CLC/TS 61496-3:2003

SLOVENSKI SIST-TS CLC/TS 61496-3:2005

STANDARD
december 2005
Varnost strojev – Električno občutljiva zaščitna oprema – 3. del: Posebne
zahteve za aktivne optoelektronske zaščitne elemente, ki se odzivajo na
difuzni odboj (IEC 61496-3:2001)
Safety of machinery – Electro-sensitive protective equipment – Part 3: Particular
requirements for Active Opto-electronic Protective Devices responsive to Diffuse
Reflection (AOPDDR) (IEC 61496-3:2001)
ICS 13.110; 31.260 Referenčna številka
©  Standard je založil in izdal Slovenski inštitut za standardizacijo. Razmnoževanje ali kopiranje celote ali delov tega dokumenta ni dovoljeno

TECHNICAL SPECIFICATION CLC/TS 61496-3
SPECIFICATION TECHNIQUE
TECHNISCHE SPEZIFIKATION December 2003

ICS 13.110; 29.260 Supersedes EN 61496-3:2001

English version
Safety of machinery –
Electro-sensitive protective equipment
Part 3: Particular requirements for
Active Opto-electronic Protective Devices
responsive to Diffuse Reflection (AOPDDR)
(IEC 61496-3:2001)
Sécurité des machines – Sicherheit von Maschinen –
Equipements de protection Berührungslos wirkende
électro-sensibles Schutzeinrichtungen
Partie 3: Prescriptions particulières Teil 3: Besondere Anforderungen an
pour les équipements utilisant des aktive optoelektronische diffuse
dispositifs protecteurs opto-électroniques Reflektion nutzende Schutzeinrichtungen
actifs sensibles aux réflexions diffuses (AOPDDR)
(AOPDDR) (IEC 61496-3:2001)
(CEI 61496-3:2001)
This Technical Specification was approved by CENELEC on 2003-12-02.

CENELEC members are required to announce the existence of this TS in the same way as for an EN and to
make the TS available promptly at national level in an appropriate form. It is permissible to keep conflicting
national standards in force.
CENELEC members are the national electrotechnical committees of Austria, Belgium, Czech Republic,
Denmark, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Lithuania, Luxembourg, Malta,
Netherlands, Norway, Portugal, Slovakia, Spain, Sweden, Switzerland and United Kingdom.

CENELEC
European Committee for Electrotechnical Standardization
Comité Européen de Normalisation Electrotechnique
Europäisches Komitee für Elektrotechnische Normung

Central Secretariat: rue de Stassart 35, B - 1050 Brussels

© 2003 CENELEC - All rights of exploitation in any form and by any means reserved worldwide for CENELEC members.

Ref. No. CLC/TS 61496-3:2003 E

Foreword
The text of the International Standard IEC 61496-3:2001, prepared by IEC TC 44, Safety of
machinery - Electrotechnical aspects, was approved by CENELEC as CLC/TS 61496-3 on 2003-12-02
without any modification.
This Technical Specification supersedes EN 61496-3:2001.
The following date was fixed:
– latest date by which the existence of the CLC/TS
has to be announced at national level (doa) 2004-02-01
Annex ZA has been added by CENELEC.
__________
Endorsement notice
The text of the International Standard IEC 61496-3:2001 was approved by CENELEC as a Technical
Specification without any modification.
__________
- 3 - CLC/TS 61496-3:2003
Annex ZA
(normative)
Normative references to international publications
with their corresponding European publications
This Technical Specification incorporates by dated or undated reference, provisions from other
publications. These normative references are cited at the appropriate places in the text and the
publications are listed hereafter. For dated references, subsequent amendments to or revisions of any
of these publications apply to this Technical Specification only when incorporated in it by amendment
or revision. For undated references the latest edition of the publication referred to applies (including
amendments).
NOTE When an international publication has been modified by common modifications, indicated by (mod), the relevant
EN/HD applies.
Publication Year Title EN/HD Year
1)
IEC 60068-2-14 1984 Environmental testing EN 60068-2-14 1999
Part 2: Tests - Test N: Change of
temperature
IEC 60068-2-75 1997 Part 2-75: Tests - Test Eh: Hammer EN 60068-2-75 1997
tests
IEC 60825-1 1993 Safety of laser products EN 60825-1 1994
Part 1: Equipment classification, + corr. February 1995
requirements and user's guide
IEC 61496-1 1997 Safety of machinery - Electro-sensitive EN 61496-1 1997
protective equipment
Part 1: General requirements and tests

– – High-visibility warning clothing EN 471 1994

__________
1)
EN 60068-2-14 includes A1:1986 to IEC 60068-2-14.

NORME CEI
INTERNATIONALE IEC
61496-3
INTERNATIONAL
Première édition
STANDARD
First edition
2001-02
Sécurité des machines –
Equipements de protection électro-sensibles –
Partie 3:
Prescriptions particulières pour les équipements
utilisant des dispositifs protecteurs opto-
électroniques actifs sensibles aux réflexions
diffuses (AOPDDR)
Safety of machinery –
Electro-sensitive protective equipment –
Part 3:
Particular requirements for Active Opto-
electronic Protective Devices responsive
to Diffuse Reflection (AOPDDR)
 IEC 2001 Droits de reproduction réservés  Copyright - all rights reserved
Aucune partie de cette publication ne peut être reproduite ni No part of this publication may be reproduced or utilized in
utilisée sous quelque forme que ce soit et par aucun procédé, any form or by any means, electronic or mechanical,
électronique ou mécanique, y compris la photocopie et les including photocopying and microfilm, without permission in
microfilms, sans l'accord écrit de l'éditeur. writing from the publisher.
International Electrotechnical Commission 3, rue de Varembé Geneva, Switzerland
Telefax: +41 22 919 0300 e-mail: inmail@iec.ch IEC web site http://www.iec.ch
CODE PRIX
Commission Electrotechnique Internationale
XA
PRICE CODE
International Electrotechnical Commission
Pour prix, voir catalogue en vigueur
For price, see current catalogue

61496-3 © IEC:2001 – 3 –
CONTENTS
Page
FOREWORD . 7
INTRODUCTION . 11
Clause
1 Scope . 13
2 Normative references . 15
3 Definitions. 15
4 Requirements. 15
4.1 Functional requirements. 15
4.2 Design requirements . 17
4.3 Environmental requirements. 25
5 Testing. 31
5.1 General. 31
5.2 Functional tests. 31
5.3 Performance testing under fault conditions . 41
5.4 Environmental tests. 43
6 Marking for identification and for safe use . 65
7 Accompanying documents . 65
Annex A (normative) Optional functions of the ESPE. 85
Annex B (normative) Catalogue of single faults affecting the electrical equipment of
the ESPE, to be applied as specified in 5.3 . 91
Annex C (informative)  Bibliography . 93
Annex AA (informative) Examples of the use of an AOPDDR in different applications . 95
Annex BB (informative) Relationship between ranging accuracy and probability
of detection . 103
Figure 1a – Example of a maximum detection zone of an AOPDDR. 69
Figure 1b – Example of a detection zone of an AOPDDR . 69
Figure 2 – Minimum diffuse reflectivity of materials . 71
Figure 3a – Influence on detection capability by background . 71
Figure 3b – Influence on detection capability by incandescent light – Example 1. 73
Figure 3c – Influence on detection capability by incandescent light – Example 2. 73
Figure 3d – Influence on detection capability by light reflected by the background . 75
Figure 3e – Influence on detection capability by stroboscopic light – Example 1. 75
Figure 3f – Influence on detection capability by stroboscopic light – Example 2 . 77
Figure 3g – Light interference test. 77
Figure 3h – Interference between two AOPDDRs of identical design. 79
Figure 4a – Configuration for the endurance test – Example 1. 81
Figure 4b – Configuration for the endurance test – Example 2. 81
Figure 5 – Test of homogeneous pollution. 83

61496-3 © IEC:2001 – 5 –
Page
Figure AA.1 – Example of the use of an AOPDDR on machinery . 97
Figure AA.2 – Example of the use of an AOPDDR on an AGV . 99
Figure AA.3 – Example of the use of an AOPDDR as a whole-body trip device . 101
Figure BB.1 – Relationship between ranging accuracy and detection zone. 103
Figure BB.2 – Relationship between ranging accuracy, detection zone and the
probabilistic part of the tolerance zone. 105
Figure BB.3 – Relationship between ranging accuracy, detection zone and tolerance
zone – Example 1. 107
Figure BB.4 – Relationship between ranging accuracy, detection zone and tolerance
zone – Example 2. 107
Figure BB.5 – POD of a single measurement (logarithmic) for a MooM-evaluation
with 1 ≤ M ≤ 50 . 109
Figure BB.6 – POD of a single measurement for a MooM-evaluation with 1 ≤ M ≤ 50
in relation to σ in the case of a normal distribution. 111
Table 1 – Verification of detection capability requirements (see also 4.2.12.1). 33
Table 2 – Overview of light interference tests. 51

61496-3 © IEC:2001 – 7 –
INTERNATIONAL ELECTROTECHNICAL COMMISSION
____________
SAFETY OF MACHINERY –
ELECTRO-SENSITIVE PROTECTIVE EQUIPMENT –
Part 3: Particular requirements for Active Opto-electronic
Protective Devices responsive to
Diffuse Reflection (AOPDDR)
FOREWORD
1) The IEC (International Electrotechnical Commission) is a worldwide organization for standardization comprising
all national electrotechnical committees (IEC National Committees). The object of the IEC is to promote
international co-operation on all questions concerning standardization in the electrical and electronic fields. To
this end and in addition to other activities, the IEC publishes International Standards. Their preparation is
entrusted to technical committees; any IEC National Committee interested in the subject dealt with may
participate in this preparatory work. International, governmental and non-governmental organizations liaising
with the IEC also participate in this preparation. The IEC collaborates closely with the International Organization
for Standardization (ISO) in accordance with conditions determined by agreement between the two
organizations.
2) The formal decisions or agreements of the IEC on technical matters express, as nearly as possible, an
international consensus of opinion on the relevant subjects since each technical committee has representation
from all interested National Committees.
3) The documents produced have the form of recommendations for international use and are published in the form
of standards, technical specifications, technical reports or guides and they are accepted by the National
Committees in that sense.
4) In order to promote international unification, IEC National Committees undertake to apply IEC International
Standards transparently to the maximum extent possible in their national and regional standards. Any
divergence between the IEC Standard and the corresponding national or regional standard shall be clearly
indicated in the latter.
5) The IEC provides no marking procedure to indicate its approval and cannot be rendered responsible for any
equipment declared to be in conformity with one of its standards.
6) Attention is drawn to the possibility that some of the elements of this International Standard may be the subject
of patent rights. The IEC shall not be held responsible for identifying any or all such patent rights.
International Standard IEC 61496-3 has been prepared by IEC technical committee 44: Safety
of machinery – Electrotechnical aspects, in collaboration with CENELEC technical committee
44X: Safety of machinery – Electrotechnical aspects.
This International Standard is to be used in conjunction with IEC 61496-1:1997.
The text of this standard is based on the following documents:
FDIS Report on voting
44/287/FDIS 44/293/RVD
Full information on the voting for the approval of this standard can be found in the report on
voting indicated in the above table.
This publication has been drafted in accordance with the ISO/IEC Directives, Part 3.
Annexes A and B form an integral part of this standard.
Annexes C, AA and BB are for information only.

61496-3 © IEC:2001 – 9 –
The committee has decided that the contents of this publication will remain unchanged
until 2006. At this date, the publication will be
reconfirmed;
withdrawn;
replaced by a revised edition, or
amended.
This standard has the status of a dedicated product standard and may be used as a normative
reference in a dedicated product standard for the safety of machinery.

61496-3 © IEC:2001 – 11 –
INTRODUCTION
An electro-sensitive protective equipment (ESPE) is applied to machinery presenting a risk of
personal injury. It provides protection by causing the machine to revert to a safe condition
before a person can be placed in a hazardous situation.
This part supplements or modifies the corresponding clauses in IEC 61496-1 to specify
particular requirements for the design, construction and testing of electro-sensitive protective
equipment (ESPE) for the safeguarding of machinery, employing active opto-electronic
protective devices responsive to diffuse reflection (AOPDDRs) for the sensing function.
Where a particular clause or subclause of part 1 is not mentioned in this part 3, that clause or
subclause applies as far as is reasonable. Where this part states "addition", "modification" or
"replacement", the relevant text of part 1 should be adapted accordingly.
Supplementary annexes are entitled AA, BB, etc.
Each type of machine presents its own particular hazards, and it is not the purpose of this
standard to recommend the manner of application of the ESPE to any particular machine. The
application of the ESPE should be a matter for agreement between the equipment supplier, the
machine user and the enforcing authority. In this context, attention is drawn to the relevant
guidance established internationally, for example, ISO/TR 12100.
NOTE Annex AA contains application examples providing general information and addressing specific
characteristics relevant to the use of the ESPE described in this part of IEC 61496. An application standard for
various types of ESPE is in preparation.

61496-3 © IEC:2001 – 13 –
SAFETY OF MACHINERY –
ELECTRO-SENSITIVE PROTECTIVE EQUIPMENT –
Part 3: Particular requirements for Active Opto-electronic
Protective Devices responsive to
Diffuse Reflection (AOPDDR)
1 Scope
Replacement:
This part of IEC 61496 specifies additional requirements for the design, construction and
testing of electro-sensitive protective equipment (ESPE) for the safeguarding of machinery,
employing active opto-electronic protective devices responsive to diffuse reflection (AOPDDRs)
for the sensing function. Special attention is directed to requirements which ensure that an
appropriate safety-related performance is achieved. An ESPE may include optional safety-
related functions, the requirements for which are given both in annex A of this part and in
annex A of IEC 61496-1.
This part does not specify the dimensions or configurations of the detection zone and its
disposition in relation to hazardous parts for any particular application, nor what constitutes a
hazardous state of any machine. It is restricted to the functioning of the ESPE.
AOPDDRs are devices that have a detection zone specified in two dimensions wherein
radiation in the near infrared range is emitted by a transmitter element(s). When the emitted
radiation impinges on an object (for example, a person or part of a person), a portion of the
emitted radiation is reflected to a receiving element(s) by diffuse reflection whereby the
presence of the object can be detected.
NOTE Under certain circumstances, limitations of the sensor in relation to its use need to be considered. For
example:
– Objects that generate mirror-like (specular) reflections may not be detected if the diffuse reflectance value is
less than that specified for the "black" test piece.
– The determination of the minimal reflection factors for the detection of obstacles is based on the clothing of a
person. Objects having a reflectivity lower than that considered in this part may not be detected.
Excluded from this part are AOPDDRs employing radiation of wavelength outside the range
820 nm to 946 nm, and those employing radiation other than that generated by the AOPDDR
itself. For sensing devices that employ radiation of wavelengths outside this range, this part
may be used as a guide. Also excluded are AOPDDRs having a stated detection capability
outside the range 50 mm to 100 mm.
This part may be relevant to applications other than those for the protection of persons, for
example, for the protection of machinery or products from mechanical damage. In such
applications, additional requirements may be necessary, for example, when the materials that
have to be detected by the sensing function have different properties from those of persons
and their clothing.
This part does not deal with electromagnetic compatibility (EMC) emission requirements.
Opto-electronic devices that perform only one-dimensional spot-like distance measurements,
for example, proximity switches, are not covered by this part.

61496-3 © IEC:2001 – 15 –
2 Normative references
Addition:
IEC 60068-2-14:1984, Environmental testing – Part 2: Tests – Test N: Change of temperature
IEC 60068-2-75:1997, Environmental testing – Part 2-75: Tests – Test Eh: Hammer tests
IEC 60825-1:1993, Safety of laser products – Part 1: Equipment classification, requirements
and user’s guide
IEC 61496-1:1997, Safety of machinery – Electro-sensitive protective equipment – Part 1:
General requirements and tests
EN 471:1994, High-visibility warning clothing
3 Definitions
Addition:
3.301
active opto-electronic protective device responsive to diffuse reflection (AOPDDR)
device, whose sensing function is performed by opto-electronic emitting and receiving
elements, that detects the diffuse reflection of optical radiations generated within the device by
an object present in a detection zone specified in two dimensions
3.302
AOPDDR detection capability
ability to detect the specified test pieces (see 4.2.13) in the detection zone
3.303
tolerance zone
zone outside the detection zone which is necessary to achieve the required probability of
detection of the specified test piece(s) (see 4.2.13) within the detection zone
4 Requirements
This clause of part 1 is applicable except as follows:
4.1 Functional requirements
4.1.3 Types of ESPE
Replacement:
In this part of IEC 61496 only a type 3 ESPE is considered. It is the responsibility of the
machine supplier and/or the user to prescribe if this type is suitable for a particular application.
The type 3 ESPE shall fulfil the fault detection requirements of 4.2.2.4 of this part. In normal
operation, the output circuit of each of at least two output signal switching devices (OSSDs) of
the type 3 ESPE shall go to the OFF-state when the sensing device is actuated, or when the
power is removed from the device.

61496-3 © IEC:2001 – 17 –
Additional functional requirements:
4.1.4 Zone with limited detection capability
The nearest boundary of the detection zone shall not be further than 50 mm from the optical
window in the plane of detection.
A zone between the optical window and the beginning of the detection zone is referred to as a
zone with limited detection capability. In order to ensure no hazard can arise in a particular
application due to the presence of this zone between the optical window and the detection
zone, its dimensions and appropriate information for use shall be provided by the supplier.
4.2 Design requirements
4.2.2 Fault detection requirements
4.2.2.2 Particular requirements for a type 1 ESPE
This subclause of part 1 is not applicable.
4.2.2.3 Particular requirements for a type 2 ESPE
This subclause of part 1 is not applicable.
4.2.2.4 Particular requirements for a type 3 ESPE
Replacement:
A single fault in the sensing device resulting in a complete loss of the stated AOPDDR
detection capability shall cause the ESPE to go to a lock-out condition within the specified
response time.
NOTE 1 For AOPDDR using rotating mirrors for scanning the detection zone, this requirement can be fulfilled by
scanning on a defined reference object located outside the detection zone and the tolerance zone.
A single fault resulting in a deterioration of the stated AOPDDR detection capability shall cause
the ESPE to go to a lock-out condition within a time period of 5 s following the occurrence of
that fault.
NOTE 2 Examples of deterioration of the AOPDDR detection capability include:
– increase of the minimum detectable object size;
– increase in the minimum detectable reflectance;
– decrease of measurement accuracy.
A single fault resulting in an increase in response time beyond the specified value or preventing
at least one OSSD going to the OFF-state shall cause the ESPE to go to a lock-out condition
immediately, i.e. within the response time, or immediately upon any of the following demand
events where fault detection requires a change in state:
– on actuation of the sensing function;
– on switch off/on;
– on reset of the start interlock or the restart interlock, if available (see A.5 and A.6 of
IEC 61496-1);
– on the application of an external test signal, if available.
NOTE 3 An external test signal may be required if, for example, in a particular application, the frequency of
actuation of the sensing function is foreseeably low and the OSSDs are monitored only at the change of state.

61496-3 © IEC:2001 – 19 –
It shall not be possible for the ESPE to achieve a reset from a lock-out condition, for example,
by interruption and restoration of the mains power supply or by any other means, when the fault
which initiated the lock-out condition is still present.
In cases where a single fault which does not cause a failure to danger of the ESPE is not
detected, the occurrence of further faults shall not cause a failure to danger. For verification of
this requirement, see 5.3.4.
4.2.2.5 Particular requirements for a type 4 ESPE
This subclause of part 1 is not applicable.
Additional design requirements:
4.2.12 Integrity of the AOPDDR detection capability
4.2.12.1 General
The design of the AOPDDR shall ensure that the detection capability is not decreased below
the limits specified by the supplier and in this standard by any of the following:
− ageing of components;
− component tolerances (for example, spectral sensitivity of the receiver element);
− distance-dependent changes of sensitivity related for example to optics;
− limits of adjustment;
− insecure fixing of optical and mechanical components within the AOPDDR;
− environmental interference, especially:
a) system noise;
b) electrical interference according to 4.3.2 of IEC 61496-1;
c) pollution on the surface of the optical window of the housing;
d) condensation on the surface of the optical window of the housing;
e) ambient temperature;
f) ambient light;
g) background (for example, contrast between object and background);
h) vibration and bump;
i) humidity;
j) supply voltage variations and interruptions.
If a single fault (as specified in annex B of IEC 61496-1), which under normal operating
conditions (see 5.1.2.1 of IEC 61496-1) would not result in a loss of the stated AOPDDR
detection capability but, when occurring with a combination of the above conditions, would
result in such a loss, that fault, together with that combination of conditions, shall be
considered as a single fault and the AOPDDR shall respond to such a single fault as required
in 4.2.2.4.
NOTE The technique of scanning on a reference object can satisfy the requirement in respect of ageing of
components. Other techniques giving the same level of assurance may be used.

61496-3 © IEC:2001 – 21 –
4.2.12.2 Detection and tolerance zones
The supplier shall specify the tolerance zone(s). The supplier shall take into account worst-
case conditions including, for example, signal-to-noise ratio S/N and standard deviation σ
considering all influences listed in this standard and any additional influences specified by the
supplier (environmental influence, component faults, etc.).
The tolerance zone depends on systematic interferences, measurement faults, resolution of the
measurement values, etc. and is necessary to assure detection within the detection zone.
Figures 1a and 1b show examples of tolerance zones.
The test pieces (see 4.2.13) shall be detected with a minimum probability of detection of
–7
1 – 2,9 × 10 throughout the detection zone(s). To achieve this minimum probability of detection,
the tolerance zone is added to the detection zone (see figure BB.2, annex BB).
NOTE 1 Probability of detection as used in this part is determined by the accuracy of measurement and is not
related to the probability of faults.
NOTE 2 Special attention may be required when the detection zone of AOPDDR is made up by more than one
transmitting and/or receiving unit to ensure that the AOPDDR does not have (a) zone(s) with limited detection
capability between the fields of view of these units.
The boundary between the detection zone and the tolerance zone shall be the median point of
the distribution of measurement values determined using a test piece of reflectivity equal to or
between that of the "black" test piece and the "white" test piece. The supplier shall declare the
reflectivity of the test piece used and the calculations used. This requirement may be verified
by inspection of the supplier's declaration.
NOTE 3 The value for the ranging accuracy and the tolerance zone is not necessarily a constant. It can, for
example, be a function of the measurement distance.
NOTE 4 If the AOPDDR has a facility to automatically set its detection zone(s), the ranging error of the set values
is taken into account when determining the tolerance zone (see clause A.11).
NOTE 5 Annex BB gives additional information about the relationship between ranging accuracy and probability of
detection.
4.2.12.3 Scanning geometry, scanning frequency and response time
The supplier shall specify the relevant parameters of the detection zone(s), including range and
scanning angle. The scanning geometry and/or scanning frequency shall be sufficient to ensure
that a test piece with a diameter of the specified minimum detectable object size is detected at
the maximum range of the detection zone(s). The supplier shall define values in the range of
50 mm to 100 mm as the minimum detectable object size of the AOPDDR. The minimum
detectable object size may be distance dependent.
NOTE 1 The restriction of the minimum detectable object size to the range of 50 mm to 100 mm is based on
current applications. Additional requirements may be necessary for AOPDDRs having detection capabilities outside
this range.
Objects of the minimum detectable size that are either stationary or moving within the detection
zone at any speed up to 1,6 m/s shall be detected by the ESPE within the specified response
time. The response time shall be determined by the supplier taking into account worst-case
conditions, especially for the scanning frequency and the movement of objects. Where the
supplier states that an AOPDDR can be used to detect objects moving at speeds greater than
1,6 m/s, the requirements shall be met at any speed up to and including the stated maximum
speed(s).
61496-3 © IEC:2001 – 23 –
NOTE 2 The detection capability may be determined by the optical geometry of the AOPDDR so that one complete
beam will impinge on the specified test pieces in the maximum range of detection zone and tolerance zone for a
special design. In this case, the distance between the centre of two adjacent transmitter beams (except the first and
the last one) will not exceed half the diameter of the test pieces. For other designs, it can be more difficult to carry
out the verification according to 5.2.1.2 and 5.2.11, especially when movement of objects is taken into account, as
required above.
NOTE 3 An example for the calculation of the response time is given in annex AA.5.
All points on a path projected from any point on the border of the detection zone to the
receiving element(s) of the AOPDDR shall be within the detection zone (see 4.2.12.2) or the
zone of limited detection capability (see 4.1.4).
4.2.13 Test pieces for type testing
4.2.13.1 General
The test pieces are part of the AOPDDR and shall therefore be provided by the supplier for use
in the type tests of clause 5. They shall be marked with a type reference and identification of
the AOPDDR with which they are intended to be used.
The test pieces shall have a diameter equal to the maximum specified detection capability
(minimum diameter). Other diameters within the range of 50 mm to 100 mm may be required
for testing depending on the detection capability of the AOPDDR.
NOTE The minimum effective length of the test pieces has been selected for ease of use.
4.2.13.2 Black test piece
The black test piece shall be a cylinder with a minimum effective length of 0,3 m. The surface
of the test piece shall have a diffuse reflectance value in the range of 1,6 % to 2,0 % including
measurement accuracy, at the wavelength of the transmitter and under normal conditions. This
value shall be verified by measurement. Where this reflectance value is used for calculation,
the nominal value of 1,8 % shall be used.
NOTE Figure 2 shows the results of an investigation to determine the reflectance of the black test piece.
4.2.13.3 White test piece
The white test piece shall be a cylinder with a minimum effective length of 0,3 m. The surface
of the test piece shall have a diffuse reflectance value in the range of 80 % to 90 % at the
wavelength of the transmitter.
4.2.13.4 Retro-reflective test piece
The retro-reflective test piece shall be a cylinder with a minimum effective length of 0,3 m. The
surface of the test piece shall be of retro-reflecting material. The material shall comply with the
requirements for retro-reflection of EN 471 class 2 or equivalent.
–1 –2
NOTE Table 5 in EN 471 defines the minimum coefficient of retro-reflection for class 2 material as 330 cd ⋅ lx ⋅ m
with an entrance angle of 5° and an observation angle of 0,2° (12').
4.2.14 Wavelength
AOPDDRs shall operate at a wavelength within the range of 820 nm to 946 nm.
NOTE This range of wavelengths is based on the present availability of components together with research which
shows it to be suitable for materials used as clothing.

61496-3 © IEC:2001 – 25 –
4.2.15 Radiation intensity
The radiation intensity generated and emitted by the AOPDDR shall at no time, even in the
presence of a component failure, exceed the maximum power or energy levels for a class 1
laser in accordance with 9.3, 9.4 and table 1 of IEC 60825-1. The marking as a class 1 laser
shall be carried out as required in 5.2 of IEC 60825-1.
4.2.16 Mechanical construction
When the detection capability can be decreased below the limit stated by the supplier, as a
result of a change of position of components, the fixing of those components shall not rely
solely on friction.
NOTE The use of oblong mounting holes without additional means could lead for example to a change of the
position of the detection zone under mechanical interference such as bump.
4.3 Environmental requirements
Addition:
NOTE These requirements may not fulfil the needs of certain applications (for example: use on vehicles, including
automatic guided vehicles (AGVs), forklifts, mobile machinery, etc.).
4.3.1 Ambient air temperature range and humidity
Addition:
The ESPE shall not fail to danger when subjected to a rapid change of temperature and
humidity leading to condensation on the optical window.
This requirement is verified by the condensing test of 5.4.2.
4.3.2 Electrical disturbances
Addition:
The requirements listed in 4.3.2 of part 1 for a type 4 ESPE shall apply to these type 3 ESPEs.
4.3.3 Mechanical environment
Additional mechanical requirements:
4.3.3.3 Change of temperature
The ESPE shall be free of damage, including displacement and/or cracks of the optical window,
after the tests of 5.4.4.3 and it shall be capable of continuing in normal operation.
4.3.3.4 Impact resistance
4.3.3.4.1 Normal operation
The ESPE shall be free of damage, including displacement and/or cracks of the optical window,
after the tests of 5.4.4.4.2 and it shall be capable of continuing in normal operation.

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4.3.3.4.2 Fail to danger
The ESPE shall not fail to danger after the tests of 5.4.4.4.3.
4.3.4 Enclosures
Addition:
Means shall be provided for the secure fixing of the enclosure(s).
Enclosures of the AOPDDR containing optical components shall provide a degree of protection
of at least IP65 (see IEC 60529) when mounted as specified by the supplier.
Additional environmental requirements:
4.3.5  Light interference on AOPDDR receiving elements and other optical components
The ESPE shall continue in normal operation when subjected to the following:
− incandescent light;
− fluorescent light operated with high-frequency electronic power supply;
− radiation from an AOPDDR of identical design if no mounting restrictions related to possible
interference are given by the supplier of the AOPDDR.
The ESPE shall not fail to danger when subjected to the following:
− high-intensity incandescent light (simulated daylight using a quartz lamp);
− fluorescent light operated with its rated power supply and with a high-frequency electronic
power supply;
− stroboscopic light;
− radiation from an AOPDDR of identical design.
These requirements are verified by the tests of 5.2.1.2 and 5.4.6.
4.3.6 Pollution interference
The supplier shall specify the maximum level of homogeneous pollution in percentage of
transmission which will not result in a decrease of the stated detection capability.
The AOPDDR shall continue in normal operation when the received signal energy of the
detection system itself is attenuated by up to 30 % by homogeneous pollution.
Pollution between the transmitting and/or receiving element(s) and the beginning of the
detection zone(s) (including optical components) of the AOPDDR resulting in a loss of the
stated detection capability shall cause the OSSDs to go to the OFF-state.
These requirements are verified by the tests of 5.4.7.
NOTE The tests listed in 5.4.7 may not cover all possible forms of pollution, for example, oil, grease and process
materials.
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Any pollution monitoring means for detecting a loss of the stated detection capability shall
comply with all the relevant requirements of this standard.
4.3.7 Background interference
The stated tolerance zone shall not be increased by background interference. This requirement
is verified by the tests of 5.4.8.
NOTE 1 The supplier may specify the AOPDDR for a maximum reflectance value that is monitored by the
AOPDDR itself and which leads to the OFF-state of the OSSDs if the specified maximum reflectance value is
exceeded. Background interference by materials with higher values of reflectance can thereby be excluded.
NOTE 2 Backgrounds that may interfere with the measurement results include corner cube reflectors, tiles, sheet
metal, white paper, etc.
NOTE 3 Retro-reflectors are considered as a background within the tests of detection capability and measurement
accuracy (see 5.4.8). If retro-reflectors in the background lead to measurement faults, it may be possible in specific
applications to use other measures instead of an addition to the tolerance zone.
4.3.8 Manual interference
It shall not be possible to reduce the stated detection capability by covering the optical window
of the housing of the AOPDDR or other parts (if applicable) or by placing objects within the
zone of limited detection capability (see 4.1.4). In such cases the OSSDs shall go to the OFF-
state within a time period of 5 s and the OSSDs shall remain in the OFF-state until the manual
interference is removed.
4.3.9 Optical shadowing in the detection zone
The AOPDDR detection capability shall be maintained when small objects are present in the
detection zone. This shall be verified by analysis and by a test according to 5.4.10. The
analysis shall include examination of any software filtering algorithms provided.
NOTE Software filtering algorithms may be provided to disregard small objects, for example, to increase reliability
of operation.
4.3.10 Ageing of components
Drift or ageing of components that would reduce the detection capability below the value stated
shall not cause a failure to danger of the ESPE, shall be detected within a time period of 5 s
and shall lead to a lock-out condition.
If a reference object is used for monitoring ageing and drift of components, variations in its
properties (for example, reflectance) shall not cause a failure to danger of the ESPE. If a
reference object is used to monitor ageing and drift of components, it shall be considered to be
part of the AOPDDR and shall be provided by the supplier of the AOPDDR.

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5 Testing
This clause of part 1 is applicable except as follows:
5.1 General
5.1.1.2 Operating condition
Addition:
Unless otherwise stated in this part, and if the facility is provided to set the detection zone, the
detection zone and the tolerance zone shall be set up as follows:
− radius respectively width and length (or equivalent values) of the detection zone of 1,0 m;
− addition of the tolerance zone.
For an AOPDDR with a stated maximum detection distance of less than 1,0 m, this distance
shall be used where 1,0 m is specified in clause 5.
For an AOPDDR without the facility to set the detection zone, the fixed detection zone shall be
used for all tests.
During these tests the test piece(s) shall be used normal to the plane of the AOPDDR detection
zone.
5.2 Functional tests
5.2.1 Sensing function and detection capability
Replacement:
5.2.1.1 General
The sensing function and the integrity of the detection capability shall be tested as specified,
taking into account the following:
− the tests shall verify that the specified test pieces are detected when the axis of the test
piece is placed inside the stated detection zone(s);
− the tests shall verify the dimensions of the tolerance zone (i.e. the ranging accuracy) stated
by the supplier;
− the number, selection and conditions of the individual tests shall be such as to verify the
requirements of 4.2.12.1.
Table 1 shows an overview of the minimum tests required.

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Table 1 – Verification of detection capability requirements (see also 4.2.12.1)
Distance between detection zone origin at
the AOPDDR and test piece axis
Test Conditions
6)
Test piece 0,5 m 1,0 m Every Max.
0,1 m
6)
1,0 m range
radius
a Reflectance Black test piece X X X XXX
(see 4.2.13.2)
b Reflectance White test piece X X X XXX
(see 4.2.13.3)
c Reflectance Retro-reflective test piece X X X XXX
(see 4.2.13.4)
1)
d Ageing of components X
1)
e Undetected faults of X
components
f Electrical disturbances 4.3.2, 5.2.3.1 and 5.4.3 X
except supply voltage of IEC 61496-1 apply
variations and supply
voltage interruptions
g Supply voltage variations Black test piece X
and supply voltage (see 4.2.13.2)
interruptions
1)
h Pollution on the surface X
of the optical window of
the housing
2)
i Ambient temperature 50 °C or maximum X
variation
j Ambient temperature 0° or minimum, non- X
3)
variation condensing
k Humidity 5.4.2 applies X
l Light interference See table 2 X
Worst-case distance
m Background interference
between "black" test piece
and background according
4)
to the design
Background reflectance:
5)
a) corner cube reflector
X
b) from 1,8 % to 5 %
X
c) other relevant reflecti-
X
vities between a) and b)
n Vibration and bump 5.4.4 applies X
1)
Effects of ageing of components, undetected faults of components and pollution on the surface of the optical
window of the housing should be addressed within the endurance test, otherwise additional tests may be
necessary.
2)
AOPDDR in test chamber – open test chamber – start test within 1 min.
3)
AOPDDR in test chamber – open test chamber – test without condensation.
4)
The background shall be arranged as indicated in figure 3a.
5)
See also 4.3.7, note 1 and 5.4.8.
6)
If the specified distances cannot be achieved because of physical constraints, then the test piece shall be
placed as close as possible to the specified distance in the plane of detection.

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5.2.1.2 Integrity of the detection capability
5.2.1.2.1 General
It shall be verified that the stated AOPDDR detection capability is maintai
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