SICK DL100 Pro User manual

OPERATING INSTRUCTIONS
DL100 Pro RS-422
Distance sensor

Described product
DL100 Pro RS-422
These operating instructions describe all DL100 Pro devices with an RS-422 interface
and with the type designation DL100-2xxxx103 and firmware version V001.004.000 or
higher.
Manufacturer
SICK AG
Erwin-Sick-Str. 1
79183 Waldkirch
Germany
Legal information
This work is protected by copyright. Any rights derived from the copyright shall be
reserved for SICK AG. Reproduction of this document or parts of this document is
only permissible within the limits of the legal determination of Copyright Law. Any modi‐
fication, abridgment or translation of this document is prohibited without the express
written permission of SICK AG.
The trademarks stated in this document are the property of their respective owner.
© SICK AG. All rights reserved.
Original document
This document is an original document of SICK AG.
    
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Contents
1 About this document........................................................................ 6
1.1 Information on the operating instructions.............................................. 6
1.2 Explanation of symbols............................................................................ 6
1.3 Further information................................................................................... 7
2 Safety information............................................................................ 8
2.1 Intended use............................................................................................. 8
2.2 Improper use............................................................................................. 8
2.3 Cybersecurity............................................................................................ 8
2.4 Limitation of liability................................................................................. 8
2.5 Modifications and conversions................................................................ 9
2.6 Requirements for skilled persons and operating personnel.................. 9
2.7 Operational safety and specific hazards................................................. 9
2.8 Warning signs on the device.................................................................... 10
2.9 UL conformity............................................................................................ 11
3 Product description........................................................................... 12
3.1 Function..................................................................................................... 12
3.2 Configuration............................................................................................. 12
3.3 Type label.................................................................................................. 13
3.4 Display and control elements.................................................................. 13
3.4.1 LEDs.......................................................................................... 13
3.4.2 Display...................................................................................... 14
3.4.3 Operating pushbuttons............................................................ 15
3.5 Scope of delivery....................................................................................... 15
4 Transport and storage....................................................................... 16
4.1 Transport................................................................................................... 16
4.2 Transport inspection................................................................................. 16
4.3 Storage...................................................................................................... 16
5 Mounting............................................................................................. 17
5.1 Mounting procedure................................................................................. 17
5.2 Mounting instructions............................................................................... 17
5.3 Select and mount the reflector ............................................................... 17
5.4 Placement of multiple distance sensors................................................. 20
5.5 Arranging the distance sensor to the adjacent optical data transmis‐
sion system............................................................................................... 22
5.5.1 Arrangement of ISD400-7xxx.................................................. 22
5.5.2 Assignment to ISD300, ISD400-1xxx or ISD400-6xxx.......... 23
5.6 Mounting the alignment bracket and distance sensor.......................... 24
5.7 Aligning the distance sensor and reflector with each other.................. 26
5.8 Received signal level................................................................................ 27
6 Electrical installation........................................................................ 29
CONTENTS
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6.1 Safety......................................................................................................... 29
6.2 Wiring instructions.................................................................................... 29
6.3 Y-distribution............................................................................................. 31
6.4 Connecting the device electrically........................................................... 32
6.5 Connection diagrams............................................................................... 33
6.5.1 MF1, MF2 supply voltage connection diagram...................... 33
6.5.2 Ethernet connection diagram................................................. 33
7 Operation............................................................................................ 35
7.1 Parameter description.............................................................................. 35
7.1.1 Main menu............................................................................... 35
7.1.2 SwVers menu........................................................................... 36
7.1.3 HwVers menu........................................................................... 36
7.1.4 Menu menu.............................................................................. 36
7.1.5 RS422 menu............................................................................ 36
7.1.6 More? menu............................................................................. 38
7.1.7 MFx On menu........................................................................... 38
7.1.8 MF1 menu................................................................................ 38
7.1.9 MF1 – Dist submenu............................................................... 39
7.1.10 MF1 – Speed submenu........................................................... 40
7.1.11 MF1 – Srvice submenu........................................................... 41
7.1.12 MF1 – LsrOff submenu........................................................... 42
7.1.13 MF1 – Preset submenu........................................................... 43
7.1.14 MF2 menu................................................................................ 44
7.1.15 Offset menu............................................................................. 44
7.1.16 SpecFu menu........................................................................... 45
7.1.17 Performing a reset................................................................... 46
8 Ethernet interface.............................................................................. 48
8.1 Features.................................................................................................... 48
8.2 IP network configuration.......................................................................... 48
9 SOPAS ET configuration software................................................... 49
9.1 Purpose..................................................................................................... 49
9.2 Connection of device to computer and establishment of connection.. 49
9.3 Logging into the device............................................................................. 49
9.4 Firmware update....................................................................................... 49
10 RS-422 interface............................................................................... 53
10.1 Basics........................................................................................................ 53
10.2 Protocol types........................................................................................... 53
10.3 Commands................................................................................................ 54
10.3.1 Requesting measurement data and operating data............. 54
10.3.2 Continuous output of measured values (start on com‐
mand)....................................................................................... 56
10.3.3 Continuous output of measured values (automated start
after switching on)................................................................... 57
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10.3.4 Interface functions.................................................................. 58
10.3.5 Resolution setting.................................................................... 59
10.3.6 Special functions..................................................................... 59
10.3.7 Examples for command sequences....................................... 60
10.3.8 Output rates and response times........................................... 61
11 Maintenance...................................................................................... 63
11.1 Cleaning..................................................................................................... 63
11.2 Maintenance plan..................................................................................... 63
12 Troubleshooting................................................................................. 64
12.1 General faults, warnings, and errors....................................................... 64
12.2 Device status (LED PWR)......................................................................... 64
12.3 Warning messages................................................................................... 64
12.4 Error messages......................................................................................... 65
12.5 Communication problems........................................................................ 66
12.5.1 Ethernet problems................................................................... 66
12.5.2 RS-422 faults........................................................................... 66
12.6 Returns...................................................................................................... 67
12.7 Repairs...................................................................................................... 67
12.8 Disposal..................................................................................................... 67
13 Technical data.................................................................................... 68
13.1 Optics......................................................................................................... 68
13.2 Performance data..................................................................................... 68
13.3 Supply........................................................................................................ 69
13.4 Inputs......................................................................................................... 69
13.5 Outputs...................................................................................................... 69
13.6 Interfaces.................................................................................................. 69
13.7 Ambient data............................................................................................. 69
13.8 Structural design...................................................................................... 70
13.9 Dimensional drawing................................................................................ 71
14 Accessories........................................................................................ 72
14.1 Mounting systems..................................................................................... 72
14.2 Cooler housing.......................................................................................... 73
15 Annex.................................................................................................. 74
15.1 Menu structure......................................................................................... 74
15.2 Declarations of conformity and certificates............................................ 77
CONTENTS
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1 About this document
1.1 Information on the operating instructions
These operating instructions provide important information on how to use devices from
SICK AG.
Prerequisites for safe work are:
•Compliance with all safety notes and handling instructions supplied.
•Compliance with local work safety regulations and general safety regulations for
device applications
The operating instructions are intended to be used by qualified personnel and electrical
specialists.
NOTE
Read these operating instructions carefully to familiarize yourself with the device and its
functions before commencing any work.
The operating instructions are an integral part of the product. Store the instructions
in the immediate vicinity of the device so they remain accessible to staff at all times.
Should the device be passed on to a third party, these operating instructions should be
handed over with it.
These operating instructions do not provide information on the handling and safe
operation of the machine or system in which the device is integrated. Information on
this can be found in the operating instructions for the machine or system.
1.2 Explanation of symbols
Warnings and important information in this document are labeled with symbols. Sig‐
nal words introduce the instructions and indicate the extent of the hazard. To avoid
accidents, damage, and personal injury, always comply with the instructions and act
carefully.
DANGER
…indicates a situation of imminent danger, which will lead to a fatality or serious
injuries if not prevented.
WARNING
…indicates a potentially dangerous situation, which may lead to a fatality or serious
injuries if not prevented.
CAUTION
…indicates a potentially dangerous situation, which may lead to minor/slight injuries if
not prevented.
NOTICE
…indicates a potentially harmful situation, which may lead to material damage if not
prevented.
NOTE
…highlights useful tips and recommendations as well as information for efficient and
trouble-free operation.
1 ABOUT THIS DOCUMENT
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1.3 Further information
NOTE
Further documentation for the device can be found on the online product page at:
•www.sick.com/DX100
There, additional information has been provided depending on the product, such as:
•Model-specific online data sheets for device types, containing technical data,
dimensional drawing, and specification diagrams
•Declarations of conformity and certificates of the product family
•Dimensional drawings and 3D CAD dimension models of the device types in
various electronic formats
•Other publications related to the devices described here
•Publications dealing with accessories
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2 Safety information
2.1 Intended use
The long range distance sensor is intended for non-contact measurement of distan‐
ces to system components that are in linear motion. The distance measurement is
performed on a reflector.
SICK AG assumes no liability for losses or damage arising from the use of the product,
either directly or indirectly. This applies in particular to use of the product that does not
conform to its intended purpose and is not described in this documentation.
2.2 Improper use
Any use outside of the stated areas, in particular use outside of the technical specifica‐
tions and the requirements for intended use, will be deemed to be incorrect use.
•The device does not constitute a safety component in accordance with the respec‐
tive applicable safety standards for machines.
•The device must not be used in explosion-hazardous areas, in corrosive environ‐
ments or under extreme environmental conditions.
•Any use of accessories not specifically approved by SICK AG is at your own risk.
WARNING
Danger due to improper use!
Any improper use can result in dangerous situations.
Therefore, observe the following information:
■Product should be used only in accordance with its intended use.
■All information in the documentation must be strictly observed.
■Shut down the product immediately in case of damage.
2.3 Cybersecurity
Overview
To protect against cybersecurity threats, it is necessary to continuously monitor and
maintain a comprehensive cybersecurity concept. A suitable concept consists of organi‐
zational, technical, procedural, electronic, and physical levels of defense and considers
suitable measures for different types of risks. The measures implemented in this
product can only support protection against cybersecurity threats if the product is used
as part of such a concept.
You will find further information at www.sick.com/psirt, e.g.:
•General information on cybersecurity
•Contact option for reporting vulnerabilities
•Information on known vulnerabilities (security advisories)
2.4 Limitation of liability
Relevant standards and regulations, the latest technological developments, and our
many years of knowledge and experience have all been taken into account when
compiling the data and information contained in these operating instructions. The
manufacturer accepts no liability for damage caused by:
■Non-adherence to the product documentation (e.g., operating instructions)
■Incorrect use
■Use of untrained staff
2 SAFETY INFORMATION
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■Unauthorized conversions or repair
■Technical modifications
■Use of unauthorized spare parts, consumables, and accessories
2.5 Modifications and conversions
NOTICE
Modifications and conversions to the device may result in unforeseeable dangers.
Interrupting or modifying the device or SICK software will invalidate any warranty claims
against SICK AG. This applies in particular to opening the housing, even as part of
mounting and electrical installation.
2.6 Requirements for skilled persons and operating personnel
WARNING
Risk of injury due to insufficient training.
Improper handling of the device may result in considerable personal injury and material
damage.
■All work must only ever be carried out by the stipulated persons.
The following qualifications are required for various activities:
Table 1: Activities and technical requirements
Activities Qualification
Mounting, maintenance ■Basic practical technical training
■Knowledge of the current safety regulations in the workplace
Electrical installation,
device replacement
■Practical electrical training
■Knowledge of current electrical safety regulations
■Knowledge of the operation and control of the devices in their
particular application
Commissioning, configura‐
tion
■Basic knowledge of the computer operating system used
■Basic knowledge of the design and setup of the described
connections and interfaces
■Basic knowledge of data transmission
Operation of the device for
the particular application
■Knowledge of the operation and control of the devices in their
particular application
■Knowledge of the software and hardware environment for the
particular application
2.7 Operational safety and specific hazards
Please observe the safety notes and the warnings listed here and in other sections
of this product documentation to reduce the possibility of risks to health and avoid
dangerous situations.
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CAUTION
Optical radiation: Class 2 Laser Product
The human eye is not at risk when briefly exposed to the radiation for up to 0.25
seconds. Exposure to the laser beam for longer periods of time may cause damage to
the retina. The laser radiation is harmless to human skin.
■Do not look into the laser beam intentionally.
■Never point the laser beam at people's eyes.
■If it is not possible to avoid looking directly into the laser beam, e.g., during
commissioning and maintenance work, suitable eye protection must be worn.
■Avoid laser beam reflections caused by reflective surfaces. Be particularly careful
during mounting and alignment work.
■Do not open the housing. Opening the housing may increase the level of risk.
■Current national regulations regarding laser protection must be observed.
Caution – Use of controls or adjustments or performance of procedures other than
those specified herein may result in hazardous radiation exposure.
It is not possible to entirely rule out temporary disorienting optical effects, particularly
in conditions of dim lighting. Disorienting optical effects may come in the form of 
dazzle, flash blindness, afterimages, photosensitive epilepsy, or impairment of color
vision, for example.
WARNING
Electrical voltage!
Electrical voltage can cause severe injury or death.
■Work on electrical systems must only be performed by qualified electricians.
■The power supply must be disconnected when attaching and detaching electrical
connections.
■The product must only be connected to a voltage supply as set out in the require‐
ments in the operating instructions.
■National and regional regulations must be complied with.
■Safety requirements relating to work on electrical systems must be complied with.
WARNING
Risk of injury and damage caused by potential equalization currents!
Improper grounding can lead to dangerous equipotential bonding currents, which may
in turn lead to dangerous voltages on metallic surfaces, such as the housing. Electrical
voltage can cause severe injury or death.
■Work on electrical systems must only be performed by qualified electricians.
■Follow the notes in the operating instructions.
■Install the grounding for the product and the system in accordance with national
and regional regulations.
2.8 Warning signs on the device
A class 2 laser is installed in the device. The housing is labeled with a warning sign.
2 SAFETY INFORMATION
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1
2
3
Complies with 21 CFR 1040.10 and
1040.11 except for
conformance with
IEC 60825-1 Ed. 3., as
described in Laser Notice
No. 56, dated May 8, 2019
EN/IEC 60825-1:2014
MEAN OUTPUT P < 1mW
CW-MODULATION ± 0.85 P
WAVELENGTH = 655nm
FREQUENCY ≥ 90 MHz
o
o
LASER
2
Figure 1: Warning symbol on the device: Class 2 Laser Product (EN/IEC 60825-1:2014), identical
laser class for issue EN/IEC 60825-1:2007
1Complies with 21CFR 1040.10 and 1040.11 except for conformance with IEC
60825-1Ed. 3, as described in Laser Notice No. 56 dated 8May2019.
2Laser radiation – Never look into the light beam– Class2 Laser Product (EN/IEC
60825-1:2014)
3Laser output aperture
2.9 UL conformity
NFPA79 applications only. Adapters including field wiring cables are available.
For more information visit:
bwww.sick.com/DX100
SAFETY INFORMATION 2
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3 Product description
3.1 Function
The device consists of a laser, receiving optics and an integrated evaluation unit. The
laser emits a light beam which is reflected back to the receiving optics by the reflector.
The integrated evaluation unit determines the distance between the sensor and the
reflector using phase-correlated time-of-flight measurement.
For the measurement, either the reflector or the device can move in a linear fashion
along the laser beam.
The measured distance is transmitted via the data interface and can be used for
control purposes or in a position control loop, for example.
3.2 Configuration
1 2 3 4
1 1
1 1
3
4
2
8
5
5
6
6
7
Figure 2: Distance sensor structure
1M5 threaded mounting hole
2Device zero point
3Sender optical axis
4Receiver optical axis
5Hole for the star grip screw of the optional alignment bracket
6Latch hook for alignment bracket
7Electrical connection
8Display and control elements
3 PRODUCT DESCRIPTION
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3.3 Type label
The type label gives information for identification of the device.
8
5
9
1
2
3
74
ß
6
Figure 3: Type label
1Type code
2Part number
3Electrical data and environmental data
4MAC address
5Pin assignment
6Interface
7Pictogram: Distance sensor reflector operation
82D code with part number and serial number
9Manufacturer, place of manufacture
ßSerial number, year and month of manufacture
3.4 Display and control elements
2
1
3
EscSet
Eth
PWR
MF1 MF2
LNK
BUS
Figure 4: Display and control elements
1LEDs
2Display
3Pushbuttons
3.4.1 LEDs
The status of the device and the status of all interfaces is displayed by LEDs in
accordance with the following table.
PRODUCT DESCRIPTION 3
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Table 2: LEDs
LED Description
PWR Device status display
For measures, see "Troubleshooting", page 64.
■LED off: No operation
■LED green: Interference-free operation
■LED flashes orange: Warning
■LED flashes red: Error
LNK Connection status (link) Ethernet port
■LED flashes orange: Data exchange active
■LED green: Connection (link) to the next participant available.
■LED off: No physical connection to the next participant available. For
measures, see "Ethernet problems", page 66.
MF1 Multifunctional input/output MF1
•LED on: Output level HIGH
•LED off: Output level LOW
MF2 Multifunctional output MF2
•LED on: Output level HIGH
•LED off: Output level LOW
BUS RS-422 interface see "Commands", page 54.
•LED on: Receiving data (incoming measured value query/command)
•LED off: not receiving data (no incoming measured value query/com‐
mand)
3.4.2 Display
The device has a display which provides a range of information. You can also call up
and set parameters using the display.
Symbols for operating modes
The device has two different operating modes, “measured value display” and “menu
display”, which are indicated on the display by the symbols RUN and MEN.
Table 3: Symbols for operating modes
Icon Description
EscSet
250000
RUN
The device is in “measured value display” operating mode
when it is switched on. The RUN symbol and the current dis‐
tance value are displayed. This operating mode enables you
to display other process values.
EscSet
Menu
MEN
The MEN symbol is displayed in “menu display” operating
mode. In this operating mode, device parameters can be read
out or set depending on the interface.
3 PRODUCT DESCRIPTION
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NOTE
In the display, distance values always have the resolution “mm”, speed values the reso‐
lution “mm/s”. Positive numerical values do not have a sign, negative numerical values
have the “-” sign. This limits the display range to 5decimal places when numerical
values are negative. In the “measured value display” operating mode, the sign and
the highest decimal place are cut off and replaced by a "!" when the value -99,999 is
undercut.
3.4.3 Operating pushbuttons
The device can be operated using the following 4 pushbuttons:
Table 4: Pushbuttons
Button Description
■Scroll through process values or (main) menu
■Reduce value
■Scroll through process values or (main) menu
■Increase value.
■Enter menu operation
■Switches to the next lower menu level
■Confirm selection
■Leave value/option input of a parameter without saving.
■Jump back to the next highest menu level or to the measured value display.
3.5 Scope of delivery
Included in scope of delivery:
■Distance sensor
■Protective caps for connections (on the device)
■Printed Safety Notes, multilingual (brief information and general safety notes)
The actual scope of delivery may differ for special designs, additional orders or due to
the latest technical changes.
PRODUCT DESCRIPTION 3
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4 Transport and storage
4.1 Transport
NOTICE
Damage due to improper transport!
■The product must be packaged with protection against shock and damp.
■Recommendation: Use the original packaging.
■Note the symbols on the packaging.
■Do not remove packaging until immediately before you start mounting.
4.2 Transport inspection
Immediately upon receipt in Goods-in, check the delivery for completeness and for any
damage that may have occurred in transit. In the case of transit damage that is visible
externally, proceed as follows:
•Do not accept the delivery or only do so conditionally.
•Note the scope of damage on the transport documents or on the transport compa‐
ny's delivery note.
•File a complaint.
NOTE
Complaints regarding defects should be filed as soon as these are detected. Damage
claims are only valid before the applicable complaint deadlines.
4.3 Storage
•Do not store outdoors.
•Store in a place protected from moisture and dust.
•Recommendation: Use the original packaging.
•Do not expose to any aggressive substances.
•Protect from sunlight.
•Avoid mechanical shocks.
•Storage temperature: see "Technical data", page 68.
•Relative humidity: see "Technical data", page 68.
•For storage periods of longer than 3months, check the general condition of all
components and packaging on a regular basis.
4 TRANSPORT AND STORAGE
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5 Mounting
5.1 Mounting procedure
1. Choose a mounting site bearing in mind the mounting instructions, see "Mounting
instructions", page 17.
2. Selecting and mounting the reflector, see "Select and mount the reflector ",
page 17.
3. Mounting alignment bracket and distance sensor, see "Mounting the alignment
bracket and distance sensor", page 24.
4. Establishing electrical connection, see "Electrical installation", page 29.
5. Aligning distance sensor and reflector to one another see "Aligning the distance
sensor and reflector with each other", page 26.
5.2 Mounting instructions
•Observe the technical data.
•Protect the sensor from direct sunlight.
•To prevent condensation, avoid exposing the device to rapid changes in tempera‐
ture.
•The mounting site has to be designed for the weight of the device.
•Use a sensor with optional heater at low ambient temperatures such as in cold
storage.
•Use a sensor with an optional cooler housing at higher temperatures.
•Maintain a sufficient distance to other distance sensors, see "Placement of multi‐
ple distance sensors", page 20.
•Maintain a sufficient distance to the data transmission photoelectric sensors, see
"Arranging the distance sensor to the adjacent optical data transmission system",
page 22.
5.3 Select and mount the reflector
NOTE
You can find suitable reflectors and suitable reflective tape at www.sick.com/DX100.
Reflector size
■Select a reflector size that always allows the entire light spot to hit the reflector.
■If the reflector is mounted to a vehicle and the distance sensor is secured in place
at a fixed location, you can calculate the minimum size of the reflector using the
distance-based light spot size, see "Optics", page 68.
■If the distance sensor is installed onto a vehicle, a larger reflector is typically nec‐
essary for taking into account the rolling movements of the vehicle and therefore
of the laser.
NOTE
The reflector must always be at least 100mm x 100mm in size, even if the light
spot is smaller due to a shorter measuring distance.
Reflector tilt
bTo avoid direct surface reflections, mount the reflector with a tilt of approx.
+1° … +3° in one of the 2 axes (horizontal or vertical).
MOUNTING 5
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1
2
3
4
Set Esc
<
<
Figure 5: Reflector tilt
1Distance sensor
2Tilt of the vertical axis of the reflector approx. +1°…+3°
3Reflector
4Tilt of the horizontal axis of the reflector approx. +1°…+3°
■Shiny surfaces that are parallel to the laser beam axis may cause beam switching
or light scatter and lead to incorrect measurements as a result. Therefore, align
the reflector by giving it a 1 ... 3° tilt away from shiny surfaces into the free space.
Shiny surfaces include, for example, storage profiles, pallets with stretch film,
poles or rails.
■If the sensor is mounted in the driving axis of an automated storage and retrieval
system, tilt the reflector toward the ceiling away from the rail .see figure 6,
page 19.
■If the sensor is mounted in the stroke axis of an automated storage and retrieval
system, tilt the reflector away from the mast system see figure 7, page 20.
5 MOUNTING
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Set Esc
<
<
ca. 1° … 3°
1
2
3
4
5
Figure 6: Reflector tilt for shiny surfaces and horizontal driving axis
1Device
2Shiny surface suchas a shelving section, stretch wrap
3Reflector
4Tilt of approx. 1° to 3°
5Shiny surface suchas a rail
MOUNTING 5
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Set Esc
<
<
ca. 1° … 3°
1
2
3
4
Figure 7: Reflector tilt for shiny surfaces and vertical stroke axis
1Sensor
2Shiny surface such as a masted automated storage and retrieval system
3Reflector
4Tilt of approx. 1° to 3°
5.4 Placement of multiple distance sensors
To mount several distance sensors side-by-side, you will need to maintain a minimum
distance when mounting. The minimum distance a of the optical axis depends on the
maximum travel distance smax. This applies to mounting with light beams in both the
same and opposite directions.
5 MOUNTING
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