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industry guide

Efficient Solutions for the
Cement Industry

Achieving more with intelligent sensors
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3 lines max.
Groundbreaking solutions

Using intelligent sensors in process monitoring
and emission measurement...
Contents

10

Systems and project engineering	

8014937/2012-12
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6
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Challenges	
Senso...
Company
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We deliver “Sensor Intelligence.”
SICK sensor solutions for industri...
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Company

Innovation for the leading edge

A corporate culture for sustainable...
Industries
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“Sensor Intelligence.” for all requirements
SICK is a renowned ex...
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Industries

For your specific industry

For performance across the board

Wit...
SICK LifeTime Services
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For safety and productivity:
SICK LifeTime Services
S...
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SICK LifeTime Services

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Consulting &
Design

Verification &
Optimization

Tra...
PS_header1
3 lines max. the cement industry
Challenges for

Sensor highlights and customized analysis
technology from SICK...
Photo: media library Lafarge ©

Optimum material flow

Machine safety

Plant monitoring

Materials such as coal, rock, and...
Sensor solutions for the
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cement industry
3 lines max.

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ce m e n t i n d u s t r y | S I C K

8014937/201...
The following pages contain example applications
to demonstrate the use of SICK products in different phases of production...
Focus 1:
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Raw materials
3 lines max. extraction and processing

1

Conveyor belt supervision and crusher
monitor...
3

Process monitoring and precipitator protec- ▸
tion measurement at the preheater
The composition of the exhaust gas at t...
Focus 2a:
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Burning process
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2

1

sampling probe is suited to handle these process conditions.
Depe...
3

3

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Product: SIDOR, see page 33

Monitoring the coal bunker
The coal dust used as fuel is stored in bunkers. Coal bun...
Focus 2b:
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Burning process
3 lines max.

1

2

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and accurately perform non-contact gas velocity measurement, m...
and dust concentrations make measurement
more difficult. SICK provides a complete solution with the SCP3000 gas sampling p...
Focus 2c:
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Burning process
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ensure that the limit values are kept and also
provide an indicat...
to EN 15267-3 in Europe. With its broad
range of products for performing emissions
monitoring, SICK offers flexible, compl...
Focus 3a:
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Packing and
3 lines max. logistics

2

1

3

tor the usage of the bags fed from the roll.

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Packagi...
code reader)

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Tracking shipments
Reliable classification and tracking: From
identifying individual packages for trackin...
Focus 3b:
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Packing and
3 lines max. logistics

1

3
2

correct position for loading by robots. A safety
system e...
Focus 3c:
Packing and logistics

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entiation is handled at the feed area by the
M4000 Advanced multiple light beam ...
Systems and project engineering
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Everything from stand-alone devices to compl...
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SystemsPS_header1_small_blue
and project engineering

Project management according to international...
Product overview
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Versatile product range for industrial automation
From the ...
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Product overview

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Detection and ranging solutions
•• Laser measurement techno...
Product overview
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Automation light grids
•• Advanced automation light grids
•...
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Product overview

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Motor feedback systems
•• Interfaces: incremental, HIPERFAC...
DUSTHUNTER S | Dust Measuring Devices
FLOWSIC100 CEMS | Gas flow measuring devices
DUSTHUNTER S – At a glance
•• For very ...
Gas Analyzers | GM700
Gas Analyzers | SIDOR

GM700 – At a glance
•• High selectivity due to high spectral

•• No moving pa...
GMS800 | Gas Analyzers
MCS100FT | Gas Analyzers
GMS800 – At a glance
•• 7 different analyzer modules: DEFOR
(NDUV, UVRAS),...
Gas Analyzers | MERCEM300Z
Analyzer systems | MAC800

MERCEM300Z – At a glance
•• Accurate measurement of “total mercury” ...
MKAS systems | Analyzer systems
MCS100E systems | Analyzer systems
MKAS systems – At a glance
•• Up to 3 S710 or SIDOR ana...
Analyzer systems | MCS300P HW
Analyzer systems | SCP3000

MCS300P HW – At a glance
•• Simultaneous measurement of up to
6 ...
MEAC2000 | Data Acquisition Systems
W280-2 | Compact photoelectric sensors
MEAC2000 – At a glance
•• Evaluation according ...
Small photoelectric sensors | W12-3
Small photoelectric sensors | W14-2

W12-3 – At a glance
•• Best-in-class optical perf...
W9-3 | Small photoelectric sensors
W27-3 Reflex Array | Compact photoelectric sensors
W9-3 – At a glance
•• High-performan...
Miniature photoelectric sensors | G6
Analog positioning sensors | MPS

G6 - At a glance
•• PinPoint LED for a bright, prec...
IM Standard | Inductive proximity sensors
IQ Standard | Inductive proximity sensors
IM Standard – At a glance
•• Precise o...
Safety controllers | Flexi Soft
Electro-mechanical safety switches | i10 Lock

Flexi Soft – At a glance
•• Modularly expan...
ES21 | Safety command devices
E100 | Safety command devices
ES21 – At a glance
•• Either as surface-mounted version

•• Su...
Safety light curtains | C4000 Palletizer
Multiple light beam safety devices | M4000 Advanced

C4000 Palletizer – At a glan...
L27 | Single-beam photoelectric safety switch
AFS/AFM60 SSI | Absolute encoders
L27 – At a glance
•• Type 2 (IEC 61496), P...
Incremental encoders | DFS60
Image-based code readers ||LECTOR®62x
Image-based code readers LECTOR®62x

DFS60 – At a glanc...
LBV300 | Level sensors
Bulkscan LMS511 | Flow sensors
LBV300 – At a glance
•• Tough device design
•• Several housing mater...
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ce m e n t i n d u s t r y...
Connectivity –
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Always well-connected with SICK

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Current data via standardized...
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Connectivity –
Always well-connected with SICK

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Operational management level
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Notes
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Services

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www.mysick.com – search online and order
Search online quickly and ...
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SICK at a glance

Leading technologies

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Efficient Solutions For The Cement Industry

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Transcript of "Efficient Solutions For The Cement Industry"

  1. 1. industry guide Efficient Solutions for the Cement Industry Achieving more with intelligent sensors
  2. 2. PS_header1 3 lines max. Groundbreaking solutions Using intelligent sensors in process monitoring and emission measurement Achieving high process energy efficiency and ensuring high product quality are the hallmarks of cost-effective cement production. The use of alternative fuels is becoming increasingly important. This makes it even more necessary to monitor the relevant processes using continuous gas analysis measurement technology. Compliance with the local emission limit values must also be ensured. SICK analyzer systems and the related technologies are best suited to handle the demanding requirements of cement plant operations. SICK‘s broad product range makes it possible to find the optimal solutions for measuring the required operational parameters, even at high gas temperatures and dust concentrations. SICK analyzer systems are successfully used worldwide for providing continuous monitoring of emission limit values. SICK is the only manufacturer that can provide the full range of sensors for measuring dust concentration, volume flow, and gas concentration and for performing data acquisition. Titlephoto: media library Lafarge © SICK sensors are used for controlling the processes related to cement production, including mass determination when transporting raw material, level measurement in silos, and object recognition in packaging machines. SICK stands for automation and benefits from decades of practical experience and expertise in just about every industry – this is what Sensor Intelligence is all about. 2 ce m e n t i n d u s t r y | S I C K 8014937/2012-12 Subject to change without notice
  3. 3. Contents 10 Systems and project engineering 8014937/2012-12 Subject to change without notice 4 6 8 Challenges Sensor solutions for the cement industry Photo: media library Lafarge © About SICK Industries SICK LifeTime Services 26 Product Portfolio overview Range of products 28 32 Connectivity SICK “Finders” / Partner Portal 50 59 ce m e n t i n d u s t r y | S I C K 3 12
  4. 4. Company PS_header1_small_blue PS_header2_small_blue We deliver “Sensor Intelligence.” SICK sensor solutions for industrial automation are the result of exceptional dedication and experience. From development all the way to service: The people at SICK are committed to investing all their expertise in providing with the very best sensors and system solutions possible. A company with a culture of success Over 5,800 people are on staff, with products and services available to help SICK sensor technology users increase their productivity and reduce their costs. Founded in 1946 and headquartered in Waldkirch, Germany, SICK is a global sensor specialist with nearly 50 subsidiaries and representations worldwide. 4 ce m e n t i n d u s t r y | S I C K Our exemplary corporate culture fosters an optimum worklife balance, thus attracting the best employees from all over the world. SICK is one of the best employers – we have been among the winners of the prestigious German “Great Place to Work” award for many years in succession. 8014937/2012-12 Subject to change without notice
  5. 5. PS_header2_small_blue PS_header1_small_blue Company Innovation for the leading edge A corporate culture for sustainable excellence SICK sensor systems simplify and optimize processes and allow for sustainable production. SICK operates at many research and development centers all over the world. Co-designed with customers and universities, our innovative sensor products and solutions are made to give a decisive edge. With an impressive track record of innovation, we take the key parameters of modern production to new levels: reliable process control, safety of people and environmental protection. SICK is backed by a holistic, homogeneous corporate culture. We are an independent company. And our sensor technology is open to all system environments. The power of innovation has made SICK one of the technology and market leaders – sensor technology that is successful in the long term. 8014937/2012-12 Subject to change without notice ce m e n t i n d u s t r y | S I C K 5
  6. 6. Industries PS_header1_small_blue PS_header2_small_blue “Sensor Intelligence.” for all requirements SICK is a renowned expert in many industries, and is entirely familiar with the critical challenges they face. While speed, accuracy and availability take center stage in all industries, technical implementations vary greatly. SICK puts its vast experience to use to provide with precisely the solution you need. For applications worldwide Hundreds of thousands of installations and applications go to prove that SICK knows the different industries and their processes inside out. This tradition of uncompromising expertise is ongoing: As we move into the future, we will continue to design, 6 ce m e n t i n d u s t r y | S I C K implement and optimize customized solutions in our application centers in Europe, Asia and North America. You can count on SICK as a reliable supplier and development partner. 8014937/2012-12 Subject to change without notice
  7. 7. PS_header2_small_blue PS_header1_small_blue Industries For your specific industry For performance across the board With a track record of proven expertise in a great variety of industries, SICK has taken quality and productivity to new heights. The automotive, pharmaceutical, electronics and solar industries are just a few examples of sectors that benefit from our know-how. In addition to increasing speed and improving traceability in warehouses and distribution centers, SICK solutions provide accident protection for automated guided vehicles. SICK system solutions for analysis and flow measurement of gases and liquids enable environmental protection and sustainability in, for example, energy production, cement production or waste incineration plants. SICK provides the right technology to respond to the tasks involved in industrial automation: measuring, detecting, monitoring and controlling, protecting, networking and integrating, identifying, positioning. Our development and industry experts continually create groundbreaking innovations to solve these tasks. 8014937/2012-12 Subject to change without notice www.sick.com/industries ce m e n t i n d u s t r y | S I C K 7
  8. 8. SICK LifeTime Services PS_header1_small_blue PS_header2_small_blue For safety and productivity: SICK LifeTime Services SICK LifeTime Services is a comprehensive set of high-quality services provided to support the entire life cycle of products and applications from plant walk-through all the way to upgrades. These services increase the safety of people, boost the productivity of machines and serve as the basis for our customers’ sustainable business success. The benefit of SICK services Each of our products and solutions is accompanied by a comprehensive range of services tuned precisely to the requirements of the product or solution – along its entire life cycle. Backed by extensive industry expertise and more than 60 years 8 ce m e n t i n d u s t r y | S I C K of experience, LifeTime Services stand for maximum availability and an exceptional service life of our products and solutions. 8014937/2012-12 Subject to change without notice
  9. 9. PS_header1_small_blue SICK LifeTime Services PS_header2_small_blue Consulting & Design Verification & Optimization Training & Education •• •• •• •• •• •• •• •• •• •• •• •• User training •• Seminars •• WebTraining Plant walk-through Risk assessment Safety concept Feasibility studies Software and hardware design Inspection Maintenance Barcode checks Accident investigation Stoptime measurement Machine safety inspection Product & System Support Upgrade & Retrofits •• •• •• •• •• Machine conversion •• Sensor upgrades •• Retrofitting of technology Commissioning Exchange units and repairs Remote support Hotline www.sick.com/services 8014937/2012-12 Subject to change without notice ce m e n t i n d u s t r y | S I C K 9
  10. 10. PS_header1 3 lines max. the cement industry Challenges for Sensor highlights and customized analysis technology from SICK The cement sector plays an important role within the building materials industry. Productivity and product quality are the decisive factors on the international stage. The cement industry, with its high level of energy and raw materials use, is particularly concerned with conserving natural resources and protecting the global climate. Cement plants are therefore equipped with the most modern sensors and analyzer systems in order to meet market requirements for quality and cost efficiency. By providing intelligent solutions, SICK has proven itself in all areas of cement production – from the extraction of raw materials to the distribution of the end product. Emission measurement Quality control Service The cement industry continuously monitors emission levels in order to ensure environmentally friendly production. SICK’s analysis technology provides the process control center with all required values from the measured components. These values can then be further processed in an emission data acquisition system if required. SICK offers an intelligent, rugged rotary kiln inlet measurement solution for monitoring clinker production. As when measuring emissions, it is also important here to reconcile high measurement availability with low maintenance cost. SICK is a single source for a complete range of services – expert advice, skilled planning services, detailed project planning and engineering, installation, and commissioning. We also provide reliable post-sales maintenance and repair support. 10 ce m e n t i n d u s t r y | S I C K 8014937/2012-12 Subject to change without notice
  11. 11. Photo: media library Lafarge © Optimum material flow Machine safety Plant monitoring Materials such as coal, rock, and clinker are valuable. Accurately determining stored or transported quantities is vital for ensuring optimum production flow. SICK’s level sensors and volume measurement systems make it possible to manage storage and transport in order to match requirements. Whether on the packaging machine or when palletizing cement bags, safety solutions from SICK ensure operator safety, optimize production, reduce the machine footprint, and minimize downtimes. Monitoring the electrostatic precipitator to prevent explosion due to the sudden buildup of an excessive concentration of CO is just as much a part of the proven complete solution as monitoring the coal bunker for smoldering fire. 8014937/2012-12 Subject to change without notice ce m e n t i n d u s t r y | S I C K 11
  12. 12. Sensor solutions for the PS_header1 cement industry 3 lines max. 12 Ce ce m e n t i n d u s t r y | S I C K 8014937/2012-12 Subject to change without notice
  13. 13. The following pages contain example applications to demonstrate the use of SICK products in different phases of production. Focus 1 14 Raw materials extraction and processing Focus 2a 16 Burning process Focus 2b 18 Burning process Focus 2c 20 Burning process Focus 3a 22 Packaging and logistics Focus 3b 24 Packaging and logistics Focus 3c 25 Packaging and logistics 8014937/2012-12 Subject to change without notice ce m e n t i n d u s t r y | S I C K 13
  14. 14. Focus 1: PS_header1 Raw materials 3 lines max. extraction and processing 1 Conveyor belt supervision and crusher monitoring The Bulkscan® LMS511 laser volume flowmeter provides non-contact detection of the volume flow on conveyor belts, based on the principle of laser light time-of-flight measurement. The Bulkscan® LMS511 features rug- control at the crusher or at transfer points. Integrated loading center of gravity detection enables maximum transport performance and the detection of one-sided loads and one-sided conveyor belt loads. Conveyor belt control permits the detection of belt slippage, thus identifying elevated belt wear costs. ◂ ged construction, high reliability, and wearfree operation allows continuous quantity 2 1 Product: Bulkscan® LMS511, see page 48 14 ce m e n t i n d u s t r y | S I C K 8014937/2012-12 Subject to change without notice
  15. 15. 3 Process monitoring and precipitator protec- ▸ tion measurement at the preheater The composition of the exhaust gas at the outlet of the preheater provides information about the progression of the burning process, as well as indications of an imminent risk of explosion for the downstream electrostatic precipitator. To acquire this information, changes in the concentration of the gas components CO, NO, O2, and, if applicable, 3 SO2, are measured at the preheater. The occurrence of high CO peaks in the exhaust gas indicates a risk for the downstream electrostatic precipitator. The MAC800 extractive analyzer system with the GMS800 gas analyzer is suited to this measurement task involving high dust loading, the gas temperatures, and the space limitations. This system enables reliable process gas monitoring, thus providing an economical solution for increasing plant efficiency and safety Product: GMS800, see page 34 is easy to install and can be commissioned without filling. These product features make the LBV300 suitable not only for use in raw materials extraction and processing, but also for monitoring the filling level of the finished cement. ◂ Overfill protection for aggregates and raw meal Before burning, the raw meal and the aggregates are crushed in a pulverizer. Reliable monitoring of the filling level is indispensable for ensuring continuous production. With no mechanical moving parts, the LBV300 vibrating level switch is highly rugged and is also immune to deposit formation. In addition, it 2 Product: LBV300, see page 48 8014937/2012-12 Subject to change without notice ce m e n t i n d u s t r y | S I C K 15
  16. 16. Focus 2a: PS_header1 Burning process 3 lines max. 2 1 sampling probe is suited to handle these process conditions. Depending on the plant, the measurement point is located at a suitable point between the calciner outlet and the preheater outlet. ◂ ◂ Optimizing secondary firing in the calciner In many cement plants, a calciner with secondary firing is interposed between the preheater and the rotary kiln. The CO, NO, O2, and, if applicable, SO2 gas components in the kiln exhaust gas are continuously monitored in order to optimize the operation of the calciner. An MCS300P HW hot-measuring analyzer system with a back-purging gas 1 Product: MCS300P HW, see page 37 16 ce m e n t i n d u s t r y | S I C K 8014937/2012-12 Subject to change without notice
  17. 17. 3 3 ◂ Product: SIDOR, see page 33 Monitoring the coal bunker The coal dust used as fuel is stored in bunkers. Coal bunkers present the risk of smoldering fires in which CO can accumulate to form explosive mixtures with the air. By performing continuous measurement of the CO concentration, smoldering fires can be identified at an early stage (due to the rise in CO) and handled in a timely manner. In addition, smoldering fires. The MKAS Compact analyzer system with an Ex-protected sampling probe is the ideal solution. The integrated SIDOR gas analyzer allows the simultaneous measurement of CO and O2 and can be adjusted using ambient air. This sophisticated system provides the reliability needed for safety-related measurements. ◂ Monitoring CO and O2 to protect the coal mill Coal dust is a commonly used fuel for cement kilns. Inert gas is introduced into the coal mill to prevent fires. A rise in the O2 concentration indicates a leak and the entry of air. By performing continuous O2 measurement, leaks can be identified early and handled in a timely manner. If required, CO measurement can be extended to detecting O2 measurement can be integrated in order to monitor inert gas. The MKAS Compact analyzer system with an Ex-protected sampling probe is the ideal solution. The integrated SIDOR gas analyzer allows the simultaneous measurement of CO and O2 and can be adjusted using ambient air. The long maintenance intervals reduce operating costs. 2 Product: SIDOR, see page 33 8014937/2012-12 Subject to change without notice ce m e n t i n d u s t r y | S I C K 17
  18. 18. Focus 2b: PS_header1 Burning process 3 lines max. 1 2 3 and accurately perform non-contact gas velocity measurement, making them especially suited to optimization. The FLOWSIC100 H-AC model is especially suited for performing measurements under conditions of high gas temperature and dust concentration. The low-maintenance FLOWSIC100 devices allow efficient process regulation even with highly fluctuating flows. ◂ Flue gas conditioning for performing downstream dedusting In the cooling tower, the hot exhaust gas from the heat exchanger is cooled by injecting water if necessary. This protects filter systems from excessively high gas temperatures and increases filtering efficiency when using electrostatic precipitators. The devices in SICK’s FLOWSIC100 product family continuously 1 Product: FLOWSIC100 CEMS, see page 32 18 ce m e n t i n d u s t r y | S I C K 8014937/2012-12 Subject to change without notice
  19. 19. and dust concentrations make measurement more difficult. SICK provides a complete solution with the SCP3000 gas sampling probe and the MCS300P HW analyzer system. ◂ Monitoring process gases at the rotary kiln inlet The quality of the cement clinker is highly dependent on the process conditions in the rotary kiln. Performing gas analysis in the rotary kiln process provides the opportunity to optimize the kiln firing and the burning process simultaneously. The extreme measurement conditions under high temperatures 2 3 Product: SCP3000, see page 37 8014937/2012-12 Subject to change without notice Product: MCS300P HW, see page 37 ce m e n t i n d u s t r y | S I C K 19
  20. 20. Focus 2c: PS_header1 Burning process 3 lines max. 1 2 ensure that the limit values are kept and also provide an indicator of possible leaks or other malfunctions in the filtering equipment. The DUSTHUNTER SP100 scattered light measuring device with a single-side mountable measuring probe is especially suited for fabric filters, while the DUSTHUNTER T200 transmissiometer is suited for electrostatic precipitators. Both devices have an integrated device monitoring and thus require very little maintenance. ◂ Monitoring exhaust gas dedusting downstream from the clinker cooler and the coal mill Dedusting equipment is used in cement plants for maintaining compliance with the regulatory dust limit values in exhaust gas in accordance with local regulations. Electrostatic precipitators or fabric filters are used for dedusting. The measurement results 1 Product: DUSTHUNTER S, see page 32 20 ce m e n t i n d u s t r y | S I C K 8014937/2012-12 Subject to change without notice
  21. 21. to EN 15267-3 in Europe. With its broad range of products for performing emissions monitoring, SICK offers flexible, complete one-stop solutions. Dust measuring devices in the DUSTHUNTER product family, in-situ gas analyzers such as the GM700, and extractive gas analyzer systems such as the MCS100E HW and MCS100FT all find application here. Analyzers for special components, such as the MERCEM300Z for mercury (Hg), round out the portfolio of solutions. The FLOWSIC100 CEMS product family provides volume flow measurement, and the MEAC2000 system performs data acquisition. The use of extractive or insitu technology provides an ideal way to meet local measurement requirements. ◂ Measuring exhaust gas emissions Environmental regulations stipulate that certain pollutants in the exhaust gas emitted by cement plants, as well as the reference values, must be continuously monitored. The emissions monitoring regulations vary from country to country. In many countries, the emission measurement technology must be performance-tested, for example, according 2 Product: MCS100FT, see page 34 8014937/2012-12 Subject to change without notice ce m e n t i n d u s t r y | S I C K 21
  22. 22. Focus 3a: PS_header1 Packing and 3 lines max. logistics 2 1 3 tor the usage of the bags fed from the roll. ◂ Packaging machine (rotary packing machine) The bagging equipment is specifically tailored to the more stringent requirements of cement packaging. SICK sensors handle all packaging machine detection tasks, from the packaging material feed system to the finished filled cement bags. Here, the WL12-3 and WL9-3 small photoelectric sensors moni- 1 2 Product: WL12, see page 39 22 ce m e n t i n d u s t r y | S I C K Product: WL9, see page 40 8014937/2012-12 Subject to change without notice
  23. 23. code reader) ◂ Tracking shipments Reliable classification and tracking: From identifying individual packages for tracking the serial number or production line, to identifying palettes in distribution. IDpro stands for SICK’s expertise in performing automated identification (1D or 2D codes, transponders) using laser measurement sensors, cameras, and RFID. (Image: LECTOR®62x image-based 3 Product: Lector®62x, see page 47 8014937/2012-12 Subject to change without notice ce m e n t i n d u s t r y | S I C K 23
  24. 24. Focus 3b: PS_header1 Packing and 3 lines max. logistics 1 3 2 correct position for loading by robots. A safety system ensures personnel protection and process safety. The C4000 Palletizer safety light curtain ensures intelligent human-material differentiation at the output of the palletizer system. Three L27 single-beam photoelectric safety switches monitor the feed area. The protective devices must be reset via the reset pushbutton. ES21 emergency stop pushbuttons complete the protection. The Flexi Soft safety controller links the signals from the safety sensors and actuators, thus ensuring the operation of the safety functions. ◂ Palletizing Automatic palletizers stack the filled cement bags onto pallets. The WL27-3 compact photoelectric sensor and the WT14-2 small photoelectric sensor ensure reliable detection in automatic feed systems. The transport speed of the cement bags is monitored by the DSF60 incremental encoder. The MPS analog positioning sensor detects the empty pallets in the 1 2 Product: L27, see page 46 24 ce m e n t i n d u s t r y | S I C K 3 Product: MPS, see page 41 Product: ES21, see page 44 8014937/2012-12 Subject to change without notice
  25. 25. Focus 3c: Packing and logistics 5 4 6 entiation is handled at the feed area by the M4000 Advanced multiple light beam safety device with a UE403 and four WL280-2 compact photoelectric sensors, and at the output area by a C4000 Palletizer safety light curtain. The i10 Lock and i110S electromechanical safety switches monitor the access door. ES21 emergency stop pushbuttons complete the protection. An E100 enabling switch is used for safe setup operation. The Flexi Soft safety controller links the signals from the safety sensors and actuators, thus ensuring the operation of the safety functions. ◂ Stretch banding machine After the pallet has reached its position, the stretch film is secured to the palette and wrapped using upward and downward movements of the film. SICK’s IQ40, AFM60, and WL280-2 products handle both the measurement of palette dimensions and the detection tasks for controlling the wrapping process. Access protection with human-material differ- 4 5 Product: IQ40, see page 42 8014937/2012-12 Subject to change without notice 6 Product: AFM60, see page 46 Product: i10 Lock, see page 43 ce m e n t i n d u s t r y | S I C K 25
  26. 26. Systems and project engineering PS_header1_small_blue PS_header2_small_blue Everything from stand-alone devices to complete analyzer systems SICK provides application-related system solutions based on an extensive range of products. In addition to standard solutions, SICK also provides customized system solutions for the cement industry. Ready-to-use analyzer containers Whether used for emissions or process measurements, the analyzers should be installed in the immediate vicinity of the measurement points. Analysis containers serve an important function here by protecting the highly precise measuring systems and signal processing devices from the harsh ambient conditions at the installation site in the cement plant. Custom planning and engineering Planning and engineering at SICK is combined with decades of experience in of emissions and process monitoring. SICK’s engineers use the latest CAD systems to plan and design solutions to handle the cement plant requirements. In doing so, the latest technology in analyzers and sample conditioning is deployed, and the current communications interfaces are used to ensure rapid data transfer. Systems are designed in accordance with the applicable international standards, as well as many national standards. Implemented solutions are extensively and clearly documented. The system documentation thus forms the basis for creating comprehensive project documentation and for supplying replacement parts rapidly. Customers have an experienced project team and a worldwide service organization at their disposal through commissioning and afterwards to ensure reliable and sustained system operation. 26 ce m e n t i n d u s t r y | S I C K 8014937/2012-12 Subject to change without notice
  27. 27. PS_header2_small_blue SystemsPS_header1_small_blue and project engineering Project management according to internationally recognized methods SICK ensures globally consistent and effective project management. No matter in what country our customers award a project contract to SICK, our international project teams provide consistent project results based on the same high standards of quality. Experienced project teams support the projects starting with the contract award and continuing through to acceptance at the construction site. These teams work to adhere to the scheduled project delivery deadlines, organize the system ac- 8014937/2012-12 Subject to change without notice ceptance in the plant or on-site, and update the project documentation in consultation with the customer. The project team remains available even after the conclusion of the project. The responsible project team begins supporting complex projects as early as the bidding phase. This ensures that all project requirements are correctly understood and included in the bid. ce m e n t i n d u s t r y | S I C K 27
  28. 28. Product overview PS_header1_small_blue PS_header2_small_blue Versatile product range for industrial automation From the simple acquisition task to the key sensor technology in a complex production process: With every product from its broad portfolio, SICK offers a sensor solution that best combines cost effectiveness and safety. www.sick.com/products Photoelectric sensors •• Miniature photoelectric sensors •• Small photoelectric sensors •• Compact photoelectric sensors •• Fiber-optic sensors and fibers •• Cylindrical photoelectric sensors •• MultiTask photoelectric sensors •• Inductive proximity sensors •• Capacitive proximity sensors •• Magnetic proximity sensors •• Analog positioning sensors •• Sensors for T-slot cylinders •• Sensors for C-slot cylinders •• Sensor adapters for other cylinder types •• Bar code scanners •• Image-based code readers •• Hand-held scanners •• RFID Proximity sensors Magnetic cylinder sensors Identification solutions 28 ce m e n t i n d u s t r y | S I C K 8014937/2012-12 Subject to change without notice
  29. 29. PS_header1_small_blue Product overview PS_header2_small_blue Detection and ranging solutions •• Laser measurement technology System solutions •• Volume measurement systems •• Code reading systems •• Dimension weighing scanning systems •• Vision systems •• Level sensors •• Pressure sensors •• Flow sensors •• Temperature sensors •• •• •• •• •• Array sensors •• Register sensors •• Markless sensors Fluid sensors Registration sensors Contrast sensors Color sensors Luminescence sensors Fork sensors Distance sensors •• Short range distance sensors (displacement) •• Mid range distance sensors •• Long range distance sensors •• Linear measurement sensors 8014937/2012-12 Subject to change without notice •• •• •• •• Ultrasonic sensors Double sheet detector Optical data transmission Position finders ce m e n t i n d u s t r y | S I C K 29
  30. 30. Product overview PS_header1_small_blue PS_header2_small_blue Automation light grids •• Advanced automation light grids •• Standard automation light grids •• Smart light grids •• Vision sensors •• Smart cameras •• 3D cameras •• •• •• •• •• Single-beam photoelectric safety switches •• Mirror and device columns •• Upgrade kits Vision Opto-electronic protective devices Safety laser scanners Safety camera systems Safety light curtains Multiple light beam safety devices Safety switches •• Electro-mechanical safety switches •• Non-contact safety switches •• Safety command devices •• Safety relays •• Safety controllers •• Network solutions sens:Control – safe control solutions 30 ce m e n t i n d u s t r y | S I C K 8014937/2012-12 Subject to change without notice
  31. 31. PS_header1_small_blue Product overview PS_header2_small_blue Motor feedback systems •• Interfaces: incremental, HIPERFACE® and HIPERFACE DSL® •• Safety motor feedback systems •• Rotary and linear motor feedback systems for asynchronous, synchronous motors and linear motors •• Absolute encoders •• Incremental encoders •• Linear encoders •• Wire draw encoders •• Gas analyzers •• Dust measuring devices •• Analyzer systems •• Liquid analyzers •• Data acquisition systems •• Tunnel sensors •• Gas flow meters •• Mass flow meters •• Volume flow measuring devices Encoders Analyzers and systems Gas flow measuring devices Software •• Safexpert® safety software 8014937/2012-12 Subject to change without notice ce m e n t i n d u s t r y | S I C K 31
  32. 32. DUSTHUNTER S | Dust Measuring Devices FLOWSIC100 CEMS | Gas flow measuring devices DUSTHUNTER S – At a glance •• For very low to medium dust concen- •• Automatic check of zero and refer- trations •• For small to large duct diameters •• Contamination check (not DUST- ence point HUNTER B50) Your benefits •• Easy installation, commissioning, and •• Approved according to EN 15267-3 operation •• Measurement independent of gas velocity, humidity and particle charge •• Low maintenance due to self-moni- (not DUSTHUNTER SB50) toring -- www.mysick.com/en/DUSTHUNTER_S For more information, just enter the link and get direct access to technical data, CAD design models, operating instructions, software, application examples and much more. FLOWSIC100 CEMS – At a glance •• Rugged titanium transducers for high durability •• Corrosion-resistant material for application in aggressive gases (option) •• Integral measurement over the duct diameter with types H, M and S •• Probe type PR for economic installation from one side of the duct •• Automatic function control with zero and span point check Your benefits •• Reliable flow measurement for ducts •• Measurement without pressure with small up to very large diameters •• High durability of the device •• Minimum operating and maintenance costs •• Accurate measuring results under difficult measuring conditions loss, therefore no influences on the process •• User-friendly operation via SOPAS ET software •• Reliable function monitoring due to enhanced diagnosis -- www.mysick.com/en/FLOWSIC100_CEMS For more information, just enter the link and get direct access to technical data, CAD design models, operating instructions, software, application examples and much more. 32 ce m e n t i n d u s t r y | S I C K 8014937/2012-12 Subject to change without notice
  33. 33. Gas Analyzers | GM700 Gas Analyzers | SIDOR GM700 – At a glance •• High selectivity due to high spectral •• No moving parts: minimal wear and resolution •• Short response times •• No calibration required •• No gas sampling and conditioning tear required Your benefits •• Unbiased measuring values due to in-situ measurement directly in the process •• Best application solution using probe or cross-duct type •• High reliability during operation •• Also applicable for harsh environment conditions •• Detection of fast and short-term process fluctuations -- www.mysick.com/en/GM700 For more information, just enter the link and get direct access to technical data, CAD design models, operating instructions, software, application examples and much more. SIDOR – At a glance •• Detector with high long-term stability •• Paramagnetic or electrochemical O2 measurement •• Automatic adjustment with component-free ambient air •• Insensitive to contaminations Your benefits •• Automatic adjustment, self-monitoring •• TÜV approval and ATEX type approval and fault diagnosis •• Test gas adjustment only every 6 months •• Long maintenance intervals •• Repairable on site •• Exchange of components without for measurement of CH4, CO2 and O2 complicated temperature adjustment in the factory -- www.mysick.com/en/SIDOR For more information, just enter the link and get direct access to technical data, CAD design models, operating instructions, software, application examples and much more. 8014937/2012-12 Subject to change without notice ce m e n t i n d u s t r y | S I C K 33
  34. 34. GMS800 | Gas Analyzers MCS100FT | Gas Analyzers GMS800 – At a glance •• 7 different analyzer modules: DEFOR (NDUV, UVRAS), FIDOR (FID), MULTOR (NDIR), OXOR-E (electrochemical O2), OXOR-P (paramagnetic O2), THERMOR (TC) and UNOR (NDIR) •• 4 different types of enclosures •• Gas module with sample gas pump and/or control sensors •• New enclosure type for easy and quick integration in analyzer cabinets •• Remote diagnosis via Ethernet with software SOPAS ET Your benefits •• Approved according to EN 15267-3 •• Minimal influence of ambient temper- and EN 14181 •• Installations in Non-Ex-areas and Ex-areas (Zone 1 and 2 according to ATEX) possible •• Minimum service and maintenance work as well as easy reconditioning of existing installations due to modular design •• Adjustment without test gases via optional adjustment unit ature through thermostatic controlled modules •• System solutions with turn-key analyzer cabinets MAC800 •• Reliable measuring results by proven measurement technology •• Easy maintenance and repair due to replacement of complete assemblies or modules -- www.mysick.com/en/GMS800 For more information, just enter the link and get direct access to technical data, CAD design models, operating instructions, software, application examples and much more. MCS100FT – At a glance •• Lowest approved HF measuring range of 0 ... 3 mg/m³ •• Automatic spectrum adjustment via AutoVAL for reliable measuring values •• Operation via touchscreen •• Sample gas transport by an ejector without moving parts •• Approved according to EN 15267-3 •• Remote control and diagnosis via software SOPAS ET •• Automatic adjustment, backflushing and filter cleaning Your benefits •• Proper HF limit value monitoring •• Only one analyzer for more than 10 measuring components •• Easy integration into the customer network environment •• Long maintenance interval of 6 months for most components •• Type approved measurement of greenhouse gases such as N2O, CH4 and CO2 •• Low maintenance requirements -- www.mysick.com/en/MCS100FT For more information, just enter the link and get direct access to technical data, CAD design models, operating instructions, software, application examples and much more. 34 ce m e n t i n d u s t r y | S I C K 8014937/2012-12 Subject to change without notice
  35. 35. Gas Analyzers | MERCEM300Z Analyzer systems | MAC800 MERCEM300Z – At a glance •• Accurate measurement of “total mercury” directly in a thermal converter (patented) •• Measuring operation without using consumables •• Very low maintenance gas sampling using an ejector pump – no moving parts •• Integrated adjustment cell for automatic drift correction •• Automatic adjustment of the entire measuring system with a built-in test gas generator (optional) •• Modular design with the entire system Your benefits •• Reliable results of the actual measuring values of elemental Hg and Hg compounds in gases •• Very low operating expenses •• Minimum maintenance expenditure •• Long-term stability minimizes technician time requirements due to selfadjusting measuring system •• Measuring certainty using the fully automated adjustment with test gas •• Convenient and fast access for easy service and user-friendly remote diagnosis -- www.mysick.com/en/MERCEM300Z For more information, just enter the link and get direct access to technical data, CAD design models, operating instructions, software, application examples and much more. MAC800 – At a glance •• Cold-extractive analyzer system certified according to EN 15267-3 •• Plug-and-play analyzer modules with 24 V power supply •• Operating unit for displaying all measured values and status information on a touch screen •• External sensors via interfaces connectable •• Display and control of external sensors is possible •• Remote control of the complete system via Ethernet, Modbus or additional GPRS modem Your benefits •• Cost-effective investment because of •• Easy service due to clear separation easy modifications for future needs •• Easy commissioning and trouble-free on-site approval of the automatic measuring system (AMS) by the relevant authorities •• Full overview via touchscreen and integration of remote sensors (p, T, volume flow, dust) of the electrical and the analytical sections •• High availability through easy and fast change of modules •• Ethernet or Modbus connection to networks -- www.mysick.com/en/MAC800 For more information, just enter the link and get direct access to technical data, CAD design models, operating instructions, software, application examples and much more. 8014937/2012-12 Subject to change without notice ce m e n t i n d u s t r y | S I C K 35
  36. 36. MKAS systems | Analyzer systems MCS100E systems | Analyzer systems MKAS systems – At a glance •• Up to 3 S710 or SIDOR analyzers or •• Can be upgraded with optional com- NOx-converter •• Includes the major system components •• Wired and tested – ready for use ponents Your benefits •• Due to modular concept adaptable to •• Fulfills the requirements for an auto- the measuring task •• Proven system components offer a reliable solution matic measuring system according to EU standards •• Reduced response times due to sample gas bypass -- www.mysick.com/en/MKAS_systems For more information, just enter the link and get direct access to technical data, CAD design models, operating instructions, software, application examples and much more. MCS100E systems – At a glance •• Extractive measurement of up to 8 IR-active gas compounds •• Additional oxygen and total hydrocarbon analyzers as an option •• Test gas supply at the gas sampling probe or at the analyzer •• Back-purging of gas sampling probe for cleaning of filters •• Fast sample gas exchange for minimizing adsorption and desorption effects •• Automated sample point switching Your benefits •• Measurement of several gas compo- •• QAL3 drift test according to EN nents with one analyzer •• Heated gas paths enables measurement of difficult gases like HCl and NH3 •• Long maintenance intervals (typically 3 months) due to self monitoring of the analyzer 14181 with internal calibration filter wheel – no test gas required •• Especially low measurement ranges for SO2, NO, NO2 possible -- www.mysick.com/en/MCS100E_systems For more information, just enter the link and get direct access to technical data, CAD design models, operating instructions, software, application examples and much more. 36 ce m e n t i n d u s t r y | S I C K 8014937/2012-12 Subject to change without notice
  37. 37. Analyzer systems | MCS300P HW Analyzer systems | SCP3000 MCS300P HW – At a glance •• Simultaneous measurement of up to 6 components plus O2 •• Sample flow control and sample gas pressure measurement •• Temperature of heated system components up to 220 °C •• Automatic sample point switching for up to 8 sample points (option) •• Automatic adjustment of zero and span point •• Integrated adjustment unit without span gas (option) •• Extended operation via PC and software •• Flexible I/O modules Your benefits •• Economic, automatic adjustment without expensive test gases •• Easy remote control by integration in existing networks •• Automatic control of the complete measuring system and probe •• Low maintenance and reliable due to hot measurement •• In combination with probe SCP3000 also for measurements at high dust loads and high temperatures -- www.mysick.com/en/MCS300P_HW For more information, just enter the link and get direct access to technical data, CAD design models, operating instructions, software, application examples and much more. SCP3000 – At a glance •• For gas temperatures up to 1400 °C •• For very high dust loads up to 2000 g/m³ •• Effective shock blower prevents blockage on probe inlet •• Rotating unit prevents backing of deposits on probe surface •• Self-test functions to protect components against power, coolant or compressed air malfunction •• Pneumatic or electric retraction of the probe in case of power, coolant or compressed air malfunction Your benefits •• Minimum installation requirements due to modular design •• Reduced maintenance costs: up to 100 hours per year due to automatic purging and cleaning of probe and filter •• Automatic monitoring and remote control functions of the complete system via PLC •• Comfortable touch screen with intuitive menus for easy use •• High operational availability and functional reliability due to anti-stick and back-purging system •• Secure operation due to self-test functions and emergency retraction of the probe •• Approved system for harsh process conditions -- www.mysick.com/en/SCP3000 For more information, just enter the link and get direct access to technical data, CAD design models, operating instructions, software, application examples and much more. 8014937/2012-12 Subject to change without notice ce m e n t i n d u s t r y | S I C K 37
  38. 38. MEAC2000 | Data Acquisition Systems W280-2 | Compact photoelectric sensors MEAC2000 – At a glance •• Evaluation according to EU directives 2000/76/EC and 2001/80/EC •• Evaluation according to 13., 17., 27. and 30. FICA and TA -Luft (Technical. Instructions on Air Quality Control) •• Inclusion of operational parameters and plant conditions •• Visualization of emission and operational data •• Remote data transfer, remote diagnosis and remote control •• Alarm signals when exceeding the limit values Your benefits •• Software monitors all communications with connected field devices and control systems •• All values are stored on hard disk, thus it is possible to look at data history even after many years •• A routine back-up is made regularly on a second hard disk •• Screen displays and output of actual and historical data are freely configurable -- www.mysick.com/en/MEAC2000 For more information, just enter the link and get direct access to technical data, CAD design models, operating instructions, software, application examples and much more. W280-2 – At a glance •• highly visible red light spot thanks to •• AC/DC devices are compliant with the Bright Light LED •• Light/dark switching (DC devices only) •• Rotatable connector, cable connection or terminal chamber •• Versions for 10 – 30 V DC or 24 – 240 V DC/AC voltage supply EN61000-6-3 (electromagnetic interference for “residential, commercial and light-industrial environments”) •• Stainless steel mounting bracket and P250 reflector (for WL280 only) are included in delivery •• UL recognized Your benefits •• Visible red light of the Bright Light •• All necessary mounting and operating LED for simpler alignment of the sensors •• DC variants with light/dark switching ensure application flexibility, reducing the number of devices required for an application •• Rotatable connector provides flexibility for space-restricted installations accessories are included in delivery, enabling quick and easy setup: since mounting bracket (stainless steel 1.4301) and reflector with the WL280 are included in delivery scope •• DC devices and AC/DC devices available in the same housing, allowing electrical flexibility -- www.mysick.com/en/W280-2 For more information, just enter the link and get direct access to technical data, CAD design models, operating instructions, software, application examples and much more. 38 ce m e n t i n d u s t r y | S I C K 8014937/2012-12 Subject to change without notice
  39. 39. Small photoelectric sensors | W12-3 Small photoelectric sensors | W14-2 W12-3 – At a glance •• Best-in-class optical performance due •• Rugged die-cast zinc housing, op- to superior OES technology •• Autocollimation with retro-reflective sensors •• Background and foreground suppression with second emitter LED on proximity sensors •• Highly visible, precise light spot and high-energy IR transmitters tional with Teflon® coating •• Connection via cable or rotatable connector •• Mounting options with through holes, base blind holes, oblong through holes and dovetail •• IO-Link communication available (optional) Your benefits •• Reliable detection due to superior IP 69K •• Wide range of products enclosed in ASIC (application-specific integrated circuit) technology and immunity to optical interference factors from the industrial environment •• PinPoint LED technology provides a bright, small and precise light spot that enables quick and easy sensor alignment •• Precise switching characteristics ensure reliable object detection, reducing downtime caused by re-adjusting sensors during recipe changes -- www.mysick.com/en/W12-3 a rugged metal housing enables application flexibility in a broad range of industrial environments •• Remote diagnostics and maintenance using IO-Link reduces overall downtime (optional) •• Flexible mounting options reduce installation time •• Easy installation using SICK accessories For more information, just enter the link and get direct access to technical data, CAD design models, operating instructions, software, application examples and much more. W14-2 – At a glance •• Outstanding background suppression with OES3 technology •• Highly visible and precise light spot due to PinPoint LED in selected products •• Slim, durable plastic housing •• Complete sensor family with proximity, retro-reflective and through-beam variants Your benefits •• Reliable object detection at a costeffective price •• PinPoint LED technology provides a highly visible red light that enables quick and easy setup •• Broad product range gives users a variety of choices to fit their application •• Rugged plastic housing in a slim design simplifies installation •• Quick and easy installation using SICK accessories saves time Class 2 C ® US LISTED 87LL -- www.mysick.com/en/W14-2 For more information, just enter the link and get direct access to technical data, CAD design models, operating instructions, software, application examples and much more. 8014937/2012-12 Subject to change without notice ce m e n t i n d u s t r y | S I C K 39
  40. 40. W9-3 | Small photoelectric sensors W27-3 Reflex Array | Compact photoelectric sensors W9-3 – At a glance •• High-performance sensor in ultra- •• Two emitter LEDs for best-in-class rugged VISTAL™ housing •• PinPoint LED for highly visible and precise light spot •• Variable mounting with M3 or M4 background suppression hole pattern •• Wide range of connection options Your benefits •• Robustness with the VISTAL™ housing •• Best in class performance •• Wide variance in connection, mouting and optic -- www.mysick.com/en/W9-3 For more information, just enter the link and get direct access to technical data, CAD design models, operating instructions, software, application examples and much more. W27-3 Reflex Array – At a glance •• Minimum Detectable Object > 10 mm •• Minimum distance between sensor with a 40 mm detection area for the standard resolution variant •• Sensing range from 0 up to max. 3.5 m •• Intensive red light for easy alignment •• CTA automatically adjusts the switch- and reflector 0.5 m ing threshold as contamination occurs over time Your benefits •• Reliable detection regardless of •• PinPoint technology and optical align- target position within the array: detection height 50 mm (MDO: > 12 mm) or detection height 24 mm (MDO: > 5 mm) •• Less installation effort compared to light grids or multiple single-point photoelectric sensors ment procedure enables simple and quick commissioning •• Continuous Threshold Adjustment (CTA) ensures less downtime -- www.mysick.com/en/W27-3_Reflex_Array For more information, just enter the link and get direct access to technical data, CAD design models, operating instructions, software, application examples and much more. 40 ce m e n t i n d u s t r y | S I C K 8014937/2012-12 Subject to change without notice
  41. 41. Miniature photoelectric sensors | G6 Analog positioning sensors | MPS G6 - At a glance •• PinPoint LED for a bright, precise light spot •• Durable metal threaded inserts •• SICK ASIC technology - the result of decades of experience in photoelectric sensors •• Large, user-friendly potentiometer •• Large, bright indicator LEDs •• IP 67 enclosure rating Your benefits •• Easy alignment and precise object detection due to a highly visible PinPoint LED •• Quick and easy mounting and high durability due to threaded metal inserts •• SICK ASIC technology provides high performance and excellent reliability •• Easy to adjust due to large, userfriendly potentiometers •• Easy to monitor due to large, bright indicator LEDs •• Easy installation with SICK accessories -- www.mysick.com/en/G6 For more information, just enter the link and get direct access to technical data, CAD design models, operating instructions, software, application examples and much more. MPS - At a glance •• Magnetic position sensor for pneu- •• Superior precision: 0.05 mm resolu- matic and hydraulic cylinders with T-slot •• Output signal: analog, 4 – 20 mA current and 0 -10 V (in one sensor) tion, 0.1 mm repeatability, 0.3 mm linearity, 1 ms measurement rate •• Electric setting of zero point and end point via teach-in button (optional) •• Various lengths available from 32 256 mm Your benefits •• Maximum flexibility with several dif- •• Efficient measurement of stroke due ferent measuring ranges from 32 to 256 mm •• Easy analog output setup: adjustable zero and end point can be taught via single button •• Drop-in T-slot mounting from above makes assembly easy •• Selectable installation direction to optimize cabeling to minimal blind zones, increasing machine throughput •• Simple commissioning due to “inrange” indicator •• Output signal: analog, 4 – 20 mA current and 0 -10 V (in one sensor) reduces inventory cost by part number reduction -- www.mysick.com/en/MPS For more information, just enter the link and get direct access to technical data, CAD design models, operating instructions, software, application examples and much more. 8014937/2012-12 Subject to change without notice ce m e n t i n d u s t r y | S I C K 41
  42. 42. IM Standard | Inductive proximity sensors IQ Standard | Inductive proximity sensors IM Standard – At a glance •• Precise operating distances due to ASIC technology •• Extra tough thanks to high fastener torque and hot melt adhesive filling •• M8 to M30 sizes available •• Operating distance from 1.5 mm to 20 mm •• IP 67 enclosure rating •• Operating temperature from -25° C to +70° C •• DC, AC and AC/DC versions available •• Customer-specific models available Your benefits •• Reduced machine downtime •• Reduced mechanical damage •• Fewer maintenance costs due to •• High resistance to shock and vibrations longer service life -- www.mysick.com/en/IM_Standard For more information, just enter the link and get direct access to technical data, CAD design models, operating instructions, software, application examples and much more. IQ Standard – At a glance •• Long sensing distance up to 60 mm •• DC, AC and AC/DC versions available •• Wide range of housing and mounting options •• Variety of connection options including terminal, cable (flying leads) and connector types •• Customer-specific models and value add options are available Your benefits •• Increased machine throughput with less machine downtime •• Maintenance cost reduction and reduced mechanical damage due to long sensing range Class 2 C ® US LISTED 87LL 42 ce m e n t i n d u s t r y | S I C K •• Reduced maintenance cost due to longer service life •• Time-saving quick and easy installation -- www.mysick.com/en/IQ_Standard For more information, just enter the link and get direct access to technical data, CAD design models, operating instructions, software, application examples and much more. 8014937/2012-12 Subject to change without notice
  43. 43. Safety controllers | Flexi Soft Electro-mechanical safety switches | i10 Lock Flexi Soft – At a glance •• Modularly expandable (12 ... 144 inputs/outputs) •• Intuitive configuration software: easy operation, simulation mode, wiring diagrams, freely downloadable •• Configuration memory in the system plug •• Safely link up to four Flexi Soft safety controllers via EFI •• Integration into all common fieldbus systems •• Enhanced sensor functionalities via EFI interface •• 38 TÜV certified function blocks Your benefits •• Prevention of redundant inputs and •• Standard RS-232 diagnosis via the outputs saves money •• Fast commissioning via a system plug that saves and stores system configurations •• Less downtimes due to gateways, e.g., PROFInet I/O, PROFIBUS-DP, EtherCAT, CANopen, Modbus TCP, Ethernet (TCP/IP) main module enables real-time diagnostics for quick commissioning, faster troubleshooting and reduced downtime •• Simulation mode allows a user to verify the safety functions before installation •• Fast hardware selection by drag and drop from a list of simple to understand element icons -- www.mysick.com/en/Flexi_Soft For more information, just enter the link and get direct access to technical data, CAD design models, operating instructions, software, application examples and much more. i10 Lock – At a glance •• Narrow plastic housing •• Rigid or mobile actuators •• 3 M20 x 1.5 cable entry glands •• Locked by spring force and magnetic force •• Lock and door monitoring •• IP 67 enclosure rating Your benefits •• Small design simplifies installation •• Practical, simple adjustment due to and makes it easy to mount directly on the guard door frame •• Flexible electrical connectivity due to three cable entry glands •• Improved diagnostics due to additional signaling contacts various actuators that are suitable for any door •• Different switching elements offer the appropriate solution for electrical installation -- www.mysick.com/en/i10_Lock For more information, just enter the link and get direct access to technical data, CAD design models, operating instructions, software, application examples and much more. 8014937/2012-12 Subject to change without notice ce m e n t i n d u s t r y | S I C K 43
  44. 44. ES21 | Safety command devices E100 | Safety command devices ES21 – At a glance •• Either as surface-mounted version •• Surface-mounted version for direct with housing or as built-in version (Ø 22 mm) •• Built-in version for machine control panels with self-monitoring contacts between the pushbutton and switching element mounting on different machines and systems •• Rotational or key unlocking •• Variants with LED ring lighting •• Available with protective collar to prevent inadvertent actuation Your benefits •• Increased safety due to self-monitor- •• User-friendly status indicator identi- ing contacts •• Reduction in accidental faults due to variants with a protective collar fied by a colored mark or LED ring around the pushbutton simplifies diagnostics •• Successful down to the last detail: award-winning and appealing design -- www.mysick.com/en/ES21 For more information, just enter the link and get direct access to technical data, CAD design models, operating instructions, software, application examples and much more. E100 – At a glance •• Plastic housing with connected cable •• 3-stage functional structure (off-onoff) •• Slow-action switching elements with four contacts •• Variant with additional plus/minus buttons •• Complies to the standard IEC/EN 60947-5-8 Your benefits •• Personal protection with enabling switches: increased safety in setup mode when protective devices are deactivated •• Plus/minus buttons for additional control of direction of movement •• Different cable lengths available to meet customer application requirements -- www.mysick.com/en/E100 For more information, just enter the link and get direct access to technical data, CAD design models, operating instructions, software, application examples and much more. 44 ce m e n t i n d u s t r y | S I C K 8014937/2012-12 Subject to change without notice
  45. 45. Safety light curtains | C4000 Palletizer Multiple light beam safety devices | M4000 Advanced C4000 Palletizer – At a glance •• Type 4 (IEC 61496), PL e (EN ISO 13849) •• Self-teaching, dynamic blanking detects goods and pallets •• Direction recognition •• Multiple sampling •• Reduced resolution •• Muting alternative •• Beam coding •• Object gap suppression Your benefits •• Cost-effective: No additional muting •• The assorted feasibility of pallets sensors or protective measures are required. •• A compact sensor pair reduces the mounting requirements considerably – additional muting sensors are not required •• With the dynamic and self-teaching blanking function, the system can reliably differentiate between people and material – this provides maximum safety allows the passage of mesh boxes, Euro pallets and half pallets, increasing plant availability •• Saves storage space: pallets can be parked permanently in the protective field •• One system monitors several conveyor belts, reducing sensor costs •• Quick commissioning: Euro pallets, mesh boxes etc. are detected without any programming -- www.mysick.com/en/C4000_Palletizer For more information, just enter the link and get direct access to technical data, CAD design models, operating instructions, software, application examples and much more. M4000 Advanced – At a glance •• Type 4 (IEC 61496), PL e (EN ISO •• External device monitoring (EDM), 13849) •• Robust housing with three mounting grooves •• 7-segment display •• Wide scanning range, up to 70 m restart interlock (RES), application diagnostic output (ADO), SDL interface •• Muting in combination with the UE403 switching amplifier •• Laser alignment aid and LED optional integrated •• Configuration and diagnostics via PC Your benefits •• The wide scanning range allows the •• Customer-friendly interfaces and device to be customized according to the application •• Robust design with a high level of resistance to environmental changes ensures high machine availability, even under special ambient conditions •• Mounting grooves on three housing sides ensure more mounting flexibility and simplify machine integration status display simplify commissioning and maintenance •• For 2- and 4-sensor muting, the onsite connection of the muting signals significantly minimizes wiring costs and simplifies commissioning and maintenance •• Reduced downtime due to 360° visible LED, diagnostics displays and configuration memory in the UE403 switching amplifier -- www.mysick.com/en/M4000_Advanced For more information, just enter the link and get direct access to technical data, CAD design models, operating instructions, software, application examples and much more. 8014937/2012-12 Subject to change without notice ce m e n t i n d u s t r y | S I C K 45
  46. 46. L27 | Single-beam photoelectric safety switch AFS/AFM60 SSI | Absolute encoders L27 – At a glance •• Type 2 (IEC 61496), PL c (EN ISO 13849), only in conjunction with suitable testing device, e.g. Flexi Classic, DeviceNet Safety •• Compact size with ranges up to 35 m •• Integrated heating •• Enclosure rating IP 67 •• Temperature range from –40 °C ... + 55 °C Your benefits •• Easy integration due to small, com- •• Flexible device integration makes it pact versions with maximum range •• Directly connect to a safety controller – without a separate evaluation unit, reducing costs possible to set up individual protective fields •• Well suited to withstand extreme ambient conditions such as heat, cold or moisture -- www.mysick.com/en/L27 For more information, just enter the link and get direct access to technical data, CAD design models, operating instructions, software, application examples and much more. AFS/AFM60 SSI – At a glance •• High-resolution absolute encoders with up to 30 bits (AFM60) or up to 18 bits (AFS60) •• Face mount flange, servo flange, blind or through hollow shaft •• SSI, SSI + Incremental or SSI + Sin/ Cos interface •• Programmable resolution and offset (dependent on type) •• Connection system: M12, M23 connector or cable outlet •• Enclosure rating: IP 67 (housing), IP 65 (shaft) •• Operating temperature: –30 °C to +100 °C (depends on type) Your benefits •• Programmability of the encoders •• Suitable for applications with limited means less storage, greater machine availability and easy installation •• Precise positioning due to high resolutions •• Large selection of mechanical interfaces and electrical contacting possibilities: Suitable for all applications space requirements (extremely short installation depth of 30 mm) •• Very good rotation accuracy due to increased bearing distance •• One programming tool and software with automatic encoder detection for AFS60/AFM60/DFS60 -- www.mysick.com/en/AFS_AFM60_SSI For more information, just enter the link and get direct access to technical data, CAD design models, operating instructions, software, application examples and much more. 46 ce m e n t i n d u s t r y | S I C K 8014937/2012-12 Subject to change without notice
  47. 47. Incremental encoders | DFS60 Image-based code readers ||LECTOR®62x Image-based code readers LECTOR®62x DFS60 – At a glance •• Compact installation depth •• High resolution up to 16 bits •• Optionally programmable: Output volt- •• Electrical interfaces: 5V & 24V TTL/ age, zero pulse position, zero pulse width and number of pulses •• Connection: Radial or axial cable outlet, M23 or M12 connector, axial or radial servo flange, blind or through hollow shaft •• Remote zero set possible RS-422, 24 V HTL/push pull •• Mechanical interfaces: face mount or Your benefits •• Reduced storage costs and downtime •• Permanent and safe operation due to due to customer-specific programming •• Variety of different mechanical and electrical interfaces enable the encoder to be optimally adjusted to fit the installation situation •• Excellent concentricity even at high speeds •• High resolution of up to 16 bits ensures precise measurements a high enclosure rating, temperature resistance and a long bearing lifetime •• Programmability via the PGT-08 programming software and the PGT-10-S display programming tool allow the encoder to be adapted flexibly and quickly according to customer needs •• Programmable zero pulse position simplifies installation -- www.mysick.com/en/DFS60 For more information, just enter the link and get direct access to technical data, CAD design models, operating instructions, software, application examples and much more. LECTOR®62x – At a glance •• Decoding of most popular code types: 1D, 2D, direct part marking •• Easy integration with industrial networks: serial, USB, several fieldbus technologies •• Auto setup with function buttons, aiming laser, focus adjustment and green feedback LED – for quick setup without PC •• Compact design and industrial housing •• Analysis tools include live image capturing, code verification and read rate view Your benefits •• Intelligent decoding algorithms pro- •• Compact design and flexible interface vide reliable reading performance for improved read rates and throughput •• IDpro facilitates integration with most popular industrial networks •• Intuitive setup with function buttons, auto setup, aiming laser, focus adjustment and green feedback LED reduces training and installation time and costs connections make it easy to install in reduced spaces •• Quick analysis of read rate performance and code quality allows for efficient control •• Cloning back-up systems ensure low machine downtime in the event of unexpected incidents •• SICK LifeTime Services give you peace of mind -- www.mysick.com/en/LECTOR62x For more information, just enter the link and get direct access to technical data, CAD design models, operating instructions, software, application examples and much more. 8014937/2012-12 Subject to change without notice ce m e n t i n d u s t r y | S I C K 47
  48. 48. LBV300 | Level sensors Bulkscan LMS511 | Flow sensors LBV300 – At a glance •• Tough device design •• Several housing materials and electrical outputs available •• Immune to deposit formation •• Commissioning without filling •• Process temperature up to 250 °C •• Very high repeatability •• ATEX versions (1D/2D/1G/2G) available •• Tube-extended version (LBV330) up to 6 m and rope extensions version (LBV320) up to 80 m available for vertical mounting Your benefits •• Easy installation and commissioning, •• Testing in place possible – no mount- no calibration necessary •• Easy operation and integration, saves time •• Maintenance-free sensor, reduces downtime ing required, which reduces installation time •• Flexible and tough system for a multitude of applications •• Solutions for vertically mounted switches in difficult installation conditions and surroundings -- www.mysick.com/en/LBV300 For more information, just enter the link and get direct access to technical data, CAD design models, operating instructions, software, application examples and much more. Bulkscan LMS511 – At a glance •• Non-contact measurment of volume and mass flow of bulk material •• Laser pulses with high angular resolution ensure outstanding image resolution •• 5-echo pulse evaluation produces highly reliable measurements •• Offers non-contact belt monitoring •• Integrated center-of-gravity calculator •• Robust structure for harsh ambient conditions •• Can also measure at low temperatures thanks to integrated heater •• Compact housing with enclosure rating IP67 Your benefits •• Maximizes conveyor throughput •• Reduces maintenance costs by preventing belt slippage •• Increases the conveyor belt’s service life •• Reduces loading time •• Increases efficiency by optimizing belt capacity •• Simple installation •• Low maintenance costs •• Offers savings through minimized energy consumption -- www.mysick.com/en/Bulkscan_LMS511 For more information, just enter the link and get direct access to technical data, CAD design models, operating instructions, software, application examples and much more. 48 ce m e n t i n d u s t r y | S I C K 8014937/2012-12 Subject to change without notice
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  50. 50. Connectivity – PS_header1_small_blue Always well-connected with SICK PS_header2_small_blue Current data via standardized communication SICK’s products have a standardized data communications system for digital controllers to ensure that all data, measured values, and parameters are available at all times and can be conveniently visualized and processed. Moreover, this is available across systems from the customer’s system network. Data can thus be processed further in the internal computer system at any time. Signals, interfaces and protocols • Analog and digital signals • Interfaces: • Serial interfaces such as RS-232/RS-485/RS-422 • Ethernet network • OPC • Protocols • Modbus or Modbus TCP Data acquisition and processing systems OPC Ethernet Modbus Ethernet/RS-485 I/O analog, digital Analyzers and Systems Operation Analyzers and systems are operated: • Directly from the analyzer’s operating unit • Via a controller, enabling visualization and configuration for numerous analyzers • Remotely via Ethernet or a mobile network • With SOPAS ET, SICK’s visualization and configuration Software Remote diagnostics Remote access to the devices and systems is also possible online using analog telephone, cell phone, or Ethernet network connections via SICK’s RDU remote diagnostics unit. Customer benefits: • Rapid assistance in the event of malfunction • Efficient solution: remote diagnostics allow reduction of on-site service calls • Optimized and targeted service calls: if on-site service is required, the technician has already developed the required solution via remote diagnostics 50 ce m e n t i n d u s t r y | S I C K TCP/IP Internet Plant Measuring point/device network 8014937/2012-12 Subject to change without notice
  51. 51. PS_header1_small_blue Connectivity – Always well-connected with SICK PS_header2_small_blue Operational management level Ethernet Measuring systems Dust Operational monitoring OPC Server Volume flow ERP system, plant management system Control unit Reference parameters Temperature, pressure Ethernet Gas components In-situ gas analysis Extractive gas analysis Data acquisition system Analysis systems Ethernet Remote diagnostics, remote maintenance Remote diagnostics Optional 8014937/2012-12 Subject to change without notice ce m e n t i n d u s t r y | S I C K 51
  52. 52. Notes PS_header1_small_blue 52 ce m e n t i n d u s t r y | S I C K PS_header2_small_blue 8014937/2012-12 Subject to change without notice
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  54. 54. Notes PS_header1_small_blue 54 ce m e n t i n d u s t r y | S I C K PS_header2_small_blue 8014937/2012-12 Subject to change without notice
  55. 55. PS_header2_small_blue 8014937/2012-12 Subject to change without notice PS_header1_small_blue Notes ce m e n t i n d u s t r y | S I C K 55
  56. 56. Notes PS_header1_small_blue 56 ce m e n t i n d u s t r y | S I C K PS_header2_small_blue 8014937/2012-12 Subject to change without notice
  57. 57. PS_header2_small_blue 8014937/2012-12 Subject to change without notice PS_header1_small_blue Notes ce m e n t i n d u s t r y | S I C K 57
  58. 58. Notes PS_header1_small_blue 58 ce m e n t i n d u s t r y | S I C K PS_header2_small_blue 8014937/2012-12 Subject to change without notice
  59. 59. PS_header1_small_blue Services PS_header2_small_blue www.mysick.com – search online and order Search online quickly and safely – with the SICK “Finders” Efficiency – with the e-commerce tools from SICK Product Applications Literature Service Connection diagram Accessories Spare part Software Product Finder: We can help you to quickly target the product that best matches your application. Applications Finder: Select the application description on the basis of the challenge posed, industrial sector, or product group. Literature Finder: Go directly to the operating instructions, technical information, and other literature on all aspects of SICK products. Find out prices and availability: Determine the price and possible delivery date of your desired product simply and quickly at any time. Request or view a quote: You can have a quote generated online here. Every quote is confirmed to you via e-mail. Order online: You can go through the ordering process in just a few steps. For safety and productivity: SICK LifeTime Services SICK LifeTime Services is a comprehensive set of high-quality services provided to support the entire life cycle of products and applications from system design all the way to upgrades. These services increase the safety of people, boost the productivity of machines and serve as the basis for our customers’ sustainable business success. Consulting & Design Globally available experts for cost-effective solutions T FI H TRA OR T C EC K RET R O 8014937/2012-12 Subject to change without notice Product & System Support Fast and reliable, by telephone or on location PP SICK LifeTime Services SU IN C O N S U LT Verification & Optimization Checks and recommendations for increased availability Upgrade & Retrofits Uncovers new potential for machines and systems Training & Education Employee qualification for increased competitiveness ce m e n t i n d u s t r y | S I C K 59
  60. 60. 8014937/2012-12 ∙ JPF ∙ Pre USmod int39 SICK at a glance Leading technologies Unique product range Comprehensive services With a staff of more than 5,800 and nearly 50 subsidiaries and representations worldwide, SICK is one of the leading and most successful manufacturers of sensor technology. The power of innovation and solution competency have made SICK the global market leader. No matter what the project and industry may be, talking with an expert from SICK will provide you with an ideal basis for your plans – there is no need to settle for anything less than the best. •• Non-contact detecting, counting, classifying, positioning and measuring of any type of object or media •• Accident and operator protection with sensors, safety software and services •• Automatic identification with bar code and RFID readers •• Laser measurement technology for detecting the volume, position and contour of people and objects •• Complete system solutions for analysis and flow measurement of gases and liquids •• SICK LifeTime Services – for safety and productivity •• Application centers in Europe, Asia and North America for the development of system solutions under realworld conditions •• E-Business Partner Portal www.mysick.com – price and availability of products, requests for quotation and online orders Worldwide presence with subsidiaries in the following countries: México Nederland  Norge  Österreich Polska  România  Russia  Schweiz Singapore Slovenija South Africa  South Korea Suomi  Sverige  Taiwan Türkiye  United Arab Emirates USA Please find detailed addresses and additional representatives and agencies in all major industrial nations at www.sick.com Australia   Belgium/Luxembourg  Brasil  Ceská Republika  Canada China  Danmark Deutschland España  France  Great Britain  India  Israel  Italia  Japan SICK AG | Waldkirch | Germany | www.sick.com

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