019 Inxpect SpA...

  • Page 14: Controller Lbk-C22

    In the absence of other control systems, LBK System can be connected to the devices that control the power supply or machinery start-up (e.g. external relays on the power supply line).
  • Page 15 (contact closed): no motion detected and normal functioning 3.2.7 Auxiliary outputs The controller has two relay outputs, which can be configured via the Inxpect Safety application, for: pre-alarm failure muting status 3.2.8 Auxiliary outputs status...

  • Page 16: Sensors Lbk-S01

    = restart enabled) The inputs are type1, type 2 and type 3 (see "Voltage and current limits for digital inputs" on page 62). The function of the inputs can be configured through the Inxpect Safety application. 3.2.10 SNS input The controller also has an SNS input (high logic level (1) = 24 V) to check the correct functioning of the chip that detects the status of the inputs.

  • Page 17: Inxpect Safety Application

    Update the firmware. Perform the configuration back up and load a configuration. Download the log. Other general functions. Ignore unsaved changes. Login  Enable access to the configuration functions. Password required. LBK System | Instruction manual v1.3 SEP 2019 | LBK-System_instructions_en v1.3 | © 2018-2019 Inxpect SpA...

  • Page 18: Functioning Principles

    ("Restart prevention function" on the next page) when in alarm state for access detection (status Alarm) 4.2.2 Selectable safety functions In the manual system configuration via the Inxpect Safety application, you can select which safety functions each sensor performs: Both (default) Always access detection: even when the system is in Alarm status, the sensor has the field of vision and the sensitivity of the No alarm status.

  • Page 19: Access Detection Function

    If necessary, implement additional safety measures. Note: for linear barrier application, the stopping area is calculated automatically by the Inxpect Safety application based on the set dimensions of the dangerous area and the configuration of the sensors.
  • Page 20 The system manages three types of restart prevention: Type Conditions for enabling machinery restart Automatic The time interval set through the Inxpect Safety application has passed since the last motion detection*. Manual The status of the restart enable button indicates that the restart is enabled (digital input status = 1).

  • Page 21: Muting

    1. Connect the machinery restart enable button conveniently, see "Electrical connections" on page 63. 2. In the Inxpect Safety application > Settings > Sensors, set Restart time out = 0. Safe manual 1. Connect the machinery restart enable button conveniently, see "Electrical connections"...

  • Page 22: Anti-Tampering Function

    The muting function is enabled only if both logic signals of the dedicated input meet certain characteristics. Below is a graphic representation of the signal characteristics. In the Inxpect Safety > Settings > Digital Input-Output application it is necessary to set the parameters that define the characteristics of the signal.

  • Page 23: Anti-Masking Function

    See "Checks with anti-tampering function disabled" below. In the application Inxpect Safety in Settings click Sensors to disable the anti-tampering function. 4.6.3 Checks with anti-tampering function disabled When the anti-tampering function is disabled, perform the following checks.
  • Page 24 See "Checks with anti-masking function disabled" below. To change the sensitivity level or disable the function, in the Inxpect Safety application, in Settings then click Sensors. 4.7.6 Checks with anti-masking function disabled When the masking function is disabled, perform the following checks.

  • Page 25: Sensor Position

    Three examples are presented as follows: sensor tilted upwards: α positive straight sensor: α = 0 sensor tilted downwards: α negative LBK System | Instruction manual v1.3 SEP 2019 | LBK-System_instructions_en v1.3 | © 2018-2019 Inxpect SpA...

  • Page 26: Sensor Field Of Vision

    (see "Factors that influence the reflected signal" on page 18). Dimensions of the 110° field of vision Side view Top view Dimensions of the 50° field of vision Side view Top view LBK System | Instruction manual v1.3 SEP 2019 | LBK-System_instructions_en v1.3 | © 2018-2019 Inxpect SpA...

  • Page 27: Dangerous Area Calculation

    5.3 Dangerous area calculation 5.3.1 Introduction The dangerous area of the machinery to which LBK System is applied must be calculated as indicated in standards ISO 13855:2010 and ISO 13857:2008. For LBK System the fundamental factors for calculation are height (h) and inclination (α) of the sensor, see "Sensor position" on page 25.

  • Page 28: Calculation Of Position For Sensor Height < 1 M

    3 = Configuration 3 with sensor facing down (α negative, field of vision intersecting the ground at two points) X = Configuration not possible WARNING! With configurations not listed in these tables or marked with an “x”, safety functions are not guaranteed. LBK System | Instruction manual v1.3 SEP 2019 | LBK-System_instructions_en v1.3 | © 2018-2019 Inxpect SpA...
  • Page 29 Distance between the ground and the field of vision of the sensor α Sensor inclination degrees Sensor installation height Dalarm Alarm linear distance DalarmReal Real alarm distance Start detection distance End detection distance LBK System | Instruction manual v1.3 SEP 2019 | LBK-System_instructions_en v1.3 | © 2018-2019 Inxpect SpA...
  • Page 30 5.4.4 Configuration 1 (sensor upwards) To guarantee that the sensor also detects access by people crawling, respect the following condition: 110° field of vision 50° field of vision LBK System | Instruction manual v1.3 SEP 2019 | LBK-System_instructions_en v1.3 | © 2018-2019 Inxpect SpA...
  • Page 31 To guarantee that the sensor also detects the presence of people crawling near the sensor, respect the following condition: 110° field of vision 50° field of vision 5.4.6 Configuration 3 (sensor downwards) To guarantee optimum performance, respect the following conditions: 110° field of vision LBK System | Instruction manual v1.3 SEP 2019 | LBK-System_instructions_en v1.3 | © 2018-2019 Inxpect SpA...

  • Page 32: Calculation Of Position For Sensor Height > 1 M

    5.  Sensor position 50° field of vision 5.4.7 Calculate the real alarm distance The actual alarm distance DalarmReal is the value to be entered in the application Inxpect Safety, in Manual configuration and in the Alarm distance parameter. DalarmReal indicates the maximum distance between the sensor and the object that is to be detected.
  • Page 33 5.5.5 Calculate the real alarm distance The actual alarm distance DalarmReal is the value to be entered in the application Inxpect Safety, in Manual configuration and in the Alarm distance parameter.

  • Page 34: Outdoor Installations

    In general, avoid installations with the sensor at height facing downwards. 5.6.4 Position not exposed to precipitation If the installation position of the sensor will not be exposed to precipitation, no special precautions are required. LBK System | Instruction manual v1.3 SEP 2019 | LBK-System_instructions_en v1.3 | © 2018-2019 Inxpect SpA...

  • Page 35: Applications

    Safety application. Other Flexibility in sensors Sensors configuration and area Manual applications configuration to obtain actually monitored defined by the configuration maximum coverage in designer. dangerous areas. LBK System | Instruction manual v1.3 SEP 2019 | LBK-System_instructions_en v1.3 | © 2018-2019 Inxpect SpA...

  • Page 36: Linear Barrier (Complete Restart Prevention)

    The machinery designer must enclose the tolerance area to prevent transit in the area and thus avoid false alarms. The tolerance area is calculated and provided by the Inxpect Safety application. LBK System | Instruction manual v1.3 SEP 2019 | LBK-System_instructions_en v1.3 | © 2018-2019 Inxpect SpA...
  • Page 37 Inxpect Safety application during the configuration phase. 6.2.5 Calculation of the monitored area The monitored area is calculated automatically by the Inxpect Safety application. Given the dimensions of the dangerous area and any pre-alarm area, the system calculates: the number of necessary sensors...

  • Page 38: Linear Barrier (Limited Restart Prevention)

    Note: the following illustrations show, as an example, sensor configurations all with 110° field of vision. Sensor configurations with all 50° field of vision or mixed configurations are also possible. LBK System | Instruction manual v1.3 SEP 2019 | LBK-System_instructions_en v1.3 | © 2018-2019 Inxpect SpA...
  • Page 39 The machinery designer must enclose the tolerance area to prevent transit in the area and thus avoid false alarms. The tolerance area is calculated and provided by the Inxpect Safety application. LBK System | Instruction manual v1.3 SEP 2019 | LBK-System_instructions_en v1.3 | © 2018-2019 Inxpect SpA...
  • Page 40 Given the geometry of the sensor field of vision, blind spots are generated within the monitored area. Sensitivity to motion is greatly reduced in blind spots. The greater the distance between sensors [A] the wider the blind spot areas become [B]. LBK System | Instruction manual v1.3 SEP 2019 | LBK-System_instructions_en v1.3 | © 2018-2019 Inxpect SpA...
  • Page 41 NOTICE: auxiliary functions are necessary in the immediate vicinity of the sensor to guarantee the system restart prevention function. 6.3.7 Calculation of the monitored area The monitored area is calculated automatically by the Inxpect Safety application. Given the dimensions of the dangerous area and any pre-alarm area, the system calculates: the number of necessary sensors...

  • Page 42: Other Applications

    6.4.3 Examples Circular dangerous area around a robot Dangerous area on three sides out of four of a machinery LBK System | Instruction manual v1.3 SEP 2019 | LBK-System_instructions_en v1.3 | © 2018-2019 Inxpect SpA...
  • Page 43 6.  Applications Dangerous area laterally delimited by transit areas LBK System | Instruction manual v1.3 SEP 2019 | LBK-System_instructions_en v1.3 | © 2018-2019 Inxpect SpA...

  • Page 44: Installation And Use Procedures

    Note: if the execution process fails, it may be that the dependencies needed by the program are not installed on the computer. To receive assistance, send an email to safety-support@inxpect.com. 1. Download the application from the website www.inxpect.com/industrial/tools and install it on the computer.

  • Page 45: Install And Configure Lbk System

    Note: this setting does not have any effect on system performance. 7.2.3 Define the area to be monitored WARNING! During configuration, LBK System is disabled. Prepare opportune safety measures in the dangerous area protected by the system before configuring the system.
  • Page 46 3. Direct the sensor up to the desired inclination, 4. Tighten the screws. see "Sensor position" on page 25. Note: a notch is equal to 10° of inclination. LBK System | Instruction manual v1.3 SEP 2019 | LBK-System_instructions_en v1.3 | © 2018-2019 Inxpect SpA...
  • Page 47 4. Direct the sensor up to the desired inclination, support. see "Sensor position" on page 25. Note: a notch is equal to 10° of inclination. 5. Tighten the screws. LBK System | Instruction manual v1.3 SEP 2019 | LBK-System_instructions_en v1.3 | © 2018-2019 Inxpect SpA...
  • Page 48 Chain with controller inside of the chain and two sensors with termination connector 7.2.9 Save and print the configuration 1. In the Inxpect Safety application, click APPLY CHANGES: the sensors will memorize the inclination set and the surrounding environment. The application will transfer the configuration to the controller, and once transfer is complete it will generate a configuration report.

  • Page 49: Validate Safety Functions

    3. If deactivated, see "Troubleshooting validation" on the next page. Specifications Stop for at least one time interval set as the restart delay (Inxpect Safety > Settings > Sensors). Stop in several different points, with special attention to the areas in close proximity to the sensor and any blind spots, see "Examples of stopping points"...
  • Page 50 Stopping points for 50° field of vision 7.3.6 Validate the system with Inxpect Safety The Inxpect Safety application supports during the safety functions validation phase and allows the actual field of vision of the sensors to be checked based on their installation position.

  • Page 51: Manage The Configuration

    The reports are documents that cannot be changed, and can only be printed and signed by the person assigned to the task. 7.4.2 Change the configuration WARNING! During configuration, LBK System is disabled. Prepare opportune safety measures in the dangerous area protected by the system before configuring the system. 1. Start the Inxpect Safety application.

  • Page 52: Other Functions

    For the default values of the parameters, see "Default values" on page 67. 7.5.5 Identify a sensor In Settings > Sensor ID Nodes, click Blink led near the desired sensor ID: the LED on the sensor flashes for 5 seconds. LBK System | Instruction manual v1.3 SEP 2019 | LBK-System_instructions_en v1.3 | © 2018-2019 Inxpect SpA...

  • Page 53: Maintenance And Troubleshooting

    If the problem persists, contact assistance for relay replacement. Steady At least one of the controller Check the status of the terminal block and peripherals is in error connections. LBK System | Instruction manual v1.3 SEP 2019 | LBK-System_instructions_en v1.3 | © 2018-2019 Inxpect SpA...

  • Page 54: System Log

    The log file reports the following information separated by ";": time stamp (in ms) from system start sensor that generated the event type of error details of error LBK System | Instruction manual v1.3 SEP 2019 | LBK-System_instructions_en v1.3 | © 2018-2019 Inxpect SpA...
  • Page 55 Short-circuit error between two relays or between two relay commands CIRCUIT 8.2.7 Sensor/controller voltage errors (POWER ERROR) Error Meaning UNDERVOLTAGE Undervoltage error for the indicated voltage* OVERVOLTAGE Overvoltage error for the indicated voltage* LBK System | Instruction manual v1.3 SEP 2019 | LBK-System_instructions_en v1.3 | © 2018-2019 Inxpect SpA...

  • Page 56: Cleaning And Spare Parts

    Error detected by diagnostics relative to the micro-controller, its internal peripherals or memories. 8.2.10 System boot (SYSTEM BOOT) Each time LBK System starts, a "SYSTEM BOOT" event is recorded with the incremental progressive number of the restart. The time stamp is reset to zero.

  • Page 57: Periodic Tests

    Note: keep a record of the date and result of the tests performed. 8.4.2 Periodic test with Inxpect Safety The Inxpect Safety application (Maintenance page) provides a wizard for performing the periodic test. The periodic test checks: correct detection of motion by the installed sensors...
  • Page 58 8.  Maintenance and troubleshooting 8.5.3 Install firmware updates WARNING! LBK System is not disabled during the firmware update. Make sure that the machinery is in safe conditions before installing updates. NOTICE: the sensor and controller firmware must be updated to the same version.

  • Page 59: Technical References

    9. Technical references Contents This section includes the following topics: 9.1 Technical data 9.2 Terminal blocks and connectors pin-outs 9.3 Electrical connections 9.4 Default values LBK System | Instruction manual v1.3 SEP 2019 | LBK-System_instructions_en v1.3 | © 2018-2019 Inxpect SpA...

  • Page 60: Technical Data

    (sensors- controller) Functional 20 years duration MTTFd 40 years 4.34E-08 [1/h] 99.03% DCavg 98.33% Electrical Polarity inversion protections Overcurrent through resettable integrated fuse (max. 5 s @ 8 LBK System | Instruction manual v1.3 SEP 2019 | LBK-System_instructions_en v1.3 | © 2018-2019 Inxpect SpA...

  • Page 61: Terminal Blocks And Connectors Pin-Outs

    Common safety output 1 Length 30 m from controller to sensor (configuration with one sensor) Relay output normally open Common safety output 2 Relay output normally open LBK System | Instruction manual v1.3 SEP 2019 | LBK-System_instructions_en v1.3 | © 2018-2019 Inxpect SpA...
  • Page 62 11 to 30 from 11 to 30 Current limits 0 15 mA 30 mA 15 mA 1 from 2 to 15 from 6 to 30 from 2 to 15 LBK System | Instruction manual v1.3 SEP 2019 | LBK-System_instructions_en v1.3 | © 2018-2019 Inxpect SpA...

  • Page 63: Electrical Connections

    9.  Technical references 9.3 Electrical connections 9.3.1 Connection of safety outputs to the machinery control system 9.3.2 Connection of safety outputs to an external safety relay LBK System | Instruction manual v1.3 SEP 2019 | LBK-System_instructions_en v1.3 | © 2018-2019 Inxpect SpA...
  • Page 64 Note: the indicated restart enable button closes the contact when pressed. Note: the cables used for wiring the digital inputs must have a maximum length of 30 m. LBK System | Instruction manual v1.3 SEP 2019 | LBK-System_instructions_en v1.3 | © 2018-2019 Inxpect SpA...
  • Page 65 9.3.6 Connection of the muting input and output (two groups of sensors) Note: the cables used for wiring the digital inputs must have a maximum length of 30 m. LBK System | Instruction manual v1.3 SEP 2019 | LBK-System_instructions_en v1.3 | © 2018-2019 Inxpect SpA...
  • Page 66 9.  Technical references 9.3.7 Pre-alarm output connection LBK System | Instruction manual v1.3 SEP 2019 | LBK-System_instructions_en v1.3 | © 2018-2019 Inxpect SpA...

  • Page 67: Default Values

    Normal Restart sensitivity Normal, High, Very High Normal Restart time out 0 ms 120 000 ms 5000 ms Masking Disabled, Low, Medium, High High Tampering Disabled, Enabled Enabled LBK System | Instruction manual v1.3 SEP 2019 | LBK-System_instructions_en v1.3 | © 2018-2019 Inxpect SpA...
  • Page 68 0 mm (for each sensor) Field of vision (for each 110°, 50° 110° sensor) Safety functions (for each Both (default), Always access detection, Always restart Both (default) sensor) prevention LBK System | Instruction manual v1.3 SEP 2019 | LBK-System_instructions_en v1.3 | © 2018-2019 Inxpect SpA...

  • Page 69: Appendix

    10.2 Service and warranty 10.1 Disposal LBK System contains electrical parts. As specified by the European Directive 2012/19/EU, never dispose of the product as standard urban waste. It is the responsibility of the owner to dispose of these products, as well as other electrical and electronic equipment, through specific waste collection facilities indicated by the government or local public authorities.
  • Page 70 LBK System | Instruction manual v1.3 SEP 2019 | LBK-System_instructions_en v1.3 | © 2018-2019 Inxpect SpA...
  • Page 72 Inxpect SpA Via Serpente, 91 LBK System 25131 Brescia (BS) Instruction manual v1.3 Italy SEP 2019 www.inxpect.com LBK-System_instructions_en v1.3 safety-support@inxpect.com Copyright © 2018-2019 Inxpect SpA +39 030 5785105...

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