PLS to S3000 Upgrade Instructions - Sensors Incorporated to...PLS TO S3000 UPGRADE 3 Introduction This document is provided to guide authorized maintenance personnel through the process

Using CDS v3.x.x

I N S T R U C T I O N M A N U A L

PLS to S3000 Upgrade Instructions

Mike

New Stamp

TABLE OF CONTENTS

Introduction pg. 3

Summary of Steps pg. 4

Tools Required pg. 4

Estimated Time to Complete pg. 4

PLS Configuration pg. 5

Uploading the PLS Configuration pg. 5

Saving the PLS Configuration pg. 5

Viewing the PLS Configuration Printout pg. 6

Hardware Conversion – Steps to rewire the PLS to the S3000 pg. 7

S3000 Scanner Configuration Using CDS V3.x.x pg. 10

Initial CDS v3.x.x setup pg. 11

Scanner Configuration pg. 14

Monitoring Case Configuration pg. 18

Determining the Field Set pg. 20

Creating the Safety Field pg. 22

Creating the Warning Field pg. 25

Saving the Program pg. 26

Downloading the Program pg. 26

Upgrade Complete pg. 30

PLS TO S3000 UPGRADE

3

Introduction

This document is provided to guide authorized maintenance personnel through the process ofreplacing an existing stand-alone SICK PLS Safety Laser Scanner with a SICK S3000 Safety LaserScanner.

The S3000 series safety laser scanners provide the following enhancements:

• Configuration MemoryProgram information is stored in the system plug. Replacing a scanner no longer requiresuploading and downloading programs.

• Improved DiagnosticsA seven-segment LED provides alphanumeric codes for specific diagnostic information.

• Faster Response TimeThe S3000 has a reduced response time of 60 ms compared to 80 ms for the PLS.

• Improved SoftwareCDS software is a common platform for programming current and future generation SICKsafety devices. The interface is streamlined and much more user friendly.

• Mechanical CompatibilityThe S3000 mounting holes and scanning plane are the same as the PLS. The existingmounting hardware can be used without any mechanical adjustments. The only case wheremounting may be different is if the three (3) threaded inserts on the bottom of the PLS areused for mounting the scanner. These inserts do not exist on the S3000. In such cases, anadaptor plate or alternative mounting may be required.

• Enhanced FunctionalityThe S3000 series is available with longer safety ranges and the ability to switch betweenmultiple field sets.

• Modular DesignAdditional functionality can be added without purchasing a new scanner.

NOTEThese instructions are intended for standalone applications only. Do not use these instructions forSICK PLS scanners connected to an LSI interface or for PLS scanners being used in mobile vehicleapplications. Contact SICK for specific information about these applications.

CAUTIONThese instructions assume that a proper risk assessment was performed for the original PLSinstallation and that the proper safety distances, field set sizes, and integration have been followed.Contact the appropriate plant safety personnel before replacing the PLS if there is any question orconcern that the existing installation does not comply with plant safety requirements.


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Summary of Steps

• Upload and save existing PLS configuration• Remove power to the PLS scanner• Unplug PLS connectors and remove scanner• Disassemble PLS power supply connector and cut wires• Re-wire cable to S3000 system plug• Mount S3000 to existing brackets• Attach S3000 system plug to scanner and apply power• Configure the S3000 scanner settings• Create the safety and warning field sets• Download the program to the scanner• Verify proper operation

Tools Required

• Allen wrench – 3 mm• Slotted screwdriver - 2.5 mm wide• Wire cutters• Wire strippers• Programming cable/connector for PLS• Programming cable for S3000• Laptop with PLS Configuration software and Configuration and Diagnostics Software (CDS)

Estimated Time to Complete

Initial upgrade: 120 minutesAdditional upgrades: 60 - 90 minutes


5

Saving the PLS Configuration

Uploading the PLS Configuration

Change User category to Authorizedclient or Maintenance. Enter thedefault password SICK_PLS (casesensitive) and click Logon.

Click File, then Save As... Enter a filename and change the save location ifnecessary and click SAVE.

Load PLS software. Follow theCommunication Assistant to connect tothe PLS.

When connected, click Yes to receivethe configuration.


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Viewing the PLS Configuration Printout

You will need to refer to the PLS Configuration information whileprogramming the S3000.

Click File, then Page Layout. The screen should look like the onebelow. Keep this window open while programming the S3000 so theinformation is readily available.


7

Hardware Conversion

CAUTIONMake sure you have successfully uploaded and saved the PLS configuration before proceeding withthe hardware conversion.

Step 1Remove supply power from the PLS.

Step 2Loosen the two allen head screws (3-mm hex head) and remove the power connector from PLShousing.

Step 3Remove the two screws holding the 9 pin female D-Sub connector shell to the power connectorhousing.

Step 4Loosen the cord grip and push the cable into the connector to expose the D-Sub connector andwires.

Step 5Verify that the wire colors match the pin position as shown in the table below. Note any differences.


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Step 6Cut the wires ¼ in. from the black end of the D-SUB connector and remove the cable from the powerconnector housing.

Step 7Remove the PLS from the mounting bracket.

Step 8Mount the S3000 using the same hardware and brackets. It should fit exactly in place of the PLS.

Step 9The system plug is shipped separately, but if it is already connected to the S3000, loosen the twoallen head screws (3-mm hex head) and pull up to remove the black system plug from the S3000.

Step 10Remove the two allen head screws (3-mm hex head) that hold the terminal board in the system plughousing.

Step 11Remove the terminal board and place it in an area protected from static electricity.

Step 12Loosen the cord grip on the system plug and insert the cable into the system plug housing. Pullenough cable through to provide easy access to the wires.


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FUNCTION COLOR S30000VDC BROWN TERM 2

RESTART BLUE TERM 5+24VDC RED TERM 1

NOT USEDWEAK SIGNAL GRAY *TERM 7 or 9

NOT USEDNOT USED

OSSD 2 TURQUOISE TERM 4OSSD 1 ORANGE TERM 3

Step 13Strip back 1/8 in. of insulation on each lead. Terminate each wire according to the table below. If theWeak Signal Output in the PLS Configuration is set to “Contamination,” connect the gray wire toterminal 7. If it is set to “Contamination or Object in Warning Field” or to “Object in Warning Field,”connect to terminal 9.* Based on Weak Signal Output setting in PLS Configuration.

Step 14Slide the terminal board back into the system plug housing and secure with the two allen headscrews.

Step 15Tighten the cord grip on the system plug.

Step 16Plug the system plug back into the S3000 and tighten the two allen head screws.

Step 17Turn on the supply power to the S3000 scanner. The scanner will go through an initializationprocedure for a few seconds and then will be ready to program. There should be a “6” showing in the7-segment Hex display.


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S3000 Scanner Configuration Using CDS v3.x.x

There are two different versions of the CDS software. It is recommended that CDS v3.x.x be used, butCDS v2.x.x will work to successfully configure an S3000 also. CDS v2.x.x is an earlier version whichhas a different look-and-feel and utilizes different configuration dialogs and in some cases may nottake advantage of new features available with the CDS v3.x.x.

The following configuration instructions are provided in detail for CDS v3.x.x. There is a similardocument available that describes the software conversion process using CDS v2.x.x. Should youneed this version, please contact your local sales support contact to request one.


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Initial CDS v3.x.x Set-up

Open the CDS 3.x.x software to get to thisdisplay.

Select S3000 Laser Scanner

Right click (or left double click) the com port thatwill be used to connect to the S3000. Select Adddevice from the menu.

If it is not known which com port to select,first connect the S3000 to the com port onthe PC. Highlight Serial Connection (RK512),then select the Identify Project icon from thetool bar. This will identify which com port isconnected to the S3000.


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Initial CDS v3.x.x Set-up - continued

Right click (or left double click) on the S3000 (1)and select Open device window.

Select the type of S3000 scanner to be used. Inmost cases for PLS upgrades it will be:

Sensor head: Low Range (4.om)I/O module: StandardI/O module software package: Basic package

Check that the model number displayed in theResults type code field at the bottom of thiswindow matches the model number of S3000being used.

When this is done click the Finish button.


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Initial CDS v3.x.x Set-up - continued

This now gives you the configurationmenus so you can set up your S3000in the same operating modes as thePLS.


14

Scanner Configuration

This is the device window. From here you can select the function you need to edit by either clicking on thetabs on the right or the noun name in the window tree on the left. This is true for all of the following stepsfor the scanner configuration set up and the field set editing. In the following steps, each tab will beselected and the necessary configuration changes will be described. It is also possible to select thefunctions from the window tree on the left.Note: the question marks in blue provide a quick link to the help file for the function you want to change.Double click on the question mark and you will get the help file explanation.

Use any descriptive text to identifythe scanner installation. In the Device name S3000 (1) field,

type in the name of the sensor listedin the PLS configuration.


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Scanner Configuration - continued

Set this to stationary. This is thesame as “area protection” in thePLS Configuration.

To match the PLS, the resolution must be setto 70 mm. Selecting a smaller resolution willshorten the maximum safety range allowed.

Do not use 150 mm as this will change thesafety distance and could result in seriousinjury or death.

Select 4.00 m [60 ms] as this gives youthe same range and angular resolution asthe PLS.

When using the S3000 Standard, the Inputstab should not show up in the device windowsince only one field set is possible just like thePLS. If this is the case, no configuration isrequired. Move to the next tab.

If using a higher level I/O module such as anS3000 Advanced or Professional, this tab isavailable. Leave these boxes uncheckedwhen doing a PLS upgrade. They are used forswitching between multiple monitoring cases,which was not possible with the PLS.


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Select the S3000 restart to match the PLS configuration from the list below. If delayed restart was used with thePLS, be sure to configure the duration in the S3000 configuration.

PLS Configuration S3000 ConfigurationThe immediate restart is used = Without restart interlock (Auto Reset)The manual restart is used = With restart interlock (Manual Reset)The delayed restart after x s is used = Time delayed by x Seconds (Auto Reset after time delay)

The PLS does not have Externaldevice monitoring capabilities. Makesure that this box remainsunchecked.


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This is an auxiliary output to indicate thatthe scanner lens is dirty, the scanner hasan error, or both.

Choose On contamination or Oncontamination or error.


Then click here to change the Field Setname to match the PLS Configuration formonitoring the area name.

Click here to highlight theField Set.


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If these numbers match, you do not need to makeany changes. Proceed to Defining the Field Set onpage 20.

If they don’t match, go to Monitoring caseConfiguration below and proceed as follows.

Double click here, on the monitoringcase name to open the configurationdialog window for this monitoring case.

Monitoring Case Configuration


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The basic scanner configuration has been set. The next section will step you through creating the Field Set shapes forthe safety and warning fields.

Monitoring Case Configuration - continued

The default Monitoring case name does notneed to be changed. If desired, you can changeit to be the same as the Field Set name.

Do not change the default values.

Make sure both check boxes are unchecked.

Change this number by clicking on the drop-down arrow and select the figure thatmatches the PLS Configuration.


20

Change back to the PLS software and close the PLS Configuration printout. Your screen should be similar to the onebelow. The safety field should be shown in blue.

Press F7 to open the Options dialog. Makesure the Units are set to Metric. 100 cmshould work fine. If the field is small, you maywant to use 50 cm. Click OK when done.

Make sure these settings match.

Zoom in or out to make sure thecomplete safety field is in view.

Defining the Field Set


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This is the Field Set tab preview.Highlight the Field Set as shown by the blue background.There are four functions that you can do from here.

Delete a Field Set by highlighting the Field Set and clickingon the Delete icon. At least one Field Set has to remain; theconfiguration software will not allow you to delete the lastField Set.

Add a new Field Set by clicking on the Add Field Set icon.This is not recommended when doing a conversion from aPLS to an S3000.

Edit the existing field by clicking on the Edit icon or doubleclicking with the left mouse key on the Field Set name.

You can change the Field Set name by typing a new name inthe name bar.

Change back to the S3000 software. Open the devicewindow and select via the Field Set tab or Field Setfrom the tree.

Defining the Field Set - continued


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TIP: At any time during editing, you can press andhold your right mouse button and move yourmouse to pan your view.

If there is an existing field, highlight thepoints and hit the Delete icon. This willclear any existing fields.

Maximize the window. Zoom in or out as necessary to match theapproximate size of the grid in the PLS software. Your screenshould look similar to the screen below. The grid size may notexactly match the PLS but make sure that the maximum gridsmatch, i.e. 200 cm.

The grid area may or may not matchclosely to the grid area in the PLSsoftware. Just make sure that themaximum number on the PLS and S3000grids are close.

Creating the Safety Field


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DRAWING TOOLSLeft click the button and select from the following tools:

Freehand Line - Left click and hold to draw freehand shapes.Single left click will place a point and connect the closest radialpoint on either side.

Straight Line - Left click places the first of three points. End pointautomatically snaps to the closest radial point depending on theposition of the cursor. Second left click places the midpoint. Area isadded or subtracted to connect the three points.

Sector of Circle - Left click sets the beginning radial position.Counter clockwise cursor movement adds to the existing area.Clockwise cursor movement subtracts from the existing area.

Click here to toggle on and off thesurrounding contour. This does not updatein real time so turn off and on to refresh.

Use the arrow tool to select singleor multiple points. Points can bedeleted or moved. Click and hold todrag points to a new position.

Press and hold Ctrl or Shift keys whileusing the drawing tools for additionalfunctionality like restricting tohorizontal or vertical movement.

Shows the coordinate position of your cursor. This isuseful for precisely placing your points.

The PLS software also shows the coordinates of thecursor position. You can easily find coordinateinformation for key points and use that to place yourpoints.

A red arc shows the maximumsafety distance.

Creating the Safety Field - continued


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Creating the Safety Field - Continued

The PLS Configuration printout showsthe Field Set shapes as well as all ofthe coordinates.

You can use this information toprecisely place points in the S3000Field Set.


25

Creating the Warning Field

Click here to switch to the Warning field. Use the same process tocreate the Warning field as used for the safety field.

You can skip this part if you do not have a Warning field setup in thePLS and are not signaling when there is an object in the Warningfield.

Switch to the Warning field in thePLS software by selecting it fromthe drop down box here.


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Saving The Program

After completing the Warning field,click File, then Close.

Before downloading, save the program.Click Project, then Save As…

Enter a filename and change the savelocation if necessary. Click the SAVEbutton when done.

To download the program to the S3000, right click onS3000 [1] then Configuration Draft, then Transfer.

Click Yes when prompted to start the transmission.

Downloading the Program


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NOTE: If there is any information that does not seem correct, click on the Reject buttonand go back through the previous steps and make the appropriate corrections.When you have finished reviewing the information, click the Release button todownload the program to the scanner.

Downloading the Program - Continued

After reading and verifying, clickOK to continue.

Review the information on this screen to verify thateverything is correct. Use the up and down arrows onthe right to scroll through the configuration.


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The program will take about 12 seconds todownload. A window will pop up when thedownload is complete. Press OK to finish.

It is important to verify the proper functioning of the scanner before putting it into operation. The S3000has an online monitoring function to monitor the performance of the scanner.

Open the device window, expand the diagnostics tree: then left click on Data Recorder.


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The data recorder will show the area contour, safety and warning fields,and any infringements in the safety zone.The status of the front LEDs is also shown on the left.


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Upgrade using CDS v 3.x.x Complete

This should complete the upgrade and the S3000 should be working correctly.

If you have any questions or problems performing this upgrade, support is available through yourlocal Authorized SICK Distributor or by calling SICK directly at (800) 325-7425.

Technical information is also available through our web site at www.sickusa.com.

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S A F E T Y S Y S T E M S

Products from SICK providecomprehensive safeguarding ofboth workers and machinery. Asexperts in sensor technology,SICK develops and manufacturespioneering products that provideprotection in hazardous zones,dangerous locations and forsafeguarding access points. Byproviding services, whichencompass all aspects of machinesafety and security, SICK issetting new standards in safetytechnology.

A U T O M AT I CI D E N T I F I C AT I O N

Our wide range of sensorsprovides solutions to suit anyapplication in the field ofautomation. Even under ruggedambient conditions, objects arereliably detected, counted andpositioned regardless of theirform, location and surface finish.

A N A LY Z E R S A N D P R O C E S SI N S T R U M E N TAT I O N

Whether the tasks involve identification, handling, classifi-cation or volume measurement,innovative automatic identificationsystems and laser measurementsystems from SICK functionreliably, even under rapid cycletimes. Products from SICKconform to the latest standardsand can be easily integrated inall industrial environments andexternal applications.

I N D U S T R I A L S E N S O R S

SICK is one of the world’s leadingmanufacturers of sensors, safetysystems, and automatic identifi-cation products for industrialapplications. SICK holds morethan 450 patents for its innovativeproducts. Through its IndustrialSensors, Safety Systems,Automatic Identification, andEnvironmental and ProcessAnalysis divisions, the companyhas operations in 65 countries.SICK North America is headquar-tered in Minneapolis, MN.

R A N G E O F E X P E R T I S E

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More representatives and agencies in all major industrial nations atwww.sick.com

Documents

PLS to S3000 Upgrade Instructions - Sensors Incorporated to...PLS TO S3000 UPGRADE 3 Introduction This document is provided to guide authorized maintenance personnel through the process