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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

safeRS3

Safe Radar System

Summary of Contents for safeRS3

Page 1: ...OPERATING INSTRUCTIONS safeRS3 Safe Radar System...

Page 2: ...y 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...

Page 3: ...he restart prevention function 15 3 1 9 Responsibility 15 3 1 10 Limits 15 3 1 11 Disposal 16 3 2 Conformity 16 3 2 1 Standards and Directives 16 3 2 2 CE 16 3 2 3 Other conformities and national conf...

Page 4: ...iguration 33 4 7 1 System configuration 33 4 7 2 Dynamic system configuration 33 4 7 3 Dynamic system configuration activation 34 4 7 4 Dynamic configuration through the digital inputs 34 4 7 5 Dynami...

Page 5: ...7 5 9 3 Muting activation conditions 48 5 9 4 Enable muting signal characteristics 49 5 9 5 Muting status 49 5 10 Anti tampering functions anti rotation around axes 49 5 10 1 Anti rotation around axes...

Page 6: ...evention of unexpected restart 61 6 6 5 Recommendations for positioning the sensor 61 6 7 Outdoor installations 62 6 7 1 Position exposed to precipitation 62 6 7 2 Recommendations for covering the sen...

Page 7: ...or 78 7 5 6 Change network parameters 78 7 5 7 Change Modbus parameters 78 7 5 8 Change Fieldbus parameters 78 8 Maintenance and troubleshooting 79 8 1 Troubleshooting 79 8 1 1 Control LED 79 8 1 2 Se...

Page 8: ...MUNICATION ERROR 92 8 4 10 Input redundancy error INPUT REDUNDANCY ERROR 92 8 4 11 Fieldbus error FIELDBUS ERROR 92 8 4 12 RAM error RAM ERROR 93 8 4 13 Sensor configuration errors SENSOR CONFIGURATIO...

Page 9: ...l emergency button 106 9 3 4 Connection of restart signal 107 9 3 5 Connection of the muting input and output one group of sensors 108 9 3 6 Connection of the muting input and output two groups of sen...

Page 10: ...ry These devices systems cause the machine or plant system to switch over to a safe status before a person is exposed to a dangerous situation Field of view Sensor area of vision characterized by a sp...

Page 11: ...its delivery to decommissioning It must be stored so that it is accessible to operators in a clean location and in good condition In the event of manual loss or damage contact Technical Support Alway...

Page 12: ...1 SICK Subject to change without notice 2 THIS MANUAL 2 1 4 Intended users of this instruction manual The recipients of the instruction manual are l The machinery manufacturer onto which the system wi...

Page 13: ...s The recipients of this manual and the skills required for each activity presented herein are as follows Recipient Assignments Skills Machinery manufacturer l Defines which protective devices should...

Page 14: ...inery Detection of motion within the dangerous area maintains the safety outputs deactivated to prevent machinery starting It performs the following optional safety functions l Stop signal force all t...

Page 15: ...compatible with the requirements set forth in the risk assessment l Check that the temperature of the areas where the system is stored and installed is compatible with the storage and operating temper...

Page 16: ...AC 2010 SIL 2 EN ISO 13849 1 2015 PL d EN ISO 13849 2 2012 IEC EN 61496 1 2013 IEC EN 61508 2010 Part 1 7 SIL 2 IEC EN 61000 6 2 2019 ETSI EN 305 550 1 V1 2 1 ETSI EN 305 550 2 V1 2 1 ETSI EN 301 489...

Page 17: ...product conformities and any national configurations please refer to the National configuration addendum document The PDF can be downloaded from the site www sick com 3 SAFETY 8027489 2022 03 01 SICK...

Page 18: ...following l detection of current distance and angle of the targets detected by each sensor l up to four safe protective fields to define different behaviors of the machines l programmable coverage ang...

Page 19: ...FINET is provided with a safety communication on a Fieldbus interface The Fieldbus interface allows safeRS3 Control PROFINET to communicate in real time with the PLC of the machinery in order to do th...

Page 20: ...es available l safeRS3 Control PROFINET two Ethernet ports for Fieldbus an Ethernet port for system configuration and Modbus communication and a micro USB port l safeRS3 Control I O a micro USB port S...

Page 21: ...utton safeRS3 Control PROFINET safeRS3 Control I O E Micro USB port for connecting the PC and communicating with the safeRS3 Designer application safeRS3 Control PROFINET safeRS3 Control I O F Micro U...

Page 22: ...ontrol I O N Ethernet Fieldbus port n 1 with LEDs safeRS3 Control PROFINET O Ethernet Fieldbus port n 2 with LEDs safeRS3 Control PROFINET 4 2 4 System status LEDs The LEDs are each dedicated to a sen...

Page 23: ...tion The available functions are the following l Stop signal optional safety function manages a specific signal to force all the safety outputs detection signals if present to OFF state l Restart sign...

Page 24: ...er up the initial values set to 0 are used for the input variables the system remains in a safe state with the OSSDs deactivated until the input data are passivated 4 2 8 SNS input The control also ha...

Page 25: ...re The selected output remains in OFF state for at least 100 ms Note when an OSSD is configured as detection signal 4 a second OSSD is automatically assigned to it to provide a safe signal l Fieldbus...

Page 26: ...following l activated output 24 V DC no motion detected and normal functioning l deactivated output 0 V DC motion detected in the protective field or failure detected in the system Idle signal is 24 V...

Page 27: ...perform the following functions l Detect motion in their field of view l Send the motion detection signal to the control through CAN bus l Signal to the control through CAN bus the failures or faults...

Page 28: ...ition the sensor at a specific angle around x axis tilt 10 steps D Mounting bracket E Tamper proof screw to position the sensor at a specific angle around y axis pan 10 steps F Connectors for connecti...

Page 29: ...ows Available functions Access type l Display the system status Dashboard l Display the sensors configuration Configuration l Restore factory default settings if not using Ethernet connection Settings...

Page 30: ...nsors Choose the protective fields dependency Enable the anti tampering functions Synchronize more controls Configure the inputs and outputs function Configure show and change the network parameters i...

Page 31: ...Sensor l status of each protective field target detected or not or error status l muting status from the control Safe SYSTEM SETTING COMMAND safeRS3 Control PROFINET l set the ID of the dynamic confi...

Page 32: ...us Parameters ON to enable the feature Within the Ethernet network the control acts like a server The client must send requests to the IP address of the server on the Modbus listening port default por...

Page 33: ...nt of the most important system parameters providing the means to switch dynamically among different preset configurations Via the safeRS3 Designer application once the first system configuration defa...

Page 34: ...be used The result is the following If Then it is possible to dynamically switch between only one digital input is used for the dynamic configuration two preset configurations see Example 1 below and...

Page 35: ...lease refer to the Fieldbus manual WARNING Before activating the dynamic system configuration through the safety Fieldbus ensure it has not already been activated through the digital inputs If the act...

Page 36: ...eater the surface exposed to the radar the greater the reflected signal l position with respect to the sensor all other factors being equal objects positioned directly in front of the radar generate a...

Page 37: ...e The angular coverage has a fixed value in a range from 10 to 100 The angular coverage of the protective field must be wider than or equal to the angular coverage of the following protective fields 5...

Page 38: ...dent mode is set and thus protective fields are dependent on each other if a sensor detects motion within a protective field all the outputs related to the following protective fields are also deactiv...

Page 39: ...tes a detection signal for target A but target B could not be detected In the safeRS3 Designer application click on Settings Sensors Protective field dependency to set the dependency mode of the prote...

Page 40: ...ent before deciding to ignore the detection signal of the protective field 1 WARNING The blind area generated by the moving robotic arm can prevent the sensor from detecting targets in the following o...

Page 41: ...re deactivated l the restart prevention function is activated 5 4 3 Safety function restart prevention The restart prevention function remains active and the safety outputs deactivated as long as moti...

Page 42: ...function access detection This is the only safety function available for the Always access detection Access detection allows what follows When Then no motion is detected in the protective field the s...

Page 43: ...the system reaction to vibrating and moving parts is different WARNING When the restart prevention function is active the monitored area may be affected by the position and inclination of the sensors...

Page 44: ...system would never reactivate the detection signals after a motion is detected in the area The option is active in the protective field area defined by the angular coverage and detection distance set...

Page 45: ...are no restrictions does the function ensure that a person is detected when standing up D 5 8 2 Types of managed restart NOTICE It is the responsibility of the machinery manufacturer to assess if auto...

Page 46: ...motion detection1 and 2 the status of the restart signal indicates that the restart is now possible see Restart signal on page 116 Both default and Always restart prevention Note1 machinery restart is...

Page 47: ...anual 2 If there is a digital input configured as Restart signal Settings Digital Input Output connect the machinery button for the restart signal as convenient see Electrical connections on page 104...

Page 48: ...ing function is enabled for one sensor it is enabled for all the protective fields of the sensor regardless the protective fields are dependent or independent and the anti tampering functions are disa...

Page 49: ...gic level 1 to enable muting 5 9 5 Muting status Any output dedicated to the muting status Muting enable feedback signal is activated if at least one of the groups of sensors is in muting NOTICE It is...

Page 50: ...rotation around axes function is disabled below WARNING Take precautions to prevent tampering if the function is disabled for one axis and if the rotation around that axis is not protected with tamper...

Page 51: ...ystem configuration must be saved again Note It is recommended to start the memorization process after at least 3 minutes from turning on the system to guarantee that the sensor has reached the operat...

Page 52: ...re masking is likely to occur only if voluntary Low The system detects masking only if the sensor occlusion is complete and the objects are highly reflective e g metal water near the sensor Installati...

Page 53: ...redictable positions l the monitored area includes moving parts that vary their position while the sensors are in muting l the sensor is positioned on a part that can be moved l the presence of static...

Page 54: ...round or reference plane of the sensor 6 1 3 Sensor inclination Sensor inclination is the rotation of the sensor around its x axis Inclination is defined as the angle between a line perpendicular to t...

Page 55: ...that influence the reflected signal on page 36 6 2 3 Dimensions for the access detection function Note the tolerance area dimensions described are related to the detection of humans The tolerance are...

Page 56: ...n of the field of view The field of view is shifted of 2 5 To understand the actual position of the sensor field of view consider the LED position l downward with sensor LED up l right with sensor LED...

Page 57: ...depth of the dangerous area S use the following formula Where Variable Description Value Measurement unit K Maximum dangerous area access speed 1600 mm s T Total system stopping time safeRS3 machiner...

Page 58: ...Detection distance linear Must be within the range of distances allowed see Installation configurations below m Dalarm Detection distance real m D1 Start detection distance for configuration 2 and 3 e...

Page 59: ...function Below are some recommendations for the sensor positioning for the access detection function l if the distance between the ground and the bottom portion of the field of view is greater than 3...

Page 60: ...Below is an example 6 6 Installations on moving elements 6 6 1 Introduction safeRS3 Sensor can be mounted on moving vehicles or moving parts of the machinery The characteristics of the protective fie...

Page 61: ...ccur when the static object will be close enough to limit the detection of the sensor Note if the anti masking function is active when the sensor is moving also this could generate false alarms since...

Page 62: ...utions l make a cover to protect the sensor from rain hail or snow l position the sensor so that it does not frame the ground where puddles might form 6 7 2 Recommendations for covering the sensor Bel...

Page 63: ...on If the installation position of the sensor is not exposed to precipitation no special precautions are required 6 SENSOR POSITION 8027489 2022 03 01 SICK Subject to change without notice O P E R A T...

Page 64: ...fails the dependencies needed by the application may be missing Update your operating system or contact our Technical Support team to receive assistance 1 Download the application from the www sick c...

Page 65: ...on page 102 and Electrical connections on page 104 NOTICE If at least one input is connected the SNS input V SNS and the GND input V SNS must also be connected NOTICE When powered the system takes ab...

Page 66: ...uration 2 Add the desired number of sensors in the plane 3 Define the position and inclination of each sensor 4 Define the selected safety working modes the detection distance the angular coverage and...

Page 67: ...rectly onto the floor or another support NOTICE Make sure the support does not inhibit machinery commands 2 With an Allen key loosen the screw at the bottom to pan the sensor 3 Pan the sensor until it...

Page 68: ...1 SICK Subject to change without notice 7 INSTALLATION AND USE PROCEDURES 5 Loosen the tamper proof screws to tilt the sensor 6 Direct the sensor up to the desired inclination see Sensor position on p...

Page 69: ...1 Unscrew the screw at the bottom and remove the bracket with the sensor and the aligning ring 2 Attach the roll bracket to the base Use the tamper proof screw provided with the bracket 3 Mount the br...

Page 70: ...e without notice 7 INSTALLATION AND USE PROCEDURES 7 2 7 Examples of sensor installation NOTICE Refer to the sensor LED position to identify the sensor field of view see Position of the field of view...

Page 71: ...art a second chain 5 Repeat step 4 for all the sensors to be installed 6 Insert the bus terminator product code 6073830 into the free connector of the last sensor of the chain s 7 2 9 Assign the Node...

Page 72: ...he unassigned Node ID in the Configured sensors list 3 To change a Node ID click Change for the already assigned Node ID in the Configured sensors list 4 Select the SID of the sensor and confirm autom...

Page 73: ...safeRS3 Designer application facilitates installation and configuration of the system but the validation process described below is still required 7 3 2 Validate the access detection function Example...

Page 74: ...and the limit areas e g intersection with any side guards see Example of access points below l Access standing as well as crawling l Access moving slowly and quickly 7 3 3 Example of access points Acc...

Page 75: ...the safety outputs do not remain deactivated see Troubleshooting validation on the next page 7 3 5 Example of stopping points Stopping points for 100 field of view 7 3 6 Validate the system with safe...

Page 76: ...meout Change the restart timeout through the safeRS3 Designer application Configuration select the affected sensor and protective field 7 4 Manage the configuration 7 4 1 Configuration reports After c...

Page 77: ...ttings General click BACKUP 2 Select the file destination and save 7 4 4 Load a configuration 1 In Settings General click RESTORE 2 Select the previously saved cfg file see Back up the configuration a...

Page 78: ...status The configuration must be validated and if necessary modified through the safeRS3 Designer application by clicking APPLY CHANGES For the default values of the parameters see Parameters on page...

Page 79: ...at the system is operating at the correct operating temperature see General specifications on page 96 S3 Steady red OSSD ERROR or INPUT REDUNDANCY ERROR At least one input or output is in error If at...

Page 80: ...D Check the preset configurations within the safeRS3 Designer application S1 S4 together Steady red SENSOR CONFIGURATION ERROR Error during the configuration of the sensors Check the sensors connected...

Page 81: ...URE ERROR or SENSOR POWER ERROR Sensor in temperature error or is receiving an incorrect supply voltage Check the sensor connection and that the cable length is within the maximum limits Verify that t...

Page 82: ...oximity to the protective field Change the sensors sensitivity Change the configuration on page 76 Machinery in safe status without motion in the protective field No power supply Check electrical conn...

Page 83: ...ile log is divided in two sections Section Description Content Size Reset 1 Event log Information events Error events 3500 On demand using the safeRS3 Designer application 2 Diagnostic event log Error...

Page 84: ...t of the device it is provided as relative time from the latest boot Format Rel x d hh mm ss Example Rel 0 d 00 01 32 Note when a new system configuration is performed even the older timestamps are up...

Page 85: ...ion access field 2 3100 mm 20 61 Rel 0 d 00 01 01 INFO SENSOR 1 Detection access field 1 1200 mm 30 0 Rel 0 d 00 00 00 INFO CONTROL Dynamic configuration 1 0 0 d 00 00 00 INFO CONTROL System Boot 61 S...

Page 86: ...the events are logged in accordance to the following table Event Level 0 default Level 1 Level 2 Level 3 Level 4 Level 5 Diagnostic errors x x x x x x System Boot x x x x x x System configuration x x...

Page 87: ...and protective field at exit Format CONTROL k Detection access field n distance mm azimuth SENSOR k Detection access distance mm azimuth CONTROL Detection exit field n SENSOR k Detection exit 8 3 INF...

Page 88: ...gnal is received the event is logged as WAITING or RECEIVED Format Restart signal WAITING RECEIVED Example 20 2020 11 18 16 47 25 INFO CONTROL Restart signal RECEIVED 8 3 6 Detection access Every time...

Page 89: ...as disabled or enabled Note the event indicates a change of the muting status of the system It does not correspond to the muting request Format Muting disabled enabled Example 20 2020 11 18 16 47 25...

Page 90: ...Session OPEN via USB 8 3 13 Validation Every time a validation activity starts or ends on the device it is logged The interface used USB ETH is logged as well Format Validation STARTED ENDED via USB E...

Page 91: ...Inputs reference voltage VSNS Error ADC Analog digital converter 8 4 4 Peripheral error PERIPHERAL ERROR Error detected by diagnostics relative to the micro controller its internal peripherals or memo...

Page 92: ...circuit error between MOS output 2 and 4 OSSD 3 4 CROSS CHECK Short circuit error between MOS output 3 and 4 8 4 7 Flash errors FLASH ERROR A flash error represents an error on the external flash 8 4...

Page 93: ...om the control 8 5 3 Status error and fault STATUS ERROR FAULT ERROR The status error occurs when the sensor is in an internal invalid status or it has reached an internal fault condition 8 5 4 Protoc...

Page 94: ...reference SIGNAL PATTERN ERROR Radar internal fault or unexpected signal pattern 8 5 8 Temperature errors TEMPERATURE ERROR Error Meaning BOARD TEMPERATURE TOO LOW Board temperature below minimum BOAR...

Page 95: ...COL ERROR Control and sensors have different and incompatible firmware versions POLLING TIMEOUT Timeout on data polling 8 7 Cleaning and spare parts 8 7 1 Cleaning Keep the sensor clean and free of an...

Page 96: ...nd 20 vertical plane Decision probability 1 2 5E 07 CRT Certified Restart Timeout 4 s Guaranteed response time 100 ms Total consumption 33 W controland six sensors Electrical protections Polarity inve...

Page 97: ...ity of skilled personnel adequate tools and spare parts Considering the type of device the MRT corresponds to the time necessary for the device replacement 9 1 3 Ethernet connection if available Defau...

Page 98: ...emperature From 30 to 60 C from 22 to 140 F Storage temperature From 40 to 80 C from 40 to 176 F Note1 the unit shall be supplied by an isolated power source which fulfils the requirements of l Limite...

Page 99: ...e 4 Outdoor use Yes Operating temperature From 30 to 60 C from 22 to 140 F Storage temperature From 40 to 80 C from 40 to 176 F 130 158 85 85 71 135 107 4 132 2 85 85 130 158 9 TECHNICAL REFERENCES 80...

Page 100: ...N bus on page 103 Connectors shall be type 3 raintight Impedance 120 12 f 1 MHz Shield Shield with twisted wires in tin plated copper To be connected to ground circuit on the power supply terminal blo...

Page 101: ...7 6 mm 0 30 in k 3 mm 0 11 in s 2 5 mm 0 10 in d3 4 mm 0 15 in 9 1 9 Bottom screws specifications The bottom screws can be l cheese head l button head Note Avoid using countersunk head screws 9 TECHNI...

Page 102: ...stics of the digital inputs mandatory if at least one input is used 5 V V SNS common reference for all digital inputs mandatory if at least one input is used 6 Digital Out GND common reference for all...

Page 103: ...rminal block Symbol Description 12 V DC output H CAN H L CAN L GND Note the maximum operating temperature of the cables must be at least 70 C 9 2 5 Connectors M12 CAN bus 2 1 4 3 5 Male connector 2 1...

Page 104: ...ical connections 9 3 1 Connection of safety outputs to the machinery control system Digital I O settings through the safeRS3 Designer application Digital input 1 Not configured Digital input 2 Not con...

Page 105: ...ital input 1 Not configured Digital input 2 Not configured Digital output 1 Detection signal 1 Digital output 2 Detection signal 1 Digital output 3 Not configured Digital output 4 Not configured 9 TEC...

Page 106: ...cated emergency button opens the contact when pressed Note the cables used for wiring the digital inputs must have a maximum length of 30 m 98 4 ft Digital I O settings through the safeRS3 Designer ap...

Page 107: ...tart signal closes the contact when pressed Note the cables used for wiring the digital inputs must have a maximum length of 30 m 98 4 ft 9 TECHNICAL REFERENCES 8027489 2022 03 01 SICK Subject to chan...

Page 108: ...one group of sensors Note the cables used for wiring the digital inputs must have a maximum length of 30 m 98 4 ft Digital I O settings through the safeRS3 Designer application Digital input 1 Not con...

Page 109: ...gs through the safeRS3 Designer application Digital input 1 Muting group 1 Digital input 2 Muting group 2 Digital output 1 Not configured Digital output 2 Not configured Digital output 3 Not configure...

Page 110: ...CHNICAL REFERENCES 9 3 7 Detection signal 2 connection Digital I O settings through the safeRS3 Designer application Digital input 1 Not configured Digital input 2 Not configured Digital output 1 Not...

Page 111: ...configured Digital output 3 Not configured Digital output 4 System diagnostic signal 9 4 Parameters 9 4 1 Parameter list Parameter Min Max Default value Settings Account Password Not available Setting...

Page 112: ...f all the detection distances for each sensor must not exceed 5000 mm 0 mm Angular coverage 10 100 100 Safety working mode for each protective field of each sensor Both default Always access detection...

Page 113: ...synchronization Control channel 0 3 0 Settings Activity History Log verbosity level 0 5 0 Settings Network Parameters IP Address 192 168 0 20 Netmask 255 255 255 0 Gateway 192 168 0 1 TCP port for con...

Page 114: ...l input signals 9 5 1 Stop signal Part Description Detection signal 1 Detection signal 2 Both deactivate on the falling edge of at least one of the two input channels of the input signal They remain i...

Page 115: ...thout pulse enabled as long as both channels are at a high logic level 1 and deactivated when both channels go to low logic level 0 l With pulse enabled as long as both the input signals follow the co...

Page 116: ...tate as soon as the last channel has correctly completed the transition 0 1 0 Restart signal CH1 Restart signal CH2 Interchangeable channel Both channels of Restart signal must have a transition of lo...

Page 117: ...nd the system deactivates the safety outputs Dynamic configuration number See Dynamic configuration through the digital inputs on page 34 Dt Activation deactivation delay Less than 50 ms 9 TECHNICAL R...

Page 118: ...on can be performed by means of a PC based configuration tool called the safeRS3 Designer application The system configuration is described in Installation and use procedures on page 64 10 1 3 Compete...

Page 119: ...ucts as well as other electrical and electronic equipment through specific waste collection facilities indicated by the government or local public authorities Correct disposal and recycling will contr...

Page 120: ...8080 7425 E Mail enquiry my sick com Mexico Phone 52 472 748 9451 E Mail mexico sick com Netherlands Phone 31 0 30 229 25 44 E Mail info sick nl New Zealand Phone 64 9 415 0459 0800 222 278 tollfree...

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