SICK FlexChain User manual

OPERATING INSTRUCTIONS
FlexChain

Described product
FlexChain
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.
2006/42/EG
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 Customer service...................................................................................... 6
2 Safety information............................................................................ 7
2.1 Intended use............................................................................................. 7
2.2 Limitation of liability................................................................................. 7
2.3 Requirements for skilled persons and operating personnel.................. 7
2.4 Hazard warnings and operational safety................................................. 8
2.5 Repair........................................................................................................ 8
3 Product description........................................................................... 9
3.1 Product ID.................................................................................................. 9
3.1.1 Type labels................................................................................ 9
3.2 Product features and functions............................................................... 9
3.2.1 Device view............................................................................... 9
4 Mounting............................................................................................. 11
4.1 Scope of delivery....................................................................................... 11
4.2 Installation requirements......................................................................... 11
4.3 Installing the system................................................................................. 11
5 Electrical installation........................................................................ 12
5.1 Notes on electrical installation................................................................ 12
5.2 Schematic arrangement........................................................................... 13
5.3 Pin assignment of the connections......................................................... 14
5.4 Connecting the supply voltage................................................................. 15
5.5 Digital interfaces....................................................................................... 16
6 Commissioning.................................................................................. 17
6.1 Simplified illustration................................................................................ 17
7 Operation............................................................................................ 20
7.1 Configuration via SOPAS ET..................................................................... 20
7.1.1 Home........................................................................................ 20
7.1.2 Teach & Positioning................................................................. 21
7.1.3 Zones........................................................................................ 24
7.1.4 Logics........................................................................................ 27
7.1.5 PINS.......................................................................................... 28
7.1.6 Process data............................................................................ 29
7.1.7 Settings.................................................................................... 31
8 Troubleshooting................................................................................. 32
CONTENTS
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9 Maintenance...................................................................................... 33
9.1 Maintenance............................................................................................. 33
10 Decommissioning............................................................................. 34
10.1 Disassembly and disposal....................................................................... 34
10.2 Returning devices..................................................................................... 34
11 Technical data.................................................................................... 35
11.1 Host performance..................................................................................... 35
11.2 Host interfaces.......................................................................................... 35
11.3 Host software features............................................................................. 36
11.4 System response time.............................................................................. 36
11.5 Mechanics/electronics/host.................................................................... 36
11.6 Technical data guests............................................................................... 37
11.6.1 General data GL6-C................................................................. 37
11.6.2 General data GSE6-C.............................................................. 38
11.6.3 General data GTB6-C............................................................... 38
11.7 Dimensional drawings.............................................................................. 38
11.8 FlexChain host membrane keyboards..................................................... 41
12 Accessories........................................................................................ 42
13 Annex.................................................................................................. 43
13.1 EU declaration of conformity and certificates........................................ 43
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 specific machine.
1.2 Scope
These operating instructions serve to incorporate the device into a customer system.
Instructions are given in stages for all actions required.
These instructions apply to all listed device variants of the product.
Available device variants are listed on the online product page.
bwww.sick.com/FlexChain
Commissioning is described using one particular device variant as an example.
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, per‐
sonal injury, and material damage.
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.
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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 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 FlexChain is a sensor system comprising a central unit (host) and connected guests
(sensors) that is used for optical and non-contact detection of objects.
The FlexChain must be mounted and installed according to these operating instruc‐
tions, and may only be operated according to its intended function.
The FlexChain is not equipped with any direct safety devices. The system designer must
provide measures to ensure the safety of persons and systems in accordance with the
legal guidelines.
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 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.
2.3 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:
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■Instructed personnel have been briefed by the operating entity 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 assigned 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 the operation and control of the devices in their
particular application
Commissioning,
configuration
■Basic knowledge of the design and setup of the described con‐
nections and interfaces
■Basic knowledge of data transmission
■Knowledge of the operation and control of the devices in their
particular application
Operation of the devices in
their particular application
■Knowledge of the operation and control of the devices in their
particular application
■Knowledge of the software and hardware environment in the
application
2.4 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.
2.5 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.
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3 Product description
3.1 Product ID
3.1.1 Type labels
3.2 Product features and functions
3.2.1 Device view
4
3
1
2
6
5
Figure 1: FlexChain host
1Port-A, pigtail M8, 4-pin, female
2Port B, pigtail M8, 4-pin, female
3PLC, pigtail M12, 5-pin / 8-pin, male
4USB, pigtail M8, 4-pin, female
5Control panel
Structure
A FlexChain system comprises a host and a number of guests (sensors). As shown in
the image below, the system components are connected sequentially (bus topology). A
system comprises a host and at least one guest. Up to 60 guests in total can be con‐
nected to a host.
Function
The FlexChain system operates similarly to a light grid. That is, each individual channel
in the system is processed sequentially. This principle means that only one channel at a
time is active. Consequently, there is no possibility of mutual interference within a sys‐
tem, and the guests can be installed arbitrarily close to one another without any inter‐
ference occurring. Due to this sequential processing, the scan time and the response
time of the system depend on the number of connected guests. The total times are
short, however, because the processing interval between two channels is in the µs
range (see also the technical data).
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Host:
– Supplies the guests with current
– Collects the status of each individual channel
– Requests diagnostic data from the individual guests
– Processes the collected data (if desired)
– Forwards the collected and/or processed data via various interfaces
Guest:
– Guests are connected to one another via a standard M8 pigtail
– Guests forward information to the master.
– Can be arranged differently within the system.
– Guests employing different technologies can be integrated into the same system
– Sender & receiver sensors must always be connected to separate ports (port A/
port B).
– Up to 60 sensors can be connected to the system.
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4 Mounting
4.1 Scope of delivery
•FlexChain host with 2x bus terminator
•Quickstart
•Safety notes
The FlexChain guests and mounting accessories are not included in the scope of deliv‐
ery and need to be purchased separately.
4.2 Installation requirements
•Typical space requirement for the device, see type-specific dimensional drawing,
see "Technical data", page 35.
•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.
•Protect the device from external light sources.
•The device must only be mounted using the pairs of mounting threads/fixing holes
provided for this purpose.
•Shock and vibration-free mounting.
4.3 Installing the system
Installing the FlexChain host
<0,7 Nm
Figure 2: FlexChain host - installation
–25°C ... +50 °C
–13°F ... +122 °F
Figure 3: FlexChain host - installation
Installing the FlexChain guest
The procedure for installing a guest can vary significantly depending on the device fam‐
ily or device type. See the instructions supplied with the device for installation instruc‐
tions.
MOUNTING 4
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5 Electrical installation
5.1 Notes on electrical installation
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
60950-1 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.
NOTICE
Device damage due to incorrect connection!
Incorrect connection may result in damage to the FlexChain system or peripheral
devices.
■If connection cables are required, use twisted pair connection cables.
■Standard M8 4-pin connection cables can also be used in many applications.
■The electrical installation must only be performed by electrically qualified person‐
nel.
■Standard safety requirements must be observed when working on electrical sys‐
tems!
■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
60950-1 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.
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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.
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 Schematic arrangement
The first guest is connected to the host using the pigtail. It can be connected to either
port A or port B. Up to 30 sensors in total can be connected per port.
All guests have an M8 4-pin male connector and an M8 4-pin female connector (pig‐
tail). The pigtail can always be connected to the male connector of the next guest.
The bus terminator must be connected at the end of the system. This is included in the
scope of delivery of the FlexChain host.
With regard to the arrangement of the guests on Port A and Port B, there is only one
restriction for sender and receiver sensors: the sender and the associated receiver
must not be connected to the same port.
If the pigtail cable is insufficiently long, it can be extended using an M8 4-pin cable.
Ensure that the total cable length of the system does not exceed 40 m when doing so.
ELECTRICAL INSTALLATION 5
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FlexChain Host
Port A Port B
5.3 Pin assignment of the connections
Overview of pin assignment - FlexChain host
Table 1: DC
Flex‐
Chain
host
PLC
USB Port A/
port B
Standard
IO-Link
Advanced
IO-Link RS485
CANopen
System/Q CAN con‐
nector
1+ (L+) + (L+) + (L+) + (L+) n.c. +5 V CANH
2Q2 / IN1 Q2 / IN1 Q2 / IN1 Q2 / IN1 n.c. D- CANL
3M M M M GND D+ 12 Vout
4Q1 / C Q1 / C Q1 / C Q1 / C CAN1_H GND GND
5Q3 / In2 Q3 / IN2 n.c. n.c. CAN1_L - -
6- Q4 / IN3 n.c. - - -
7- Q5 / IN4 RS485_A - - -
8- Q6 / IN5 RS485_B - - -
12
5
4 3
1
3
5
4
7
6
8
2
1
3
5
4
7
6
8
2
12
5
4 3
12
5
4 3
4
3
1
2
4
3
1
2
The system can be configured via the USB interface and SOPAS. An M8->USB-A adapter
cable is required to connect the system to a computer (part number: 6051163).
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Overview of pin assignment - FlexChain guests
Table 2: DC
GL6-C
1+ (L+)
2M
3CAN-High
4CAN-Low
2
1
4
3
Table 3: DC
GSE6-C
1CAN high
2CAN low
312 Vout
4GND
2
1
4
3
Table 4: DC
GTB6-C
1+ (L+)
2M
3CAN high
4CAN low
2
1
4
3
5.4 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:
•24 V voltage supply ± 20% or DC 19.2 V – 28.8 V (SELV/PELV as per currently
applicable standards)
•The current consumption depends on the number of connected sensors and is
typically 100 mA and maximum 850 mA.
To ensure protection against short-circuits/overload in the customer’s supply cables,
the wire cross-sections used must be appropriately selected and protected.
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5.5 Digital interfaces
The digital interfaces can be configured via SOPAS, or directly via the serial interfaces
(except RS-485). Apart from PIN4, every digital interface can be configured as a digital
input or digital output.
Furthermore, every digital interface can be assigned a number of different functions
(see Configuration via SOPAS).
The signal state (HIGH/LOW) is shown on the FlexChain host display.
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6 Commissioning
6.1 Simplified illustration
Perform any other operation with the SOPAS ET user interface. Download at:
www.sick.com
1. Connect sensors to port A and port B.
2. Connect the power supply. The Power LED lights up green.
3. Perform AutoAssign
AutoAssign detects all connected guests. Automated assignment of guest posi‐
tions and zones, e.g. A1 ... AN, B1 ... BM.
Menu
>2s
Menu
4. Perform teach-in
Perform teach-in for sensors. Set sensors with potentiometer directly on the sen‐
sor.
Menu
Menu
>2s
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5. Baud rate (RS485, CANopen)
Set baud rate for FlexChain host variant with RS485 and CANopen.
Menu
Menu
Menu
>2s
>2s
6. NodeID (CANopen)
Set NodeID for FlexChain host with CANopen. A single value or several values can
be set or deleted (bit display).
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Menu
Menu
Menu
>2s
>2s
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7 Operation
7.1 Configuration via SOPAS ET
To configure the system via SOPAS you will need the SOPAS software, the SOPAS Device
Description (SDD), and a USB connection.
NOTE
The USB interface is intended only for configuring the device and must be unplugged
during operation.
The SOPAS screen for FlexChain is divided into a number of tabs (orange). Every tab
provides a specific set of parameterization functions. You can easily jump back and for‐
ward between the tabs.
7.1.1 Home
The Home tab does not contain any settings. The purpose of this tab is to provide you
with information and status details for the connected FlexChain system.
The Home tab is divided into three areas.
The area on the left (red) shows information about the current status of the system.
This includes, for example, the status of the switching input and switching output pins,
the system status, the teach-in status, etc.
The middle area (green) provides a live display of the channel status. This area shows
which channel is blocked or not blocked by an object. If there is something wrong with a
sensor, this is also indicated directly in this display.
The area on the right (blue) lists the technical values and settings. Details such as the
response time and the number of connected guests are shown here. Furthermore, you
can select a specific guest in the green area by clicking on it. The information for the
selected guest then appears in the “Guest Information” area on the right hand side.
7 OPERATION
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