SICK Bulkscan User manual

OPERATING INSTRUCTIONS
Bulkscan®
FLOW SENSORS
Laser volume owmeter for the throughput measurement of bulk goods
en

OPERATING INSTRUCTIONS | Bulkscan® 8014829/ZV98/2018-05-07 | SICK
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Copyright
This work is protected by copyright. All rights reserved by SICK AG. Reproduction of this
document or parts of this document is only permissible within the limits of the legal de-
termination of Copyright Law. Alteration or abridgment of the document is not permitted
without the explicit written approval of SICK AG.

OPERATING INSTRUCTIONS| Bulkscan®8014829/ZV98/2018-05-07| SICK
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Inhalt
1 About this document .......................................................................................7
1.1 Purpose of this document ........................................................................................7
1.2 Target group...............................................................................................................7
1.3 Information depth .....................................................................................................7
1.4 Scope .........................................................................................................................7
1.5 Abbreviations used....................................................................................................8
1.6 Symbols used ............................................................................................................8
2 On safety............................................................................................................9
2.1 Authorized personnel................................................................................................9
2.2 Correct use ................................................................................................................9
2.3 General safety notes and protective measures.......................................................9
2.3.1 Electrical installation work..................................................................... 10
2.3.2 Laser radiation........................................................................................ 10
2.3.3 Damaging potential equalization currents due to different ground po-
tentials ................................................................................................................. 12
2.4 Quick stop and quick restart ................................................................................. 13
2.5 Environmental protection ..................................................................................... 13
2.5.1 Power consumption................................................................................ 13
2.5.2 Disposalafternaldecommissioning ................................................... 13
2.6 IP technology .......................................................................................................... 13
3 Product description....................................................................................... 14
3.1 Special features of the Bulkscan® ....................................................................... 14
3.2 Operating principle of the Bulkscan®................................................................... 14
3.2.1 Measurement principle ......................................................................... 14
3.3 Application examples............................................................................................. 15
3.4 Status indicators .................................................................................................... 16
4 Congurable functions ................................................................................. 17
4.1 Setting the belt speed............................................................................................ 17
4.2 Measurement of the volume ................................................................................. 18
4.3 Measurement of the mass .................................................................................... 18
4.4 Measurementofvolumeowrate ........................................................................ 19
4.5 Measurementofthemassowrate ..................................................................... 19
4.6 Measurement of the bulk density ......................................................................... 20
4.7 Measurement of the bulk height........................................................................... 20
4.8 Monitoring the center of gravity ............................................................................ 21
4.9 Monitoring the bulk edge (only valid for Bulkscan® LMS511) ........................... 23
4.10 Monitoring the conveyor belt edge (only valid for Bulkscan® LMS511)............. 24
4.11 Averaginglter........................................................................................................ 25
4.12 Digital inputs........................................................................................................... 25
4.13 Digital outputs ........................................................................................................ 26
4.14 Analog module BAM100........................................................................................ 28
4.15 Data interfaces....................................................................................................... 28
4.15.1 Ethernet interface................................................................................... 29

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4.15.2 Serial host interface ............................................................................... 29
4.15.3 Serial auxiliary interface/USB on Bulkscan® LMS511.........................29
4.15.4 Serial auxiliary interface on Bulkscan® LMS111 ................................ 30
5 Mounting......................................................................................................... 31
5.1 Placing mounting materials ready......................................................................... 31
5.2 Selecting the mounting location ........................................................................... 31
5.3 Mounting the sensor.............................................................................................. 32
5.3.1 Direct mounting of the Bulkscan® LMS511......................................... 33
5.3.2 Mounting of Bulkscan® LMS511 with mounting kit 1......................... 34
5.3.3 Mounting of Bulkscan® LMS511 with mounting kit 2......................... 35
5.3.4 Mounting of Bulkscan® LMS511 with mounting kit 3......................... 36
5.3.5 Mounting of Bulkscan® LMS511 with mounting bracket on existing
mounting kit LMS2xx ............................................................................................. 37
5.3.6 Mounting of Bulkscan® LMS511 with mounting bracket and mast
bracket ................................................................................................................. 38
5.3.7 Direct mounting of Bulkscan® LMS111 .............................................. 39
5.3.8 Mounting of Bulkscan® LMS111 with mounting kit 1a or 1b............. 39
5.3.9 Mounting of Bulkscan® LMS111 with mounting kit 2 or 3................. 41
5.3.10 Mounting of Bulkscan® LM511 with weather protection hood .......... 41
5.3.11 Mounting of Bulkscan® LM111 with weather protection hood .......... 42
5.4 Removing the sensor ............................................................................................. 43
6 Electrical installation .................................................................................... 44
6.1 Requirements for the electrical installation ......................................................... 44
6.1.1 Avoiding potential differences ............................................................... 44
6.1.2 Suitable power supply ............................................................................ 46
6.1.3 Cable lengths and wire cross-sections.................................................. 46
6.2 Carrying out the electrical installation on the Bulkscan®................................... 46
6.2.1 Supply voltage connection ..................................................................... 47
6.2.2 Ethernet interface connection ............................................................... 47
6.2.3 Connection of the digital inputs/outputs of Bullkscan® LMS511...... 48
6.2.4 Serial interface connection of Bullkscan® LMS511............................ 48
6.2.5 Mini-USB connection of Bullkscan® LMS511...................................... 49
6.2.6 Serial interface connection of Bulkscan® LMS111............................. 50
6.2.7 Connection of the digital inputs/outputs on Bulkscan® LMS111...... 50
6.2.8 "AUX" connection of Bulkscan® LMS111 ............................................. 51
6.3 Wiring the inputs and outputs to the external components ................................ 51
6.3.1 Wiringnon-oatingdigitalinputs ........................................................... 51
6.3.2 Wiringoatingdigitalinputs .................................................................. 52
6.3.3 Wiring encoder inputs ............................................................................ 52
6.3.4 Input circuits IN1 and IN2 on Bulkscan® LMS511.............................. 53
6.3.5 Connecting the outputs to a PLC on Bulkscan® LMS511................... 53
6.3.6 Connection of the switching outputs on Bulkscan® LMS111 to a PLC,
non-oating.............................................................................................................54
6.3.7 Connection of the switching outputs on Bulkscan® LMS111 to a PLC,
oating ...................................................................................................................54

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6.3.8 Analog inputs/outpus with analog module BAM100........................... 55
6.3.8.1 Module design ..................................................................... 55
6.3.8.2 Installation of Bus Terminals on mounting rails ................ 55
6.3.8.3 Power supply BC9050......................................................... 57
6.3.8.4 Analog input terminal KL3454 ........................................... 58
6.3.8.5 Analog output KL4424........................................................ 59
7 Conguration ................................................................................................. 60
7.1 ConguringtheBulkscan®withSOPAS................................................................ 60
7.1.1 InstallingtheSOPAScongurationsoftware......................................... 60
7.1.2 Establishing communication with the Bulkscan®................................ 61
7.2 CongurationoftheBulkscan®usingtelegrams ................................................ 62
8 Commissioning.............................................................................................. 64
8.1 Teaching-in the reference contour ........................................................................ 64
8.1.1 Compensation of the conveyor belt level .............................................. 66
8.1.2 Optimization for conveyor belts with slits or gaps (only valid for
Bulkscan® LMS511) ............................................................................................. 67
8.2 Performing a test measurement ........................................................................... 68
8.3 Setting tolerances .................................................................................................. 68
8.3.1 Tolerance against vibration.................................................................... 69
8.3.2 Toleranceagainstreection................................................................... 69
8.3.3 Optimization for outdoor applications................................................... 69
8.3.4 Ignore measurement points below the reference contour (only valid for
Bukscan® LMS511) .............................................................................................. 70
8.3.5 Contour smoothing (only valid for Bukscan® LMS111)....................... 71
8.4 Monitoring of the contamination degree .............................................................. 71
8.5 Scan frequency....................................................................................................... 72
8.6 Taking a reference measurement (compensation function) ............................... 73
9 Maintenance and care.................................................................................. 76
9.1 Cleaning the front screen ...................................................................................... 76
9.2 Replacing a Bulkscan® ......................................................................................... 76
10 Fault diagnosis............................................................................................... 77
10.1 Response to errors................................................................................................. 77
10.2 SICK Suport ............................................................................................................ 77
10.3 Error and status indicators on the 7 segment display......................................... 77
10.4 Status indication BAM100 .................................................................................... 78
11 Technical data................................................................................................ 80
11.1 Bulkscan® LMS511 data sheet............................................................................ 80
11.2 Bulkscan® LMS111 data sheet............................................................................ 82
11.3 Analog module BAM100 data sheet..................................................................... 84
11.4 Dimensional drawings ........................................................................................... 85
11.4.1 Dimensional drawing Bulkscan® LMS511........................................... 85
11.4.2 Dimensional drawings mounting kits (only for Bulkscan®LMS511).. 86

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11.4.3 Dimensional drawing mounting bracket for existing LMS2xx mounting
kit (only for Bulkscan®LMS511).......................................................................... 89
11.4.4 Dimensional drawing mounting bracket with mast bracket (only for
Bulkscan®LMS511) ............................................................................................. 90
11.4.5 Dimensional drawing Bulkscan® LMS111........................................... 91
11.4.6 Dimensional drawing mounting kits (only for Bulkscan® LMS111) ... 92
11.4.7 Dimensional drawing weather protection hood for Bulkscan® LMS511
(part. no 2063050)................................................................................................ 94
11.4.8 Dimensional drawing weather protection hood for Bulkscan® LMS111.
................................................................................................................. 95
11.4.9 Dimensional drawing analog module BAM100 .................................... 95
12 Ordering information .................................................................................... 96
12.1 Scope of delivery.................................................................................................... 96
12.2 Accessories............................................................................................................. 96
13 Appendix......................................................................................................... 99
13.1 Telegram reference ................................................................................................ 99
13.1.1 Notation and examples .......................................................................... 99
13.1.2 Logging in to the sensor/Logging out of the sensor........................... 101
13.1.3 Savingthecongurationinthenon-volatilememory ........................102
13.1.4 Device information ...............................................................................102
13.1.5 Operating mode/Teach-in ....................................................................102
13.1.6 Measured values .................................................................................. 103
13.1.7 Measurement .......................................................................................103
13.1.8 System...................................................................................................104
13.1.9 Edge monitoring (only for Bulkscan® LMS511) ................................. 105
13.1.10 Digital inputs......................................................................................... 106
13.1.11 Digital outputs ......................................................................................106
13.1.12 Reference measurement (compensation function)............................108
13.1.13 Service data.......................................................................................... 109
13.1.14 Error codes (sFA)................................................................................... 110

OPERATING INSTRUCTIONS| Bulkscan®8014829/ZV98/2018-05-07| SICK
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ABOUT THIS DOCUMENT
1 About this document
Please read this chapter carefully before you begin working with this documentation
and the Bulkscan® LMS511 or Bulkscan® LMS111.
1.1 Purpose of this document
These operating instructions guide the technical personnel during the safe mounting,
electricalinstallation,congurationandcommissioningaswellasduringthemain-
tenanceofthelaservolumeowmeterBulkscan®LMS511orBulkscan®LMS111,
referred to for short as the Bulkscan® in the following.
1.2 Target group
These operating instructions are intended for planning engineers, developers and
operators of plants and systems in which the Bulkscan® is to be used. They are also
intended for people who integrate the Bulkscan® into a machine, initialize its use, or
who are in charge of servicing and maintaining the device.
1.3 Information depth
These operating instructions contain information about the Bulkscan® on the following
topics:
◦Product description.
◦Mounting.
◦Electrical installation.
◦ Commissioningandconguration.
◦Care and maintenance.
◦Fault diagnosis and troubleshooting.
◦Conformity and approval.
WhenplanningandusingsensorssuchastheBulkscan®,specictechnicalskillsare
required that are not covered by this documentation.
When operating the Bulkscan®, the national, local and statutory rules and regulations
must always be observed.
YoucanndfurtherinformationontheBulkscan®onlineatwww.sick.com.
1.4 Scope
These operating instructions are original operating instructions.
These operating instructions are referring to the following software versions:
Component Function Version
LMS511-20190 Firmware V2.24
LMS111-10190 Firmware V1.02
SOPAS ET Congurationsoftware V3.x
For a table overview of user levels and passwords, see Chapter 7.1.2 Establishing com-
munication with the Bulkscan® LMS511 or Bulkscan® LMS111.
Note:
Note:

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ABOUT THIS DOCUMENT
1.5 Abbreviations used
Communication Language = proprietary SOPAS ET communication language (ASCII =
CoLaA or binary = CoLaB)
Checksum
Light Emitting Diode
SICKOPENPORTALforAPPLICATIONandSYSTEMSEngineeringTool=conguration
softwareforthecongurationofmultiplesystemsinasingleproject
SICK OPENPORTALforAPPLICATIONandSYSTEMSSingleDevice=congurationsoft-
wareforthecongurationofasinglesystem
1.6 Symbols used
Recommendations are designed to assist you in the decision-making process with
respect to the use of a certain function or a technical measure.
Notes inform you about special aspects of the device.
Display symbols show the status of the 7 segment display of a sender or receiver:
Constant display of characters, e.g., t.
  Successivedisplayofcharacters,e.g.,rst1,then2.
LED symbols describe the status of a diagnostics LED. Examples:
The LED is illuminated constantly.
 TheLEDisashing.
The LED is off.
Instructions for taking action are indicated by an arrow. Read carefully and follow the
instructions for action.
Warning!
Awarningindicatesaspecicorpotentialhazard.Thisisintendedtoprotectyou
against accidents.
Read carefully and follow the warnings!
SoftwarenotesshowwhereyoucanmaketheappropriatesettingsintheSOPAScong-
uration software.
CoLa
CS
LED
SOPAS ET
SOPAS SD
Recommendations
, , 
, , 
 Take action

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ON SAFETY
2 On safety
This chapter concerns your own safety and the safety of the equipment operator.
 Please read this chapter carefully before you begin working with the Bulkscan®.
2.1 Authorized personnel
The Bulkscan® must only be installed, commissioned, and serviced by adequately
qualiedpersonnel.
Risk of damage!
RepairworkonBulkscan®mayonlybeperformedbyqualiedandauthorizedservice
personnel from SICK AG.
Thefollowingqualicationsarenecessaryforthevarioustasks:
Activities Qualication
Mounting and mainte-
nance
Basic practical technical training
Knowledge of the current safety regulations in the workplace
Electrical installation
and replacement
Practical electrical training
Knowledge of current electrical safety regulations
Knowledge of the operation and control of the devices in their partic-
ular application (e.g., conveyor system)
Commissioning, opera-
tion,andconguration
Knowledge of the operation and control of the devices in their partic-
ular application (e.g., conveyor system)
Knowledge of the software and hardware¬ environment in the relat-
ed application
Basic knowledge of the Windows operating system used
Basic knowledge of data transmission
Tab. 1: Qualied safety personnel
2.2 Correct use
The Bulkscan® is a non-contact optical sensor for the measurement of volume, volume
owrate,mass,massowrate,determiningthecenterofgravityofbulkonconveyor
belts, monitoring of the bulk edges (only for Bulkscan® LMS511) and monitoring of the
conveyor belt edges (only for Bulkscan® LMS511).
It must only be used by authorized personnel and only in industrial environments.
IntheeventofanyotherusageormodicationtotheBulkscan®,e.g.,duetoopening
the housing during mounting and electrical installation, or to the SICK software, any
claims against SICK AG under the warranty will be rendered void.
TheBulkscan®mustonlybeoperatedinthespeciedambienttemperaturerange
(see "11.1 Bulkscan® LMS511 data sheet“ on page 80) or (see "11.2 Bulkscan®
LMS111 data sheet“ on page 82).
2.3 General safety notes and protective measures
Safety notes!
Observe the following to ensure the correct and safe use of the Bulkscan®.
• The notes in these operating instructions (e.g., regarding the use, mounting, installa-
tion or integration into the machine controller) must be observed.
Note

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ON SAFETY
• AllofcialandstatutoryregulationsgoverningoperationoftheBulkscan®mustbe
complied with.
• Thenationalandinternationallegalspecicationsapplytotheinstallationanduse
of the sensor, to its commissioning and to technical inspections repeated at regular
intervals, in particular:
◦The accident prevention regulations and work safety regulations.
◦And any other relevant safety regulations.
• The manufacturer and operator of the system in which the Bulkscan® is installed are
responsibleforcoordinatingandcomplyingwithallapplicablesafetyspecications
and regulations, in cooperation with the relevant authorities.
• Thechecksmustbecarriedoutbyqualiedsafetypersonnelorspeciallyqualied
and authorized personnel and must be recorded and documented to ensure that the
tests can be reconstructed and retraced at any time.
• These operating instructions must be made available to the operator of the system
inwhichtheBulkscan®isused.Thesystemoperatormustbeinstructedbyqualied
safety personnel and read the operating instructions.
• The Bulkscan® does not constitute a safety component according to the EC Machin-
ery Directive (2006/42/EC).
• The Bulkscan® is not a device for the protection of people in the context of the relat-
ed safety standards for machinery.
• The Bulkscan® must not be used in explosion hazard areas.
• Any other use that is not described as correct use is prohibited.
• TheuseofaccessoriesnotspecicallyapprovedbySICKisatownrisk.
2.3.1 Electrical installation work
• Only authorized personnel are allowed to perform the electrical installation work.
• Electrical connections between the Bulkscan® and other devices may only be made
when there is no power to the system.
• Select and implement wire cross-sections and their correct fuse protection in accor-
dance with the applicable standards.
 Do not open the housing.
 Observe the current safety regulations when working on electrical systems.
2.3.2 Laser radiation
WARNUNG WARNING AVERTISSEMENT
Laserstrahlung! Laser radiation! Rayonnement laser !
LASER PRODUKT KLASSE 1 CLASS 1 LASER PRODUCT APPAREIL À LASER DE
CLASSE 1
Wellenlänge: 905 nm
(unsichtbares Infrarotlicht)
EN/IEC 60825-1:2014
Identische Laserklasse für
Ausgabe EN/IEC 60825-
1:2007
Bulkscan® LMS511-20190
Bulkscan® LMS111-10190:
Impulsleistung: 29,6 W
Impulsbreite: 2,9 ns
Wavelength: 905 nm
(invisible infrared light)
EN/IEC 60825-1:2014
Identical laser class for issue
EN/IEC 60825-1:2007
Bulkscan® LMS511-20190
Bulkscan® LMS111-10190:
Pulse power: 29.6 W
Pulse width: 2.9 ns
Longueur d‘onde: 905 nm
(lumière infrarouge invisibles)
EN/IEC 60825-1:2014
Même classe laser pour
l’édition EN/CEI 60825-
1:2007
Bulkscan® LMS511-20190
Bulkscan® LMS111-10190:
Puissance d‘impulse: 29,6 W
Durée d‘impulse: 2,9 ns