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O P E R A T I N G I N S T R U C T I O N S S3000 Safety laser scanner...
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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.
These operating instructions are addressed to planning engineers, machine designers and the operators of machines and systems which are to be protected by one or several S3000 safety laser scanners. They also address people who integrate the S3000 into a machine, a system or a vehicle, initialize its use, or who are in charge of servicing and maintaining the device.
General information on accident prevention using opto-electronic protective devices can be found in the competence brochure “Guidelines Safe Machinery”. When operating the S3000, the national, local and statutory rules and regulations must be observed. We also refer you to the SICK AG homepage on the Internet at www.sick.com.
Refer to notes for special features of the device. Note Display indicators show the status of the 7<segment display on the S3000: Constant indication of characters, e.g. 8 Flashing indication of characters, e.g. 8 Alternating indication of characters, e.g.
ESPE and are allocated the task by the organization operating the ESPE. Applications of the device The S3000 safety laser scanner is used to protect persons and systems. It is intended to be used to monitor hazardous areas indoors. The S3000 is not intended to be used outdoors.
— any warranty claim against SICK AG shall become void. General safety notes and protective measures Pay attention to the safety notes! Please observe the following items in order to ensure the correct use of the S3000 safety laser scanner. WARNING...
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The operating instructions must be made available to the operator of the machine where the S3000 is used. The machine operator is to be instructed in the use of the device by qualified safety personnel and must be instructed to read the operating instructions.
Operating instructions S3000 Environmental protection The S3000 safety laser scanner is constructed in such a way that it adversely affects the environment as little as possible and uses only a minimum of power and natural resources. At work, always act in an environmentally responsible manner.
Operating instructions S3000 Product description This chapter provides information on the special features and properties of the S3000 safety laser scanner. It describes the construction and the operating principle of the device, in particular the different operating modes. Special features 190°...
The control of the machine, system or vehicle must be electrical. It must be possible to transfer the dangerous machine, system or vehicle state to a safe state using the OSSDs on the S3000 at any time, i.e. before a person has reached the hazardous point or hazardous area.
90° 0° In the S3000 there is also a mirror rotating at constant speed that deflects the light pulses such that they cover an arc of 190°. In this way an object can be detected in the protec- tive field within 190°. The first beam of a scan starts at –5° relative to the back of the scanner.
2 Simultaneous monitoring Depending on the field mode selected, on the S3000 either simultaneous monitoring of two fields sets each with one protective field and one warning field (dual field mode) or with two protective fields (dual protective field mode) is possible, or a field set with one protective field and two warning fields (triple field mode) can be monitored.
Active field set Active simultaneous field set S3000 variants The S3000 variants are formed by three sensor heads and five I/O modules. 3.3.1 Device components The S3000 safety laser scanner comprises three components: the sensor head with the opto-electronic acquisition system...
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I/O modules Five I/O modules are available for the S3000. With the aid of these I/O modules, the S3000 covers the various applications. Fig. 9: Available I/O modules...
The second field set on the S3000 Standard can only be used as a simultaneous field set. Maximum possible number of field sets — the actual number is the same as for the S3000 variant to which an S3000 Remote is connected.
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(as navigation aid, e.g. during docking maneuvers) Please note the additional functions of the S3000 I/O module Expert; with this module Notes expanded applications are possible via the RS-422 interface for measured data. You will find further details on this topic in the documentation “Telegram Listing Standard” (part no.
3.4.1 LEDs and 7@segment display The LEDs and the 7<segment display indicate the operational status of the S3000. They are positioned on the front of the safety laser scanner. Above the LEDs there are symbols that are used in the remainder of these operating instructions to describe the LEDs.
S3000 Interoperability The S3000 safety laser scanner can be integrated in an EFI system. An EFI system can comprise two safety laser scanners, a sens:Control device with one to two safety laser scanners or a Flexi Soft safety controller with up to four safety laser scanners.
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The Flexi Soft safety controller provides two EFI strings; up to two safety laser scanners (S3000, S300, S300 Mini, also mixed) can be connected to each of these strings. It is therefore possible to realize applications with up to four safety laser scanners (see also section 7.3.1).
100 % compatible with safety laser scanners already in use in the field. To ensure compatibility, the S3000 safety laser scanners with firmware J B02.41 and serial number > 12210000 can be operated in compatibility mode. The following tables show which devices can form an EFI system.
Monitoring case switching In an EFI system, the host defines the number of possible monitoring cases. If an S3000 is configured as a guest with a higher level device (S3000 host, sens:Control device), more monitoring cases may therefore be available depending on the system configuration.
< 12210000. You configure an S3000 Remote with I/O module with serial number < 11240000. You use an S3000 with a system plug in which a configuration is saved, … – that only supports the compatibility mode. – that has been configured in the compatibility mode.
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The second field set on the S3000 Standard can only be used as a simultaneous field set. Maximum possible number of field sets — the actual number is the same as for the S3000 variant to which an S3000 Remote is connected.
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JB02.41 – S3000 Remote Tab. 8: Required compatibility mode with different firmware versions of the S3000 in an EFI system with other safety laser scanners = Compatibility mode required X = Compatibility mode not required – = EFI system not possible The S300 Mini does not support the compatibility mode.
Display direction of the 7@segment display The depiction of numbers on the 7<segment display can be rotated by 180° with the aid of the CDS. This is useful, for example, when the S3000 must be rotated by 180° owing to the specific assembly.
Chapter 4 S3000 Application With the help of the CDS you can configure the S3000 for the required application. Depending on whether you select a stationary or a mobile application, different configuration options are available: Tab. 9: Comparison of mobile...
If you select the Triple option, you can configure field sets with three fields. These field sets comprise one protective field and two warning fields. On the S3000 Expert and S3000 Remote the number of field sets that can be configured Note is dependent on the selected field mode (see section 4.9 on page 51).
If you have selected the Dual protective fields field mode, then the Transfer unallocated fields as infringed option is selected automatically. Incremental encoder The S3000 Professional and the S3000 Expert have two dual-channel dynamic control inputs using which the possible monitoring cases can be switched as a function of the velocity.
EFI system If devices are connected together via EFI, the S3000 can receive control commands from other devices, e.g. a second S3000 or Flexi Soft safety controller. Tab. 43 on page 158 shows the possible control commands of the S3000.
For the input delay choose the time in which your defined control device can switch to a corresponding input condition. Independent of the basic response time chosen for the S3000, you can increase the input delay in 30-ms steps (for 60 ms basic response time) or 60-ms steps (for 120 ms basic response time).
FPLC that must shutdown the dangerous state. Do not use the OSSD bit for safety relevant functions! If the local OSSDs on the S3000 are not used, the OSSD state is always transferred as WARNING active via EFI. In this case the OSSD bit in the Flexi Soft safety controller is not allowed to be used for safety-related functions.
OSSDs are not switched back to the ON state. The table shows how the S3000 reacts if the external device monitoring detects a contactor malfunction: Tab. 14: Behavior of the Without internal restart The system locks completely (lock-out).
Configuration of the S3000 without restart interlock After the OSSDs on the S3000 have been switched to the OFF state due to an object in the protective field, the OSSDs are re-enabled again immediately when there is no longer an object in the active protective field.
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Note instructions the term reset is used. If you want to activate the restart interlock on the S3000 (internal) and also a restart interlock on the machine (external), then each restart interlock has its own control switch. After operating the control switch for the internal restart interlock (with protective field unoccupied) …...
Fig. 20: Configuration example universal I/O connections of the S3000 If you operate the S3000 in the compatibility mode, then the connections on the Note universal I/O are used as application diagnostic output, warning field output and application diagnostic output for reset required.
The number of field sets that can be configured is dependent on the safety laser scanner variant. On the S3000 Expert and S3000 Remote the number of field sets that can be configured is also dependent on the field mode selected (dual field mode/dual protective field mode/ triple field mode) and the angular resolution configured.
Fig. 21: Creating a field set in the CDS The area to be monitored is scanned radially by the S3000. The S3000 cannot see Note through objects during this process. The area behind objects that are in the area to be monitored (pillars, grilles, etc.) can thus not be monitored.
(e.g. at ), the protective field corresponds to the surrounding contour. The measuring error tolerances for the S3000 are automatically subtracted from the Note protective field size. As a result the protective field is slightly smaller than the surface...
S3000 4.9.3 Using the contour as a reference In addition to the protective field, the S3000 can also monitor a contour (e.g. the floor in vertical applications or the wall in horizontal applications). Fig. 24: Schematic diagram of contour as reference For contour monitoring you define a contour segment .
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Use lateral, vertical boundaries of the opening (e.g. door frame) and the floor as reference. Recommendation If in this case the position of the S3000 is changed in one or more planes, the distance to the reference changes and the S3000 switches its OSSDs to the OFF state.
Chapter 4 S3000 4.10 Monitoring cases The S3000 supports a configuration with multiple monitoring cases. By switching the monitoring case you can switch to different monitoring conditions in the case of a change to the monitoring situation. Ensure for each monitoring case that the minimum distance to the hazardous area is...
If several safety laser scanners are connected to a Flexi Soft safety controller, then a velocity routing can be configured. In this way the velocity information that is determined by an S3000 Professional or Expert with the aid of incremental encoders is distributed to all safety laser scanners.
EFI2.1 EFI2.2 The velocity signals of the S3000 Expert are broken down into a 12 + 1 bit pattern, 12 velocity bits and one bit for validation. These signals are available as input signals, are duplicated and placed twice on the n:n function blocks (0 and 1 as well as 2 and 3).
Then choose on the Cases tab a further field set as a simultaneous field set within the related monitoring case. On a system with one S3000 the first protective field in both field sets acts on the internal OSSDs in the S3000. In a system with several devices connected via EFI, the both field sets can act on different OSSDs (see section 4.6 on page 46).
If, in mobile applications, vehicles are not moved for a time (e.g. for battery charging), the OSSDs can be switched to the OFF state and the laser on the S3000 can be switched off. In this way the power consumption of the device is reduced.
Stand-by mode via EFI The S3000 can be switched to the stand-by mode via EFI (see section 12.5 “EFI status information and control commands” on page 156). You will need an external safety controller (e.g. Flexi Soft).
S3000 ensured. WARNING Mount the S3000 in a dry place and protect the device from dirt and damage. Notes Avoid strong electrical fields. These can, e.g., be produced by welding cables, induction cables in the immediate vicinity and also by mobile telephones operated nearby.
Note the protective field sizes for all protective fields used. You can operate the S3000 in stationary horizontal operation with 50 mm or with 70 mm resolution. For each resolution you can choose between 60 ms and 120 ms response time.
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With a protective field installed horizontally, there is a risk that people may reach over the protective field and in this way reach the hazardous area before the S3000 shuts down the dangerous state. For this reason the calculation of the minimum distance must take into account a supplement to prevent persons from finding themselves in a hazardous situation by reaching over (see EN ISO 13 857, table 1) before the S3000 triggers.
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The minimum supplement to prevent reaching over is 850 mm (arm length). Note In summary there are three usual mounting variants for the scan plane of the S3000. The optimal variation depends on the related application. Fig. 32: Mounting variations for the scan plane Tab.
The reason in this case would be that the beams miss the ankle on the left and right If you mount the S3000 higher, the scan plane is at fibula height and the leg is also detected with an object resolution of 70 mm...
(the stopping/run-down time is shown in the machine documentation or must be determined by taking a measurement. — On request SICK service can perform a stoptime measurement on your system.) response time of the S3000...
Response time T of the S3000 The total response time of the S3000 must not be more than 90 ms for access protection! If a critical response time is exceeded (for an object diameter of 150 mm and a speed of WARNING 1.6 m/s that is 90 ms) a person may no longer be detected under certain circumstances.
You can operate the S3000 with 30 mm or 40 mm resolution for hazardous point protection. At each resolution you can choose a response time between 60 ms and 120 ms (due to the proximity of the hazardous point in the majority of cases only the shorter response time can be used).
The S3000 may only be used to protect vehicles powered by electric motor. Notes Due to the movement of the S3000 itself in a mobile application, a resolution of 70 mm is sufficient for the detection of people. In the following calculations only take into account the velocity of the vehicle, not the speed of the person walking.
5.4.3 Height of the scan plane Mount the S3000 such that the scan plane is at a maximum height of 200 mm! In this way persons lying down will be reliably detected. Tilting the protective field so that objects with a diameter of 200 mm are not detected, is not allowed. We recommend WARNING aligning the scan plane at 150 mm.
S3000 5.4.4 Methods of preventing unprotected areas When the S3000 is mounted on a plane surface, there are areas in front of the mounting surface that are not covered by the safety laser scanner Fig. 42: Unprotected areas for mobile applications These unprotected areas become larger if you mount the S3000 using mounting kits.
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Build the S3000 into the vehicle trim at least such that the unprotected areas are 70 mm and the S3000 projects a maximum of 109 mm beyond the front of the vehicle. The vehicle may then be accelerated to a velocity of 0.3 m/s within a second.
Chapter 5 Operating instructions S3000 Measures to protect areas not covered by the S3000 During mounting the S3000, areas may be found that are not covered by the safety laser scanner. Fig. 44: Unprotected areas for stationary applications These areas become larger if the S3000 is mounted using the mounting kits.
Set the timing for the switching such that the S3000 already detects a person in the protective field with an adequate minimum distance before the dangerous state...
The origin of the scan plane is 63 mm above the bottom edge of the S3000. If you mount the S3000 using mounting kit 3, then the origin of the scan plane is 102 mm above the bottom edge of mounting kit 3 (see section 12.6.3 “Scan plane origin”...
5.7.1 Direct mounting The S3000 has four M6 × 8 threaded holes on the rear. Using these holes you can mount the S3000 directly if you can drill through the mounting surface from the rear. The maximal tightening torque for the threaded holes is 12 Nm.
Mounting with mounting kit 2 With the aid of mounting kit 2 (only in conjunction with mounting kit 1) you can align the S3000 in two planes. The maximum adjustment angle is ±11° in both planes. Fig. 52: Mounting with...
With the aid of mounting kit 3 (only in conjunction with mounting kits 1 and 2) you can mount the S3000 such that the scan plane is parallel to the mounting surface. This enables e.g. stable floor mounting or ensures that mounting kit 2 remains precisely adjustable cross-wise on uneven wall surfaces.
Mounting with the Heavy Duty mounting bracket With the aid of the Heavy Duty mounting bracket you can mount the S3000 such that the scan plane is between 100 mm and 350 mm above the floor. With the aid of the mounting bracket you can align the S3000 in three planes.
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Route all cables and connection cables such that they are protected from damage. Notes If you use the S3000 for the protection of hazardous areas: Ensure that also the controller connected and all devices related to safety have the required category as per EN ISO 13849-1 or the required performance level as per EN ISO 13849! If you use screened cables, lay the screen evenly around the cable gland.
In principle the best screening action can only be achieved with the connection of the screen at both ends using large area connections. To connect the screen on the S3000 use the EMC cable glands M12 (see Tab. 50 on page 165).
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IP 54 or better screened cable max. pulse frequency: 100 kHz min. number of pulses: 50 pulses per cm You can procure suitable incremental encoders from SICK AG, tel.: +49 211/5301-250 or Recommendation at www.sick.com. Or contact your local SICK representative. Control inputs You can only connect the input signals to one safety laser scanner.
To differentiate unambiguously between the host and guest device in an EFI system, one WARNING S3000 must be configured as the guest. For this purpose a jumper is wired between the connection terminals 7 (ERR) and 10 (A1). The jumper always defines the guest device. This jumper is never allowed to be fitted on the host device.
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WARNING adequate. In this way you avoid the inadvertent connection of the system plug to a neighboring S3000 and operation of an S3000 with an incorrect configuration. The spare cable enables you to change the S3000 with ease if necessary.
S3000 Pre-assembled system plugs 6.3.1 Pre-assembled system plugs with flying leads To connect the S3000 variants, the following pre-assembled system plugs are available (see also section 13.3.4 “System plug” on page 164): SX0A-B0905G – for S3000 Standard and S3000 Remote –...
The access is monitored permanently. For safety against manipulation on the S3000, e.g. the floor is used as a reference. If the alignment of the S3000 changes (e.g. due to change to the mounting), the S3000 shuts down.
For safety against manipulation on the S3000, e.g. the floor is used as a reference in each case. If the alignment of the S3000 changes (e.g. due to change to the mounting), the S3000 shuts down.
Warning field Surrounding contour The S3000 monitors the area in one direction of travel and stops the vehicle as soon as there is an object in the protective field. In addition, the surrounding contour is measured and reflectors fitted to the walls detected. Surrounding contour and reflector detection are output via the RS-422 interface using configurable telegrams.
Professional via the EFI. It monitors the areas for the second direction of travel as a function of the velocity. As soon as there is an object in the protective field, the S3000 Remote switches the OSSDs on the S3000 Professional to the OFF state over the EFI interface.
Flexi Soft S300 Professional Incremental encoder In the triple field mode, two warning fields can be configured for the front and rear S3000 Expert. Incremental encoders are connected to the front S3000 Expert and supply velocity- dependent input signals. The velocity information is transferred to the safety laser scanner on the rear via the Flexi Soft safety controller using the EFI status message and is used for monitoring case switching.
Operating instructions S3000 Applications with sens:Control With sens:Control, the safe control solutions, SICK provides you with an entire range of interface products that were specially developed for interfacing safety products and machines. For complex applications the S3000 can be integrated into sens:Control family safety systems.
H3 = Sensor for waiting for restart H8 = Sensor for warning field interruption In the case of the examples with S3000 Expert or Flexi Soft, the universal I/O connections Note are to be configured such that they indicate the related states.
S3000 Expert S300 Mini Remote S3000 Expert with S300 Mini Remote in an EFI system with relays/contactors; Operating mode: without restart interlock with external device monitoring; Protective field switching using control inputs A to D. If you use two safety laser scanners in one application, then you can only connect the Note input signals to one safety laser scanner.
Operating mode: without restart interlock with external device monitoring; direction of travel-dependent dynamic protective field switching using the incremental encoders C and D as well as static protective field switching using the control inputs A and B of the S3000. The protective fields affect the OSSDs on the host.
Expert UE10- One S3000 Expert with one S3000 Remote in an EFI system; Protective field evaluation, restart interlock and EDM via EFI using a Flexi Soft safety controller. Static protective field switching using the control inputs S1 to S4 of the Flexi Soft safety controller.
Two connection cables of different length are available for the connection of the PC/notebook to the S3000 (see section 13.3 “Accessories/spare parts” on page 163). Ensure you do not lay the service cable close to powerful electrical drives or cables Notes carrying high currents.
Also check at regular intervals after release of the machine (e.g. in the morning at the start of work) as to whether the S3000 correctly switches the OSSDs as soon as there is an object in the protective field. This test should be performed along all protective field boundaries as per the specific regulations for the application (see section 9.2 “Test notes”...
S3000 9.1.1 Power-up sequence After switching on the S3000 runs through the power up cycle. During the power up cycle, the 7<segment display indicates the device status. During the initial commissioning of an S3000 the following indications are possible: Tab. 28: 7>segment display...
No further operation if errors occur during the test! If any one of the following points is not met, it is not permitted to continue to work on the machine or operate the vehicle. In this case the installation of the S3000 must be checked WARNING by qualified safety personnel (see section 9.2.2 “Regular inspection of the protective...
However, the test in accordance with the regulations for the daily test must be performed (see section 9.2.3 on page 123). When you place a configured S3000 (e.g. after replacement of the sensor head) back into operation, the following indications are possible: Tab.
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If the system plug has also been replaced, then the configuration must be transferred to Note the S3000 with the aid of the CDS. In this case acceptance by qualified safety personnel is necessary (see section 9.1 on page 120).
Always perform a front screen calibration after the replacement of the front screen! After the replacement of the front screen with a new front screen you must perform a front screen calibration with the aid of the CDS. In this way the new front screen on the S3000 WARNING is measured and the device made functional.
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Disconnect the system plug and remove the S3000. Take the S3000 to a clean place (office, repair shop or similar). First clean the outside of the S3000. This prevents foreign bodies entering the device when it is opened. Removing the fixing screws for the front screen.
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Correctly re-mount the S3000 (see chapter 5 “Mounting” on page 66). Connect the S3000 system plug. After power up the S3000 automatically reads the saved configuration from the system plug (see section 9.3 “Re-commissioning” on page 124). Always perform a front screen calibration with the aid of the CDS after the replacement of the front screen! The level of contamination is measured continuously during the operation of the S3000.
As a matter of principle, always isolate the machine from the power supply during all work on the machine and safety laser scanner. In the case of an error or to change the functionality of the S3000, you can replace the I/O module. After re-commissioning the saved configuration is read from the system plug (see also section 9.3 on page 124).
Protect these from electrostatic discharge, contamination and moisture. If possible use anti-static floor mats and workbench covers. When working on the S3000, touch a bare metal surface from time to time to discharge static charging of your body. Only remove the components of the S3000 from their anti-static packing immediately prior to installation.
If you cannot rectify an error with the help of the information provided in this chapter, please contact your local SICK representative. Make a note of the telephone number of your SICK representative so that you or other users have this number easily at hand. You will find the telephone number on the rear of these operating instructions.
If this is configured as warning field output. On the S3000 in the triple field mode, the 7<segment display shows which warning field contains an object. If this is configured as the output for a contamination error/warning. If this is configured as the output for “Reset required”.
To place the device back in operation, proceed as follows: Rectify the cause of the fault as per Tab. 39. Switch off the power supply for the S3000, wait at least 3 seconds and then switch back on the power supply.
Check whether the correct I/O module has head device combi- been used, and replace if necessary. nation invalid If you have problems during troubleshooting, contact SICK support. Keep a copy of the Note print out of the results of the diagnostics at hand. 11.5 Extended diagnostics The CDS software supplied with the device (Configuration &...
= Supplement for the usage of external OSSDs via EFI Multiple sampling On the S3000 at least double multiple sampling is always set. From a multiple sampling of 3 you must add a supplement to the response time. The related supplement is dependent on the basic response time and the multiple sampling.
S3000 12.3 Timing behavior of the OSSDs The S3000 tests the OSSDs immediately after switch on and then at regular intervals. For this purpose the S3000 briefly switches off both OSSDs (for 300 µs) and checks whether the channels are electrically isolated during this period.
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20 ms. Power supplies according to EN 60 204<1 satisfy this requirement. Suitable power supplies are available as accessories from SICK. The absolute voltage level must not drop below the specified minimum voltage.
System plugs not included. Note System plugs without cable and pre-assembled system plugs are available from SICK AG (see section 13.3.4 “System plug” on page 164). For further information see section 6.2 “System plug assembly” on page 99 and section 6.3 “Pre-assembled system plugs”...
A field set (if necessary a simultaneous field set) is allocated to a monitoring case. Monitoring case Monitoring case switching is performed using the control inputs. In this way the S3000 can be adapted to the operating mode of the machine or system that it monitors.
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Annex Operating instructions Chapter 14 S3000 The S3000 has three universal I/O connections. These connections can be configured as Universal I/O inputs (e.g. for stand-by, EDM or reset) or as outputs (e.g. for device error, contamination or second warning field).
S3000 in an EFI system with other S3000 ............35 Tab. 8: Required compatibility mode with different firmware versions of the S3000 in an EFI system with other safety laser scanners ........ 35 Tab. 9: Comparison of mobile and stationary applications ........... 37 Tab.
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