Comprehensive Guide to CSA Z663-18: Safety Requirements for Automated Scanning Systems in Industrial Environments

Scope and Application of CSA Z663-18

CSA Z663-18, titled Safety Requirements for Automated Scanning Systems in Industrial Environments, establishes comprehensive safety criteria for the design, installation, operation, and maintenance of stationary and mobile scanning systems used for hazard detection, area monitoring, and object recognition in industrial workplaces. The standard applies to systems that emit electromagnetic radiation (including laser, structured light, and time‑of‑flight), ultrasonic waves, or that rely on passive imaging when integrated into safety‑related control systems. It covers scanning systems intended to detect personnel, objects, or environmental conditions and to initiate protective actions such as machine stop, speed reduction, or warning signals.

The standard is relevant to manufacturing plants, warehouses, logistics centers, and any industrial facility where moving machinery, autonomous vehicles, or robotic cells coexist with human workers. It specifically excludes scanning systems used solely for non‑safety purposes (e.g., quality inspection) and medical imaging devices governed by other regulations. CSA Z663-18 complements the risk assessment framework of CSA Z432 (Safeguarding of Machinery) and aligns with international safety standards such as ISO 13849, IEC 61496, and IEC 62061.

Technical Requirements and Key Specifications

The standard defines mandatory performance criteria for scanning systems based on their intended safety function. Below are the core technical requirements.

Performance Levels and Safety Integrity

Scanning systems must be categorized into Performance Levels (PL a to e) according to ISO 13849-1 or Safety Integrity Levels (SIL 1 to 3) per IEC 62061. The required level is determined by the severity of potential harm, the frequency of hazardous exposure, and the possibility of avoidance. For example, a scanning system used to protect a high‑speed robotic cell would typically require PL d or SIL 2.

Response Time and Safety Distance

The overall system response time (t_sys) — from detection to the cessation of hazardous motion — must be measured and documented. The minimum safety distance (S) is calculated using the formula:

S = (K × T) + C

• K – Approach speed of personnel (m/s) – default value 1.6 m/s for hand/arm detection, 2.0 m/s for body detection.
• T – Overall stopping time (s) = t_scan + t_processing + t_{machine stop}.
• C – Additional distance (mm) based on detection capability and resolution (e.g., 850 mm for systems with large blind zones).

Detection Capability and Reliability

Scanning systems must be able to detect test pieces (cylindrical or rectangular) with specified dimensions at defined distances. The standard mandates that the system shall detect a 70 mm diameter cylinder at any distance up to the rated range. Failure to detect must result in a safe state within the maximum allowable stopping time. Additionally, the system must undergo fault injection testing to verify that single failures (e.g., a defective laser diode) do not lead to a loss of safety function (i.e., they must result in a safe state or maintain full functionality).

Environmental Robustness

Equipment must operate reliably under the following conditions:

• Temperature range: 0 °C to +50 °C (optional extended range available for special applications).
• Humidity: 10 % to 95 % non‑condensing.
• Ingress Protection: Minimum IP54 for indoor use; IP65 or higher for outdoor or dusty environments.
• Immunity to electromagnetic interference as per IEC 61000‑6‑2.

Laser safety classification must be Class 1 or Class 1M (IEC 60825‑1) to ensure eye safety under normal use. Higher classes are permitted only if a documented risk assessment proves the additional hazard is mitigated.

Implementation Highlights for System Designers and Integrators

Implementing a scanning system compliant with CSA Z663-18 involves several critical steps beyond component selection.

Risk Assessment Integration

Before choosing a scanning system, a full risk assessment according to CSA Z432 or ISO 12100 must be performed. The scanning system can only be used to cover hazards that are adequately addressed by detection and initiating a stop. Hazards such as ejection of parts or entanglement must be mitigated by other safeguards (e.g., guards or hold‑to‑run controls).

System Architecture and Configuration

The scanning system must be configured with multiple monitoring sensor zones (warning fields and safety fields). The interface to the machine controller should typically use dual‑channel safety I/O with test pulses to detect faults. Redundant architecture (e.g., two sensors monitoring the same area) is recommended for high‑risk applications.

Installation and Commissioning

Mounting must ensure that the scanning plane covers the entire protected area without gaps. Reflective surfaces nearby can cause stray reflections; the installers must check that the sensor’s response is not impaired. A documented commissioning report including safety distance verification, response time measurement, and field acceptance tests must be prepared and kept on file.

Compliance Notes and Certification

Conformity with CSA Z663-18 can be demonstrated through self‑declaration by the manufacturer or third‑party certification by an accredited body (e.g., CSA Group, TÜV SÜD, UL). Key compliance requirements are:

Documentation

• Technical file including design rationale, risk assessment, and test reports.
• User manual in English and French (for Canadian market).
• Safety calculations and validation results.

Marking and Labeling

Each scanning system unit must bear a permanent label stating:

• Manufacturer and model
• CSA Z663-18 marking (if certified)
• Performance Level (PL) or SIL rating
• Serial number and date of manufacture
• Laser class (if applicable)

Periodic Inspection

The standard recommends re‑inspection at intervals not exceeding 12 months. The inspection must verify that the safety distances, response times, and field coverage remain unchanged. Results must be recorded and retained for at least three years.

Frequently Asked Questions