SICK PS30 Pattern Sensor Operating instructions

O P E R A T I N G I N S T R U C T I O N S

PS30

Pattern sensor

Described product

PS30

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.

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 Scope......................................................................................................... 6

1.3 Explanation of symbols............................................................................ 6

1.4 Further information................................................................................... 7

1.5 Customer service...................................................................................... 7

2 Safety information............................................................................ 8

2.1 Intended use............................................................................................. 8

2.2 Improper use............................................................................................. 8

2.3 Modifications and conversions................................................................ 8

2.4 Limitation of liability................................................................................. 8

2.5 Requirements for skilled persons and operating personnel.................. 9

2.6 Hazard warnings and operational safety................................................. 9

2.7 Repair........................................................................................................ 10

3 Product description........................................................................... 11

3.1 Product ID.................................................................................................. 11

3.2 Product features and functions............................................................... 11

3.3 Operating modes...................................................................................... 12

3.4 Display and operating elements.............................................................. 13

3.5 Display....................................................................................................... 15

3.6 Bar graph................................................................................................... 15

4 Transport and storage....................................................................... 16

4.1 Transport................................................................................................... 16

4.2 Transport inspection................................................................................. 16

4.3 Storage...................................................................................................... 16

5 Mounting............................................................................................. 17

5.1 Scope of delivery....................................................................................... 17

5.2 Mounting requirements............................................................................ 17

5.3 Mounting the device................................................................................. 19

6 Electrical installation........................................................................ 20

6.1 Notes on the electrical installation.......................................................... 20

6.2 Wiring notes.............................................................................................. 21

6.3 Note on the swivel connector................................................................... 23

6.4 System configuration................................................................................ 24

6.5 Connecting the device electrically........................................................... 24

6.6 Pin assignment of the connections......................................................... 25

7 Commissioning.................................................................................. 27

7.1 Pushbutton damage................................................................................. 27

7.2 Steps to take............................................................................................. 27

CONTENTS

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7.3 Setting up the encoder............................................................................. 27

7.4 Operation without encoder or machine cycle......................................... 30

8 Operation............................................................................................ 32

8.1 Pushbutton damage................................................................................. 32

8.2 Navigation................................................................................................. 32

8.3 Selecting an option................................................................................... 32

8.4 Changing the value................................................................................... 32

8.5 Settings menu........................................................................................... 33

8.6 Teach menu............................................................................................... 37

8.7 Monitoring menu....................................................................................... 42

8.8 Info menu.................................................................................................. 43

9 Operation via Ethernet TCP/IP........................................................ 44

10 Operation via SOPASair.................................................................... 45

10.1 Integrating the PS30 pattern sensor in the network.............................. 45

10.2 Monitoring menu....................................................................................... 46

10.3 Teach-in menu........................................................................................... 46

10.4 Settings menu........................................................................................... 49

10.5 Device info menu...................................................................................... 50

10.6 Settings menu (of the SOPASair WebUI)................................................. 51

10.7 Analysis menu........................................................................................... 51

11 Troubleshooting................................................................................. 53

11.1 Notes on troubleshooting......................................................................... 53

11.2 Possible error indicators.......................................................................... 53

11.3 Troubleshooting guide.............................................................................. 54

12 Maintenance...................................................................................... 60

12.1 Maintenance............................................................................................. 60

12.2 Cleaning the device.................................................................................. 60

13 Decommissioning............................................................................. 62

13.1 Disassembly and disposal....................................................................... 62

13.2 Returning devices..................................................................................... 62

14 Technical data.................................................................................... 63

14.1 Dimensional drawings.............................................................................. 63

14.2 Optics/features......................................................................................... 63

14.3 Supply........................................................................................................ 64

14.4 Inputs......................................................................................................... 64

14.5 Outputs...................................................................................................... 64

14.6 Interfaces.................................................................................................. 64

14.7 Encoder..................................................................................................... 65

14.8 Ambient conditions................................................................................... 65

14.9 Structural design...................................................................................... 65

CONTENTS

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15 Accessories........................................................................................ 66

15.1 Connectivity............................................................................................... 66

15.2 Mounting systems..................................................................................... 67

16 Menu structure................................................................................... 69

16.1 Setup menu............................................................................................... 69

16.2 Monitr menu.............................................................................................. 69

16.3 Teach menu............................................................................................... 69

16.4 Settng menu.............................................................................................. 70

16.5 Info menu.................................................................................................. 70

17 Annex.................................................................................................. 71

17.1 EU declaration of conformity and certificates........................................ 71

17.2 Certification according to UL60947-5-2................................................. 71

17.3 Licenses.................................................................................................... 71

18 Index.................................................................................................... 72

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.

b

www.sick.com/PS30

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 “PS30” 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, 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.

1 ABOUT THIS DOCUMENT

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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:

b

www.sick.com/PS30

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

•

IO-Link driver files and IO-Link Technical Information v1.1

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.

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2 Safety information

2.1 Intended use

The PS30 pattern sensor is an opto-electronic sensor intended for non-contact recogni‐

tion of recurring patterns. A machine cycle as the input signal, e.g., via an encoder or a

motor feedback system, is required to operate the pattern sensor.

Alternatively, the speed of the material can be stored as a constant. This alternative is

intended for applications with a constant or only slowly changing material speed.

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

•

The device does not constitute a safety-relevant device according to the EC

Machinery 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:

b

The device should be used only in line with intended use specifications.

b

All information in these operating instructions must be strictly complied with.

2.3 Modifications and conversions

Modifications and conversions to the pattern sensor and/or the installation may result

in unforeseeable dangers.

Before any technical modifications to and expansions of the pattern sensor, the prior

written approval of the manufacturer must be obtained.

2.4 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

2 SAFETY INFORMATION

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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 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 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

connections 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

2.6 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.

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2.6.1 Eye safety

CAUTION

The device is equipped with LEDs. The device meets the criteria of risk group 1 accord‐

ing to IEC 62471:2006. No special measures are required (e.g., eye protection).

2.7 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

The type label is located on the back of the pattern sensor.

1

2

3 5

4

Figure 1: Type label

1

Type designation

2

Material number

3

MAC address

4

Serial number

5

Machine-readable code

3.2 Product features and functions

3.2.1 Device view

1

2

5

3

4

Figure 2: PSS Prime light emission long housing side

1

Center of the optical axis

2

Fixing hole

3

M12 male connector, 12-pin/M12 female connector, 4-pin, rotatable

4

Function indicators

5

Display and control unit

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3.2.2 Product characteristics

1

2

Figure 3: Recorded image from the perspective of the “PS30 pattern sensor”

1

Field of view

2

Light spot

Vertical bars: Cuts of the individual lines, corresponds to the encoder resolution.

Blue square marks: Clear and contrast-rich pattern areas automatically selected by the

sensor. Five areas have been selected in this example.

Function

The PS30 pattern sensor is an opto-electronic sensor that detects recurring patterns in

a contactless manner.

The principle of operation is based on a line camera which constantly searches for con‐

trast differences and sharp edges in the print image (see figure). These distinct and

unique areas in the pattern are automatically selected by the sensor during the teach-in

process. If the image and contrast pattern stay the same, these points will be in exactly

the same locations. The sensor evaluates grayscale information.

A taught-in image is used as a reference for the subsequent detection of a recurring

contrast pattern. The print marks usually used for determining position are no longer

necessary. When a pattern matching the reference pattern is identified, a switching out‐

put is initiated.

The PS30 pattern sensor requires for its operation information about the speed of the

material, e.g., from encoder pulses, from a motor feedback system, or as a defined vari‐

able with a fixed value or a value updated via TCP/IP.

3.3 Operating modes

The PS30 pattern sensor can be operated in one of two modes:

1 Endless material

2 Single object

3.3.1 Endless material operating mode

When further processing endless materials such as film and paper webs to produce, for

example, labels and packaging with a constant repeat length, exact determination of

position is essential, e.g., to determine the cut position.

Typically, the target cut position is selected as the start point of the reference image,

and the reference image is terminated before the end of the repeat length. The start

point of the teach-in area is the position of the switching signal. A switching point offset

can also be configured.

3 PRODUCT DESCRIPTION

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1 2

3

444

Figure 4: Recorded image from the perspective of the “PS30 pattern sensor”

1

Teach Stop

2

Teach Start

3

Offset

4

Signal

3.3.2 Single object operating mode

In this case the position is to be determined for repeating, separate objects with identi‐

cal patterns but not separated by a fixed distance. An object, or a section of the object

is taught in as a reference.

The end of the teach-in area is used as the position for outputting the switching signal.

A switching point offset can be defined.

1 2

3

444

Figure 5: Endless material operating mode

1

Teach Stop

2

Teach Start

3

Offset

4

Signal

3.4 Display and operating elements

1

356 4

EscSet

2

Figure 6: Display and operating elements

1

Display

2

Pushbuttons

3

Function indicator (yellow) “Act”

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4

Function indicator (green) “Link”

5

Function indicator (yellow) “Q”

6

Function indicator (green) “ON”

Function indicators (LEDs)

Table 1: Function indicators (LEDs)

Function indicator Description

Act Data transfer display

•

Yellow LED: Data transfer

•

LED off: No data transfer

Link Ethernet connection display

•

Green LED: Ethernet connection available

•

LED off: No Ethernet connection available

Q Switching output display

•

Yellow LED: Output high

•

LED off: Output low

•

LED flashing (10 Hz): Overcurrent/short-circuit protection

has triggered

ON Operating status display

•

Green LED: Normal operation/Supply voltage on

•

LED off: No operation

Symbols on the display

The following symbols may appear on the display: “RUN”, “MEN” and “SET”.

Table 2: Symbols on the display

Icon Description

RUN RUN symbol is lit up: The display shows the current operating data

of the sensor.

MEN MEN symbol is lit up: You are in the menu structure and have not

yet reached the last selection level.

SET SET symbol is lit up: Sensor settings can be changed and,

for example, values set.

Pushbuttons

Table 3: Pushbuttons

Pushbutton Description

•

Select operating menu, parameter, or option

•

Reduce value

•

Select operating menu, parameter, or option

•

Increase value

•

Short press:

°

Switch to the next-lowest menu level

°

Save parameter change

°

Confirm selection

•

Long press (> 2 sec.):

°

Start the operating menu

3 PRODUCT DESCRIPTION

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Pushbutton Description

•

Short press: Exit parameters without saving. Switch to the

next-highest menu level.

•

Long press: Exit parameters without saving. Change to the

default display - Quality of Run.

3.5 Display

Default display

EscSet

RUN

Figure 7: Default display

Operating menus - Monitoring/Setting/Teach-in/Info

EscSet

Teach

MEN

Figure 8: Operating menu

Parameters using example of monitoring

EscSet

ErrCod

MEN

Figure 9: Parameter display

3.6 Bar graph

Teach-in quality

After teach-in has been run, the number of flashing bars indicates the quality of the

teach-in process:

•

If 3 or more bars are flashing: the teach-in process was successful.

•

If fewer than 3 bars are flashing: check whether the signal is switching correctly. If

the signal is not switching correctly, repeat the teach-in process.

Process quality

When the RUN symbol is lit up, the number of bars indicates the process quality.

•

If 2 or fewer bars are flashing: check whether the signal is switching correctly.

•

If the signal is not switching correctly, verify that the sensor is installed correctly,

and check the quality of the print image and the mechanical guiding of the object.

•

If necessary, repeat the teach-in process.

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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 sensor 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 at the receiving work station, check the delivery for complete‐

ness and for any damage that may have occurred in transit. In the case of transit dam‐

age 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 com‐

pany’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 63.

■

Relative humidity: see "Technical data", page 63.

■

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 Scope of delivery

Included with delivery:

•

PS30 pattern sensor

•

Blind plug for M12 Ethernet connection

•

Adjustment tool

•

Optional: accessories, see "Accessories", page 66

•

Quickstart

5.2 Mounting requirements

•

Typical space requirement for the device, see type-specific dimensional drawing,

see "Technical data", page 63.

•

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.

•

The device must only be mounted using the pairs of mounting threads/fixing holes

provided for this purpose.

•

Shock and vibration-free mounting.

•

The light spot must cover a significant area on the print image. Select an area with

high contrast differences and unique pattern elements as the significant area. The

center of the light spot is marked with a notch on the upper side of the housing.

•

Sensing distance: 20 mm

The sensing distance is the distance from the front edge of the sensor (housing

edge) to the sensing target (e.g., an object).

NOTE

We recommend using the supplied adjustment tool to align the pattern sensor.

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Significant areas

☺

1 2

3

Figure 10: Align the light spot on the print image

1

Start (SET/ET)

2

Stop (SET/ET)

3

Q

The gray squares correspond to the print areas with unique features.

Arrangement when scanning on a flat surface or flat material

α

1

Figure 11: Arrangement of the pattern sensor when scanning on a flat surface or flat material

1

SD

α: 15° angle

SD: 20 mm sensing distance

5 MOUNTING

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Arrangement when scanning rotary systems

α

1

Figure 12: Arrangement of the pattern sensor when scanning rotary systems

1

SD

α: 15° angle

SD: 20 mm sensing distance

Using the adjustment tool

α

1

2

3

2

3

4

Figure 13: Using the adjustment tool

1

Adjustment tool

2

20 mm

3

15°

4

SD

5.3 Mounting the device

1. Select a mounting location for the pattern sensor (see "Mounting requirements",

page 17).

2. Mount the pattern sensor using the fixing holes (see "Technical data", page 63).

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6 Electrical installation

6.1 Notes on the electrical installation

NOTICE

Device damage due to incorrect supply voltage!

An incorrect supply voltage may result in damage to the device.

■

Only operate the device with safety/protective extra-low voltage (SELV/PELV).

■

The sensor is a device of protection class III.

NOTICE

Device damage due to incorrect supply voltage!

An incorrect supply voltage may result in damage to the device.

•

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

Device 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 met 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

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.

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 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.

■

Any other covers present must be closed and lie flush on the device.

If these instructions are not complied with, the IP enclosure rating for the device is not

guaranteed!

6 ELECTRICAL INSTALLATION

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SICK PS30 Pattern Sensor Operating instructions

SICK PS30 Pattern Sensor Operating instructions

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