SICK SIM4000 User manual

OPERATING INSTRUCTIONS
SIM4000
Sensor Integration Machine

Described product
SIM4000
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 modifica‐
tion, abridgment or translation of this document is prohibited without the express writ‐
ten 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........................................................................ 5
1.1 Information on the operating instructions.............................................. 5
1.2 Explanation of symbols............................................................................ 5
1.3 Further information................................................................................... 6
1.4 Customer service...................................................................................... 6
2 Safety information............................................................................ 7
2.1 General safety notes................................................................................. 7
2.2 Intended use............................................................................................. 7
2.3 Improper use............................................................................................. 7
2.4 IP technology............................................................................................. 8
2.5 Limitation of liability................................................................................. 8
2.6 Modifications and conversions................................................................ 8
2.7 Requirements for skilled persons and operating personnel................. 9
2.8 Hazard warnings and operational safety................................................ 9
3 Product description........................................................................... 11
3.1 Device view............................................................................................... 11
3.2 Functionality.............................................................................................. 11
3.3 Product features and functions............................................................... 12
4 Transport and storage....................................................................... 14
4.1 Transport................................................................................................... 14
4.2 Transport inspection................................................................................. 14
4.3 Storage...................................................................................................... 14
5 Mounting............................................................................................. 15
5.1 Overview of mounting procedure............................................................. 15
5.2 Scope of delivery...................................................................................... 15
5.3 Preparing for mounting............................................................................ 15
5.4 Mounting the SIM4000............................................................................ 16
5.5 Mounting the SIM4000 (at a critical ambient temperature of max.
50 °C)........................................................................................................ 16
6 Electrical installation........................................................................ 19
6.1 Important information.............................................................................. 19
6.2 Preparing the electrical installation......................................................... 19
6.3 Assembling the cables (optional)............................................................ 19
6.4 Pin allocation of the connections............................................................ 21
6.5 Connecting peripheral devices................................................................ 27
6.6 Connecting voltage supply....................................................................... 27
7 Commissioning.................................................................................. 29
7.1 Preparatory commissioning..................................................................... 29
CONTENTS
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8 Operation............................................................................................ 30
8.1 Status LEDs............................................................................................... 30
9 Maintenance...................................................................................... 34
9.1 Cleaning..................................................................................................... 34
9.2 Maintenance............................................................................................. 34
10 Decommissioning............................................................................. 35
10.1 Disposal..................................................................................................... 35
11 Technical data.................................................................................... 36
11.1 Features.................................................................................................... 36
11.2 Performance............................................................................................. 36
11.3 Interfaces.................................................................................................. 36
11.4 Mechanics and electronics...................................................................... 37
11.5 Ambient data............................................................................................. 38
12 Annex.................................................................................................. 39
12.1 Dimensional drawings.............................................................................. 39
12.2 Licenses.................................................................................................... 40
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 instruc‐
tions of the particular machine.
1.2 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, per‐
sonal injury, and material damage.
DANGER
… indicates a situation of imminent danger, which will lead to a fatality or serious inju‐
ries 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.
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1.3 Further information
NOTE
All the documentation available for the device can be found on the online product page
at:
bwww.mysick.com
The following information is available for download there:
•Model-specific online data sheets for device variants, containing technical data,
dimensional drawings and diagrams
•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
1.4 Customer service
If you require any technical information, our customer service department will be happy
to help. To find your representative, 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 General safety notes
The following safety notes must always be observed regardless of specific application
conditions:
•The device must only be mounted, commissioned, operated, and maintained by
professionally qualified safety personnel.
•Electrical connections with peripheral devices must only be made when the volt‐
age supply is disconnected.
•The device is only to be operated when mounted in a fixed position.
•The device voltage supply must be protected in accordance with the specifica‐
tions.
•The specified ambient conditions must be observed at all times.
•The electrical connections to peripheral devices must be screwed on correctly.
•The cooling fins must not be covered or restricted in their functionality.
•The pin assignment of pre-assembled cables must be checked and adjusted if
necessary.
•These operating instructions must be made available to the operating personnel
and kept ready to hand.
2.2 Intended use
The device is a programmable control and evaluation unit for sensors and image proc‐
essing devices. The device also acts as a link between system and plant controls, and
the connected terminal devices. The device is mainly used in an industrial environment
in production, testing, and control. Other applications are possible depending on the
device-specific properties.
The device is programmed on a PC by using the development environment software
SICK AppSpace. Depending on the application, a browser-based, graphical user inter‐
face (HMI) can be created, which provides opportunities defined by the application
developer to influence an application at operator level.
The device connection to the peripherals is established by means of a range of indus‐
trial fieldbuses and other interfaces.
The device offers various interfaces for controlling, programming, and operating pur‐
poses, which can be activated as necessary via development environments, control sys‐
tems (programmable logic controllers), or applications.
However, configuration, programming, and control requires various technical skills,
depending on how the device is connected and used.
2.3 Improper use
Use of the device is generally only permitted in the ambient conditions specified in the
technical data.
The SIM4000 is not suitable for certain application conditions, including:
•Use in areas with explosive atmosphere (hazardous area)
•Use in safety-relevant environments (safety)
•Use in extreme ambient conditions (see technical data)
•Use under water or in a corrosive atmosphere
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2.4 IP technology
NOTE
SICK uses standard IP technology in its products. The emphasis is placed on availability
of products and services. SICK always assumes that the integrity and confidentiality of
the data and rights affected by the use of the aforementioned products will be ensured
by the customer. In all cases, appropriate security measures, such as network separa‐
tion, firewalls, virus protection, and patch management, must be taken by the customer
on the basis of the situation in question.
2.5 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:
■Failing to observe the operating instructions
■Incorrect use
■Use by untrained personnel
■Unauthorized conversions
■Technical modifications
■Use of unauthorized spare parts, consumables, 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.
2.5.1 Programmable device
The Sensor Integration Machine (SIM) is a programmable device.
Therefore the respective programmer is responsible for his/her programming perform‐
ance and the resulting working principle of the device.
The liability and warranty of SICK AG is limited to the device specification (hardware
functionality and any programming interfaces) according to the agreed conditions.
Therefore, SICK AG is not liable, among other things, for damages that are caused by
programming of the customer or third parties.
2.6 Modifications and conversions
NOTICE
Modifications and conversions to the device and/or the installation 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.
Before technical modifications to and expansions of the device, the prior written appro‐
val of the manufacturer must be obtained.
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2.7 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 operating instructions state the following qualification requirements for the various
areas of work:
■Instructed personnel have been briefed by the operator about the tasks assigned
to them and about potential dangers arising from improper action.
■Skilled personnel have the specialist training, skills, and experience, as well as
knowledge of the relevant regulations, to be able to perform tasks delegated to
them and to detect and avoid any potential dangers independently.
■Electricians have the specialist training, skills, and experience, as well as knowl‐
edge of the relevant standards and provisions to be able to carry out work on elec‐
trical systems and to detect and avoid any potential dangers independently. In Ger‐
many, electricians must meet the specifications of the BGV A3 Work Safety Regu‐
lations (e.g. Master Electrician). Other relevant regulations applicable in other
countries must be observed.
The following qualifications are required for various activities:
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 device control and operation in the particular
application concerned (e.g. conveying line)
Commissioning, configura‐
tion
■Basic knowledge of the WindowsTM operating system in use
■Basic knowledge of the design and setup of the described
connections and interfaces
■Basic knowledge of data transmission
■Basic knowledge of bar code technology
Operation of the device for
the particular application
■Knowledge of device control and operation in the particular
application concerned (e.g. conveying line)
■Knowledge of the software and hardware environment for
the particular application concerned (e.g. conveying line)
Table 1: Activities and technical requirements
2.8 Hazard warnings and operational safety
Please observe the safety notes and the warnings listed here and in other chapters of
these operating instructions to reduce the possibility of risks to health and avoid dan‐
gerous situations.
The SIM4000 is classified as a device belonging to LED risk group RG 1 in accordance
with IEC 62471:-1:2006-07/EN 62471-1:2008-09. The status indicators operate with
blue, green, yellow, and red LEDs in an irregular flashing sequence.
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The accessible beam from the LEDs does not represent a risk due to the normal restric‐
tions imposed by human behavior. It is not possible to entirely rule out temporary, diso‐
rienting optical effects on the human eye (e.g., dazzle, flash blindness, afterimages,
impairment of color vision), particularly in conditions of dim lighting. No protective
measures are required.
CAUTION
Improper use can lead to hazardous radiation exposure.
■Do not look into the illumination intentionally for extended periods of time.
■Do not open the housing.
■Observe the applicable national regulations regarding photobiological safety.
■The peak wavelengths for the status indicators are as follows (+-10 nm):
– blue 460 nm
– green 515 nm
– yellow 590 nm
– red 645 nm
■RG 0 (no risk) is not exceeded from a distance of 2 meters.
No maintenance is required to ensure compliance with LED risk group RG 1.
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3 Product description
3.1 Device view
2
3
à
1
4
6
9
5
7
8
â
ß
1I/O connection
2POWER main and CAN voltage supply
3Status indicators of the voltage supply
4Connections for 1–2 incremental encoders with 1–2 status indicators
51–2 serial connections with 1–2 status indicators
61–2 fieldbus connections with 1–2 status indicators
71–2 CAN connections with 1–2 status indicators
81–8 sensor connections with S1–S8 status indicators
91–8 Ethernet connections with 1–8 status indicators
Functional ground connection
Device status indicators
Servicing panel
Status indicators of Ethernet connections
3.2 Functionality
The SIM4000 Sensor Integration Machine – part of the SICK AppSpace ecosystem – is
opening up new possibilities for application solutions.
Data from SICK sensors such as laser scanners and cameras can be merged into a
point cloud, evaluated, archived, and transmitted. 8 Gigabit Ethernet interfaces are
available for 2D or 3D cameras, and in some cases feature a voltage supply over Ether‐
net (PoE).
Sensors can be integrated via IO-Link for distance and height measuring purposes.
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Thanks to the high-performance multi-core processor featuring hardware support, the
SIM4000 enables image preprocessing and handling of input and output signals in real
time.
The integrated HALCON image processing library, plus the open SICK AppSpace soft‐
ware platform, make it possible to develop customized application programs for even
the most demanding 2D and 3D vision applications.
The SIM4000 is equipped with industrial-standard, Ethernet-based fieldbus interfaces
and can also be integrated into a SICK CAN sensor network. The HMI and data visuali‐
zation features can be provided on any browser-enabled notebook, PC, or tablet.
The app is developed in the SDKs SICK AppStudio and in HDevelop from MVTec.
3.3 Product features and functions
3.3.1 Functions
Figure 1: Application examples
The device as part of the SICK AppSpace ecosystem is opening up new possibilities for
application solutions.
Data from SICK sensors and cameras can be merged into a point cloud, evaluated,
archived, and transmitted. 8 GigE interfaces are available and in some cases with PoE.
Sensors can be integrated via IO-Link for distance and height measuring purposes.
Thanks to the powerful multi-core CPU with co-processors for image preprocessing and
I/O handling in real time, the device is able to find solutions for sophisticated image
processing tasks by using the HALCON library as well as SICK tools.
Features:
•6 x GigE with PoE to connect to 2D/3D cameras as well as a network or PC
•2 x 10 GigE to connect to 10 GigE cameras and to quickly archive sensor or proc‐
ess data with high data volume
•Real-time-capable hardware architecture with precise synchronization of I/O sig‐
nals
•4 x serial/encoder interfaces
•2 x Ethernet-based fieldbus interfaces
•Integrated illumination control and supply
•4 x IO-Link master connections
•Housing with IP65 enclosure rating
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•Support for two SICK CAN networks with voltage supply to the sensors connected
to the CAN interfaces
•S1 to S8 sensor connections with switchable and electronically monitored LPS
(Low Power Supply) pins
Benefits:
•Tailored application development with SICK AppSpace
•High-performance, innovative application solutions thanks to the merging of sen‐
sor and camera data
•Integrated HALCON library opens up a whole host of image processing possibilities
for every industrial field of application
•Multi-sensor/camera-based data recording and archiving enable quality control,
process analysis, and predictive maintenance for vertical integration in Industry
4.0
•Real-time-capable hardware reduces integration work in, for example, time-critical
robotics applications
•Quick and easy commissioning thanks to prefabricated cables
3.3.2 SICK AppSpace
The SICK AppSpace ecosystem reveals new paths leading to solutions for customer-
specific applications and consists of software tools and programmable sensors or devi‐
ces, such as the SIM4000. The SICK AppStudio SDK is used for developing sensor
apps on programmable SICK devices. Its user interface for machine operators can be
created individually as a web GUI. The SICK AppManager software tool supports the
service in the field in the simple distribution and management of sensor apps.
Figure 2: SICK AppSpace
Detailed instructions on the SICK AppStudio as well as programming the SIM4000 can
be found www.supportportal.sick.com.
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4 Transport and storage
4.1 Transport
For your own safety, please read and observe the following notes:
NOTE
Damage to the device due to improper transport.
■The device must be packaged for transport with protection against shock and
damp.
■Recommendation: Use the original packaging as it provides the best protection.
■Transport should be performed by specialist staff only.
■The utmost care and attention is required at all times during unloading and trans‐
portation on company premises.
■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
Store the device under the following conditions:
■Recommendation: Use the original packaging.
■Do not store outdoors.
■Store in a dry area that is protected from dust.
■So that any residual damp can evaporate, do not package in airtight containers.
■Do not expose to any aggressive substances.
■Protect from sunlight.
■Avoid mechanical shocks.
■Storage temperature: see "Technical data", page 36.
■Relative humidity: see "Technical data", page 36.
■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 Overview of mounting procedure
NOTE
The mounting procedure described here for SIM4000 meets the requirements for use
in the target system.
Additional or different requirements may become necessary in the laboratory and dur‐
ing preparation, and should be taken into account as necessary, see "Commissioning",
page 29. If you have any questions or anything remains unclear in this regard, please
contact our service team.
•Mounting the bracket, if provided.
•Mounting the SIM4000.
•Assembling and laying cables.
•Connecting peripheral devices.
•Connecting the voltage supply.
5.2 Scope of delivery
•SIM4000
•1x grounding screw
•1x toothed lock washer
•6x sliding nuts
•Safety note
5.3 Preparing for mounting
Mounting requirements
NOTE
It is recommended to mount the device using the adapter holding plate (part no.
2083419) which is available as an accessory. The specific mounting instructions must
be taken into account at high ambient temperatures of max. 50 °C, see "Mounting the
SIM4000 (at a critical ambient temperature of max. 50 °C)", page 16.
•Select the mounting site: Plan space requirements and sufficient distance from
other devices. Be aware of the possibility of heat dissipation.
•Unpack the device and allow to acclimatise to avoid formation of condensation.
•Prepare vibration reduction measures, if necessary.
Preparing for mounting with holding plate
NOTE
The device can also be mounted onto an aluminum profile without holes.
1. Place the holding plate at the mounting site.
2. Mark the mounting holes.
3. Proceed to drill the mounting holes.
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5.4 Mounting the SIM4000
Mounting the SIM4000 with the adapter holding plate, available as an accessory
1. Mount the holding plate on SIM4000 using the supplied screws.
2. Place SIM4000 with the holding plate on the mounting site.
3. Secure the holding plate by tightening the 3 screws.
4. Alternatively: Pre-mount the 4 screws for suspended mounting and mount the
holding plate with the device.
NOTICE
Use self-locking or lock nuts on mounting sites that are exposed to vibrations to
prevent the holding plate from loosening.
5.5 Mounting the SIM4000 (at a critical ambient temperature of max. 50 °C)
NOTICE
To prevent damage to the device or the attached peripheral devices at high ambient
temperatures of a maximum of 50 °C, the following extended installation conditions
must be taken into account when mounting the device.
Prerequisites:
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•Device is mounted vertically (device name on top)
•Mounting takes place using the supplied sliding nuts and the holding plate, which
is available as an accessory
•Aluminum profiles for mounting on the system (min. 1,200 mm in length)
•No direct sunlight and heat radiation
•Distance to other components or housing walls: min. 400 mm (above, below, to
the left), min 500 mm (on the heat-sink side)
Degradation of ambient temperature
Depending on the following device configurations, degradation of the permitted ambi‐
ent temperature must be taken into account:
•CPU load ≥75% (can be read using SICK AppStudio)
•PoE load ≥25 W (load of attached camera)
•Load at voltage/switching outputs ≥100 W
0
10
20
30
40
50
60
0 20 40 60 80 100 120
Ambient temperature [°C]
CPU load [%]
Figure 3: Degradation of ambient temperature depending on the CPU capacity
0
10
20
30
40
50
60
0 10 20 30 40 50 60 70 80
Ambient temperature [°C]
Load PoE [W]
Figure 4: Degradation of ambient temperature depending on the PoE load
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0
10
20
30
40
50
60
0 50 100 150 200 250 300 350
Ambient temperature [°C]
Load voltage outputs [W]
Figure 5: Degradation of ambient temperature depending on the load on the voltage outputs
Mounting steps
1. Click the three sliding nuts into place into each of the vertical slots.
2. Screw the holding plate (or equivalent) to the sliding nuts with 6 screws.
3. Fit the device with the holding plate on the aluminum profile.
CAUTION
Danger from hot surfaces
An ambient temperature greater than 45 °C can lead to contact-critical heat in the lat‐
eral heat sink. It must be therefore be ensured that accidental contact is unlikely.
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6 Electrical installation
6.1 Important information
WARNING
Risk of injury and damage caused by electrical current!
Due to equipotential bonding currents, incorrect grounding can lead to the following
dangers and faults: Voltage is applied to the metal housing, cable fires due to cable
shields heating up, the product and other devices become damaged.
bGenerate the same ground potential at all grounding points.
bGround the equipotential bonding via the functional ground connection with a low
impedance (use standard cable lug with M4 hole).
NOTICE
Risk of damage to the device due to incorrect supply voltage
An incorrect supply voltage may result in damage to the device.
bOnly operate the device with the specified supply voltage.
bAll circuits connected to the device must be designed as SELV circuits (in accord‐
ance with EN 60950).
NOTE
Layout of data cables
■Use screened data cables with twisted-pair wires.
■Implement the screening 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 power supply cables and
motor cables in cable channels.
6.2 Preparing the electrical installation
To carry out the electrical installation, you will need:
•Connection cables for the peripheral devices, including the corresponding data
sheets
•Voltage supply cable (scope of delivery)
•If customers assemble the cables: crimping tool, ferrules, soldering iron, and other
installation material
6.3 Assembling the cables (optional)
NOTE
Customer assembly of the cables is only necessary in special cases. SICK offers a large
range of pre-assembled cables at www.sick.com
Depending on the peripheral devices to be connected and the connecting interface
used, various connection cables must be assembled before installing the device.
Ensure that you plan a sufficient length of cable for strain-relief clamps, for example.
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NOTICE
Risk of damage/malfunction due to incorrect PIN assignment
Incorrect wiring of the male connectors/female connectors can lead to damage to or
malfunctions in the system.
bObserve data sheets provided by the cable manufacturer.
bObserve the pin assignment.
Overview of connections
1
3
5
7
9
8
6
4
2
1I/O: Universal input/output with seven configurable inputs/outputs and four opto-decou‐
pled inputs.
2POWER IN: Voltage supply input. Up to 4 x 24 V @ 8 A can be connected, whereby the
main supply is available at both male connectors.
3INC: Two configurable RS-422 / RS-485 receivers/transceivers to connect incremental
encoders. 2x RS-422 channels (A, B) and a 0.5 A LPS voltage supply are available for
each connection to peripherals. Note: RS-485 is not currently supported.
4SERIAL: Two configurable RS-232 receivers/transceivers. One RS-232 / RS-422 (full
duplex/half duplex) and a 1 A LPS voltage supply are available for each connection to
peripherals.
5FBUS: Two Ethernet-based fieldbus interfaces.
6 ELECTRICAL INSTALLATION
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