SICK UFS User manual

OPERATING INSTRUCTIONS
UFS
Fork sensor

Described product
UFS
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.
2006/42/EC
NO
SAFETY
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Contents
1 About this document........................................................................ 5
1.1 Information on the operating instructions.............................................. 5
1.2 Scope......................................................................................................... 5
1.3 Explanation of symbols............................................................................ 5
1.4 Further information................................................................................... 6
1.5 Customer service...................................................................................... 6
2 Safety information............................................................................ 7
2.1 Intended use............................................................................................. 7
2.2 Improper use............................................................................................. 7
2.3 Limitation of liability................................................................................. 7
2.4 Repair........................................................................................................ 8
3 Product description........................................................................... 9
3.1 Product ID.................................................................................................. 9
3.1.1 Type label................................................................................. 9
3.2 Product features and functions............................................................... 9
3.2.1 Device view............................................................................... 9
3.2.2 Product characteristics........................................................... 10
4 Mounting............................................................................................. 11
4.1 Scope of delivery....................................................................................... 11
4.2 Mounting requirements............................................................................ 11
4.3 Mounting the device................................................................................. 11
5 Electrical installation........................................................................ 13
5.1 Notes on electrical installation................................................................ 13
5.2 Pin assignment of the connections......................................................... 14
5.2.1 Pin assignment........................................................................ 14
5.2.2 Switching logic.......................................................................... 14
5.3 Connecting the supply voltage................................................................. 14
5.4 Process data structure of UFS................................................................. 15
6 Commissioning.................................................................................. 16
6.1 Commissioning using the example of dynamic teach-in........................ 16
7 Operation............................................................................................ 17
7.1 Menu structure......................................................................................... 17
7.2 Teach-in..................................................................................................... 17
7.2.1 Teach-in via the control panel................................................. 18
7.2.2 External teach-in...................................................................... 20
7.2.3 Faulty teach-in.......................................................................... 21
7.3 Fine adjustment of the switching threshold............................................ 21
7.4 Adjusting the switching logic.................................................................... 22
7.5 Key lock..................................................................................................... 22
CONTENTS
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7.6 Further setting and diagnostic options via SOPAS................................. 22
7.6.1 Teach-in via SOPAS.................................................................. 22
7.6.2 Adjusting the switching threshold........................................... 22
7.6.3 Adjusting the switching logic................................................... 23
7.6.4 Key lock.................................................................................... 23
7.6.5 Additional settings via SOPAS................................................. 23
8 Troubleshooting................................................................................. 26
9 Maintenance...................................................................................... 27
9.1 Maintenance............................................................................................. 27
9.2 Cleaning the device.................................................................................. 27
10 Decommissioning............................................................................. 28
10.1 Disassembly and disposal....................................................................... 28
10.2 Returning devices..................................................................................... 28
11 Technical data.................................................................................... 29
11.1 General data............................................................................................. 29
11.2 Dimensional drawings.............................................................................. 31
12 Accessories........................................................................................ 33
13 Annex.................................................................................................. 34
13.1 EU declaration of conformity and certificates........................................ 34
13.2 Certification according to UL60947-5-2................................................. 34
13.3 Licenses.................................................................................................... 34
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 before starting any work on the device, in
order to familiarize yourself with the device and its functions.
The instructions constitute an integral part of the product and are to be stored 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 operating the machine
in which the device is integrated. For information about this, refer to the operating
instructions of the specific machine.
1.2 Scope
These operating instructions serve to incorporate the device into a customer system.
Step-by-step instructions are given for all required actions.
These instructions apply to all listed device variants of the product.
Available device variants are listed on the online product page.
bhttp://www.sick.com/UFS
Commissioning is described using one particular device variant as an example.
Simplified device designation in the document
In the following, the sensor is referred to in simplified form as “UFS” or “device”.
1.3 Explanation of symbols
Warnings and important information in this document are labeled with symbols. The
warnings are introduced by signal words that indicate the extent of the danger. These
warnings must be observed at all times and care must be taken to avoid accidents,
personal injury, and material damage.
DANGER
…indicates a situation of imminent danger, which will lead to a fatality or serious
injuries if not prevented.
ABOUT THIS DOCUMENT 1
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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.
1.4 Further information
NOTE
All the documentation available for the device can be found on the online product page
at:
bhttp://www.sick.com/UFS
The following information is available for download from this page:
•Type-specific online data sheets for device variants, containing technical data and
dimensional drawings
•EU declaration of conformity for the product family
•Dimensional drawings and 3D CAD dimension models in various electronic for‐
mats
•These operating instructions, available in English and German, and in other lan‐
guages if necessary
•Other publications related to the devices described here
•Publications dealing with accessories
1.5 Customer service
If you require any technical information, our customer service department will be happy
to help. To find your agency, see the final page of this document.
NOTE
Before calling, make a note of all type label data such as type code, serial number, etc.,
to ensure faster processing.
1 ABOUT THIS DOCUMENT
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2 Safety information
2.1 Intended use
The UFS fork sensor is an ultrasonic sensor with a transmitter and a receiver that
functions according to the through-beam principle.
It is used for non-contact detection of:
•Labels on carrier material
•Tears in films/web material
•Double layers
•Adhesive areas (splice)
2.2 Improper use
•The device does not constitute a safety-relevant device according to the EC Machi‐
nery Directive (2006/42/EC).
•The device must not be used in explosion-hazardous areas.
•Any other use that is not described as intended use is prohibited.
•Any use of accessories not specifically approved by SICK AG is at your own risk.
The device is not suitable for the following applications (this list is not exhaustive):
•As a safety device to protect persons, their hands, or other body parts
•Underwater
•In explosion-hazardous areas
•Outdoors, without additional protection
NOTICE
Danger due to improper use!
Any improper use can result in dangerous situations.
Therefore, observe the following information:
bThe device should be used only in line with intended use specifications.
bAll information in these operating instructions must be strictly complied with.
2.3 Limitation of liability
Applicable standards and regulations, the latest state of technological development,
and our many years of knowledge and experience have all been taken into account
when assembling the data and information contained in these operating instructions.
The manufacturer accepts no liability for damage caused by:
■Failure to observe the operating instructions
■Improper use
■Use by untrained personnel
■Unauthorized conversions
■Technical modifications
■Use of unauthorized spare parts, wear and tear parts, and accessories
With special variants, where optional extras have been ordered, or owing to the latest
technical changes, the actual scope of delivery may vary from the features and illustra‐
tions shown here.
SAFETY INFORMATION 2
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2.4 Repair
The product is a replacement device. The device is not intended to be repaired. Interfer‐
ence with or modifications to the device on the part of the customer will invalidate any
warranty claims against SICK AG.
2 SAFETY INFORMATION
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3 Product description
3.1 Product ID
3.1.1 Type label
1
2
3
4
1Device type number
2Part number
3Pin assignment
4Date of manufacture
3.2 Product features and functions
3.2.1 Device view
1
4
6
56
5
2
3
1Connection
2Sender
3Receiver
4Control panel
5Material positioning mark
6Cleaning opening for compressed air
Pwr
Q
Dyn
Stat
3..20s
1..3s
20..30s
L/D
>30s
L
1
2 3
1LEDs (status indicators)
2Teach-in button
3Bar graph
PRODUCT DESCRIPTION 3
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Table 1: Bar graph of values
Bar graph of values Quality of Teach/Quality of Run
Table 2: Status indicator LEDs
Flashing Q-
LED
Description
1Hz Static teach-in
3Hz Dynamic teach-in
6Hz Faulty teach-in
2 x 1Hz Successful fine adjustment/L/D switching
3 x 1Hz Key lock activated/deactivated
2 s x 6Hz Successful 1-point teach-in
Table 3: Teach-in button functions
Function Teach-in button Description
2P teach-in 1-3s Teach-in of two reference points: carrier material and
label
1P teach-in 1-3s Teach-in of single reference point: tape material
Dynamic teach-in 3-20s Teach-in of multiple reference points through dynamic
movement of the material
L/D switching 20-30s Adjustment of the switching logic (switch at label (dark) /
carrier (light))
Key lock >30s Activate/deactivate the key lock
3.2.2 Product characteristics
The UFS has the following features and fields of application:
Features
Fork sensors operate according to the through-beam principle. Transmitter and receiver
are combined in one housing by means of the fork design. Fork sensors for label
detection have a narrow fork width that is especially suitable for web material.
Fields of application
Fork sensors for label detection are used in particular for:
•Detection of labels on carrier material for synchronizing the labeling process as
well as triggering cutting, punching and folding processes
•Detection of film tears
•Distinguishes between single- and double-layer material
•Detection of adhesive areas (splice)
Example industries: food and beverage, printing, packaging.
3 PRODUCT DESCRIPTION
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4 Mounting
4.1 Scope of delivery
•Device in the version ordered
•Quickstart
4.2 Mounting requirements
•For the typical space requirements for the device, see the type-specific dimen‐
sional drawing, see "Technical data", page 29.
•Comply with technical data, such as the permitted ambient conditions for opera‐
tion of the device (e.g., temperature range, EMC interference emissions, ground
potential),
•To prevent condensation, avoid exposing the device to rapid changes in tempera‐
ture.
•Protect the device from direct sunlight.
•Shock and vibration resistant mounting.
4.3 Mounting the device
Alignment
ü ü ü û
Figure 1: UFS alignment
MOUNTING 4
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Mounting
1. Mount the sensor on a flat surface via the fixing holes using 2x M4 screws.
< 2 Nm
2. Connect the voltage supply.
3. Guide tensioned material through the fork opening.
4 MOUNTING
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5 Electrical installation
5.1 Notes on electrical installation
NOTICE
Radio interference when used in residential areas
The device complies with the Radio Safety Requirements (EMC) for the industrial sector
(Radio Safety Class A). It may cause radio interference if used in a residential area.
NOTICE
Equipment damage due to incorrect supply voltage!
An incorrect supply voltage may result in damage to the equipment.
■Only operate the device with safety/protective extra-low voltage (SELV/PELV).
■The sensor is a device of protection class III.
NOTICE
Equipment damage due to incorrect supply voltage!
An incorrect supply voltage may result in damage to the equipment.
•Only operate the device with an LPS (limited power source) in accordance with IEC
62368-1 or an NEC Class 2 power supply unit.
NOTICE
Equipment damage or unpredictable operation due to working with live parts!
Working with live parts may result in unpredictable operation.
■Only carry out wiring work when the power is off.
■Only connect and disconnect electrical connections when the power is off.
■The electrical installation must only be performed by electrically qualified person‐
nel.
■Standard safety requirements must be observed when working on electrical
systems!
■Only switch on the supply voltage for the device when the connection tasks have
been completed and the wiring has been thoroughly checked.
■When using extension cables with open ends, ensure that bare wire ends do not
come into contact with each other (risk of short-circuit when supply voltage is
switched on!). Wires must be appropriately insulated from each other.
■Wire cross-sections in the supply cable from the user’s power system must be
selected in accordance with the applicable standards.
■Only operate the device with an LPS (limited power source) in accordance with
IEC62368-1 or an NEC Class 2 power supply unit.
■All circuits connected to the device must be designed as SELV/PELV circuits.
■Operation in short-circuit protected network at max. 8A.
NOTE
Layout of data cables
■Use shielded data cables with twisted-pair wires.
■Implement the shielding design correctly and completely.
■To avoid interference, e.g., from switching power supplies, motors, clocked drives,
and contactors, always use cables and layouts that are suitable for EMC.
■Do not lay cables over long distances in parallel with voltage supply cables and
motor cables in cable channels.
ELECTRICAL INSTALLATION 5
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The IP enclosure rating for the device is only achieved under the following conditions:
■The cables plugged into the connections are screwed tight.
If these instructions are not complied with, the IP enclosure rating for the device is not
guaranteed!
5.2 Pin assignment of the connections
5.2.1 Pin assignment
UB: 10 ... 30V DC
UFS xxxx1xxx xxxx4xxx xxxx5xxx
1 = BN +(L+)
2 = WH MF
3 = BU -(M)
4 = BK Q1/C
0.14mm2
AWG26
4
3
2
1
12
4 3
5.2.2 Switching logic
Table 4: Switching logic
Dark switch‐
ing D = Dark
(factory set‐
ting)
Pwr
Q
Pwr
Q
Light switch‐
ing L = Light
Pwr
Q
Pwr
Q
5.3 Connecting the supply voltage
NOTICE
Risk of damage to the device!
The device can become damaged if it is connected to a voltage supply that is already
switched on.
•Only connect the device when the supply cable is de-energized.
The device must be connected to a power supply unit with the following properties:
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•Supply voltage DC 10.8V –26.4V (SELV/PELV as per currently valid standards)
•Electricity source with at least 3W power
To ensure protection against short-circuits/overload in the customer’s supply cables,
the wire cross-sections used must be appropriately selected and protected.
5.4 Process data structure of UFS
Process data structure data length 2bytes
No. Description Data type
Bit 0 QL1 Boolean
Bit 1 QL2 Boolean
Bit 2 Qint 1 Boolean
Bit 3 Qint 2 Boolean
Bit 4 QoR alarm Boolean
Bit 5 Teach busy Boolean
Bit 6 - 15 Measurement value UInt10
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6 Commissioning
6.1 Commissioning using the example of dynamic teach-in
3 - 20 s
3 Hz
Q
Figure 2: Dynamic teach-in sequence
1. Press the teach-in button for 3-20s, the Q-LED flashes at 3Hz. Meanwhile pass
the material through the fork opening.
NOTE
For label materials, at least 3 labels and 3 label gaps should be passed through
the fork opening.
2. Release the teach-in button. If the teach-in was successful, the bar graph displays
the teach-in quality (Quality of Teach). The Q LED indicates the output state.
3. After 3s, the bar graph disappears briefly and displays the process quality (Quality
of Run).
The switching threshold between the carrier and label is now optimally set. For demand‐
ing materials, e.g., very thin labels, it is possible to finely adjust the device (see "Fine
adjustment of the switching threshold", page 21).
6 COMMISSIONING
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7 Operation
7.1 Menu structure
1 - 3 s.
3 - 20 s.
Dyn
Stat
3..20s
1..3s
20..30s
L/D
>30s
Stat
1..3s
20 - 30 s.
Dyn
Stat
3..20s
1..3s
20..30s
L/D
>30s
Dyn
Stat
3..20s
Dyn
Stat
3..20s
1..3s
20..30s
L/D
>30s
20..30s
L/D
Dyn
Stat
3..20s
1..3s
20..30s
L/D
>30s
>30s
> 30 s.
1
2
3
4
1Static teach-in (2P teach-in, 1P teach-in)
2Dynamic teach-in
3L/D switching
4Key lock
Table 5: Teach-in button functions
Function Teach-in button Description
2P teach-in 1-3s Teach-in of two reference points: carrier material and
label
1P teach-in 1-3s Teach-in of single reference point: tape material
Dynamic teach-in 3-20s Teach-in of multiple reference points through dynamic
movement of the material
L/D switching 20-30s Adjustment of the switching logic (switch at label (dark) /
carrier (light))
Key lock >30s Activate/deactivate the key lock
7.2 Teach-in
The UFS supports three teach-in modes
•Dynamic teach-in (recommended mode)
•Static 2-point teach-in
•Static 1-point teach-in (recommended for the detection of adhesive areas only)
The teach-in process can be carried out via
•Manual operation (all three modes)
•Externally via the MF connection (dynamic teach-in only)
•SOPAS (all three modes)
OPERATION 7
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7.2.1 Teach-in via the control panel
7.2.1.1 Dynamic teach-in
NOTE
For label materials, at least 3 labels and 3 label gaps should be passed through the
fork opening.
1. Press and hold the teach-in button for 3-20s, the Q-LED flashes at 3Hz.
3 - 20 s. 3 Hz
Q
2. Meanwhile pass the material through the fork opening.
3. Release the teach-in button.
If the teach-in was successful, the bar graph displays the teach-in quality (Quality
of Teach).
The Q LED indicates the output state.
4. After 3s, the bar graph disappears briefly and displays the process quality (Quality
of Run).
Table 6: Bar graph of values
Bar graph of values Quality of Teach/Quality of Run
The switching threshold between the carrier and label is now optimally set. For demand‐
ing materials, e.g., very thin labels, it is possible to finely adjust the device (see "Fine
adjustment of the switching threshold", page 21).
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7.2.1.2 Static 2-point teach-in
1. Guide the material to be taught in (e.g., carrier) into the fork opening and position
it so that it is in the area of the mark.
2. Press and hold the teach-in button for 1... 3s.
The Q-LED flashes at 3Hz to indicate that the sensor is in teach-in mode.
1 - 3 s. 3 Hz
Q
3. Release the teach-in button.
The Q-LED flashes at 1Hz, the second reference point can be taught-in.
1 Hz
Q
4. Place the material that has not yet been taught in (e.g., carrier with label) in the
fork opening.
5. Briefly press the teach-in button again.
6. If the teach-in was successful, the bar graph displays the teach-in quality (Quality
of Teach). The Q LED indicates the output state.
7. After 3s, the bar graph disappears briefly and displays the process quality (Quality
of Run).
Table 7: Bar graph of values
Bar graph of values Quality of Teach/Quality of Run
For demanding materials, e.g., very thin labels, it is possible to finely adjust the device
(see "Fine adjustment of the switching threshold", page 21).
OPERATION 7
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7.2.1.3 Static 1-point teach-in
NOTE
The static 1-point teach-in is only recommended for detecting adhesive areas.
A 1P teach-in can be used to detect inaccessible adhesive areas (splice) or when the
application does not allow the material being taught in to be moved. This teach-in has
the lowest signal reserve, which is why a dynamic teach-in is preferable. A dynamic
teach-in, or alternatively a 2P teach-in, is also recommended for accessible adhesive
areas.
1. Guide the material to be taught in (continuous material/carrier material without
labels) into the fork opening.
2. Press and hold the teach-in button for 1... 3s.
The Q-LED flashes at 3Hz to indicate that the sensor is in teach-in mode.
1 - 3 s. 3 Hz
Q
3. Release the teach-in button.
4. As soon as the flashing frequency of the Q-LED drops to 1Hz, briefly press the
teach-in button again to complete the teach-in process.
The switching threshold is set slightly greater than the continuous/carrier material
so thicker material is detected as an adhesive area or label.
5. If the teach-in is successful, the Q-LED flashes for 2s at 6Hz.
6. The bar graph shows the teach quality (Quality of Teach).
7. After 3s, the bar graph disappears briefly and displays the process quality (Quality
of Run).
Table 8: Bar graph of values
Bar graph of values Quality of Teach/Quality of Run
For demanding materials, e.g., very thin labels, it is possible to finely adjust the device
(see "Fine adjustment of the switching threshold", page 21).
7.2.2 External teach-in
The MF connection can be used to set the switching threshold during the running
process via an external signal or for an external teach-in. The external teach-in is always
a dynamic teach-in.
7 OPERATION
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