General
1.3 Limitation of liability
Applicable standards and regulations, the latest technological develop-ments, and our many years of knowledge and experience have all been taken into account when assembling the data and information contained in these operating instructions.
The manufacturer accepts no liability for damage caused by:
• failing to observe the operating instructions
• improper use
• use by untrained personnel
• unauthorized conversions
• technical modifications
• use of unauthorized spare parts/consumable parts.
With special variants, where optional extras have been ordered, or owing to the latest technical changes, the actual scope of delivery may differ from the features and illustrations shown here.
1.4 Scope of delivery
Included in scope of delivery:
• DL100 Pro distance measuring device
• Optional: Accessories (→ Page 76, Chapter 14)
Documentation included with each distance measuring device:
• Quick-start guide
1.5 Customer service
If you require any technical information, our customer service department will be happy to help.
See the back page for relevant contact details.
NOTE!
Before calling, make a note of all type label data such as type code and serial number to ensure faster processing.
1.6 EU declaration of conformity
General 1.7 Environmental protection
WARNING!
Danger to the environment due to improper disposal of the distance measuring device.
Disposing of the distance measuring device improperly may cause damage to the environment.
For this reason:
• Always observe the valid regulations on environmental protection.
• Following correct disassembly, recycle the disassem-bled components.
• Separate the recyclable materials by type and place them in recycling containers.
Safety
2 Safety
2.1 Intended use
The DL100 Pro distance measuring device is a measuring device consist-ing of an opto-electronic sensor and integrated evaluation electronics.
The measuring device is intended solely for non-contact measurement of distances to system components that are in linear motion. The distance measurement is performed by means of a reflector.
SICK AG assumes no liability for losses or damage arising from the use of the product, either directly or indirectly. This applies in particular to use of the product that does not conform to its intended purpose and is neither described nor mentioned in this documentation.
2.2 Improper use
The DL100 Pro distance measuring devices do not constitute safety com-ponents in accordance with the EC Machinery Directive (2006/42/EC).
The distance measuring devices must not be used in explosion-hazardous areas.
Any other use that is not described as intended use is prohibited.
Never install or connect accessories if their quantity and composition are not clearly specified, or if they have not been approved by SICK AG.
WARNING!
Danger due to improper use!
Any improper use can result in dangerous situations.
For this reason:
• Distance measuring devices should be used only in accordance with their intended use.
• All information in these operating instructions must be strictly observed.
Safety
2.3 Modifications and conversions
Modifications and conversions to the distance measuring device and/or the installation may result in unforeseeable dangers.
Before any technical modifications to and expansions of the distance measuring device, the prior written approval of the manufacturer must be obtained.
2.4 Requirements for skilled persons and operating personnel
WARNING!
Risk of injury due to insufficient training.
Improper handling may result in considerable personal injury and material damage.
For this reason:
• All work must only ever be carried out by the stipulated persons.
The operating instructions state the following qualification requirements for the various areas of work:
• Instructed personnel
have been given a briefing by the operating entity about the tasks assigned to them and about potential dangers arising from improper action.
• Qualified personnel
are able to carry out the work assigned to them and independently recognize potential risks due to their specialist training, knowledge, and experience, as well as knowledge of the relevant regulations.
• Electrical specialists
are able to carry out work on electrical systems and independently recognize potential risks due to their specialist training, knowledge, and experience, as well as knowledge of the relevant standards and regula-tions.
In Germany, electrical specialists must meet the specifications of the work safety regulation BGV A3 (e.g., master electrician). Other relevant regulations applicable in other countries must be observed.
2.5 Operational safety and particular hazards
Please observe the safety notes and the warnings listed here and in other chapters of these operating instructions to reduce the possibility of risks to health and avoid dangerous situations.
Safety
2.6 Warning symbol on the device
A class 2 laser is installed in the DL100 Pro distance measuring device.
The measuring device is labeled with a warning.
Complies with 21 CFR 1040.10 and 1040.11 except for deviations pursuant to laser notice No. 50,
date June 24, 2007
EN/IEC 60825-1:2014
MEAN OUTPUT PO <1mW CW-MODULATION ± 0.85 PO
WAVELENGTH = 655nm FREQUENCY ≥ 90 MHz
Fig. 1: Warning symbol on the device: Class 2 laser (EN/IEC 60825-1:2014) Identical laser class for issue EN/IEC 60825-1:2007
Complies with 21 CFR 1040.10 and 1040.11 except for the listed tolerances in the document Laser Notice No. 50 of June 24, 2007.
Laser radiation – Never look into the light beam – Laser class 2 (EN/IEC 60825-1:2014)
Laser output aperture
Safety
2.7 Hazard warnings and operational safety
Laser radiation For your own safety, please read and observe the following instructions:
CAUTION!
Optical radiation: Laser class 2
The human eye is not at risk when briefly exposed to the radiation for up to 0.25 seconds. Exposure to the laser beam for longer periods of time may cause damage to the retina. The laser radiation is harmless to human skin.
• Do not look into the laser beam intentionally.
• Never point the laser beam at people’s eyes.
• If it is not possible to avoid looking directly into the laser beam, e.g., during commissioning and mainte-nance work, suitable eye protection must be worn.
• Avoid laser beam reflections caused by reflective surfaces. Be particularly careful during mounting and alignment work.
• Do not open the housing. Opening the housing will not switch off the laser. Opening the housing may increase the level of risk.
• Applicable national regulations regarding laser protec-tion must be observed.
Identification
3 Identification
3.1 Type label
The type label is located on the measuring device.
12
Fig. 2: Type label (example) 1 Type code
2 Device number
3 Supply voltage, multifunctional current output 4 Pictogram: Distance sensor reflector operation 5 Assignment for female contact port 1
6 MAC address 7 Serial number
8 Month and year of manufacture 9 Assignment for female contact port 2 10 Assignment for supply voltage male connector 11 Bar code
12 Manufacturer
Structure and function
4 Structure and function
4.1 Structure
Fig. 3: “DL100 Pro distance measuring device” structure 1 M5 threaded mounting hole
2 Device zero point 3 Sender optical axis 4 Receiver optical axis
5 Hole for the knurled screw of the optional alignment bracket 6 Bracket for optional alignment bracket
7 Electrical connection 8 Display and control unit
Structure and function 4.2 Function
SetEsc
EthProfibus
RPWMF1MF2LNKBF
STA
<<
1
2
4
3
Fig. 4: “DL100 Pro distance measuring device” function 1 Vehicle
2 Reflector
3 DL100 Pro distance measuring device 4 Alignment bracket
The DL100 Pro distance measuring device consists of the optics, a sender/
receiver unit, and an evaluation unit. The sender emits the laser beam. The receiver receives the light reflected from a reflector. The evaluation elec-tronics determine the distance between the sensor and the reflector using time-of-flight measurement.
For the measurement, either the reflector or the measuring device can move in a linear fashion along the laser beam.
The DL100 Pro distance measuring device is fitted with two Ethernet ports.
These are for communication via EtherCAT® and for diagnostics and param-eterization via SOPAS ET. The two interfaces are of equal status and are internally connected to a switch.
The measured distance is transferred via the “EtherCAT®” interface and can be used for control purposes or in a position control loop, for example.
4.3 Display and operating elements
R 1/2 R N
EtherCAT
Structure and function
LEDs LED Description
PWR Operating status display
• LED off: No operation
• LED green: Interference-free operation
• LED flashing orange: Warning (see warning status – upper level menu)
• LED flashing red: Malfunction (see error status – top-lev-el menu)
→For information on troubleshooting, see Page 69, Chapter 11.
MF1/2 The status of the MF1 multifunctional input/output and MF2 multifunctional output is indicated by an LED.
→ See Page 19, Table 2.
L/A2
L/A1 Ethernet
• LED off: No Ethernet available
• LED green: Ethernet available
• LED flashing steadily: Data being transmitted ERR (following the
respective fieldbus specification)
Error
• LED off: No error
• LED flashing red twice briefly: Watchdog time-out
• LED flashing red briefly: Local error
• LED flashing red, sustained: Configuration error
• LED solidly red: Application error RUN (following the
respective fieldbus specification)
Operational status
• LED off: Device has initialization status
• LED flashing green briefly: Device has safe-operational status
• LED flashing green, sustained: Device has pre-operation-al status
• LED green: Device has operational status Table 1: LEDs
LED MF1/2 LED MF1/2 MF1 MF2
Off OFF OFF
Blue ON OFF
Yellow OFF ON
White ON ON
Table 2: LED MF1/2
Structure and function
Symbols for operating modes The device has two different operating modes: “measured value display”
and “menu display”, which are indicated on the display by the symbols RUN and MEN.
Symbol Description
RUN The device is in “measured value display” operating mode when it is switched on. The RUN symbol and the current distance value are displayed → Fig. 6.
MEN The MEN symbol is displayed in “menu display” operating mode. This symbol is also displayed when there is an error and no measured value can be recorded.
Table 3: Symbols for operating modes
Pushbuttons Pushbutton Description
• Select menu, parameter, or option.
• Decrease value.
• Select menu, parameter, or option.
• Increase value.
• Switch to the next-lowest menu level.
• Save parameter change.
• Confirm selection.
• Exit parameters without saving. Switch to the next-high-est menu level.
Table 4: Pushbuttons
4.4 Display
Measured value display Default measured value display:
Esc Set
250000
RUN
Fig. 6: Measured value display Menu display
Esc Set
Menu
MEN
Fig. 7: Menu display
Structure and function
NOTE!
If the display cannot show a distance value with the 6 digit places available, only 5 digits will be shown and the 6th digit place (on the left) will show an exclamation mark (“!”).
The characters scroll while the firmware versions are being displayed.
Transport and storage
5 Transport and storage
5.1 Transport
Improper transport
WARNING!
Damage to the distance measuring device due to im-proper transport!
Substantial material damage may result in the event of improper transport.
For this reason:
• The device should be transported only by trained spe-cialist staff.
• The utmost care and attention is required at all times during unloading and transportation on company premises.
• Note the symbols on the packaging.
• Do not remove packaging until immediately before starting installation work.
5.2 Transport inspection
Improper transport Upon receipt, please check the delivery for completeness and for any dam-age that may have occurred in transit.
In the case of transit damage that is visible externally, proceed as follows:
• Do not accept the delivery or only do so conditionally.
• Note the extent of damage on the transport documents or on the trans-port company’s delivery note.
• File a complaint.
NOTE!
Complaints regarding defects should be filed as soon as these are detected. Damage claims are only valid before the applicable complaint deadlines.
Transport and storage
5.3 Storage
Store the distance measuring device under the following conditions:
• Do not store outdoors.
• Store in a dry area that is protected from dust.
• Do not expose to any aggressive substances.
• Protect from sunlight.
• Avoid mechanical shocks.
• Storage temperature: –40 … +75 °C
• Relative air humidity: max. 95%, non-condensing
• For storage periods of longer than 3 months, check the general condi-tion of all components and packaging on a regular basis.
Mounting
6 Mounting
6.1 Mounting procedure
1. Choose a mounting site, bearing in mind the mounting instructions.
→ See the following chapter.
2. Mount the alignment bracket and distance measuring device.
→ See Page 30, Chapter 6.7.
3. Make the electrical connection.
→ See Page 33, Chapter 7.
4. Align the distance measuring device and reflector to each other.
→ See Page 29, Chapter 6.6.
5. Align the distance measuring device to the reflector by adjusting the alignment bracket precisely. → See Page 32, Chapter 6.8.
6. Fix the alignment of the distance measuring device.
→ See Page 32, Chapter 6.8.
6.2 Mounting instructions
To ensure trouble-free operation, observe the following mounting instruc-tions:
• Comply with technical data such as the measuring range.
→ See Page 73, Chapter 13.3.
• At lower ambient temperatures (e.g. in deep-freeze warehouses) the distance measuring device should have integrated heating.
• Use a distance measuring device with an optional cooling housing at higher temperatures. → See Page 82, Chapter 14.4.
• Protect the distance measuring device from direct sunlight.
• To prevent condensation, avoid exposing the distance measuring device to rapid changes in temperature.
• Follow the mounting instructions for the reflector.
→ See Page 24, Chapter 6.2.
• Maintain a sufficient distance to other distance measuring devices.
→ See Page 26, Chapter 6.4.
• Maintain a sufficient distance to data transfer photoelectric sensors.
→ See Page 28, Chapter 6.5.
Mounting 6.3 Selecting and mounting the reflector
NOTE!
→ For suitable reflectors and reflective tape, see Page 76, Chapter 14.1.
Reflector size • Select a reflector size that allows the entire light spot to hit the reflector even if there are vibrations.
• If the reflector is installed onto a vehicle, a smaller reflector will typically suffice.
Requirements • Reflective surfaces near to the reflector may cause beam switching or light scatter and lead to incorrect measurements as a result. Reflective surfaces include, for example, storage profiles, pallets with stretch wrap, or rails.
• If the distance measuring device is mounted in the driving axis of a stor-age and retrieval system, tilt the reflector toward the ceiling away from the rail (approx. 1 to 3 degrees). → See the figure below.
• If the distance measuring device is mounted in the lifting axis of a storage and retrieval system, tilt the reflector away from the mast system (approx. 1 to 3 degrees).
→ See the figure below.
Set
Fig. 8: Mounting the reflector when surfaces are reflective.
Left: Mounted in driving axis; right: Mounted in lifting axis 1 Distance measuring device
2 Reflective surface 3 Reflector
4 Tilt of approx. 1 to 3 degrees
Mounting
6.4 Arrangement of multiple distance measuring devices
Multiple distance measuring devices To mount multiple distance measuring devices, you will need to maintain a minimum distance between the devices when they are mounted. The minimum distance is proportional to the maximum scanning range of the distance measuring device.
Formula a ≥ 100 mm +0.01 x smax [mm]
Example • Distance measuring device: DL100–21xxxx01
• Measuring range: 0.15... 100 m
• Maximum measured value: 60 m
• smax = 60 m Calculation
a ≥ 100 mm +0.01 x 60,000 mm → 100 mm +600 mm → 700 mm Result
a ≥ 700 mm Light beams in the same direction
smax.
a
Set
Esc <<
Set
Esc <<
Fig. 9: Placement of two distance measuring devices’ light beams in the same direction
1 DL100 Pro distance measuring device 2 Reflector
a Minimum distance smax Maximum scanning range
Mounting
Light beams in opposite directions
a
Set
Esc <<
Fig. 10: Placement of two distance measuring devices’ light beams in the opposite direction
1 DL100 Pro distance measuring device 2 Reflector
a Minimum distance
Mounting
6.5 Arranging a distance measuring device with adjacent data transfer photoelectric sensor
A beam separation of at least 100 mm must always be maintained during mounting with a ISD300, ISD400-1xxx, and ISD400-6xxx series data transfer photoelectric sensor. The maximum scanning range has no impact on the minimum distance. Different minimum distances apply to the ISD400-7xxx (ISD400 Pro) series devices. See the ISD400 Pro operating instructions.
Formula a ≥ 100 mm
a
Set
Esc <<
Fig. 11: Arranging a distance measuring device with an ISD data transfer photo-electric sensor
1 DL100 Pro distance measuring device 2 Reflector
3 ISD300, ISD400-1xxx, or ISD400-6xxx data transfer photoelectric sensor a Minimum distance
Mounting
6.6 Aligning the distance measuring device and reflector to each other
1. Bring the distance measuring device and reflector close together.
2. Align the distance measuring device so that the light spot of the sensor hits the center of the reflector.
3. Increase the distance between the distance measuring device and reflector. The light spot of the sensor must continue to hit the center of the reflector.
4. Check the attenuation. The value for the attenuation must not exceed the value in the table.
Attenuation value The table below specifies the signal attenuation values in relation to the distance between the distance measuring device and the reflector. The values in the “Typical signal attenuation” column represent the expected values when the measuring path and the distance measuring device are in perfect working order. If the signal attenuation value exceeds the value in the “Maximum signal attenuation” column, check the condition of the measuring path.
The distance measuring device issues a level warning if the signal attenu-ation value reaches the critical value of approximately –96 dB. If the signal attenuation value then continues to rise, a level and plausibility error are output, along with the measured value “0”.
Distance [m]
Typical signal
attenua-tion [dB] Maximum signal attenu-ation [dB]
Table 5: Attenuation values
Mounting
6.7 Mounting the alignment bracket and distance measuring device
The distance measuring device is mounted using the optional alignment bracket.
→ For dimensions and part numbers, see Page 72, Chapter 13.1.
Observe the following points:
• Mounting instructions: → See Page 24, Chapter 6.2.
• The operation must be accessible.
1. Mount the alignment bracket above the four slotted holes. The align-ment bracket is suitable for mounting on horizontal and vertical surfac-es.
1
1
2
Fig. 12: Mounting the alignment bracket 1 M5 mounting screw
2 Alignment bracket
2. Unscrew the knurled screw until the distance measuring device can be fitted in place.
3. Insert the distance measuring device into the alignment bracket.
Mounting
2
SetEsc
<<
3
Fig. 13: Mounting the distance measuring device 1 Knurled screw
2 Alignment bracket 3 Distance measuring device
4. Secure the distance measuring device with the knurled screw.
SetEsc
<<
Fig. 14: Securing the distance measuring device with knurled screw 1 Knurled screw
Mounting
6.8 Aligning the distance measuring device using the alignment bracket
Align the distance measuring device using the alignment bracket according to the following figures. The light spot of the sensor must continue to hit the center of the reflector.
Alignment in the X-direction
SetEsc
<<
X
1
Fig. 15: Aligning the distance measuring device in the X-direction using the align-ment bracket
1 Set screw for aligning the distance measuring device in the X-direction Alignment in the Y-direction
SetEsc
<<
Y
Fig. 16: Aligning the distance measuring device in the Y-direction using the align-ment bracket
1 Set screw for aligning the distance measuring device in the Y-direction
Electrical connection
7 Electrical connection
7.1 Safety
Incorrect supply voltage
WARNING!
Equipment damage due to incorrect supply voltage!
An incorrect supply voltage may result in damage to the equipment.
For this reason:
• Only operate the distance measuring device using a protected low voltage and safe electrical insulation as per protection class III.
Working with live parts
WARNING!
Equipment damage or unpredictable operation due to working with live parts.
Working with live parts may result in unpredictable oper-ation.
For this reason:
• Only carry out wiring work when the power is off.
• Only connect and disconnect cable connections when the power is off.
7.2 Wiring instructions
WARNING!
Faults due to incorrect wiring!
Incorrect wiring may result in operational faults.
For this reason:
• Only use shielded cables with twisted-pair wires.
• Follow the wiring instructions closely.