IEC 61496-3:2025
(Main)Safety of machinery - Electro-sensitive protective equipment - Part 3: Particular requirements for active opto-electronic protective devices responsive to diffuse reflection (AOPDDR)
Safety of machinery - Electro-sensitive protective equipment - Part 3: Particular requirements for active opto-electronic protective devices responsive to diffuse reflection (AOPDDR)
IEC 61496-3:2025 specifies additional requirements for the design, construction and testing of non‑contact electro-sensitive protective equipment (ESPE) designed specifically to detect persons or parts of persons as part of a safety-related system, 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 can include optional safety-related functions, the requirements for which are given both in Annex A of this document and in Annex A of IEC 61496‑1:2020.
NOTE "Non-contact" means that physical contact is not required for sensing.
This document 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 and how it interfaces with the machine.
AOPDDRs are devices that have either
- one or more detection zone(s) specified in two dimensions (AOPDDR-2D), or
- one or more detection zone(s) specified in three dimensions (AOPDDR-3D)
wherein radiation in the near infrared range is emitted by an emitting 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. This reflection is used to determine the position of the object.
Opto-electronic devices that perform only a single one-dimensional spot-like distance measurement, for example, optical proximity switches, are not covered by this document.
This document is limited to ESPE that do not require human intervention for detection. It is limited to ESPE that detect objects entering into or being present in a detection zone(s).
This document does not address those aspects required for complex classification or differentiation of the object detected.
This document does not address requirements and tests for outdoor application.
Excluded from this document are AOPDDRs employing radiation with the peak of wavelength outside the range 820 nm to 1 100 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 document can be used as a guide. This document is relevant for AOPDDRs having a minimum detectable object size in the range from 30 mm to 200 mm.
This document can 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 those applications, different requirements can be appropriate, for example when the materials that are recognized by the sensing function have different properties from those of persons and their clothing.
This document does not deal with electromagnetic compatibility (EMC) emission requirements.
This fourth edition cancels and replaces the third edition published in 2018. This edition constitutes a technical revision.
This edition includes the following significant technical changes with respect to the previous edition:
a) some requirement clauses and test procedures have been adapted or removed because they have been consolidated in IEC 61496-1:2020 (e.g. 5.4.6.2 Light sources and Clause A.9);
b) change of the minimum probability of detection and fault detection requirements for Type 2 AOPDDR;
c) using the AOPDDR as a trip device is described as an optional function in Clause A.13.
Sécurité des machines - Équipements de protection électrosensibles - Partie 3: Exigences particulières pour les équipements utilisant des dispositifs protecteurs optoélectroniques actifs sensibles aux réflexions diffuses (AOPDDR)
L'IEC 61496-3:2025 spécifie des exigences supplémentaires pour la conception, la construction et les essais des équipements de protection électrosensibles (ESPE) sans contact, conçus spécifiquement pour détecter des personnes ou des parties de leurs corps, dans le cadre d'un système relatif à la sécurité, et qui utilisent des dispositifs protecteurs optoélectroniques actifs sensibles aux réflexions diffuses (AOPDDR) pour la fonction de détection. Une attention particulière est portée aux exigences qui permettent de s'assurer qu'une performance relative à la sécurité appropriée est atteinte. Un ESPE peut comporter des fonctions relatives à la sécurité facultatives; les exigences de ces fonctions sont spécifiées à l'Annexe A du présent document et à l'Annexe A de l'IEC 61496‑1:2020.
NOTE L'expression "sans contact" signifie qu'un contact physique n'est pas exigé pour la détection.
Le présent document ne spécifie pas les dimensions ou les configurations de la zone de détection, ni son emplacement par rapport aux parties dangereuses dans une application particulière, ne définit pas non plus ce qui constitue un état dangereux pour une machine donnée. Il se limite au fonctionnement de l'ESPE et à son interface avec la machine.
Les AOPDDR sont des dispositifs qui comportent soit
− une ou plusieurs zones de détection bidimensionnelles (AOPDDR bidimensionnel), soit
− une ou plusieurs zones de détection tridimensionnelles (AOPDDR tridimensionnel)
dans laquelle ou lesquelles le rayonnement dans le champ proche infrarouge est émis par un ou plusieurs émetteurs. Lorsque le rayonnement émis heurte un objet (par exemple, une personne ou une partie de son corps), une partie du rayonnement émis est réfléchi par réflexion diffuse sur un ou plusieurs récepteurs. Cette réflexion permet de déterminer la position de l'objet.
Les équipements optoélectroniques qui réalisent un seul mesurage de distances unidimensionnelles ponctuelles, par exemple les interrupteurs de proximité optiques, ne sont pas couverts par le présent document.
Le présent document se limite aux ESPE qui n'exigent pas d'intervention humaine pour la détection. Il se limite aux ESPE qui détectent les objets qui entrent ou sont présents dans une ou plusieurs zones de détection.
Le présent document ne traite pas des aspects exigés pour une classification complexe ou une différenciation de l'objet détecté.
Le présent document ne traite pas des exigences ni des essais pour une application extérieure.
Les AOPDDR qui utilisent des longueurs d'onde de crête de rayonnement en dehors de la plage de 820 nm à 1 100 nm ainsi que ceux dont les longueurs d'onde de rayonnement sont différentes de celles générées par l'AOPDDR lui-même sont exclus du présent document. Ce dernier peut servir de guide pour les dispositifs de détection qui utilisent des longueurs d'onde de rayonnement en dehors de cette plage. Le présent document est pertinent pour les AOPDDR dont la taille d'objet minimale détectable est comprise dans la plage entre 30 mm et 200 mm.
Le présent document peut être pertinent pour les applications autres que la protection des personnes, par exemple la protection des machines ou des produits contre des dommages mécaniques. Dans ces applications, des exigences différentes peuvent être appropriées, par exemple lorsque les matières qui sont reconnues par la fonction de détection possèdent des propriétés différentes de celles des personnes et de leurs vêtements.
Le présent document ne traite pas des exigences d'émission concernant la compatibilité électromagnétique (CEM).
Cette quatrième annule et remplace la troisième édition parue en 2018. Cette édition constitue une révision technique.
Cette édition inclut les modifications techniques majeures suivantes par rapport à l'édition précédente:
a) certains articles d'exigences et certaines procédures d'essai ont été adaptés ou supprimés, car ils ont été consolidés dans l'IEC 61496-1:2020 (par exemple, le 5.4.6.2 "Sources de lumièr
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Standards Content (Sample)
IEC 61496-3 ®
Edition 4.0 2025-08
INTERNATIONAL
STANDARD
COMMENTED VERSION
Safety of machinery - Electro-sensitive protective equipment -
Part 3: Particular requirements for active opto-electronic protective devices
responsive to diffuse reflection (AOPDDR)
ICS 13.110; 31.260 ISBN 978-2-8327-0662-6
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CONTENTS
FOREWORD . 4
INTRODUCTION . 7
1 Scope . 8
2 Normative references . 9
3 Terms, definitions and abbreviated terms . 9
3.1 Terms and definitions. 9
3.1012 Abbreviated terms . 12
4 Functional, design and environmental requirements . 12
4.1 Functional requirements. 12
4.2 Design requirements . 13
4.3 Environmental requirements . 25
5 Testing . 29
5.1 General . 29
5.2 Functional tests . 30
5.3 Performance testing under fault conditions . 41
5.4 Environmental tests . 42
6 Marking for identification and for safe use . 63
6.1 General . 63
7 Accompanying documents . 63
Annex A (normative) Optional functions of the ESPE . 65
Annex B (normative) Catalogue of single faults affecting the electrical equipment of
the ESPE, to be applied as specified in 5.3 . 73
Annex AA (informative) Examples of the use of an AOPDDR in different applications . 74
Annex BB (informative) Relationship between position accuracy and probability of
detection for a Type 3 AOPDDR . 97
Bibliography . 104
List of comments. 105
Figure 1 – Detection zone of an AOPDDR-2D . 18
Figure 2 – Detection zone of an AOPDDR-3D . 19
Figure 3 – AOPDDR used as a trip device with orthogonal approach (200 mm minimum
detectable object size) .
Figure 4 – AOPDDR used as a trip device with orthogonal approach (150 mm minimum
detectable object size) .
Figure 3 – Shape of test pieces for AOPDDR-3D . 23
Figure 54 – Minimum diffuse reflectivity of materials . 24
Figure 65 – Test piece intrusion into the detection zone for test . 31
Figure 76 – Influence on detection capability by incandescent light – Example 1 . 36
Figure 87 – Influence on detection capability by incandescent light – Example 2 . 37
Figure 98 – Influence on detection capability by light reflected by the background . 38
Figure 109 – Configuration for the endurance test – Example 1 . 39
Figure 1110 – Configuration for the endurance test – Example 2 . 40
Figure 1211 – Interference between two AOPDDR-3D of identical design (opposite
arrangement) . 53
Figure 1312 – Interference between two AOPDDR-3D of identical design (parallel
arrangement) . 54
Figure 1413 – Example of an emitting element of an AOPDDR . 56
Figure 1514 – Example of a receiver of an AOPDDR . 56
Figure 1615 – Influence on detection capability by background . 58
Figure 1716 – Multi-path reflection test (top view) . 59
Figure 1817 – Multi-path reflection test (side view) . 59
Figure A.1 – Reference boundary monitoring – Distribution of measurement values . 68
Figure A.2 – Use of an AOPDDR with reference boundary monitoring . 69
Figure A.3 – Use of an AOPDDR as parts of a body trip device. 69
Figure A.4 – AOPDDR used as a trip device with orthogonal approach (150 mm
minimum detectable object size) . 70
Figure A.5 – AOPDDR used as a trip device with orthogonal approach (200 mm
minimum detectable object size) . 71
Figure AA.1 – Example of the use of an AOPDDR-2D on machinery .
Figure AA.2 – Example of the use of an AOPDDR-2D on an AGV .
Figure AA. AA.1 – Minimum Separation distance S – Example 1 . 83
Figure AA.4 – Overall minimum distance S without tolerance zone – Example 1 .
o
Figure AA.5 – Overall minimum distance S including tolerance zone – Example 1 .
o
Figure AA.2 – Separation distance S including tolerance zone – Example 1 . 85
Figure AA.0 AA.3 – Minimum Separation distance S – Example 2 . 86
Figure AA.7 – Overall minimum distance S without tolerance zone – Example 2 .
o
Figure AA.8 – Overall minimum distance S including tolerance zone – Example 2 .
o
Figure AA.4 – Separation distance S including tolerance zone – Example 2 . 88
Figure AA.9 AA.5 – Application example for body detection of an AOPDDR-3D . 90
Figure AA.10 AA.6 – Limited distance . 92
Figure AA.11 AA.7 – Overlap . 93
Figure AA.12 AA.8 – Reference boundary monitoring – Distribution of measurement
values . 94
Figure AA.13 AA.9 – AOPDDR-2D detection zone angled to the direction of approach –
Orthogonal approach . 95
Figure AA.14 AA.10 – AOPDDR-3D detection zone angled to the direction of approach
– Orthogonal approach . 96
Figure BB.1 – Relationship between position accuracy and detection zone . 97
Figure BB.2 – Relationship between position accuracy, detection zone and the
probabilistic part of the tolerance zone – Example 1 . 98
Figure BB.3 – Relationship between position accuracy, detection zone and the
probabilistic part of the tolerance zone – Example 2 . 99
Figure BB.4 – Relationship between position accuracy, detection zone and tolerance
zone – Example 1 . 100
Figure BB.5 – Relationship between position accuracy, detection zone and tolerance
zone – Example 2 . 100
Figure BB.6 – POD of a single measurement (logarithmic) for a MooM-evaluation with
1 ≤ M ≤ 50 . 102
Figure BB.7 – POD of a single measurement for a MooM-evaluation with 1 ≤ M ≤ 50 in
relation to σ in the case of a normal distribution . 103
Table 1 – Minimum tests required for the verification of detection capability
requirements (see also 4.2.12.1) . 32
Table 2 – Overview of light interference tests . 47
Table B.1 – Sensor array for distance measurement . 73
INTERNATIONAL ELECTROTECHNICAL COMMISSION
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Safety of machinery - Electro-sensitive protective equipment -
Part 3: Particular requirements for active opto-electronic protective
devices responsive to diffuse reflection (AOPDDR)
FOREWORD
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