SICK VMS4200 Operating instructions

ADDENDUM TO OPERATING INSTRUCTIONS
VMS4200/5200
Track and trace system

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Described product
VMS4200 / VMS5200
Document no.
8026364
Manufacturer
SICK AG
Erwin-Sick-Str. 1 · 79183 Waldkirch · Germany
www.sick.com
Legal notes
This work is protected by copyright. The associated rights are reserved by SICK AG.
Reproduction of this document or parts of this document is only permissible within
the limits of the legal provisions of copyright law. Any modification, abridgment, or
translation of this document is prohibited without the express written permission of
SICK AG.
The trademarks mentioned in this document are the property of their respective
owners.
© SICK. All rights reserved
Original documents
This document is a translation of an original document of SICK AG.

CONTENTS
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Content
1About this document.......................................................................................... 6
1.1 Limitation of liability ................................................................................. 6
1.2 Purpose of this document........................................................................ 6
1.3 Target groups............................................................................................ 6
1.4 Further information .................................................................................. 7
1.5 Other relevant technical documentation/information ........................... 7
1.6 Document conventions ............................................................................ 7
2For your safety.................................................................................................... 8
2.1 Intended use............................................................................................. 8
2.2 General safety notes ................................................................................ 8
2.3 Requirements for the qualification of personnel ................................... 9
2.4 Sources of danger .................................................................................... 9
2.5 Protective devices .................................................................................. 10
2.6 Warranty ................................................................................................. 10
2.7 RoHS Directive........................................................................................ 10
2.8 Safety conventions................................................................................. 10
2.9 Warning symbols on the system components...................................... 11
2.10 Mandatory symbols ................................................................................ 11
3System description .......................................................................................... 12
3.1 Scope of delivery .................................................................................... 12
3.2 System components .............................................................................. 13
3.2.1 LMS4x21 2D LiDAR sensors .................................................. 15
3.2.2 Incremental encoder............................................................... 16
3.2.3 Trigger photoelectric sensor (optional) .................................. 17
3.2.4 Cabinet .................................................................................... 18
3.2.5 Expanding the system with a reading station........................ 20
3.3 Operating principle................................................................................. 21
3.3.1 Triggering the recording of measured values........................ 21
3.3.2 Transport conditions ............................................................... 23
3.3.3 Recording of measured values and data processing ........... 24
3.3.4 Data output ............................................................................. 25
3.4 Additional functions ............................................................................... 27
3.5 Nominal operating conditions ............................................................... 28
3.5.1 Fixed scale values................................................................... 28
3.5.2 Dynamic scale value switchover ............................................ 30
3.6 Legal for trade operation ....................................................................... 33
3.6.1 Information labels ................................................................... 33
3.6.2 Security seal ............................................................................ 37
3.6.3 Alibi memory and firmware..................................................... 42
3.6.4 LFT display............................................................................... 45
3.6.5 Test instructions for market surveillance .............................. 48
3.7 System requirements for legal for trade operation .............................. 52
3.7.1 Requirements on the ambient conditions ............................. 52
3.7.2 Requirements on the conveying equipment.......................... 52
3.7.3 Mounting requirements .......................................................... 54
3.7.4 Object requirements ............................................................... 56
4Mounting .......................................................................................................... 58
4.1 Mounting 2D LiDAR sensors.................................................................. 58

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4.1.1 Overview .................................................................................. 58
4.1.2 Assembling profiles of the telescopic tube ........................... 59
4.1.3 Mounting the telescopic tube on the frame.......................... 60
4.1.4 Fastening the 2D LiDAR sensors to the mounting plates .... 60
4.2 Mounting the incremental encoder ...................................................... 61
4.3 Mounting the trigger photoelectric sensor ........................................... 61
4.4 Mounting the cabinet............................................................................. 62
5Electrical installation .......................................................................................63
5.1 Connection overview.............................................................................. 64
5.2 Connecting the voltage supply .............................................................. 65
5.3 Connection for LFT Ethernet switch (set up at the factory) ................. 66
5.4 Connection of 2D LiDAR sensors .......................................................... 67
5.5 Connection for the LFT display (set up at the factory)......................... 69
5.6 Connecting the incremental encoder ................................................... 70
5.7 Connection for the photoelectric retro-reflective sensor (optional) .... 71
5.8 Connecting the customer interface ...................................................... 72
6Commissioning .................................................................................................73
6.1 Switching on the system........................................................................ 73
6.2 Configuring the system with SOPAS...................................................... 74
6.2.1 Connecting the configuration PC ........................................... 74
6.2.2 Installing SOPAS ..................................................................... 75
6.2.3 Assigning IP addresses........................................................... 76
6.2.4 Opening the configuration interface...................................... 82
6.2.5 Logging on to device............................................................... 83
6.2.6 Saving the parameters permanently ..................................... 84
7Maintenance and repair...................................................................................85
7.1 Monitoring and cleaning work............................................................... 86
7.1.1 Control measurements........................................................... 86
7.1.2 Visual inspection..................................................................... 86
7.1.3 Cleaning the 2D LiDAR sensors ............................................. 87
7.1.4 Cleaning the deflector mirror ................................................. 88
7.1.5 Checking the incremental encoder components.................. 89
7.1.6 Cleaning the photoelectric retro-reflective sensor................ 89
7.1.7 Cleaning the cabinet............................................................... 90
7.2 Replacing components .......................................................................... 91
7.2.1 Replacing the 2D LiDAR sensor............................................. 91
7.2.2 Replacing the deflector mirror ............................................... 93
7.2.3 Replacing the incremental encoder components................. 94
7.2.4 Replacing the photoelectric retro-reflective sensor.............. 95
7.2.5 Replacing the battery in the SIM2000-2 Prime controller ... 96
8Fault diagnosis .................................................................................................97
8.1 Fault indications of the components .................................................... 97
8.1.1 Fault indication on the LMS4x21........................................... 97
8.1.2 SIM2000 fault indication ....................................................... 98
8.1.3 Fault indication on the trigger photoelectric sensor ............. 99
8.2 Checks on the SIM2000......................................................................100
8.2.1 Checking the triggering.........................................................100
8.2.2 Checking the incremental encoder......................................101
8.2.3 Checking the CAN cabling ....................................................102
8.3 Detailed fault analysis ......................................................................... 103

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9Technical data................................................................................................ 104
9.1 Data sheet ............................................................................................104
9.2 Dimensional drawings..........................................................................106
9.2.1 Dimensional drawings for the 2D LiDAR sensor .................106
9.2.2 Dimensional drawings for the cabinet .................................107
9.3 Compliance with EU directives ............................................................108
10 Disposal .......................................................................................................... 109

1ABOUT THIS DOCUMENT
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1About this document
These supplementary operating instructions on the VMS4200 / VMS5200 multi-
dimensional measurement system:
•Contain information that is required during the life cycle of the system.
•Must be available to all those who work with the system.
•Should be read through carefully, and the contents fully understood before working
with the system.
1.1 Limitation of liability
Applicable standards and regulations, the latest technological developments, and our
many years of knowledge and experience have all been taken into account when
assembling the data and information contained in this document.
The manufacturer accepts no liability for damage caused by:
•Failure to observe this document.
•Non-compliance with notes and regulations.
•Unauthorized mounting and installation.
•Unauthorized technical and other changes.
•Use of unauthorized spare parts, wear and tear parts, and accessories.
•Unauthorized changes, adjustments, and/or manipulations of software.
•Failure to perform and document regular maintenance work.
The actual scope of delivery may differ from the features and illustrations shown here
where special variants are involved, if optional extras have been ordered, or as a result of
the latest technical changes.
1.2 Purpose of this document
This document describes the VMS4200 / VMS5200 multi-dimensional measurement
system with an SIM200-2 Prime controller.
The supplementary operating instructions for the VMS4200/5200 MID with a SIM2000-2
Prime Controller are only valid in conjunction with the main operating instructions for the
VMS4200/VMS5200 (Multicontroller) (8022964-17I6 DE / 8022965-17I6 EN).
Unless otherwise specified in this document, the information in the main operating
instructions for the VMS4200/5200 (Multicontroller) will apply.
1.3 Target groups
This document is intended for qualified persons who operate the VMS4200 / VMS5200.

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1.4 Further information
Special local conditions
The local laws, regulations, technical rules and internal company operating instructions at
the installation location must be observed.
Storage of documents
This document and other relevant technical documentation/information:
•Must be kept available for reference.
•Must be handed over to new system operators/new specialist personnel.
1.5 Other relevant technical documentation/information
•Technical system documentation
–E297247 A (EPLAN)
Technical data
Connection diagram
Terminal diagram
•Operating instructions for the following system components:
Component Manufacturer
LMS4000 2D LiDAR sensor operating instructions SICK
SIM2000-2 Prime Sensor Integration Machine operating
instructions
SICK
Operating instructions for TTC100-2 track and trace
cabinet in combination with SIM2000-2 Prime
SICK
1.6 Document conventions
▸Instructions
Result of action
•All measurement units used in this document are metric.
•Subject to change without notice.
•Figures may differ from the actual design.

2FOR YOUR SAFETY
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2For your safety
2.1 Intended use
The VMS4200/5200 multi-dimensional measurement system is used to measure cubic
and irregularly-shaped objects on flat conveying systems in industrial environments.
The objects to be measured must be dimensionally stable, opaque, and non-reflective.
The two LMS4x21 2D LiDAR sensors are mounted horizontally above the conveying
technology and typically rotated at an angle of 45°.
The VMS4200/5200 determines the length, width and height. These dimensional values
can be used to calculate the volume of the smallest rectangular box that fully encloses
the object.
The measurement results can be transferred to the customer network via the data
interface of the SIM2000-2 Prime controller.
The VMS5200 multi-dimensional measurement system can be verified as legal for trade
and, after a successful MID conformity assessment, used for billing purposes.
NOTE! Intended use also includes observance of these supplementary operating
instructions, in particular the safety notes and repair and maintenance requirements as
well as proper installation, in particular for billing operation.
2.2 General safety notes
▸Please read this document through carefully and observe all the safety notes and
information before working on the multi-dimensional measurement system.
▸Only qualified persons from the relevant departments are permitted to work on the
multi-dimensional measurement system.
▸Follow operating processes.
▸Follow local regulations.
▸Follow all local regulations relating to working with electrical components.
•Only authorized persons are permitted access to the multi-dimensional measurement
system.
System damage/transport damage
Damage to the individual components can lead to malfunctions of the system as a whole.
▸Do not ignore any damage caused to system components during transport.
▸In case of damage, contact SICK Service.

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2.3 Requirements for the qualification of personnel
Only qualified persons with the relevant technical expertise are permitted to work on the
system.
•Qualified persons have the specialist training, skills, and experience, as well as
knowledge of the relevant regulations and standards, to be able to perform work
assigned to them and to identify and avoid any potential dangers independently.
•Electricians have the professional training, skills and experience, and knowledge of the
relevant standards and provisions to work on electrical systems and to detect and
avoid any potential dangers independently.
2.4 Sources of danger
The 2D LiDAR sensors of the VMS4200/5200 use a class 2 laser.
The human eye is not at risk when briefly exposed to the radiation for up to 0.25 seconds.
Exposure to the laser beam for longer periods of time may cause damage to the retina.
The laser radiation is harmless to human skin.
▸Never look directly into the laser beam.
▸Never point the laser beam at people’s eyes.
▸During commissioning or maintenance work, suitable eye protection must be worn.
▸Avoid laser beam reflection caused by reflective surfaces. In particular during mounting
and alignment work.
▸Do not open the housing.
▸Current national regulations regarding laser protection must be observed.
Touching live devices, which may still be energized, can lead to death, burns or electrical
shock.
▸Electrical work may only be performed on the system by qualified specialist personnel.
▸Before working on electrical components, observe the five safety rules:
▸Disconnect.
▸Secure against being switched back on.
▸Ensure that there is no voltage.
▸Ground and short-circuit.
▸Cover or enclose live parts in the vicinity.
▸Never enter the area under suspended loads.
▸Pay close attention when lifting loads.
▸Comply with lifting instructions to prevent injuries and accidents.
▸Use suitable, undamaged lifting tools.
▸Wear personal protective equipment (safety helmet, safety shoes).
Optical radiation:
Laser class 2
Electrical voltage
Suspended loads

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2.5 Protective devices
The multi-dimensional measurement system is designed in a way that allows for safe
operation. Protective devices reduce potential risks to the maximum possible extent.
•Laser protective cover for the LMS4x21 2D LiDAR sensor
2.6 Warranty
No warranty claims will be accepted if:
▸The safety notes and measures in this document are not observed.
▸Parts or components of the multi-dimensional measurement system have been
installed, mounted or modified without authorization.
▸The multi-dimensional measurement system has been altered or modified.
▸The software has been modified, customized, and/or tampered with without
authorization.
2.7 RoHS Directive
This product has been designed for specific applications in large industrial systems
according to Article 2 (4) e, RoHS 2011/65 / EU, and must therefore only be used in such
systems.
The product is neither suitable nor approved for use outside of these systems. SICK
therefore cannot provide any warranty or accept any liability whatsoever for such use.
2.8 Safety conventions
The warnings used in this manual have the following meanings:
DANGER
Identifies an imminent danger, which will lead to death or serious injuries if not
prevented.
WARNING
Identifies a situation presenting danger, which will lead to death or serious injuries if
not prevented.
CAUTION
Identifies a possibly hazardous situation which may lead to minor or moderate bodily
injuries or material damage if not prevented.
NOTE
Important information and useful notes.

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2.9 Warning symbols on the system components
Warning labels must not be removed or covered up. If labels are missing, these must be
affixed. Damaged labels must be replaced.
Symbol Meaning
Hazardous point warning
Hazardous electrical voltage warning
Laser beam warning
Suspended load warning
2.10 Mandatory symbols
Symbol Meaning
Read document
Use head protection
Use foot protection
Disconnect before maintenance or repairs

3SYSTEM DESCRIPTION
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3System description
3.1 Scope of delivery
NOTE!
▸After delivery, inspect the system for transport damage and report any such damage
immediately.
▸Check that the delivery includes all components listed on the delivery note.
System components
•2 LMS4421R-16000 2D LiDAR sensors with laser protective cover for the VMS4200 or
2 LMS4521R-16000 2D LiDAR sensors with laser protective cover for the VMS5200
•1 LFT display - VMS5200 only
•1 TTC100-2 cabinet with a SIM2000-2 Prime controller, power supply unit modules and
LFT Ethernet switch
•1 incremental encoder with mounting kit (e.g., DFV60, DBS36)
•1 modular mounting set
•2 beam blockers
•Connecting cables
Optional
•1 photoelectric retro-reflective sensor for triggered systems (e.g., RAY26)
•1 deflector mirror for reducing the mounting height of the 2D LiDAR sensors
NOTE
These operating instructions use the product name of the controller: SIM2000-Prime.
The device name is SIM2000ST-E.

SYSTEM DESCRIPTION 3
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3.2 System components
Fig. 1: Components of the VMS4200/5200
Legend
1 LMS4x21 2D LiDAR sensors with laser protective cover
2 LFT display - VMS5200 only
3 Incremental encoder (e.g., DFV60)
4 Photoelectric retro-reflective sensor for triggered systems (e.g., RAY26)
5 Cabinet with a SIM2000-2 Prime controller and power supply units
•Mount the system components according to the technical drawing on a frame provided
by the customer.
•Additional glare protection on the frame (beam blocker) prevents objects located
outside of the measuring range from being included in the calculation of measured
values.
Devices
Mounting

3SYSTEM DESCRIPTION
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Fig. 2: VMS4200/5200 with deflector mirror
Legend
1 LMS4x21 2D LiDAR sensors with laser protective cover
2 Deflector mirror
•If the 2D LiDAR sensors cannot be mounted at the prescribed minimum height, the
measurement points can be captured by a deflector mirror mounted parallel to the
2D LiDAR sensors.
•The resulting extension of the light path means that you can save space when
mounting the 2D LiDAR sensor on the conveying equipment.
•The deflection via the mirror is free of loss thanks to its special surface metallization,
as this rules out light refraction.
•The upper figure shows a visualization example of the arrangement of the 2D LiDAR
sensors and the deflector mirror over the transport belt.
•The remaining system setup and operating principle of the VMS4200/5200 satisfy the
requirements for the relevant type approval certificate.
NOTE! These supplementary operating instructions describe system variant without
deflector mirror.
System variant
with deflector mirror

SYSTEM DESCRIPTION 3
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3.2.1 LMS4x21 2D LiDAR sensors
Fig. 3: LMS4x21 2D LiDAR sensors with LFT display - VMS5200 only
Legend
1 LMS4x21 2D LiDAR sensor
2 Laser protective cover
3 LFT display for VMS5200 measurement systems approved for billing
applications
•Consists of two LMS4x21 2D LiDAR sensors with laser protective covers that are
mounted on a profile and located on the right and left above the conveying equipment.
•The LMS4x21 2D LiDAR sensors are configured as master and slave.
•Used to calculate the relevant object dimensions by detecting the object on flat
conveying systems without making contact.
•VMS5200 measurement systems operated in legal-for-trade applications also have a
separate LFT display to show the measurement results, status information, firmware
version, and logbook (version history).
Features
Function
LFT display

3SYSTEM DESCRIPTION
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3.2.2 Incremental encoder
Fig. 4: DFV60 incremental encoder
Legend
1 Measuring wheel
2 Spring-loaded mounting arm
•Measuring wheel system mounted under the conveyor belt.
•Large spring travel and pivot range of the spring arm compensates for unevenness on
the measurement surface.
•Measurement of linear movements.
•Detection of position and speed directly on the running surface of the conveyor belt
using a precision measuring wheel.
Properties
Function

SYSTEM DESCRIPTION 3
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3.2.3 Trigger photoelectric sensor (optional)
Fig. 5: Trigger photoelectric sensor and reflector
Legend
1 Photoelectric retro-reflective sensor (e.g., RAY26)
2 Reflector
•The light band emitted by the object detection photoelectric sensor is reflected back by
a reflector.
•Sender and receiver are arranged parallel to one another in the housing.
•Mounted in front of the measuring field.
•Supplies the trigger signal in systems with triggered measurement.
•The trigger signal activates the sensors and opens the internal reading gate.
•The photoelectric sensor trigger is available as an option.
Features
Function

3SYSTEM DESCRIPTION
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3.2.4 Cabinet
Fig. 6: Cabinet of the VMS4200/5200
Legend
1 Air inlet for cooling (with filter mat and cooler)
2 Terminals for voltage supply IN (100–264 V AC / 50–60 Hz)
3 SIM2000-2 Prime controller with alibi memory
4 RCD (residual current device) for protective contact plug
5 Circuit breaker
6 Power supply unit for supplying voltage to the SIM2000-2 Prime
controller and 2D LiDAR sensors
7 Air outlet for cooling (with filter mat)
8 Air outlet for cooling (with filter mat)
9 Circuit breaker
10 LFT terminals (24 V DC) and fuse module OUT
11 LFT Ethernet switch for connecting the LFT components
12 Ethernet switches for connecting additional sensors
13 Air inlet for cooling (with filter mat and fan)
•Contains power supply units for the central voltage supply to system components.
•Contains the SIM2000-2 Prime controller, the central processing unit, and the control
unit of the VMS4200/5200.
•The SIM2000-2 Prime controller contains the legally relevant memory (alibi memory).
Properties

SYSTEM DESCRIPTION 3
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•Central voltage supply for all system components.
•Coordinates all connected sensors and processes the measured values received.
•The SIM2000-2 Prime controller receives the measuring points from the LiDAR sensors
and uses the 2D sections to calculate a three-dimensional model.
•It determines the box volume and dimensional values based on the calculated 3D
model.
•The data is sent to the higher-level customer system via the SIM200-2 Prime controller
in a host telegram with a defined format.
NOTE! In the case of the VMS5200, the measurement results are saved in the
SIM2000-2 Prime controller alibi memory, which is required for legal-for-trade
verification.
Function

3SYSTEM DESCRIPTION
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3.2.5 Expanding the system with a reading station
Fig.7: Expanding the system with a reading station
Legend
1 VMS4200/5200
2 Reading systems
3 CAN bus
•Expansion of the VMS4200/5200 multi-dimensional measurement system with a
reading station.
•Depending on the application, this station can consist of scanners, cameras,
application-specific trigger elements and/or a combination of these components in any
desired arrangement.
•Allows automatic object identification using bar codes.
•Streamlines process automation.
NOTE! The multi-dimensional measurement system can also supply the focus
information for the connected camera systems.
•The devices are connected to the multi-dimensional measurement system via the CAN
bus of the SIM2000-2 Prime controller.
•The SIM2000-2 Prime controller links the acquired identification data with the
dimension values calculated by the VMS4200/5200.
•Identification data and dimension values are output together to the higher-level
system.
Properties
Function
Connection