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SICK OLM100

SICK OLM100
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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

Table of Contents

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SICK OLM100 Specifications

General IconGeneral
BrandSICK
ModelOLM100
CategorySecurity Sensors
LanguageEnglish

Summary

About This Document

Purpose of this Document

Details the information required for the safe system's lifecycle, covering components, planning, installation, checks, configuration, commissioning, maintenance, and troubleshooting.

Scope of Operating Instructions

Covers information regarding the Safe Linear Positioning safety system and its components, with priority given to safety system instructions in case of contradictions.

Symbols and Document Conventions

Explains the symbols and conventions used in the document, including safety notes (DANGER, WARNING, CAUTION, NOTICE) and instructions to action.

Further Information Sources

Provides links to additional online resources such as other documents, software, project files, and guides related to the safety system.

Safety Information

General Safety Note

Emphasizes that the provided information is a basis and requires qualified staff for project planning, risk assessment, and validation.

Intended Use of the Safety System

Describes the system's design for reliable detection of linear drive systems' position and its role as a safety component guaranteeing a safety function.

Reasonably Foreseeable Misuse and Speed Limits

Warns about potential mounting errors and the maximum permitted speed limit of 4,000 mm/s for the system.

Personnel Qualification Requirements

Specifies that configuration, installation, connection, commissioning, and servicing must be performed by qualified safety personnel only.

Product Description

Product Identification and Application Description

Details product identification on packaging and application examples like skillet conveyors, cranes, and gantry robots for safe position monitoring.

Components of the Safety System

Lists the core components of the Safe Linear Positioning system, including OLM100 sensors, Flexi Soft controller modules, and system plugs.

Additional Components and Requirements

Highlights the necessity of additional components like bar code tape and emphasizes that all safety-related components must meet PL e/Category 4 requirements.

Structure, Function, and Limits

Explains the system concept with sensors and controller, dividing the system into modules and defining its limits as ending at the Flexi Soft controller terminals.

Product Characteristics and Safety Functions

Details safety functions like Safe Stop 1/2, Safe position monitoring, Safely Limited Speed (SLS), and Emergency Stop capabilities of the system.

Safe State Definition

Describes the 'safe state' where switching outputs are off, initiated by triggered safety functions, connection problems, or internal faults.

Project Planning

Manufacturers Responsibilities and Performance Level

Outlines manufacturer duties like risk assessment, validation, and component integration, and explains performance level calculation using SISTEMA.

Operating Entity and Design Considerations

Covers the operating entity's role, the necessity of new risk assessments for changes, and design information for the safety system and sensors.

Integration, Testing, and Modifications

Details integrating the system into electrical controls, testing plans, and permitted modifications, emphasizing safety checks after changes.

Notes on Fault Detection

Explains fault detection mechanisms for bar codes, including illegible codes and gaps, and how the system reacts to these faults.

Mounting

Mounting the Sensor Unit

Provides instructions for mounting the pre-assembled sensor unit, emphasizing correct positioning, distance from the bar code tape, and safety screws.

Mounting the Bar Code Tape

Details requirements for mounting the self-adhesive bar code tape, including orientation, gap specifications, and handling of disruptive points.

Mounting the Flexi Soft Controller

Specifies that the Flexi Soft safety controller must be mounted in an environment meeting enclosure rating IP54.

Electrical Installation

General Requirements and Wiring Principles

Covers general electrical installation requirements, measures to prevent common-cause failures, and the wiring principle for components.

Safety Controller Pin Assignment

Details the pin assignment for the safety controller modules (CPU, XTIO, MOC1), showing the connection of inputs and outputs.

Interfaces and Signals

Describes system interfaces and signals, categorizing them into safety and standard interfaces, and defining test signals and their meanings.

Signal Descriptions for Drive and Safety Functions

Explains signals for PDS (SR) drive, optional safe brake control, safe SLS request, emergency stop, and restart interlock.

Configuration

Configuration Overview and Requirements

Covers chapter structure, software/firmware requirements, general configuration procedure, and pre-configured project files for the safety system.

Motion Sensor and Speed Configuration

Details configuring the BG100 motion sensor interface, speed limits, max speed, speed filter, and assigning speeds to position ranges.

Position, Safe Cam, and Stop Ramp Configuration

Explains configuring position ranges, assigning speeds to profiles, setting up safe cams (SCA), and configuring stop ramps for safe operation.

Safety Function Expansion and Control

Covers adding safety functions, activating safely limited speed via internal/external signals, configuring override functions, and controlling safety outputs via PLC.

CPU Logic and Diagnostics Pages

Describes CPU logic pages including Interface, Safe Outputs, Safe Position/Diagnostics, and Stop/start/reset, detailing function blocks and diagnostics.

Motion Control Logic Pages

Details motion control logic pages like Position_Cross_Check, Position_Monitor, and Safe Stop, explaining their functions and views for system monitoring.

Flexi Soft Logic Editor Notes

Provides notes on the Flexi Soft logic editor, covering creating/deleting links, jump addresses, logic verification, and configuration transfer.

Commissioning

Safety During Commissioning

Emphasizes safety precautions, ensuring the machine is checked by qualified personnel and operates with a functioning protective device.

Thorough Check Procedures

Outlines requirements for thorough checks before commissioning, after changes, and during operation to ensure compliance and system effectiveness.

Operating the Components

Maintenance of the Components

Troubleshooting

Electromagnetic Compatibility

Addresses potential system switches to the safe state due to high EMC levels and advises user measures for related problems.

Exchange and Repairs

States that the sensor unit can only be exchanged as a complete unit and repairs must be performed by the SICK Service team.

Decommissioning

Disassembly and Disposal

Instructs to follow applicable national disposal regulations, emphasizing recycling of constituent materials during disposal.

Technical Data

Safe Linear Positioning Data Sheet

Presents key technical specifications including SIL claim limit, performance level, PFHD, response times, resolution, and environmental data.

XTIO Module Inputs

Provides detailed input specifications for the XTIO module, including voltage levels, current, capacity, switching current, and pulse filters.

Dimensional Drawings and Response Times

Includes dimensional drawings of the OLM100 Hi sensor and details response times, including overrun calculation for the entire system.

Stopping Time and Cycle Time Calculations

Explains stopping time calculations in case of drive faults and defines Flexi Soft cycle time, including formulas and operand meanings.

Maximum Data Reception Interval

Defines the maximum data reception interval as an adjustable timeout period for valid position data, impacting response time.

Ordering Information

Safe Linear Positioning Ordering Information

Lists complete sets and retrofitting sets for Safe Linear Positioning, specifying part numbers, resolutions, and included components.

Spare Parts

Accessories

Connectivity Options

Details ordering data for connection cables for OLM sensors, specifying types, lengths, and part numbers for straight and angled connectors.

Annex

Checklist for Initial Commissioning

Provides a checklist for initial commissioning and recurring checks, covering ambient conditions, mounting, electrical installation, and plausibility signals.

Thorough Check of Hardware Requirements

Covers checks for SSI interface baud rates, drive system compliance, brake control, and external SLS request signals for safety.

Thorough Check of Flexi Soft Configuration

Includes checks for maximum speed, safely limited speeds (SLS), stop ramp configuration, and impact of parameters on response time.

Thorough Check of Flexi Soft Documentation

Covers checking position ranges, speed/position profiles, response time, Flexi Soft configuration verification, and CRC checksum documentation.

Thorough Check on Process Channel (StandstillMovement)

Details test procedures for evaluating test signals during standstill, forward movement, and backward movement for safety system checks.

Thorough Check of Safety Functions

Covers checks for external SLS request, emergency stop actuation, and faults on the transmission path to ensure proper safety function operation.

Thorough Check for Misuse and Manipulation

Focuses on checking for proper bar code tape application, signs of manipulation, and ensuring the safety system is not tampered with.

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