SICK VMS4200 Operating instructions

ADDENDUM TO OPERATING INSTRUCTIONS
VMS4200-x / 5200-x MID
Track and trace system

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Described product
VMS4200-x / 5200-x MID
Document no.
8026365
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 an original document from 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 ................................................................................ 9
2.3 Requirements for the qualification of personnel ................................... 9
2.4 Sources of danger .................................................................................. 10
2.5 Protective devices .................................................................................. 10
2.6 System warranty..................................................................................... 10
2.7 RoHS Directive........................................................................................ 11
2.8 Safety conventions................................................................................. 11
2.9 Warning symbols on the system components...................................... 12
2.10 Mandatory symbols ................................................................................ 12
3System description .......................................................................................... 13
3.1 Scope of delivery .................................................................................... 13
3.2 System components .............................................................................. 14
3.2.1 LMS4x21 LiDAR sensors ........................................................ 15
3.2.2 Photoelectric sensor array...................................................... 16
3.2.3 Object detection photoelectric sensor (optional) .................. 18
3.2.4 Cabinet .................................................................................... 19
3.2.5 Cross belt conveyor elements ................................................ 20
3.2.6 Expanding the system with a reading station........................ 22
3.3 VMS4200-x / 5200-x MID without object detection ............................ 23
3.3.1 Measurement principle........................................................... 23
3.3.2 Transport conditions for single cross belt sorters................. 25
3.3.3 Transport conditions for double belt sorters ......................... 26
3.4 VMS4200-x / 5200-x MID with object detection (optional)................. 28
3.4.1 How object detection works ................................................... 28
3.4.2 Overhang tolerance for single belt systems .......................... 31
3.4.3 Overhang tolerance for double belt systems......................... 33
3.5 Recording of measured values and data processing........................... 36
3.6 Data output............................................................................................. 37
3.7 Additional functions ............................................................................... 39
3.8 Nominal operating conditions ............................................................... 40
3.9 Legal for trade operation ....................................................................... 45
3.9.1 Information labels ................................................................... 45
3.9.2 Security seal ............................................................................ 53
3.9.3 Alibi memory and firmware..................................................... 59
3.9.4 LFT display............................................................................... 62
3.9.5 Test instructions for market surveillance .............................. 65
3.10 System requirements for legal for trade operation.............................. 69
3.10.1 Requirements on the ambient conditions ............................. 69
3.10.2 Requirements on the conveying equipment.......................... 69
3.10.3 Mounting requirements .......................................................... 71
3.10.4 Object requirements ............................................................... 74

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4Mounting ...........................................................................................................76
4.1 Mounting the LiDAR sensors................................................................. 76
4.1.1 Overview .................................................................................. 76
4.1.2 Assembling profiles of the telescopic tube ........................... 77
4.1.3 Mounting the telescopic tube on the frame.......................... 78
4.1.4 Fastening the LiDAR sensors to the mounting plates .......... 78
4.2 Mounting the photoelectric sensor array.............................................. 79
4.3 Mounting the object detection photoelectric sensor (optional) .......... 80
4.4 Mounting the cabinet............................................................................. 81
5Electrical installation .......................................................................................82
5.1 Connection overview.............................................................................. 83
5.2 Connecting the voltage supply .............................................................. 84
5.3 Connection for LFT Ethernet switch (set up at the factory) ................. 85
5.4 Connection for the LiDAR sensors ........................................................ 86
5.5 Connection for the LFT display (set up at the factory) ......................... 88
5.6 Connection for the photoelectric sensor array..................................... 89
5.7 Connection for the cross-belt signal ..................................................... 90
5.8 Connection for the object detection photoelectric sensor
(optional) ................................................................................................ 91
5.9 Connecting the customer interface ...................................................... 92
6Commissioning .................................................................................................93
6.1 Switching on the system........................................................................ 93
6.2 Configuring the system with SOPAS...................................................... 94
6.2.1 Installing SOPAS ET ................................................................ 94
6.2.2 Installing SOPAS ..................................................................... 95
6.2.3 Assigning IP addresses........................................................... 96
6.2.4 Opening the configuration interface....................................102
6.2.5 Logging on to device.............................................................103
6.2.6 Saving the parameters permanently ...................................104
7Maintenance and repair................................................................................ 105
7.1 Monitoring and cleaning work.............................................................106
7.1.1 Control measurements.........................................................106
7.1.2 Visual inspection................................................................... 106
7.1.3 Cleaning the LiDAR sensors .................................................107
7.1.4 Cleaning the photoelectric sensors .....................................108
7.1.5 Cleaning the cabinet.............................................................108
7.2 Replacing components ........................................................................ 109
7.2.1 Replacing the LiDAR sensor.................................................109
7.2.2 Replacing photoelectric sensor array components ............111
7.2.3 Replacing the object detection photoelectric sensor .........112
7.2.4 Replacing the battery in the SIM2000-2 Prime
controller ...............................................................................113
8Fault diagnosis .............................................................................................. 114
8.1 Fault indications of the components ..................................................114
8.1.1 Fault indication on the LMS4x21......................................... 114
8.1.2 SIM2000 fault indication .....................................................115
8.1.3 Fault indication on the object detection photoelectric
sensor.................................................................................... 116
8.1.4 Fault indication on the photoelectric sensor array .............117
8.2 Detailed fault analysis ......................................................................... 118

CONTENTS
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9Technical data................................................................................................ 119
9.1 Data sheet ............................................................................................119
9.2 Dimensional drawings..........................................................................121
9.2.1 Dimensional drawings for the LiDAR sensor .......................121
9.2.2 Dimensional drawings for the cabinet .................................122
9.3 Compliance with EU directives ............................................................123
10 Disposal .......................................................................................................... 124

1ABOUT THIS DOCUMENT
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1About this document
These supplementary operating instructions on the VMS4200-x/ 5200-x MID 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-x/5200-x MID multi-dimensional measurement
system with an SIM200-2 Prime controller.
The supplementary operating instructions for the VMS4200/5200-x MID with a SIM2000-2
Prime Controller are only valid in conjunction with the main operating instructions for the
VMS4200/VMS5200-x MID (Multicontroller) (8024627 DE / 8024628 EN).
Unless otherwise specified in this document, the information in the main operating
instructions for the VMS4200/VMS5200-x MID (Multicontroller) will apply.
1.3 Target groups
This document is intended for qualified persons who operate the VMS4200-x /
5200-x MID.

ABOUT THIS DOCUMENT 1
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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
–E300817 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-x / 5200-x MID multi-dimensional measurement system is used to
measure cubic and irregularly shaped objects on cross-belt sorting systems. The objects
to be measured must be dimensionally stable, opaque, and non-reflective.
The cross-belt conveyor system can be designed as a conventional single cross belt sorter
or as a double belt sorter (see also the explanations in section 3.2.5 Cross belt conveyor
elements on page 20 f.). The two LMS4x21 LiDAR sensors are mounted horizontally
above the cross belt sorter and, just like the VMS4200/5200 MID, typically rotated at an
angle of 45°. All components have been configured for use on cross-belt sorting systems.
The VMS4200-x / 5200-x MID 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.
Using the optional object detection photoelectric sensor, it is also possible to measure
overhanging cubic objects.
The VMS5200-x MID 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 this system description, in particular the
safety notes and repair and maintenance requirements as well as proper installation, in
particular for billing operation.

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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.
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.

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2.4 Sources of danger
The 2D LiDAR sensors of the VMS4200-x/5200-x MID 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).
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 LiDAR sensor
2.6 System 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.
Optical radiation:
Laser class 2
Electrical voltage
Suspended loads

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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

SYSTEM DESCRIPTION 3
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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-x MID or
2 LMS4521R-16000 2D LiDAR sensors with laser protective cover for the
VMS5200-x MID
•1 modular mounting set
•1 LFT display - VMS5200-x MID only
•1 TTC100-2 cabinet with a SIM2000-2 Prime controller, power supply unit modules
and LFT Ethernet switch
•1 photoelectric sensor array consisting of 4 WL100L photoelectric sensors
(or functionally compatible)
•2 beam blockers
•Connecting cables
Optional
•1 object detection photoelectric sensor (e.g. RAY26) for object detection.
NOTE
These operating instructions use the product name of the controller: SIM2000-Prime.
The device name is SIM2000ST-E.

3SYSTEM DESCRIPTION
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3.2 System components
Fig. 1: Components of the VMS4200-x / 5200-x MID
Legend
1 LMS4x21 LiDAR sensor with laser protective cover
2 LFT display - VMS5200-x MID only
3 Photoelectric sensor array consisting of 4 photoelectric retro-reflective
sensors for speed detection, e.g. WL100L or functionally compatible
4 Cross-belt signal
5 Object detection photoelectric sensor for object detection (optional)
6 Cabinet with a SIM2000-2 Prime controller and power supply unit(s)
•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

SYSTEM DESCRIPTION 3
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3.2.1 LMS4x21 LiDAR sensors
Fig. 2: LMS4x21 LiDAR sensors with LFT display - VMS5200-x MID only
Legend
1 LMS4x21 LiDAR sensor
2 Laser protective cover
3 LFT display for billing-capable VMS5200-x MID measurement systems
•Consists of two LMS4x21 LiDAR sensors with laser protective covers that are mounted
on a profile and located on the right and left above the cross-belt conveyor.
•The LMS4x21 LiDAR sensors are configured as master and slave.
•Used to determine the relevant object dimensions by contactlessly detecting objects
on single cross belt sorters or double belt sorters.
•VMS5200-x MID measurement systems operating in legal for trade applications also
have a separate LFT display to show the measurement results, status information,
firmware version, and the logbook (version history).
Features
Function
LFT display

3SYSTEM DESCRIPTION
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3.2.2 Photoelectric sensor array
The photoelectric sensor array is used to determine the conveyor speed in single cross
belt sorters or double belt sorters.
Fig. 3: Photoelectric sensor array
Legend
1 WL100L photoelectric retro-reflective sensor (or functionally compatible)
2 Reflector
•Optical photoelectric sensor array consisting of four photoelectric sensors with
reflector.
•Used in place of a rotary measuring wheel encoder since the conveyor belt is divided
into individual cross-belt conveyor elements.
Features

SYSTEM DESCRIPTION 3
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Fig. 4: Determining speeds with the photoelectric sensor array
Legend
1 Photoelectric sensor array
1a Photoelectric sensor signal
2 Master
3 SIM2000-2 Prime controller
3a Transfer of speed and increment data
•The feed speed of the conveyor belt is detected by the photoelectric sensor array like
a measuring wheel encoder.
•To that end, the SIM2000-2 Prime controller determines the times at which the
photoelectric sensors were passed when a transport unit passes through.
•The speed of the transport unit can be calculated together with the parameterized
distances between the individual photoelectric sensors.
•These speed values are then used to calculate the increment required to determine the
object’s position on the conveying equipment (referred to as “tracking”).
Function

3SYSTEM DESCRIPTION
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3.2.3 Object detection photoelectric sensor (optional)
Fig. 5: Object detection photoelectric sensor and reflector
Legend
1 Object detection photoelectric sensor
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.
Fig. 6: Object trigger and cross-belt signal
Legend
1 Cross belt signal: trigger signal relating to the leading edge of the carrier.
2 Object trigger: is triggered when the leading edge of the object passes
through the photoelectric sensor.
•Object is detected as it passes through the object detection photoelectric sensor.
•The object detection photoelectric sensor, together with the cross belt signal,
determines the position of the object on the belt segment in the conveying direction.
•The position of the object is required to detect the presence of overhangs.
Features
Function

SYSTEM DESCRIPTION 3
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3.2.4 Cabinet
Fig. 7: Cabinet for the VMS4200-x/5200-x MID
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 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-x / 5200-x MID.
•The SIM2000-2 Prime controller contains the legally relevant memory (alibi memory).
Properties

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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 uses the signals from the photoelectric sensor array to
calculate the incremental signal for position determination. The signals are transmitted
to the LMS4x21 master.
•The SIM2000-2 Prime controller receives the measuring points from the LiDAR sensors
and uses the 2D sections to calculate a three-dimensional model.
•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-x MID, the measurement results are saved in the
SIM2000-2 Prime controller alibi memory, which is required for legal-for-trade
verification.
3.2.5 Cross belt conveyor elements
Fig. 8: Single cross belt sorter with cross-belt conveyor elements
Legend
1 Carrier
2 Cross-belt conveyor element
3 Transported item
•The conveyor belt is divided into individual cross-belt conveyor elements that are
mounted on a carrier.
•Similar to a conventional conveyor belt, the individual cross-belt conveyor elements are
moved in a contiguous line in the conveying direction.
•The cross-belt conveyor elements can also be loaded and unloaded perpendicularly to
the conveying direction via their integrated conveyors.
•Loads are loaded onto cross-belt conveyor elements by coordinated placement on the
individual carrier units.
Function
Single cross
belt sorter