SICK sBot Stop Operating Instructions Manual Download | Manualshive

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About this document

1.1

Purpose of this document

These operating instructions contain the information required during the life cycle of the
safety system. This document describes:

•

The individual components

•

The project planning

•

The mounting and electrical installation, insofar as special measures are neces‐
sary for the safety system

•

The configuration

•

The necessary thorough checks

•

The commissioning

•

The maintenance

•

The troubleshooting

1.2

Scope

These operating instructions contain information regarding the sBot Stop safety system.

NOTICE

The operating instructions of the components also apply.
The relevant information must be made available to the employees for all work per‐
formed on the safety system.

The following documents contain additional information regarding the sBot Stop safety
system:

Table 1: Available documents

Document type

Title

Part number

Operating instructions

microScan3 Core I/O

8016344

Operating instructions

S300 Mini Standard

8014166

Operating instructions

deTec4 Core

8014251

Operating instructions

deTem4 Core

8020445

Operating instructions

S3000 Standard

8009791

Operating instructions

Flexi Classic
Modular safety controller

8011562

This document is included with the following SICK part numbers (this document in all
available language versions):

8023419

1.3

Target groups and structure of these operating instructions

These operating instructions are intended for the following target groups: project devel‐
opers (planners, developers, designers, integrators), installers, electricians, safety
experts (such as CE authorized representatives, compliance officers, people who test
and approve the application), operators, and maintenance personnel.

These operating instructions are organized by the life phases of the device: project
planning, mounting, electrical installation, commissioning, operation and maintenance.

This safety system can be integrated as presented or together with other components.

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ABOUT THIS DOCUMENT

6

O P E R A T I N G I N S T R U C T I O N S | sBot Stop

8023421/12KF/2019-01-22 | SICK

Subject to change without notice

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Summary of Contents for sBot Stop

Page 1: ...O P E R A T I N G I N S T R U C T I O N S sBot Stop Safety system ...

Page 2: ...ible 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 2 O P E R A T I N G I N S T R ...

Page 3: ...s 17 3 6 1 Protective field types 17 3 6 2 Safety Functions 18 3 7 Additional components required 21 3 7 1 Emergency stop pushbutton requirements 21 3 7 2 Reset pushbutton requirements 22 3 7 3 Robot controller requirements 22 3 7 4 Physical guard 23 4 Project planning 24 4 1 Manufacturer of the machine 24 4 1 1 Notes on automated restart 24 4 1 2 Reference standards 24 4 1 3 Quantification of com...

Page 4: ...1 7 2 1 Configuring the Flexi Classic safety controller 41 7 2 2 Configuring the safety laser scanner 42 8 Commissioning 46 8 1 Safety 46 8 2 Thorough check 46 9 Operation 47 9 1 Start sequence after start up 47 10 Maintenance 48 10 1 Regular thorough check 48 11 Troubleshooting 50 12 Technical data 51 12 1 Data sheet 51 12 2 Response time 51 13 Ordering information 52 13 1 Scope of delivery 52 13...

Page 5: ...oning and commissioning 56 16 2 Requirements for automated restart 58 16 3 Overview of sensors and actuators 59 CONTENTS 8023421 12KF 2019 01 22 SICK O P E R A T I N G I N S T R U C T I O N S sBot Stop 5 Subject to change without notice ...

Page 6: ...tructions S300 Mini Standard 8014166 Operating instructions deTec4 Core 8014251 Operating instructions deTem4 Core 8020445 Operating instructions S3000 Standard 8009791 Operating instructions Flexi Classic Modular safety controller 8011562 This document is included with the following SICK part numbers this document in all available language versions 8023419 1 3 Target groups and structure of these...

Page 7: ...ed NOTICE Indicates a situation presenting possible danger which may lead to property damage if not prevented NOTE Indicates useful tips and recommendations Instructions to action b The arrow denotes instructions to action 1 The sequence of instructions for action is numbered 2 Follow the order in which the numbered instructions are given The check mark denotes the result of an instruction 1 5 Fur...

Page 8: ...ion The robot works at a fixed position The danger results from the movement of the robot arm mechanical hazard The only access to the robot is protected by the primary protective device e g safety light curtain The protective field of the safety laser scanner must be able to cover the entire hazardous area secondary protective device It is ensured that it is not possible to bypass the protective ...

Page 9: ...vice and the protective field of the safety laser scanner are clear the robot can move In this case the movement of the robot is not prevented by this safety system The manufacturer and operator must be aware of this residual risk and bear the responsibility for it 2 4 Identifying hazards This safety system is intended to reduce mechanical hazards in accordance with ISO 10218 1 while the robot is ...

Page 10: ...elevant field and is sufficiently familiar with the application of the protective device on the machine that he she can assess its operational safety sta tus Operation and maintenance For operation and maintenance a person is considered competent when he she has the expertise and experience in the relevant field and is sufficiently familiar with the application of the protective device on the mach...

Page 11: ...ufacturer and user must ensure that the safe switching outputs are evaluated appropriately and that the hazardous state is rectified SAFETY INFORMATION 2 8023421 12KF 2019 01 22 SICK O P E R A T I N G I N S T R U C T I O N S sBot Stop 11 Subject to change without notice ...

Page 12: ...s for download www sick com SISTEMA file 3 3 Limits of the safety system The safety system ends at all inputs and outputs that are not used to wire the compo nents of the safety system For detailed information about the interfaces see Electrical installation page 38 The limits of the safety system are presented in abstract and general terms in the figure below 1 3 2 7 4 5 6 Figure 1 Limits of the ...

Page 13: ... with industrial robot systems in order to reduce the risk of injuries caused by the movement of the robot Figure 2 Example application with rotating table PRODUCT DESCRIPTION 3 8023421 12KF 2019 01 22 SICK O P E R A T I N G I N S T R U C T I O N S sBot Stop 13 Subject to change without notice ...

Page 14: ...he robot the robot performs a protective stop The person then enters the protective field of the safety laser scanner which monitors the hazardous area of the robot and prevents a restart If an automated system restart is permitted based on the risk assessment in accor dance with ISO 12100 the robot will restart automatically as soon as a person leaves the protective field of the safety laser scan...

Page 15: ...s for performing a reset after a protective stop sBot Stop with manual reset sBot Stop with automated reset NOTE Implementation with automated reset is not suitable for every application Possible use must be checked by means of the risk assessment NOTE Restart implementation is the responsibility of the manufacturer sBot Stop with manual reset Manual reset the reset pushbutton is connected to the ...

Page 16: ...ystem start and after an emergency stop The reset pushbutton is connected to the safety controller and its signal is analyzed there Depending on the robot controller and the stop category used several steps may be necessary for the protective stop These may include error acknowledgment switching on the drive and starting the program Programming can be implemented both in the robot controller and i...

Page 17: ...Laserscanner Lightcurtain Touch Panel TP Higher level PLC Protective stop Emergency stop Robot controller Flexi Classic Safety Controller Automatic restart Sequence of Reset Restart Figure 6 Schematic component network for automated reset option 2 3 6 Product characteristics 3 6 1 Protective field types This safety system operates with two different protective fields PRODUCT DESCRIPTION 3 8023421 ...

Page 18: ... the light beams is referred to as the protective field of the primary protective device Horizontal protective field During operation the safety laser scanner uses its horizontal laser beams to continu ously check whether people are present in a hazardous area The protective field of the safety laser scanner must be designed so that the entire haz ardous area is reliably monitored In conjunction w...

Page 19: ...otective stop could be ignored in a manual operating mode In this case the risks must be reduced in another way e g by the safety rated moni tored speed function in manual robot operation The manufacturer must take this into account in the risk assessment NOTE Expected frequency for requests of this safety function 1 hour and thus 8 760 year 3 6 2 3 Preventing unexpected startup following a protec...

Page 20: ...op function is triggered the dangerous movements and states of the robot are ended depending on the application Aside from triggering the emergency stop function no other action is needed from a person to create a safe state No additional dangers are created when ending the dangerous movement and sta tuses Table 6 Emergency stop Trigger Emergency stop pushbutton is actuated Condition At any time R...

Page 21: ...r evaluating the performance level achieved subsystems for SISTEMA are available under www sick com For the components included with delivery see Scope of delivery page 52 3 7 1 Emergency stop pushbutton requirements At least one device for stopping in an emergency must be installed e g emergency stop pushbutton At least two devices for stopping in an emergency e g emergency stop pushbuttons must ...

Page 22: ...1 Secure signal from safety sys tem to safety controller Yes Yes 1 SS1 corresponding stop category 1 or SS2 corresponding stop category 2 can be used When SS1 is used the signal for restart must come from a superior control Reset and restart requirements After emergency stop or switching on Manual reset is monitored by the safety system If resetting is possible and the reset pushbutton is pressed ...

Page 23: ...utomatic restart is the responsibility of the manufac turer 3 7 4 Physical guard On the basis of the manufacturer s risk assessment it may be necessary to install fixed guards such as fencing to avoid and restrict access to the hazardous area of the robot In addition to the applicable C standards for the application the following standards provide additional information on designing physical guard...

Page 24: ...ponents of the safety system are suitable for the respective application depending on the risk assessment and ambi ent conditions Among other things it is necessary to take into account the size of the protective fields and the requirements for the machine design The manufacturer has the following duties b Carrying out a risk assessment b Verifying and validating the safety functions b Integrating...

Page 25: ...d the relay 4 2 Operating entity of the machine DANGER Hazard due to lack of effectiveness of the protective device The dangerous state of the machine may not be stopped or not be stopped in a timely manner in the event of non compliance with the following instructions b Changes to the electrical integration of the safety system in the machine control and changes to the mechanical mounting of the ...

Page 26: ...ser scanner must be used The manufacturer must check after the risk assessment whether use of the respective safety laser scanner and this safety system is suitable for the application in question The requirements for use of an automated optical protective device must be met and the size of the protective field as well as the requirements for the machine design must be taken into account 4 4 2 Pri...

Page 27: ...ng S Minimum distance to hazardous area K Approach speed of the body or parts of the body 2 000 mm s according to ISO 13855 T Stopping time of the entire machine in seconds tSafetySystem Response time of safety system tRobot Robot stopping time C Entry distance C is the larger value of CRO reaching over and CRT reaching through tSafetyController Safety controller response time tRelay Response time...

Page 28: ...er tRelay tRobot C Formula symbols Meaning S Minimum distance to hazardous area K Approach speed of the body or parts of the body 2 000 mm s according to ISO 13855 T Stopping time of the entire machine in seconds T tSafetySystem tRobot C Entry distance C is the larger value of CRO reaching over and CRT reaching through tSafetySystem Response time of safety system tRobot Robot stopping time tPrimar...

Page 29: ... mm or 1 500 mm depending on variant The upper edge of the protective field therefore depends on the mounting height of the primary protective device 1200 mm 1500 mm hLowerEdge b Figure 7 Protective field of primary protective device Calculation for protective field height 1 200 mm Calculation for protective field height 1 500 mm b 1 200 mm hLowerEdge b 1 500 mm hLowerEdge Formula symbols Meaning ...

Page 30: ... through or CRO reaching over For the primary protective device deTem4 Core with a resolution d of 300 mm the stan dard sensing range of an arm is assumed for CRT CRT 850 mm CRO depends on the height of the protective field of the primary protective device and on the height of the hazardous area The values must be determined by means of ISO 13855 Chapter 6 5 1 Table 1 The height of the protective ...

Page 31: ... necessary in order to ensure a safe design for the entire application This requires additional components that are not part of the safety system such as switches fuses and contactors The circuit diagrams contain informa tion on wiring the safety system with additional components within an application The safety system can be connected to the most common industrial robots with two normally open co...

Page 32: ...t be set with the rotary switch of the Flexi Classic safety controller Program 7 must be selected on the UE410 MU The outputs Q3 and Q4 switch depending on the status of the used safety laser scan ner and primary protective device The normally open contacts of the relays at Q3 and Q4 must have a dual channel con nection to the protective stop input in the robot controller For EDM the normally clos...

Page 33: ...the primary protective device and safety laser scanner must be clear After a reset has been performed Q3 and Q4 are in HIGH status 24 V DC 4 5 1 2 Circuit diagram for manual reset with UE410 2RO A more detailed description is provided by the supplied circuit diagram PDF Reset 24V 24V 24V OV S3 A1 S1 S2 X1 X2 I1 I2 EN A2 24V Q3 Q4 Q1 Q2 I3 A B MU RO 7 I4 13 23 Y1 14 24 B1 Y2 1 2 Figure 12 Circuit d...

Page 34: ...lly closed contacts must be connected in series on S2 The normally open contacts of the relays at Q1 and Q2 must have a dual channel con nection to the emergency stop input in the robot controller For manual reset and EDM the normally closed contacts must be connected in series with the reset pushbutton on S1 24V Reset K1 K2 K3 K4 K3 K4 K1 K2 24V 24V 24V 24V S3 A1 S1 S2 X1 X2 I1 I2 EN A2 24V 24V 2...

Page 35: ...ptation is not part of this safety system Implementation of the adaptation described in this chapter makes you the manufac turer of a safety system b Carry out the adaptation of the safety system described here only subject to own responsibility b Comply with all manufacturer obligations for development and implementation of a safety system NOTE The manufacturer must adapt the documentation circui...

Page 36: ... carried out during commissioning and following modifi cations The regular thorough checks of the safety system must fulfill certain minimum requirements The minimum requirements for the thorough check of the safety system comply at least with the sum of the minimum requirements for the thor ough check of the components of the safety system see operating instructions of the components In many case...

Page 37: ...t of the scan plane is less than 300 mm then a resolution of 50 mm must be selected If the height of the scan plane is greater than 300 mm additional measures must be taken to prevent crawling beneath 5 2 Mounting the primary protective device The protective field of the primary protective device must be oriented vertically There must be no gap between the protective field of the safety laser scan...

Page 38: ...g EDM of the relays is necessary to achieve high diagnostic coverage For this reason the relays must have mechanically connected positively guided contact elements This must be evaluated by the manufacturer or integrator The number of switching cycles must also be evaluated by the manufacturer or integrator with respect to compli ance with the safety requirements 6 2 Safety controller pin assignme...

Page 39: ...A2 Voltage supply 0 V DC S1 Reset EDM emergency stop S2 Automated reset EDM protective stop S3 Connected to 24 V DC Table 18 UE410 8DI4 module inputs Connection Function I1 Emergency stop 1 I2 Emergency stop 2 I3 Emergency stop 3 I4 Emergency stop 4 I5 OSSDs of safety laser scanner I6 OSSDs of safety laser scanner I7 Not used connected to 24 V DC I8 Not used connected to 24 V DC Table 19 UE410 8DI...

Page 40: ...ignment of the individual components NOTE Information is included in the operating instructions for the components 6 ELECTRICAL INSTALLATION 40 O P E R A T I N G I N S T R U C T I O N S sBot Stop 8023421 12KF 2019 01 22 SICK Subject to change without notice ...

Page 41: ...ware or firmware Table 20 Minimum versions Software and firmware Minimum version Safety Designer 1 2 CDS Configuration Diagnostic Software 3 7 2 The software can be downloaded at www sick com 7 2 Additional configuration required 7 2 1 Configuring the Flexi Classic safety controller The Flexi Classic safety controller is configured by means of a rotary switch A screw driver is required for this CA...

Page 42: ... to the Flexi Classic safety controller 7 2 2 1 Configuring the S300 Mini Standard The S300 Mini Standard is configured with the CDS Configuration Diagnostic Soft ware For configuration refer to the S300 Mini Standard operating instructions NOTE The resolution must be set in accordance with the risk assessment and the height of the scan plane For recommended values see Mounting the safety laser sc...

Page 43: ...plication variant must be set to stationary NOTE The resolution must be set in accordance with the risk assessment and the height of the scan plane For recommended values see Mounting the safety laser scanner page 37 NOTE The height of the scan plane must be checked see Mounting the safety laser scan ner page 37 Configuring the protective field Figure 17 microScan3 Core I O configuration view exam...

Page 44: ...tware For configuration refer to the S3000 Standard operating instructions The application variant must be set to stationary NOTE The resolution must be set in accordance with the risk assessment and the height of the scan plane For recommended values see Mounting the safety laser scanner page 37 NOTE The height of the scan plane must be checked see Mounting the safety laser scan ner page 37 7 CON...

Page 45: ...CAUTION The configuration shown here is for example purposes only The protective field must be matched to the application according to the risk assessment CONFIGURATION 7 8023421 12KF 2019 01 22 SICK O P E R A T I N G I N S T R U C T I O N S sBot Stop 45 Subject to change without notice ...

Page 46: ...e mounting or the electrical connection After exceptional events such as after a manipulation has been detected after modification of the machine or after replacing components The thorough check ensures the following All relevant regulations are complied with and the safety system is effective in all of the machine s operating modes The documentation corresponds to the state of the machine includi...

Page 47: ...tart up 1 Make sure that the protective field of the primary protective device and the protec tive field of the safety laser scanner are clear 2 Press the reset pushbutton The robot can start OPERATION 9 8023421 12KF 2019 01 22 SICK O P E R A T I N G I N S T R U C T I O N S sBot Stop 47 Subject to change without notice ...

Page 48: ...operated according to their specifications Safety features must be regularly checked for reliability NOTE Safety devices must not be disassembled modified or repaired Doing so could other wise impair the security functions Emergency stop pushbutton The thorough check interval must be determined by the manufacturer of the machine based on the risk assessment At least once a year all emergency stop ...

Page 49: ...ntroller Information on regular thorough checks of the Flexi Classic safety controller can be found in the operating instructions of the safety controller The safety controller must be switched off and then back on again at least once a year Safety signs information labels b Regularly check the information labels for the following points Presence Readability b Replace the information labels if mis...

Page 50: ...ing NOTE Information is included in the operating instructions for the components 11 TROUBLESHOOTING 50 O P E R A T I N G I N S T R U C T I O N S sBot Stop 8023421 12KF 2019 01 22 SICK Subject to change without notice ...

Page 51: ...ce tPrimaryProtDev Response time of the logic tSafetyController Response time of the relay s tRelay The response time of the safety system is determined using the following formula tSafetySystem tPrimaryProtDev tSafetyController tRelay Response time of components Table 22 Overview of component response times Components Part number Response time Primary protective device deTec4 resolution 30 mm len...

Page 52: ...e 13 2 Ordering information Table 23 Orderable variants Primary protective device Safety laser scanner Flexi Classic modules Part no deTec4 Core 1 500 mm deTec4 Core 1 200 mm deTem4 Core microScan3 Core I O S300 Mini Standard S3000 Standard UE410 MU UE410 8DI Automated reset 1097907 x x x x 1097908 x x x x 1097909 x x x x 1097911 x x x x Manual reset 1097902 x x x 1097904 x x x 1097905 x x x 10979...

Page 53: ...11506 deTec4 Core 1 200 mm length sender C4C SA12030A10000 1211501 deTec4 Core 1 200 mm length receiver C4C EA12030A10000 1211502 deTem4 Core sender M4C SA0430LA10 1082690 deTem4 Core receiver M4C EA04300A10 1082692 Safety controller Table 26 Ordering information Num ber Name Description Part number 1 UE410 MU4T0 Flexi Classic main module UE410 MU 6035243 1 UE410 8DI4 Flexi Classic I O module UE41...

Page 54: ...Part Part number System plug pre assembled 5 m cable length 9 wires rear cable outlet one M20 cable gland and one M12 dummy plug 2049222 System plug pre assembled 10 m cable length 9 wires one M20 cable gland and one M12 dummy plug 2027171 System plug pre assembled 20 m cable length 9 wires one M20 cable gland and one M12 dummy plug 2027814 Configuration cable male connector M8 4 pin USB A straigh...

Page 55: ...r mounting on wall or machine No adjustment possibility 2015623 deTec4 Core and deTem4 Core Mounting brackets for the primary protective devices are included in the scope of deliv ery of the safety system 15 3 Emergency stop and reset pushbutton Table 34 Emergency stop and reset pushbutton Description Type code Part number Emergency stop with reset pushbutton ES11 SC4D8 6051329 Emergency stop push...

Page 56: ...utton 3 Initiate restart of the robot 4 Check whether the emergency stop pushbutton is installed out side the monitored area 5 Press the reset pushbutton 6 Start the robot The robot starts only after the reset pushbutton is pressed Yes No Test for Triggering a protective stop safety function Table 37 Tests for Triggering a protective stop safety function Test sequence Expected result Result OK 1 M...

Page 57: ... tective device The safety laser scanner is configured in such as way as to cover the entire area to be monitored up to the primary protective device The resolution of the safety laser scan ner is in correct proportion to the height of the scan plane It is not possible to walk behind the protective field Yes No Measured height of the scan plane Complete approval of the application The application ...

Page 58: ... risk assessment additional requirements may be nec essary Table 40 Checklist for the manufacturer Requirements It is not possible to enter the hazardous area without interrupting the protective field of the primary protective device Yes No It is not possible to walk behind the protective field of the safety laser scanner Yes No It is ensured that no people are in the hazardous area during or afte...

Page 59: ...Device Configurable KF100 Safety controller Table 42 Sensors and switches Trigger T Equipment ID Device Protective field BG100 Primary protective device Protective field BG110 Safety laser scanner Emergency stop SF200 Emergency stop pushbutton Emergency stop SF210 Emergency stop pushbutton Reset SF300 Reset pushbutton Restart SF310 Manual input on robot e g teach pendant Table 43 Actuators Reactio...

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