SICK MLG-2 WebChecker Operating instructions

SICK
Brand
SICK
Model
MLG-2 WebChecker
Category
Measuring, testing & control
Type
Operating instructions

This manual is also suitable for

O P E R A T I N G I N S T R U C T I O N
MLG-2 WebChecker
Measuring automation light grid
Described product
MLG-2 WebChecker
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/EC
NO
SAFETY
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Contents
1 About this document........................................................................ 7
1.1 Purpose of this document........................................................................ 7
1.2 Scope......................................................................................................... 7
1.3 Target group.............................................................................................. 7
1.4 Information depth..................................................................................... 7
1.5 Symbols used............................................................................................ 7
1.6 Abbreviations used................................................................................... 8
2 Safety information............................................................................ 9
2.1 Requirements for the qualification of personnel.................................... 9
2.2 Intended use............................................................................................. 9
2.3 General safety notes................................................................................ 10
3 Product description........................................................................... 11
3.1 MLG-2 type label....................................................................................... 11
3.2 Type code.................................................................................................. 11
3.2.1 Measurement field width........................................................ 12
3.2.2 Combinations of MLG-2 inputs and outputs.......................... 13
3.2.3 Optical properties.................................................................... 14
3.3 Structure and function............................................................................. 14
3.3.1 Device components................................................................. 15
3.3.2 Measurement principle........................................................... 15
3.4 Definitions................................................................................................. 17
3.5 Scan time.................................................................................................. 18
3.6 Operating reserve..................................................................................... 18
3.7 Minimum object attenuation................................................................... 19
3.8 Display and operating elements.............................................................. 19
3.8.1 MLG-2....................................................................................... 19
3.9 Inputs......................................................................................................... 20
3.9.1 Switching inputs on the receiver............................................. 20
3.9.2 Test input on the sender......................................................... 20
3.10 Application examples............................................................................... 20
3.10.1 MLG2 application examples.................................................... 20
4 Planning.............................................................................................. 22
4.1 Planning mounting distance between sender and receiver.................. 22
4.2 Identifying optimal object position.......................................................... 23
4.3 Determining measurement accuracy for actual object position............ 24
4.4 Required minimum distances for an object............................................ 25
4.5 Required minimum distances for several objects.................................. 26
4.6 Minimum and maximum object width..................................................... 26
4.7 Edge measurement and edge designation............................................. 27
4.8 Functions: Calculation of width and center positions............................ 29
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5 Mounting............................................................................................. 30
5.1 Scope of delivery....................................................................................... 30
5.1.1 MLG-2....................................................................................... 30
5.2 Recommended mounting arrangements................................................ 30
5.2.1 Mounting with light in opposite directions............................. 30
5.2.2 Mounting with light in the same direction.............................. 30
5.2.3 Minimum distance from reflective surfaces.......................... 32
5.3 Mounting procedure................................................................................. 33
5.3.1 Mounting the QuickFix bracket............................................... 34
5.3.2 Mounting the FlexFix bracket.................................................. 36
6 Electrical installation........................................................................ 38
6.1 Connect the sender and receiver............................................................ 38
6.2 T-connector for MLG-2 connection.......................................................... 41
7 Commissioning.................................................................................. 44
7.1 Putting the MLG-2 into operation............................................................ 44
7.2 Aligning sender and receiver.................................................................... 44
7.3 Performing sensor teach-in...................................................................... 45
7.4 Performing material teach-in................................................................... 46
7.5 Calling up teach-in quality and process quality...................................... 46
8 Operating MLG-2 via control panel................................................. 48
8.1 Activating and deactivating pushbutton lock.......................................... 48
8.2 Aligning sender and receiver.................................................................... 48
8.3 Performing sensor teach-in...................................................................... 49
8.4 Performing material teach-in................................................................... 49
8.5 Reset to factory settings.......................................................................... 50
9 Commissioning via SOPAS.............................................................. 51
9.1 Preparation................................................................................................ 51
9.1.1 Installing the software............................................................. 51
9.1.2 Device selection....................................................................... 51
9.2 Setting up MLG-2 (installation assistant)............................................... 51
9.3 Setting up edge measurement................................................................ 57
9.4 Parameterizing functions: Calculation of width and center positions... 57
9.5 Other configurations................................................................................. 58
10 Configuration with SOPAS................................................................ 59
10.1 “Start” page.............................................................................................. 59
10.1.1 Overview................................................................................... 59
10.1.2 “Device” area........................................................................... 59
10.1.3 “Application” area.................................................................... 60
10.1.4 “Graphic display” area............................................................. 61
10.2 “General Device Settings” page............................................................... 63
10.2.1 Overview................................................................................... 63
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10.2.2 “General settings” area........................................................... 63
10.2.3 “Communication configuration” area..................................... 64
10.3 “Enhanced Sensing” page....................................................................... 65
10.3.1 Overview................................................................................... 65
10.3.2 “Details” area........................................................................... 66
10.3.3 Menus....................................................................................... 66
10.3.4 “Graphic representation of the position and attenuation”
area........................................................................................... 66
10.3.5 “Graphic display of the width” area........................................ 67
10.4 Enhanced Sensing – menus.................................................................... 67
10.4.1 “Sensor alignment” menu....................................................... 67
10.4.2 “Blanking” menu...................................................................... 67
10.4.3 “Sensor teach-in” menu.......................................................... 68
10.4.4 “Material teach-in” menu........................................................ 68
10.4.5 “Functional configuration” menu............................................ 73
10.4.6 “Analog output” menu............................................................. 75
10.4.7 “Digital configuration” menu.................................................. 75
10.4.8 "RS-485” menu........................................................................ 77
11 IO-Link................................................................................................. 79
11.1 Configuration via acyclic service data..................................................... 79
11.2 Data storage (IO-Link)............................................................................... 79
11.3 Output of process data from the MLG-2................................................. 79
12 RS-485................................................................................................ 80
12.1 Application data........................................................................................ 80
12.2 Data volume for functions........................................................................ 81
12.3 Data volume for the separators............................................................... 81
13 Servicing............................................................................................. 82
14 Troubleshooting................................................................................. 83
14.1 Response to faults.................................................................................... 83
14.2 SICK support............................................................................................. 83
14.3 LED indicators and error indicators......................................................... 83
15 Decommissioning............................................................................. 85
15.1 Disposal..................................................................................................... 85
15.2 Returns...................................................................................................... 85
16 Technical data.................................................................................... 86
16.1 Data sheet................................................................................................. 86
16.2 Diagrams................................................................................................... 89
16.2.1 Response time......................................................................... 89
16.2.2 Optimal object position........................................................... 91
16.2.3 accuracy................................................................................... 93
16.3 Dimensional drawings.............................................................................. 94
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16.3.1 Dimensional drawing for the MLG-2....................................... 94
17 Accessories........................................................................................ 96
17.1 Accessories............................................................................................... 96
18 Annex.................................................................................................. 99
18.1 Compliance with EU directive................................................................... 99
19 List of figures..................................................................................... 100
20 List of tables....................................................................................... 102
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1 About this document
1.1 Purpose of this document
These operating instructions are for giving technical personnel of the machine manu‐
facturer or operator instructions on the mounting, configuration, electrical installation,
commissioning, operation, and maintenance of the MLG-2 measuring automation light
grid.
These operating instructions do not provide information on operating the machine into
which a measuring automation light grid is integrated. For information about this, refer
to the operating instructions of the particular machine.
1.2
Scope
These operating instructions apply to the MLG-2 Pro WebChecker measuring automa‐
tion light grid, referred to merely as the MLG-2 in the following.
1.3 Target group
These operating instructions are intended for planning engineers, developers, and oper‐
ators of plants and systems into which one or more MLG-2 measuring automation light
grids are to be integrated. They are also intended for people who integrate the MLG-2
into a machine, carry out its commissioning, or who are in charge of maintenance.
1.4 Information depth
These operating instructions contain information about the MLG-2 measuring automa‐
tion light grid on the following topics:
•
Mounting
•
Electrical installation
•
Commissioning and configuration
•
Care
•
Fault diagnosis
•
Part numbers
•
Conformity and approval
When planning and using a measuring automation light grid such as the MLG-2, techni‐
cal skills are required that are not covered by this document.
The official and legal regulations for operating the MLG-2 must always be complied
with.
NOTE
Please also refer to the SICK AG website: www.sick.de.
1.5 Symbols used
Recommendation
Recommendations are designed to assist you in the decision-making process with
respect to the use of a certain function or a technical measure.
NOTE
Notes inform you about special aspects of the device.
O, Ö, o
LED symbols describe the status of a diagnostics LED. Examples:
O
The LED is illuminated continuously.
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Ö
The LED flashes evenly.
ôKõ
The LED flashes briefly.
o
The LED is off.
b
Take action ...
Instructions for taking action are indicated by an arrow. Carefully read and follow the
instructions for action.
CAUTION
Warning!
A warning indicates a specific or potential hazard. This is intended to protect you
against accidents.
Read carefully and follow the warnings!
s r Sender and receiver
In figures and connection diagrams, the symbol s indicates the sender and r indi‐
cates the receiver.
1.6 Abbreviations used
EDS Electronic data sheet
MLG-2 Measuring automation light grid of the 2nd generation
SDD SOPAS device description
PLC Programmable logic controller
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2 Safety information
2.1 Requirements for the qualification of personnel
The MLG-2 measuring automation light grid must only be mounted, commissioned, and
maintained by authorized personnel.
NOTE
Repair work on the MLG-2 may only be performed by qualified and authorized service
personnel from SICK AG.
The following qualifications are necessary for the various tasks:
Table 1: Authorized personnel
Task Qualification
Mounting
•
Basic practical technical training
•
Knowledge of the current safety regulations in the work‐
place
Electrical installation and
device replacement
•
Practical electrical training
•
Knowledge of current electrical safety regulations
•
Knowledge of the operation and control of the devices in
their particular application (e. g., industrial robots, storage
and conveyor systems)
Commissioning, operation, and
configuration
•
Knowledge of the current safety regulations and of the
operation and control of the devices in their particular
application
•
Knowledge of automation systems
•
Knowledge of how to use automation software
2.2 Intended use
The MLG-2 is a measuring automation light grid. The MLG-2 is designed for optical and
non-contact edge detection and width measurement of flexible and rigid sheets of
material.
A measuring automation light grid is designed for mounting and may only be operated
according to its intended function. For this reason, it is not equipped with direct safety
devices.
The system designer must provide measures to ensure the safety of persons and sys‐
tems in accordance with the legal guidelines.
In the event of any other usage or modification to the MLG-2 measuring automation
light grid (e.g., due to opening the housing during mounting and electrical installation)
or in the event of changes made to the SICK software, any claims against SICK AG
under the warranty will be rendered void.
Reasonably foreseeable misuse
The MLG-2 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
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2.3 General safety notes
CAUTION
Observe the following to ensure the safe use of the MLG-2 as intended.
The measuring automation light grid must be installed and maintained by trained, quali‐
fied personnel with knowledge of electronics, precision engineering, and
control programming. The relevant technical safety standards must be observed.
All persons entrusted with the installation, operation, or maintenance of the devices
must follow the safety guidelines:
•
The operating instructions must always be available and must be followed.
•
Unqualified personnel must stay away from the system during installation and
maintenance.
•
The system must be installed in accordance with the applicable safety regulations
and mounting instructions.
•
The work safety regulations of the employers' liability insurance associations and
trade associations in the respective country must be observed during installation.
•
Failure to observe the relevant work safety regulations may lead to physical injury
or cause damage to the system.
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3 Product description
3.1 MLG-2 type label
The senders and receivers of the MLG-2 each have a type label.
2
5
1
34
1110
4
7
6
5
9
3
2
1
8
Figure 1: Sender type label
Figure 2: Receiver type label
1
Type code
2
Part number for the individual sender or receiver
3
Part number for the whole MLG-2
4
Sender or receiver symbol
5
Firmware version
6
Required voltage supply
7
Maximum output current
8
Serial number
9
2D Matrix Code, contains the part numbers of the sender/receiver, the part number of
the MLG-2, and the serial numbers
ß
Diagram of the M12/5-pin/M12/8-pin male connector
à
Pin assignment of the M12/5-pin/M12/8-pin male connector
á
Diagram of the M12/4-pin female connector
â
Pin assignment of the M12/4-pin female connector
3.2 Type code
Example
MLG-2 with 5 mm beam separation, WebChecker type, measurement field width
750 mm, analog interface, 1 input, 1 digital output as well as 2 analog outputs, no
options, 2.5 m sensing range.
Table 2: Example of an MLG-2 type code
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
M L G 0 5 W - 0 1 3 1 B 1 0 2 0 1
Table 3: Meaning of the positions in the type code
Position Meaning
1 … 3 Product family MLG
4 and 5 Beam separation 05 = 5 mm
6 Type W = WebChecker
0 = special type
7 Hyphen –
8 … 11 Detection width 0131 = see "Measurement field
width", page 12
0000 = special measurement field
width
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Position Meaning
12 Interfaces, I/O see "Combinations of MLG-2 inputs
and outputs", page 13
13 Options 1 = none
14 and 15 Optical properties 02 = sensing range 2.5 m and mini‐
mum object length 4 mm
00 = special properties
16 and 17 Preconfiguration of the I/O con‐
nections and software
01 = standard
3.2.1 Measurement field width
The MLG-2 consists of measurement modules and optionally empty modules. The mea‐
surement modules can be located on the connection side and on the head of the
MLG-2. Empty modules do not have LEDs.
rs
M
1
L
2
G
3
0
4
5
5
W
6
–
7
0
8
2
9
1
10
3
11
x
12
x
13
x
14
x
15
x
16
x
17
3
1
2
1
32
Figure 3: Configuring MLG-2 measurement field width using type code
1
Head side measurement field width and number of head side measurement modules
2
Blind zone and number of empty modules
3
Connection side measurement field width and number of connection side measurement
modules
The measurement field width is calculated from the ordered module number. Positions
9 to 11 represent the module number in the type code.
The module width is always 150 mm. The largest possible measurement field with of
3,150 mm results from the possible module number of 21. The smallest possible mea‐
surement field width is a measurement module with 150 mm.
NOTE
A maximum of 16 measurement modules can be used in one MLG-2. The light grid can
be filled with empty modules. A maximum of 19 empty modules may be used and the
total number of modules must not exceed 21.
There must be at least one measurement module on the connection side and on the
head side. If no empty modules are used, all active modules on the terminal compart‐
ment must be specified.
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Table 4: Measurement field width
Position 8 - 11 Meaning Type code specification -
Number which can be ordered
8 No selection –
9
Number of measurement modules
on the connection side of the MLG-2
(left)
1: 1 measurement module
2: 2 measurement modules
…
9: 9 measurement modules
A: 10 measurement modules
…
G: 16 measurement modules
10
Number of empty modules 0: 0 empty modules
1: 1 empty module
2: 2 empty modules
...
9: 9 empty modules
A: 10 empty modules
...
J: 19 empty modules
11
Number of measurement modules
on the head side of the MLG-2 (right)
0: 0 measurement modules
1: 1 measurement module
…
9: 9 measurement modules
A: 10 measurement modules
…
F: 15 measurement modules
Example calculation of measurement field width
•
Number of measurement modules on the connection side = 3
•
Number of empty modules = 1 piece
•
Number of measurement modules on the head side = 2
Measurement field width = (Number of measurement modules on the connection side
+ number of empty modules + number of measurement modules on the head side)
x 150 mm – 5 mm
Measurement field width = (3 measurement modules + 1 empty module +
2 measurement modules) x 150 mm – 5 mm
Measurement field width = (3 + 1 + 2) x 150 mm – 5 mm
Measurement field width = 895 mm
3.2.2 Combinations of MLG-2 inputs and outputs
Table 5: Possible combinations of MLG-2 inputs and outputs
Position 12 Inputs and outputs, data interface Connection type
B
•
2 × switching output (Q) and
•
2 x analog output (QA)
or
•
1 × input (IN) and
•
1 x switching output (Q) and
•
2 x analog output (QA)
M12, 8-pin, A-coded
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Position 12 Inputs and outputs, data interface Connection type
G
•
3 x switching output (Q) and
•
1 x analog output (QA)
or
•
1 × input (IN) and
•
2 × switching output (Q) and
•
1 x analog output (QA)
M12, 8-pin, A-coded
I
•
2 × switching output (Q) and
•
1 x RS-485 interface
or
•
1 × input (IN) and
•
1 x switching output (Q) and
•
1 x RS-485 interface
M12, 8-pin, A-coded
R
•
4 x switching output (Q)
or
•
1 × input
•
3 x switching output (Q)
or
•
2 x inputs
•
2 × switching output (Q) and
M12, 8-pin, A-coded
3.2.3 Optical properties
Table 6: Sensing range and minimum detectable object length
Position
14 and 15
Sensing range Minimum detectable object length
00 Special Special
05 2.5 m 4 mm
3.3 Structure and function
The MLG-2 is an optical automation light grid. It comprises a sender and a receiver.
The sender consists of sender optics, several sender elements (LEDs), and actuation
electronics. The receiver consists of receiver optics, several receiver elements (photodi‐
odes) and actuation electronics.
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3.3.1 Device components
M12; 5pol
M12; 4pol
M12; 8pol
rs
4
Teach
Alignment
link/data
RS485
5
7
8
6
9
1 2
3ß
Figure 4: Device components
1
Sender
2
Receiver
3
Receiver LED
4
LED display
5
Control panel at the rear of the receiver
6
Ethernet connection for configuration via TCP/IP
7
Receiver connection: Voltage supply, inputs, outputs and synchronization
8
Sender connection: Voltage supply, synchronization and test input
9
LED display
ß
Sender LED
3.3.2 Measurement principle
Providing no object is located between the sender and receiver, the light beams from
the sender LEDs will hit the receiver LEDs.
If an object is located between the sender and receiver, the light beams will be inter‐
rupted, depending on the size of the object.
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The MLG-2 works with the cross beam function. When the cross-beam function is
enabled, the light beam from a sender LED is received by three receiver LEDs in two
scans.
You get the most accurate measurement result when you place the material sheet or
sheets in the optimal object position. The optimal object position is the distance
between the sender and the object to be detected and is about 2/3 of the distance
between the sender and receiver, see figure 16, page 23. The light beams are distrib‐
uted uniformly at the optimal object position. The electronics in the receiver observe
the completely and partially interrupted light beams for evaluation. The exact object
position is determined energetically within a beam.
rs
ca. 1/3
ca. 2/3
max. 2.5 m
4
4
5
3
2
1
Figure 5: MLG-2 function
1
Sender
2
Receiver
3
Object to be detected
4
Optimal object position, approximate specifications
5
Maximum sensing range: Maximum possible distance between sender and receiver
Additional information
•
see "Planning mounting distance between sender and receiver", page 22
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3.4 Definitions
3
4
5
8
1
rs
6
7
9
2
Figure 6: Definitions for MLG-2
1
Distance between sender and receiver
2
Measurement field width
3
Area with measurement modules on the head side (left)
4
Area with empty modules
5
Area with measurement modules on the connection side (right)
6
Sender
7
Receiver
8
Beam separation
9
Minimum object length (shown longer here)
Sensing ranges
The operating range is the distance between sender and receiver for which the MLG-2
works safely. The operating range is 2.5 m and takes into account an operating reserve.
Measurement field width
The MLG-2 consists of measurement modules and optionally empty modules. The mea‐
surement modules can be located on the connection side and on the head of the
MLG-2. Empty modules do not have LEDs.
The measurement field width is calculated from the ordered module number. Positions
9 to 11 represent the module number in the type code.
Additional information
•
Type code: see "Measurement field width", page 12
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Beam separation and minimum object length
A minimum object length is required so that an object is detected by the MLG-2.
Table 7: Beam separation and minimum object length
Beam separation Minimum detectable object length (stationary
object)
5 mm 4 mm
Additional minimum distances see "Required minimum distances for an object",
page 25.
The minimum object length level depends on the following factors:
•
From the speed with which the object moves. The higher the speed, the longer the
object has to be.
•
The response time The response time depends on the measurement field width.
The wider the measurement field width, the higher the scan time and the
response time.
3.5 Scan time
With the MlG-2, not all light beams are active at the same time. The light beams are
always processed from the terminal compartment.
The scan time depends on the number of beams of the MLG-2. The higher the number
of beams, the higher the scan time.
The MLG-2 works with the cross beam function. When the cross-beam function is
enabled, the light beam from a sender LED is received by three receiver LEDs in two
scans.
rs
Figure 7: MLG-2 scan time, example of read direction of the connection side
The response times of the outputs result from the scan time.
The response time is the time it takes for an output to react following the detection of
an object. The typical response time is 3 × the scan time plus the transmission time to
the outputs. The optional Smoothing function can be used to multiply the response
time.
3.6 Operating reserve
The operating reserve defines the operational safety before contamination, vibrations,
misalignment, temperature fluctuations, etc. cause the MLG-2 to produce incorrect
measurements.
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The MLG-2 is subject to a certain level of contamination depending on its environment
and application. In principle, the MLG-2 must be cleaned regularly and a sensor teach-
in should be carried out after cleaning.
3.7 Minimum object attenuation
For the MLG-2 to detect the object, the object must dampen the energy of the light
beams either completely or at least by 20%. An attenuation of 20% is achieved by mate‐
rials with a transmission of up to 80%.
If the MLG-2 is to detect partially transparent objects, in SOPAS ET, for the Sensitivity
parameter, you have to select the Medium or Fine option.
In materials with high transmission, the temperature difference between the operating
temperature and the temperature during teach-in must be less than ± 15 K.
The following prerequisites must be met:
•
The sender and receiver must be aligned precisely with one another.
•
The front screens from the sender and receiver must always be kept clean.
3.8 Display and operating elements
3.8.1 MLG-2
Sender and receiver
The LEDs for the status and error display and the teach pushbutton are located on the
sender and receiver of the MLG-2.
1
rs
Teach
Alignment
link/data
RS485
à
9
2
4
3
6
8
7
5
ß
Figure 8: LEDs and control panel of the MLG-2
1
Sender
2
Yellow LED
3
Red LED
4
Green LED
5
Receiver
6
Yellow LED
7
Red LED
8
Green LED
9
Control panel at the rear of the receiver
PRODUCT DESCRIPTION 3
8024643/2019-09-02 | SICK O P E R A T I N G I N S T R U C T I O N | MLG-2 WebChecker
19
Subject to change without notice
ß
LEDs on the control panel
à
Teachpushbutton
Additional information
•
Meaning of the LEDs: see "LED indicators and error indicators", page 83
3.9 Inputs
3.9.1 Switching inputs on the receiver
You can assign the following switching input functions:
•
Teach-in
•
Standby
•
Triggering RS485 data output
Additional information
•
SOPAS general settings, PIN configuration: see "“General Device Settings” page",
page 63
•
SOPAS digital configuration: see "“Digital configuration” menu", page 75
3.9.2 Test input on the sender
The test input can be used to switch off the sender. This simulates a complete blocking
of the beams. This makes it possible to test the behavior of the switching or analog out‐
puts that have been configured accordingly.
3.10 Application examples
3.10.1 MLG2 application examples
The MLG-2 is suitable for optical and non-contact edge detection and width and center
calculation of flexible and rigid sheets of material. It can detect up to 10 edges. 10
functions can be calculated from this. These can be centers or widths. The material can
be opaque or partially transparent with a transmission of up to 80%.
Table 8: Application examples for the MLG-2
Figure 9: Automobile industry, position detec‐
tion of rubber bands
Figure 10: Automobile industry, position detec‐
tion of material rolls
3 PRODUCT DESCRIPTION
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Subject to change without notice
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SICK MLG-2 WebChecker Operating instructions

SICK
Brand
SICK
Model
MLG-2 WebChecker
Category
Measuring, testing & control
Type
Operating instructions
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