MANUAL
Application Box
IO Link
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IO Link Application Box
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This document is protected by the law of copyright, whereby all rights established therein remain with the
company SICK AG. Reproduction of this document or parts of this document is only permissible within the limits
of the legal determination of Copyright Law. Alteration or abridgement of the document is not permitted without
the explicit written approval of the company SICK AG.
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IO Link Application Box
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1 Introduction........................................................................................................................4
1.1 The IO-Link Application Box See through the eyes of a Sensor ......................4
1.2 Objective and addressee of this manual .............................................................4
1.3 Manual organization .............................................................................................4
1.4 Instructions prior to commissioning.....................................................................5
1.5 System prerequisites ............................................................................................5
2 Commissioning ..................................................................................................................6
2.1 Installation.............................................................................................................6
2.2 Connection ............................................................................................................6
2.3 Starting the program.............................................................................................6
3 Operation............................................................................................................................9
3.1 Operation for WTB sensors...................................................................................9
3.1.1 General tab........................................................................................10
3.1.2 Commissioning tab ...........................................................................11
3.1.3 Expert tab ..........................................................................................11
3.1.4 Version Info tab .................................................................................12
3.2 Operation for WL12GC sensors..........................................................................13
3.2.1 Status tab ..........................................................................................13
3.2.2 Measurement tab .............................................................................14
3.2.3 Parameter tab ...................................................................................15
3.2.4 Version Info tab .................................................................................16
4 Additional program functions ........................................................................................17
4.1 Swapping the connected sensor........................................................................17
4.2 Installing a new device DTM...............................................................................18
4.3 Saving a project...................................................................................................18
4.4 Uninstalling FDT-Container .................................................................................18
5 Fault analysis and system prerequisites ......................................................................20
5.1 In the event of a fault..........................................................................................20
6 Information for product demonstrations with the IO link Application Box...............21
6.1 Suppression of ambient light (all WTB3 systems).............................................21
6.2 Functions of background suppression (all WTB3 systems)..............................22
7 Application analysis with the IO link Application Box ................................................23
Content
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1 Introduction
1.1 The IO-Link Application Box See through the eyes of a
Sensor
The IO link Application Box from SICK is a device, which can be used to connect an IO link
capable sensor to a personal computer. Various sensor settings can be made via special
software and the mode of operation of the connected IO link sensor can be displayed in a
graph. As a result, the innovative IO link Application Box from SICK makes it possible for
the first time and exclusively to read the function of the sensor live via the
communication standard IO link and display it on a computer screen.
This function opens up completely new possibilities in presenting the optical IO link
sensors of the 3rd generation to our customers. The technological highlights of the
products can not only be explained theoretically as previously and demonstrated as simple
output signal display using the sensor tester; using the IO link Application Box, how the
sensor works can now be displayed impressively in a graph. In addition, sensor
applications can be tested and analyzed under real conditions to find the right sensor
solution together with customers for solving their concrete tasks.
In this way, the competence and know-how of SICK in the area of sensor technology and
sensor applications can be demonstrated and its leadership in technology can be under-
lined effectively beyond the pure product benefits of SICK sensors. The objective is to
position SICK in the perception of customers as the first partner to contact in the area of
sensors and sensor applications.
1.2 Objective and addressee of this manual
This manual is addressed to all employees of the SICK Group, who market and sell the
optical IO link sensors of the 3rd generation in direct customer contact. With the IO link
Application Box a tool is provided which is able to strengthen and support their sales
arguments and to communicate the following message to customers: SICK is a competent
technology leader in the area of sensor technology and applications.
Consequently, the objective of this manual is to familiarize the sales force of SICK subsi-
diaries with handling the IO link Application Box. Installation and operation of the IO link
Application Box are explained step by step. In addition, concrete examples show how this
tool can support product presentation impressively in front of the customer and how it can
improve customer service in case of application problems.
The IO link Application Box is not for sale to customers! It is exclusively for the use of the
SICK sales force and serves mainly as an argument aid and demonstration tool in sales
discussions with customers as well as for application analysis.
1.3 Manual organization
First, installation of the software program FDT-Container supplied with the IO link Appli-
cation Box as well as connection and operation startup of the IO link Application Box are
explained. Then the most important points of program operation using various sensor
types are explained. In addition, suggestions are provided about how concrete features of
the 3rd generation WTB series from SICK can be presented impressively and clearly using
Note
1 Introduction
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the IO link Application Box. Finally, two practical examples show how the IO link Application
Box can be used at customers' plants for application analysis.
You can find additional information and documents about the IO link Application Box in
SICK Intranet. If you still have questions, please contact Product Management.
1.4 Instructions prior to commissioning
The IO link Application Box should only be used in an office environment for demons-
tration purposes or for application analysis of IO link devices!
The IO link Application Box must not be used in facilities and processes where safety is
critical, because a fault may result in a risk of injury or death!
The IO link Application Box cannot be used to control machinery, systems and processes!
> The IO link Application Box should only be connected to USB ports that can supply the
device with an uninterrupted current of 500 mA. The IO link Application Box should
therefore, wherever possible, not be used on a portable computer running off battery.
> If using an external USB hub, this may cause the IO link Application Box to malfunction.
In this case, connect the IO link Application Box directly to the computers USB interface.
1.5 System prerequisites
Standard Intel Pentium PC or compatible, at least Pentium III 500 MHz
At least 256 MB RAM, but 512 MB RAM is recommended
Operating system: MS Windows 2000 Service Pack 3, XP Service Pack 2 or VISTA
Monitor with at least 256 colours, 65536 colours is recommended (16-bit high-colour)
Screen resolution at least 1024 x 768 pixels
Hard drive: at least 50 MB of free disk space
CD-ROM drive
a
WARNING
1 Introduction
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2 Commissioning
2.1 Installation
Before the IO link Application Box can be connected to the computer and used, the
software supplied on CD-ROM must first be installed.
Installation starts automatically when the CD-ROM is inserted into the drive. Follow the
instructions provided by the Installation Wizard. If the Installation Wizard does not start
automatically, it can be started manually via the following path:
Arbeitsplatz
→ SICK FDT DEMO (D) → SICK-FDT-Demo-Case → SICK-FDT-Demo-Case.msi
[My Computer
→ SICK FDT DEMO (D) → SICK-FDT-Demo-Case → SICK-FDT-Demo-
Case.msi]
To carry out the installation, you will need Administrator rights for the computer you are
using. If necessary, contact your relevant IT department about this.
2.2 Connection
After successful installation of the demo software, you can connect up the IO link Applica-
tion Box to your computer via a free USB interface. SICK IOL-Box 1.3 (depending on the
relevant version used) and Wakeup appear on the IO link Application Box display.
Connect an IO link compatible sensor (e.g. the WTB4C-3P3464, which is used as an
example in the following instructions) to the M12 port of the IO link Application Box. The
sensor is then activated. The status signal Connected on the IO link Application Box
display indicates that a transparent data channel between the sensor and the IO link
Application Box has been set up successfully.
If using a USB hub without a network connection, the IO link Application Box may some-
times not be supplied with the necessary power (500 mA). In this case, connect the box
directly to the computers USB interface or use a USB hub with a separate power supply.
2.3 Starting the program
Once the sensor, the IO link Application Box and the computer have been connected, as
described in the Connection section, the demonstration and diagnostics program SICK
FDT-Container can then be started. To do this, go to the Start menu and select:
Start
→ Programme → SICK → SICK FDT-Container → SICK FDT-Container
[Start
→ Programs → SICK → SICK FDT-Container → SICK FDT-Container]
Note
Note
2 Commissioning
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This opens the SICK FDT-Container program. To load a new project (to select a sensor), go
to the menu bar and select Datei
→ Öffnen [File → Open].
The project selection window then appears. From the demo projects available, select the
project WTB4-DEMO.sfdt (depending on the sensor connected to the Application Box) and
click on the Öffnen [Open] button.
The selected demo project is then displayed in the Projektbaum [Project Tree]. To link the
program to the sensor, go to the Projektbaum [Project Tree], right-click on WTB4 and select
Trennen/Verbinden
→ Verbinden [Disconnect/Connect → Connect] from the context
menu. Alternatively, you can also highlight WTB4 in the Projektbaum [Project Tree] and
click on
in the toolbar.
2 Commissioning
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Once the connection has been set up successfully, the Projektbaum [Project Tree]
background turns green, as shown in the following screenshot:
Now open the tools user interface by double-clicking on WTB4 in the Projektbaum [Project
Tree]. The user interface is then shown in the right-hand window of FDT-Container.
2 Commissioning
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3 Operation
The IO link Application Box can be operated with various IO link-capable sensors. Each of
these sensors requires its own driver software, the Device Type Manager (DTM), to display
the individual sensor functions in graphs. If a previously stored project is called at program
start of the FDT-Containers (as displayed above), the DTM starts automatically. When there
is a new project, the corresponding DTM must be selected manually (see the Swapping
the Connected Sensor chapter).
Due to the various functions, the DTMs of the individual sensor types differ substantially.
Consequently, the functions and operation of the IO link Application Box are first explained
in detail with the WTB device types using the example of the WTB4C-3P3464. After that
the operation of the IO link Application Box with the glass photoelectric switch WL12GC is
explained.
If you still have questions not answered by the explanations below, please don't hesitate to
seek additional information from the product manager responsible for the respective
sensor.
3.1 Operation for WTB sensors
At the top of the user interface is a picture of the sensor used, with information about its
serial number and the software version. Directly below there are two sliders to adjust the
sensors Scanning Distance and Hysteresis. To the right of this is a round switching output
indicator (grey
→ object not in scanning range, yellow → object in scanning range). In the
centre of the user interface are four tabs: General, Commissioning, Expert and Version
Info. These tabs allow parameterisation and function monitoring/display for the sensor. At
the bottom are the command buttons.
When using the Commissioning, Expert or Version Info tab the sensors orange LED
switching indicator and the sender LED start flashing. This is a regular operating condition
when the sensor is connected to the IO link Application Box. It is not a malfunction.
Irrespective of the tab selected, you can adjust the scanning distance and the hysteresis
via the sliders and transfer these settings to the sensor via the Apply button. If you do not
click on the Apply button, the program simulates the changed scanning distance or hyste-
resis on the Commissioning and Expert tabs without writing these values to the sensor.
When you click OK, the settings made are written to the sensor and the user interface is
closed. Cancel closes the user interface without writing the settings to the sensor. The
Refresh button reads the current internal settings for the sensor and displays them on the
user interface.
With this icon on the right-hand side of the program window, the flash animation
3 gewinnt! or Connect 3 (English version) can be started. It contains a number of
interesting and illustrative explanations about the service scope of the new 3rd generation
sensor from SICK.
Note
3 Operation
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3.1.1 General tab
The General tab gives you the option to carry out default settings for the sensor. Via the
User Text field, you can give the sensor any name you choose or store other text infor-
mation (max. ten spaces). The scanning distance of the sensor can be taught via the SICK
FDT-Container software. To do this, point the sensor towards the object to be detected and
click on Teach. It is also possible to use the Lock Teach Button function to deactivate the
Teach function on the sensor to prevent the scanning distance from being changed
inadvertently.
The SICK photoelectric switches in the 3rd generation have a range of innovative solutions
to ensure reliable object recognition even under adverse conditions (e.g. dirty lens or
incidence of ambient light). The Diagnosis field on the General tab shows whether the
sensor has detected a source of interference and has implemented measures to com-
pensate. These are:
VMA Detecting of declining remission energy due to e.g. dirty
sensor lens or reflector
RF Interference Active suppression of high-frequency ambient light
Pulse Interference Active suppression of low-frequency ambient light
Short Circuit Short circuit detection
Via the Suppression of passive interference function, the sensor can effectively blind out
even strongly reflective objects in the background using a second transmitter LED (diffuse
LED). If this function is deactivated, operating faults may occur at the sensor output if
there are strongly reflective objects in the sensors background.
3 Operation
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3.1.2 Commissioning tab
The Commissioning tab shows the operating status of the sensor over a period of time.
The following data is displayed on the left of the window:
Red line Signal level (distance between sensor and object or
background)
Solid yellow line Set scanning distance
Yellow dashed line Set switching hysteresis (switch-on and switch-off points)
Green line Switching output of the sensor
The chart on the right-hand side shows the frequency distribution in terms of the distance
between the sensor and the object or object background. You can reset both displays
using the Clear button.
3.1.3 Expert tab
The Expert tab contains a graph to show the incidence of reflected light on the sensors
16 segment receiver element. The higher the column on the graph, the more light the
relevant receiver element is receiving. The red line indicates the mean average of the light
distribution on the receiver element and therefore the currently calculated distance
between the sensor and the object. The yellow line and the shaded area around it indicate
the set scanning distance and the hysteresis switching limits. Below the graph is the
current Scanning Distance and Hysteresis, given in millimetres.
A photoelectric proximity switch is not designed for distance measurements; the values
specified for the scanning distance and hysteresis are to be used purely as a guide. Their
accuracy is around ± 10%.
Note
3 Operation
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The status of the switching output is displayed on the Expert tab by means of the column
colours:
Red columns Object is within the set scanning distance
→ Sensor sets switching output to 1
Green columns No Object is within the set scanning distance
→ Sensor sets switching output to 0
3.1.4 Version Info tab
The Version Info tab contains various product-related information, which is stored on the
sensor and read out when the program is called up.
Once you have transferred all required settings to the sensor via the Apply button, you can
close the user interface again with OK. Before disconnecting the sensor and the IO link
Application Box or the Application Box and the computer, you must first sever the connec-
tion via the SICK FDT-Container. To do this, right-click on Application Box in the Projekt-
baum [Project Tree] and choose the following options from the context menu that appears:
Trennen/Verbinden
→ Trennen
[Disconnect/Connect
→ Disconnect]
Alternatively, you can highlight Application Box in the Projektbaum [Project Tree] and click
on the
icon in the toolbar.
3 Operation
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3.2 Operation for WL12GC sensors
The sensor WL12GC-2P2434 is an IO link capable photoelectric reflex switch of the W12
series, which is designed specifically for detection of glass, foils or other transparent
materials. Compared with the WTB series, the WL12GC provides considerably more setting
options and functions, which is the reason why the DTM for the WL12GC differs substan-
tially from those of the WTB devices. Due to the greater scope of functions, not all func-
tions, settings options and possibilities of the WL12GC can be dealt with in detail here. The
objective is to explain the various views (tabs) of the DTM and the basic functions.
To parameterize the sensor via the DTM, the rotary switch on the sensor housing must be
set to Ext (External).
3.2.1 Status tab
The Status tab provides an overview of the current operating state of the sensor. The
operating states (Status), error messages (Diagnosis) and sensor settings (Detection
Mode) are displayed. These are in detail:
Status
Signal Switching state display
Invalid PD Invalid process date, which can occur during a teach procedure
or a receive level overflow, for example
Teach Display during the teach procedure
Diagnosis
Receive Level
Overflow
Reception signal is too strong, e.g., if the reflector is positioned
considerably closer to the sensor after it is teached.
Threshold Error Calculation of switching threshold during teach-procedure failed
Reflector Peak Error Interruption of the teach procedure, e.g., at a power outage
Missing Reflector Teaching of the sensor without reflector within sensing range
Reflector Range Error Insufficient energy backflow from reflector; faulty switching is
possible
Teach Error Teach procedure failed
Note
3 Operation
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Detection Mode
Display of the currently selected detection mode and subtype, which can be set via the
Parameter tab.
3.2.2 Measurement tab
The Measurement tab shows the live signal curve of the sensor, analog to the Commissio-
ning tab for the WTB devices. You can see in detail:
Black line Strength of the reflected sender light detected by the sensors
receiver element
Red line Switch-on threshold
Green line Switch-off threshold
Blue/white line Threshold value for adapting the switching thresholds if there is a
lens or reflector that is slowly becoming soiled
Yellow line Switching output of the sensor
The current numeric values of the signal level and the individual switching points are listed
to the right of the graph. Directly below that, the switching signal can be hidden and
threshold adapting deactivated. In addition, the rotary switch on the sensor housing can be
deactivated.
3 Operation
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3.2.3 Parameter tab
The Parameter tab provides the setting of different detection modes. Four detection
modes and three subtypes can be selected:
Bottle detection
(auto adjustment off)
Detection of single, separate bottles. Adapting of switching
thresholds deactivated at soiling of sensor lens or reflector
Bottle flow Detection of single bottles within a continuous delivery flow
Film detection Detection of transparent foils
Bottle detection Detection of individual, separate bottles with adapting of
switching thresholds at soiling of sensor lens or reflector
The subtype must be selected depending on the degree of transparency of the objects to
be detected. It determines the distance between the switching thresholds (red and green
lines in the Measurement graph) and the reflector signal level, hence the sensitivity of the
sensor:
Subtype 1 Detection of highly transparent objects, i.e., switching at a very small drop
of the signal level
Subtype 2 Detection of normal transparent objects, e.g., thick or soiled white glass
Subtype 3 Detection of only slightly transparent objects, e.g., stained glass
3 Operation
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3.2.4 Version Info tab
The Version Info tab contains various product related information, which is stored on the
sensor and read out when the program is called up.
3 Operation
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4 Additional program functions
4.1 Swapping the connected sensor
To swap the connected sensor, after having severed the communication link as described
above, you have to open a new project. To do this, go to the toolbar and click on
(Erstelle ein neues Projekt [Create a New Project]). The old project is closed automatically.
If it is not already displayed, open the DTM Catalogue (DTM = Device Type Manager,
device-specific software), where you can select the new device. To call up the DTM Cata-
logue, go to the program menu and select:
Ansicht
→ DTM-Katalog
[View
→ DTM Catalogue]
The DTM catalogue appears on the right in the SICK FDT-Container. Select Hersteller
[Manufacturer] as a filter and then select SICK AG. Now double-click on Application Box
and then on the device you require. Your selection appears in the Projektbaum [Project
Tree] on the left of the SICK FDT-Container. Now connect the new sensor to the IO link
Application Box and press the black reset button on the left-hand side of the IO link
Application Box. To set up a communication link to the connected sensor, highlight the
sensor model in the Projektbaum [Project Tree], go to the toolbar and click on
(Verbindung mit Gerät aufbauen [Link to Device]). Then open the DTM by double-clicking
on the device model.
4 Additional program functions
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4.2 Installing a new device DTM
To be able to operate a new IO link compatible sensor on the Application Box, the DTM for
the sensor must first be installed. To do this, run the corresponding DTM installation file on
Windows by double-clicking and follow the instructions of the Installation Wizard. After
successful installation of the DTM, the DTM Catalogue of FDT-Container must be updated.
First close all open projects via the program menu:
Datei
→ Schließen
[File
→ Close]
Then use the program menu to open the Catalogue Management window:
Werkzeuge
→ Katalogmanagement... [Tools → Catalogue Management...]
Click on Durchsuche Registry [Search Registry] to search the computer for newly installed
DTMs. These are then displayed on the left of the Catalogue Management window. High-
light the new DTMs with the Alle >> [All >>] button and click on Aktualisieren und Schlie-
ßen [Update and Close]. The new DTMs are now available in the DTM Catalogue of the
SICK FDT-Container and can be called up as described in the section Swapping the
connected sensor.
4.3 Saving a project
You have the option to save an open project to the hard drive. To do this, click on the Save
icon
in the toolbar of FDT-Container and, in the window that then appears, select
where you want to save it to, as well as the file name. Alternatively, you can select the
Save function via the program menu:
Datei
→ Speichern or Datei → Speichern unter...
[File
→ Save] or [File → Save As...]
4.4 Uninstalling FDT-Container
To uninstall the SICK FDT-Container, go to the Windows Start menu and select:
Start
→ (Einstellungen →)Systemsteuerung → Software
[Start
→ (Settings →) Control Panel → Software]
4 Additional program functions
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From the list of installed programs, select the SICK FDT-Container, click on Entfernen
[Remove] or Ändern/Entfernen [Change/Remove] and follow the next Uninstall
instructions.
4 Additional program functions
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5 Fault analysis and system prerequisites
5.1 In the event of a fault
Fault pattern Possible causes and countermeasure
Link-up attempt fails When the sensor was swapped, was the
reset button on the left side of the IO link
Application Box housing pressed? Press
the reset button!
Is another program using the serial
interface? End the program!
Was the USB driver installed success-
fully? Check this in Windows Device
Manager!
Windows has flagged the serial interface
as already in use even though the
relevant program is no longer open. In
Windows Device Manager, switch to a
different address (COM1 COM8)!
Can the USB port provide the necessary
500 mA supply current? USB hubs
cannot be used without a power supply!
Use the computer's USB interface!
Nothing shown on the LCD display of the
IO link Application Box
Problems with the USB driver. Unplug the
USB connector and plug it in again!
Problems with the bootloader. Unplug
the USB connector and plug it in again,
keeping the reset button on the side of
the IO link Application Box pressed!
Can the USB port provide the necessary
500 mA supply current? USB hubs
cannot be used without a power supply!
Use the computer's USB interface!
After swapping the IO link Application Box,
the serial interface address changes
Windows assigns a different COM port
address to every individual IO link
Application Box. In Windows Device
Manager, switch to the required address
(COM1 COM8)!
5 Fault analysis and system prerequisites
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