SICK OLM100 Operating Instructions Manual
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SICK OLM100 Operating Instructions Manual

SICK OLM100 Operating Instructions Manual

Safe linear positioning safety system
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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
Safe Linear Positioning
Safety system

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Summary of Contents for SICK OLM100

  • Page 1 O P E R A T I N G I N S T R U C T I O N S Safe Linear Positioning Safety system...
  • Page 2 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‐...

  • Page 3: Table Of Contents

    Mounting Flexi Soft................... Electrical installation................ 24 General requirements................8020941/12O9/2019-08-05 | SICK O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning Subject to change without notice...
  • Page 4 Verification of the logic............7.7.4 Transfer configuration............. O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning 8020941/12O9/2019-08-05 | SICK Subject to change without notice...
  • Page 5 Thorough check of faults on the transmission path....17.1.10 Thorough check for foreseeable misuse and manipulation. 8020941/12O9/2019-08-05 | SICK O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning...
  • Page 6 17.1.12 Thorough check of the check intervals........O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning 8020941/12O9/2019-08-05 | SICK Subject to change without notice...

  • Page 7: About This Document

    Operating instructions Flexi Soft modular safety con‐ 8012999 troller hardware This document is included with the following SICK part numbers (this document in all available language versions): 8020939 Target groups and structure of these operating instructions These operating instructions are intended for the following target groups: project devel‐...

  • Page 8: Symbols And Document Conventions

    Further information www.sick.com The following information is available via the Internet: This document in other languages ■ Operating instructions and installation instructions of SICK components suitable ■ for the safety system The Flexi Soft Designer configuration software ■ Pre-configured project file for Flexi Soft Designer for this safety system ■...

  • Page 9: Safety Information

    8020941/12O9/2019-08-05 | SICK O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning...
  • Page 10 O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning 8020941/12O9/2019-08-05 | SICK Subject to change without notice...

  • Page 11: Product Description

    The Flexi Soft safety controller from SICK, which also forms part of the safety system, uses appropriate diagnostics mea‐ sures to check whether the absolute positions of the OLM100 Hi sensors are plausible. Components of the safety system Safe Linear Positioning components •...

  • Page 12: Additional Components Required

    PL e. O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning 8020941/12O9/2019-08-05 | SICK Subject to change without notice...

  • Page 13: Structure And Function

    EN 62061). Structure and function On the sensor side, the safety system consists of two OLM100 Hi linear measurement sensors with a shared bar code tape. On the controller side, the system consists of the safe Flexi Soft controller, which is made up of the CPU main module, safe XTIO I/O mod‐...

  • Page 14: Limits Of The Safety System

    Figure 2: Block diagram for the safety chain Sensor Flexi Soft safety controller Actuator O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning 8020941/12O9/2019-08-05 | SICK Subject to change without notice...

  • Page 15: Product Characteristics

    8020941/12O9/2019-08-05 | SICK O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning...

  • Page 16: Safe State

    • If the statuses of the test signals supplied by the process are implausible or imper‐ missible • If there are faults with the OLM100 Hi sensor • If there are internal faults with the FX3 modules • If an impermissible OLM100 Hi sensor is used When the safety system initiates the safe state, the machine manufacturer and user must ensure that the hazard is rectified.

  • Page 17: Project Planning

    "General requirements", page 8020941/12O9/2019-08-05 | SICK O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning Subject to change without notice...

  • Page 18: Operating Entity Of The Machine

    O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning 8020941/12O9/2019-08-05 | SICK Subject to change without notice...

  • Page 19: Extension And Modification

    (see "Safety controller pin assign‐ ment", page 26). 8020941/12O9/2019-08-05 | SICK O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning Subject to change without notice...

  • Page 20: Notes On Fault Detection

    Up to the length of five bar codes (max. bar code gap = 150 mm) O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning 8020941/12O9/2019-08-05 | SICK Subject to change without notice...

  • Page 21: Mounting

    This reduces the risk posed by foreseeable misuse on the part of the user and by manipulation. The OLM100 Hi sensors are parameterized in advance and special firmware blocks access so that parameters cannot be entered using the SOPAS ET software. Only the approved sensors may be used.

  • Page 22: Mounting The Bar Code Tape

    -26 mm ±38.5 mm 100 ± 20 mm (3.94 ± 0.78) The mounting requirements set out in the operating instructions for the OLM100 Hi must also be followed. Mounting the bar code tape WARNING There is a risk of death or serious injury as diagnostics for the protective device are not reliable.

  • Page 23: Mounting Flexi Soft

    SmartPOS repair tape can be stuck over faulty bar code tape across a maximum length of 100 mm. The mounting requirements set out in the operating instructions for the OLM100 Hi must also be followed. Mounting Flexi Soft The Flexi Soft safety controller must be mounted in an environment corresponding to enclosure rating IP54 (as per EN 60529), e.g., inside a control cabinet with enclosure...

  • Page 24: Electrical Installation

    The components must be wired as follows in line with the documentation for the com‐ ponents. O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning 8020941/12O9/2019-08-05 | SICK Subject to change without notice...
  • Page 25 “Forward/Reverse” OLM 2 OLM 1 Linear measurement sensor Linear measurement sensor OLM100 Hi OLM100 Hi (with sign-of-life test) Figure 4: Wiring principle From the connector plug on the FX3-MOC1 to the SSI signal splitter, the X-junction must be contained within an electrical installation area.

  • Page 26: Safety Controller Pin Assignment

    (see "Safety controller pin assign‐ ment", page 26). O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning 8020941/12O9/2019-08-05 | SICK Subject to change without notice...
  • Page 27 SF210.2 start button Vacant Vacant Vacant Vacant Vacant Vacant 8020941/12O9/2019-08-05 | SICK O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning Subject to change without notice...

  • Page 28: Interfaces And Signals

    This allows for cable breaks and the like to be detected. O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning 8020941/12O9/2019-08-05 | SICK Subject to change without notice...

  • Page 29: Ssi Interface

    The interface for OLM 2 is set to 167 kBaud. The process controller SSI interface requires a 120 ohm terminator. 8020941/12O9/2019-08-05 | SICK O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning...

  • Page 30: Signal For Pds (Sr) - Drive (Safety-Related)

    O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning 8020941/12O9/2019-08-05 | SICK Subject to change without notice...

  • Page 31: Safe Sls Request Signal

    An automated restart must only be performed if there is no risk of a hazardous situa‐ tion. 8020941/12O9/2019-08-05 | SICK O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning...

  • Page 32: Configuration

    If additional functions are to be added to the software, this is only possible outside of the certified part of the software. For this purpose, APIs can be found in the safety application software supplied by SICK. For further details on using these APIs for modu‐ lar extension and modification, see "Expanding and modifying the safety system",...

  • Page 33: Pre-Configured Project Files

    BG100.2 OLM sensor 2 as SSI master 24+1 bit Checksum 0xABCCACFD 8020941/12O9/2019-08-05 | SICK O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning Subject to change without notice...
  • Page 34 BG100.2 OLM sensor 2 as SSI master 31+1 bit Checksum 0x40B50E17 O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning 8020941/12O9/2019-08-05 | SICK Subject to change without notice...

  • Page 35: Configuring The Interface For Bg100 Motion Sensor

    • Input ENC2 = OLM sensor 2 8020941/12O9/2019-08-05 | SICK O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning Subject to change without notice...
  • Page 36 ENC1 input of the MOC1 module. Double-click on the SSI symbol to open up the element settings. O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning 8020941/12O9/2019-08-05 | SICK Subject to change without notice...

  • Page 37: Configuring Speed Limits

    Figure 7: Settings window for Position Monitor function block 8020941/12O9/2019-08-05 | SICK O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning Subject to change without notice...
  • Page 38 10 speed ranges. The lowest speed limit (speed limit 1) is always the standstill speed. O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning 8020941/12O9/2019-08-05 | SICK Subject to change without notice...
  • Page 39 10 mm (this is a default setting). 8020941/12O9/2019-08-05 | SICK O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning...

  • Page 40: Configuring Position Ranges

    Ranges requiring a safely limited speed to be monitored must be defined. O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning 8020941/12O9/2019-08-05 | SICK Subject to change without notice...

  • Page 41: Assigning Maximum Speeds To The Position Ranges

    The maximum possible measuring range of the respective sensor unit must be taken into account too. Larger position values are not permitted. Table 34: Maximum position range depending on sensor unit OLM100 Hi, part number OLM100 Hi, part number 1087575...

  • Page 42: Configuring Safe Cam (Sca)

    This is shown in the following figure: Figure 11: Safe cam setting range O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning 8020941/12O9/2019-08-05 | SICK Subject to change without notice...
  • Page 43 Figure 12: Safe cam setting range for a storage and retrieval system 8020941/12O9/2019-08-05 | SICK O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning...
  • Page 44 Figure 14: Safe cam setting range for a range with a safely limited speed (SLS) O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning 8020941/12O9/2019-08-05 | SICK Subject to change without notice...

  • Page 45: Configuring Stop Ramps

    2 (SS2) or in order to reset the func‐ tion block after a fault has occurred. 8020941/12O9/2019-08-05 | SICK O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning...
  • Page 46 The screenshot below shows the standard configuration, with ramp monitoring deactivated. O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning 8020941/12O9/2019-08-05 | SICK Subject to change without notice...
  • Page 47 Safe Stop 2 function. Figure 17: Standstill Monitoring function block 8020941/12O9/2019-08-05 | SICK O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning Subject to change without notice...
  • Page 48 Otherwise, the operator of the machine will be put at risk. O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning 8020941/12O9/2019-08-05 | SICK Subject to change without notice...

  • Page 49: Expanding And Modifying The Safety System

    • Example: additional Safe Stop 1 requirement 8020941/12O9/2019-08-05 | SICK O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning Subject to change without notice...
  • Page 50 Further topics • "Extension and modification", page 19 O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning 8020941/12O9/2019-08-05 | SICK Subject to change without notice...

  • Page 51: External And Internal Signal For Activating The Safely Limited Speed

    The lowest speed ID (either from the Speed/Position Profile function block or the Speed Enable ID input) always has priority. 8020941/12O9/2019-08-05 | SICK O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning...

  • Page 52: Configuring The Override Function

    If an override function is used, the Override request jump address must be used. O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning 8020941/12O9/2019-08-05 | SICK Subject to change without notice...

  • Page 53: Controlling The Safety Outputs Directly Via Plc

    Jump addresses provide internal status information that can be used in the application. 8020941/12O9/2019-08-05 | SICK O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning...

  • Page 54: Contents Of The Cpu Logic

    This page contains the disclaimer, the version number, and a short description of the application. O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning 8020941/12O9/2019-08-05 | SICK Subject to change without notice...

  • Page 55: Interface Page

    NOTE This page is protected with a password and cannot be configured. 8020941/12O9/2019-08-05 | SICK O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning...
  • Page 56 Figure 28: Function block view - Safe Stop reset SAPP-FB O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning 8020941/12O9/2019-08-05 | SICK Subject to change without notice...

  • Page 57: Safe Position And Diagnostics Page

    Plausibility test SAPP-FB function block Figure 30: Function block view - Plausibility test SAPP-FB 8020941/12O9/2019-08-05 | SICK O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning...
  • Page 58 Sensor2_test_active jump address from Sensor2 test SAPP-FB output O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning 8020941/12O9/2019-08-05 | SICK Subject to change without notice...
  • Page 59 This function block collates requests for the evaluation of the safe position and gener‐ ates the Safe Position signal. 8020941/12O9/2019-08-05 | SICK O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning...
  • Page 60 If the voltage supply to the Flexi Soft safety controller is interrupted, this text message will be lost. O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning 8020941/12O9/2019-08-05 | SICK Subject to change without notice...

  • Page 61: Stop/Start/Reset Page

    8020941/12O9/2019-08-05 | SICK O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning...
  • Page 62 • "Configuring additional safety functions", page 49 O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning 8020941/12O9/2019-08-05 | SICK Subject to change without notice...
  • Page 63 • "Configuring additional safety functions", page 49 8020941/12O9/2019-08-05 | SICK O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning Subject to change without notice...

  • Page 64: Contents Of The Motion Control Logic

    The purpose of this function block is to cross-check the speed. O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning 8020941/12O9/2019-08-05 | SICK Subject to change without notice...
  • Page 65 Inhibiting the Diagnostics function block during internal tests Figure 42: Function block view - Inhibit_Error_Message signal 8020941/12O9/2019-08-05 | SICK O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning...

  • Page 66: Position_Monitor Page

    1 can have two values (depending on input 4). O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning 8020941/12O9/2019-08-05 | SICK Subject to change without notice...
  • Page 67 (1 = valid/0 = invalid). The status bit is forwarded to the CPU logic. 8020941/12O9/2019-08-05 | SICK O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning...
  • Page 68 The status bit of sensor 1 is forwarded to the CPU logic. O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning 8020941/12O9/2019-08-05 | SICK Subject to change without notice...

  • Page 69: Safe Stop Page

    Enable torque • Enable brake • Stop request 8020941/12O9/2019-08-05 | SICK O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning Subject to change without notice...
  • Page 70 The screenshot below shows the standard configuration, with ramp monitoring deacti‐ vated. O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning 8020941/12O9/2019-08-05 | SICK Subject to change without notice...

  • Page 71: Notes On The Flexi Soft Logic Editor

    In the Delete page dialog box, click on the Yes button. ✓ The link is deleted. 8020941/12O9/2019-08-05 | SICK O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning Subject to change without notice...

  • Page 72: Jump Addresses

    Transmit configuration to the Flexi Soft main module (see operating instructions 8012998). O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning 8020941/12O9/2019-08-05 | SICK Subject to change without notice...

  • Page 73: Commissioning

    8020941/12O9/2019-08-05 | SICK O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning...

  • Page 74: Operating The Components

    Information is included in the operating instructions for the components. O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning 8020941/12O9/2019-08-05 | SICK Subject to change without notice...

  • Page 75: Maintenance Of The Components

    NOTE Information is included in the operating instructions for the components. 8020941/12O9/2019-08-05 | SICK O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning Subject to change without notice...

  • Page 76: Troubleshooting

    Individual sensors may not be exchanged. The sensor unit may only ever be repaired by the SICK Service team. O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning...

  • Page 77: Decommissioning

    (particularly pre‐ cious metals). 8020941/12O9/2019-08-05 | SICK O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning...

  • Page 78: Technical Data

    The external supply voltage must jumper a brief power failure of 20 ms as specified in IEC 60204-1. Suit‐ able power supply units are available as accessories from SICK. O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning...

  • Page 79: Xtio Module Inputs

    Further technical data can be found in the “Flexi Soft Modular Safety Controller Hard‐ ware” operating instructions. 8020941/12O9/2019-08-05 | SICK O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning...

  • Page 80: Dimensional Drawings

    Dimensional drawings 206 ±0.2 88 ±1 190 ±0.2 Figure 49: Dimensional drawing for the OLM100 Hi on a mounting plate 13.4 Response times Overrun for the entire system The overrun for the entire system is made up of at least two phases.

  • Page 81: Stopping Time In The Event Of A Drive Fault

    In this document, the stopping time is calculated on the basis of a standard cycle time of 8 ms. 8020941/12O9/2019-08-05 | SICK O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning...

  • Page 82: Maximum Data Reception Interval

    O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning 8020941/12O9/2019-08-05 | SICK Subject to change without notice...

  • Page 83: Ordering Information

    1 x X-junction (part number 2097764) The main module and system plug must be ordered separately. 8020941/12O9/2019-08-05 | SICK O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning...

  • Page 84: Spare Parts

    Sensor unit, resolution 0.01 mm, SSI 32 bit 1090629 X-junction 2097764 O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning 8020941/12O9/2019-08-05 | SICK Subject to change without notice...

  • Page 85: Accessories

    6049328 Connection cable, 10 meters DSL-1208-B05MASCO 6049329 8020941/12O9/2019-08-05 | SICK O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning Subject to change without notice...

  • Page 86: Annex

    Flexi Soft hardware. sheet). O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning 8020941/12O9/2019-08-05 | SICK Subject to change without notice...

  • Page 87: Thorough Check Of The Hardware Requirements

    (SLS). 8020941/12O9/2019-08-05 | SICK O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning Subject to change without notice...

  • Page 88: Thorough Check Of The Flexi Soft Configuration

    O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning 8020941/12O9/2019-08-05 | SICK Subject to change without notice...

  • Page 89: Thorough Check Of The Flexi Soft Documentation

    The checksum of the verified Flexi Soft program has been determined. CRC: 8020941/12O9/2019-08-05 | SICK O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning Subject to change without notice...

  • Page 90: Thorough Check On The Process Channel (Standstill)

    Then you must reset the safety system and carry out a restart. O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning 8020941/12O9/2019-08-05 | SICK Subject to change without notice...

  • Page 91: Thorough Check On The Process Channel (Backward Move- Ment)

    Set test signal 2 “backward” to active (XTIO input I2). 8020941/12O9/2019-08-05 | SICK O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning Subject to change without notice...

  • Page 92: Thorough Check Of The Safety Functions

    Then you must reset the safety system and carry out a restart. O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning 8020941/12O9/2019-08-05 | SICK Subject to change without notice...

  • Page 93: Thorough Check For Foreseeable Misuse And Manipulation

    The bar code tape is not contami‐ nated in any way. 8020941/12O9/2019-08-05 | SICK O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning Subject to change without notice...
  • Page 94 Yes ⃞ No ⃞ • Check the cable laying. The approved X-junction and, if required, the permitted connection cables from SICK are the only options that can be used for electri‐ cally connecting the OLM sensors. • The X-junction is wired from the...
  • Page 95 Specify a responsible party. Check interval: Responsible party: 8020941/12O9/2019-08-05 | SICK O P E R A T I N G I N S T R U C T I O N S | Safe Linear Positioning Subject to change without notice...
  • Page 96 E-Mail office@sick.com.gr E-Mail info@sick.ru Vietnam Hong Kong Singapore Phone +65 6744 3732 Phone +852 2153 6300 Phone +65 6744 3732 E-Mail sales.gsg@sick.com E-Mail ghk@sick.com.hk E-Mail sales.gsg@sick.com Detailed addresses and further locations at www.sick.com SICK AG | Waldkirch | Germany | www.sick.com...

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