SICK VMS4300 User manual

OPERATING INSTRUCTIONS
VMS4300/5300
Track and trace systems

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Described product
VMS4300 / VMS5300
Document no.
8026508
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 retro-reflective sensor (optional).........17
3.2.4 Cabinet.................................................................................18
3.2.5 Expanding the system with a reading station.......................20
3.3 Triggering the recording of measured values .....................................21
3.4 Operating mode and transport types ..................................................23
3.4.1 IDS operating mode .............................................................23
3.4.2 NSDS operating mode..........................................................25
3.4.3 Impermissible transport types..............................................27
3.5 Determining measurement results and outputting data ....................29
3.5.1 Recording of measured values and 3D modeling ................29
3.5.2 Calculation of the dimension values ....................................31
3.5.3 Data output ..........................................................................32
3.6 Additional functions............................................................................34
3.7 Nominal operating conditions.............................................................35
3.7.1 Fixed scale values ................................................................35
3.7.2 Dynamic scale value switchover ..........................................38
3.8 Legal for trade operation ....................................................................40
3.8.1 Information labels ................................................................40
3.8.2 Security seal.........................................................................46
3.8.3 Alibi memory and firmware ..................................................52
3.8.4 LFT display ...........................................................................55
3.8.5 Test instructions for market surveillance.............................59
3.9 System requirements for legal for trade operation.............................63
3.9.1 Requirements on the ambient conditions............................63
3.9.2 Requirements on the conveying equipment.........................63
3.9.3 Mounting requirements........................................................65
3.9.4 Object requirements.............................................................67

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4Mounting........................................................................................................ 68
4.1 Mounting 2D LiDAR sensors .............................................................. 68
4.1.1Overview .............................................................................. 68
4.1.2 Assembling the profiles of the telescopic tube.................... 69
4.1.3 Mount the center profile using a mounting plate ................ 70
4.1.4 Mount the telescopic tube on the frame ............................. 70
4.1.5 Fastening the 2D LiDAR sensors to the mounting plates .... 71
4.2 Mounting the incremental encoder.................................................... 72
4.3 Mounting the trigger photoelectric retro-reflective sensor ................. 72
4.4 Mounting the cabinet ......................................................................... 73
5Electrical installation .................................................................................... 74
5.1 Connection overview .......................................................................... 75
5.2 Connecting the voltage supply ........................................................... 76
5.3 Connection for the Ethernet switch (set up at the factory)................. 77
5.4 Connection for the APU8520 - SIM2000 CAN connection
(set up at the factory)......................................................................... 78
5.5 Connection of 2D LiDAR sensors ....................................................... 79
5.6 Connection for the LFT display........................................................... 81
5.7 Connection of the incremental encoder............................................. 82
5.8 Connection for the photoelectric retro-reflective sensor trigger
(optional)............................................................................................ 83
5.9 Connecting the customer interface.................................................... 84
6Commissioning .............................................................................................. 85
6.1 Switching on the system .................................................................... 85
6.2 Configuring the system with SOPAS ................................................... 86
6.2.1 Connecting the configuration PC ......................................... 86
6.2.2 Installing SOPAS .................................................................. 86
6.2.3 Assigning IP addresses........................................................ 87
6.2.4Opening the configuration interface .................................... 93
6.2.5 Log on to device................................................................... 94
6.2.6 Saving the parameters permanently ................................... 95
7Maintenance and repair ................................................................................ 96
7.1 Monitoring and cleaning work............................................................ 97
7.1.1 Control measurements........................................................ 97
7.1.2 Visual inspection.................................................................. 97
7.1.3 Cleaning the 2D LiDAR sensors........................................... 98
7.1.4 Checking the incremental encoder components................. 99
7.1.5 Clean the trigger photoelectric sensor................................. 99
7.1.6 Cleaning the cabinet.......................................................... 100
7.2 Replacing components..................................................................... 101
7.2.1 Replacing the 2D LiDAR sensor......................................... 101
7.2.2 Replacing the incremental encoder components.............. 103
7.2.3 Replace the trigger photoelectric sensor........................... 104
8Fault diagnosis............................................................................................. 105
8.1 Fault indications of the components................................................ 105
8.1.1 Fault indication on the LMS4x21....................................... 105
8.1.2 SIM2000 fault indication................................................... 106
8.1.3 Fault indication on the trigger photoelectric
retro-reflective sensor........................................................ 107

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8.2 Checks on the SIM2000 ...................................................................108
8.2.1 Checking the triggering ......................................................108
8.2.2 Checking the incremental encoder ....................................109
8.2.3 Checking the CAN cabling ..................................................110
8.3 Detailed fault analysis ......................................................................111
9Technical data ..............................................................................................112
9.1 Data sheet ........................................................................................112
9.2 Dimensional drawings ......................................................................114
9.2.1 Dimensional drawings for the 2D LiDAR sensor.................114
9.2.2 Dimensional drawings for the cabinet................................115
9.3 Licenses............................................................................................116
9.4 Compliance with EU directives..........................................................117
10 Disposal ........................................................................................................118

1ABOUT THIS DOCUMENT
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1About this document
These operating instructions on the VMS4300 / VMS5300 multi-dimensional
measurement system:
•Contains information that is required during the life cycle of the system.
•Must be available to all those who work with the system.
•Must be read carefully to ensure that the contents are 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 VMS4300 / VMS5300 multi-dimensional measurement
system.
1.3 Target groups
This document is intended for qualified persons who operate the VMS4300 / VMS5300.

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1.4 Further information
Special local conditions
The local laws, regulations, technical rules and internal company operating instructions
at the usage site 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
–E302925 (EPLAN)
Technical data
Connection diagram
Terminal diagram
•Operating instructions for the following system components:
Component Manufacturer
LMS4000 2D LiDAR sensor operating instructions SICK
SIM2000 Sensor Integration Machine operating instructions SICK
Operating instructions for the APU85x Application Processing
Unit
SICK
1.6 Document conventions
▸Instructions
•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 VMS4300/5300 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 measured values are recorded by means of three LMS4x21 2D LiDAR sensors
mounted above the conveying equipment. The two outer 2D LiDAR sensors are normally
rotated at an angle of 45°, and the sensor mounted centrally is aligned parallel to the
surface of the conveying equipment.
The VMS4300/5300 distinguishes between two operating modes:
•In IDS operating mode, objects that are either singulated or lying adjacent to one
another (side-by-side) can be measured. The objects must not be touching each other
at the corners or edges.
•In NSDS operating mode, only cubic objects that are either singulated or lying adjacent
to one another (side-by-side) can be measured (responsibility of the operator).
The VMS4300/5300 determines the length, width and height of the smallest enveloping
cuboid. These dimension values can be used to calculate the volume of this cuboid.
The measurement results can be transferred to the customer network via the data
interface of the SIM2000 system controller.
The VMS5300 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.
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 permit authorized persons to access 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 VMS4300/5300 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 reflections 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 2D LMS4x21 LiDAR sensor
•Glare protection plates
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
•3 LMS4421R-16000 2D LiDAR sensors with laser protective cover for the VMS4300 or
3 LMS4521R-16000 2D LiDAR sensors with laser protective cover for the VMS5300
•1 LFT display - VMS5300 only
•1 TTC200-2 cabinet with a SIM2000 system controller, an APU8520 dimensioning
controller, power supply unit modules, and Ethernet switch.
•1 incremental encoder with mounting kit (e.g., DFV60, DBS36)
•1 modular mounting set
•Glare protection plates
•Connecting cables
Optional
•1 Trigger photoelectric sensor for triggered systems (e.g., RAY26)

SYSTEM DESCRIPTION 3
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3.2 System components
Fig. 1: Components of the VMS4300/5300
Legend
1 LMS4x21 2D LiDAR sensor with laser protective cover
2 LFT display - VMS5300 only
3 Incremental encoder (e.g., DFV60)
4 Trigger photoelectric sensor for triggered systems (e.g., RAY26)
5 Cabinet with a system controller, dimensioning controller, power supply
units, and Ethernet switch
•The system components are mounted on a frame as per the technical drawing.
Devices
Mounting

3SYSTEM DESCRIPTION
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Fig. 2: Glare protection plates
•The glare protection plates mounted at the sides confine the laser beams of the
LMS4x21 to the application space.
•Objects or items located outside the measuring range are disregarded when calculating
the measured values.
Glare protection
plates

SYSTEM DESCRIPTION 3
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3.2.1 LMS4x21 2D LiDAR sensors
Fig. 3: LMS4x21 2D-LiDAR sensors with LFT display
Legend
1 LMS4x21 2D LiDAR sensor
2 Laser protective cover
3 LFT display for VMS5300 measurement systems approved for billing
applications
4 Mounting kit
•The VMS4300/5300 multi-dimensional measurement system consists of three 2D
LMS4x21 LiDAR sensors with laser protective covers that are mounted on a mounting
kit and located on the right and left as well as centrally above the conveyor.
•The LMS4x21 2D LiDAR sensors are configured as master and slave.
•The 2D LiDAR sensors are used to calculate the relevant object dimensions by
contactlessly detecting objects on flat conveying systems.
The officially verifiable VMS5300 measurement systems also include a separate
LFT display
•to display the measurement results,
•to display status information, the firmware version, and the logbook (version history)
as well as
•to display the measured values stored in the alibi memory.
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 retro-reflective sensor (optional)
Fig. 5: Photoelectric sensor and reflector trigger
Legend
1 Trigger photoelectric sensor (e.g., RAY26)
2 Reflector
•The light band emitted by the trigger 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 retro-reflective sensor trigger is available as an option.
Features
Function

3SYSTEM DESCRIPTION
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3.2.4 Cabinet
Fig. 6: Components in the cabinet
Legend
1 Air inlet for cooling (with filter mat and fan)
2 Terminals for mains voltage IN (230 VAC, 50 Hz)
3 SIM2000 system controller
4 RCD/MCB circuit breaker
5 Circuit breaker
6 Power supply units
7 Air outlet for cooling (with filter mat)
8 Air outlet for cooling (with filter mat)
9 APU8520 dimensioning controller
10 Terminals (24 V DC) and fuse module OUT
11 Ethernet switch
12 Air inlet for cooling (with filter mat and fan)
•Contains power supply units for the central voltage supply to system components.
•An Ethernet switch is used to connect system components.
•Contains the SIM2000 system controller and the APU8520 dimensioning controller,
which are the central control and processing units of the VMS4300/5300.
Properties

SYSTEM DESCRIPTION 3
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•Coordinates all connected sensors and processes the measured values received.
•The data is sent to the higher-level customer system via the system controller in a
host telegram with a defined format.
NOTE! In the case of the VMS5300, the measurement results are saved in the
SIM2000 alibi memory, which is required for legal-for-trade verification.
•The APU8520 dimensioning controller is the processing unit of the system.
•The dimensioning controller receives the measuring points from the 2D LiDAR sensors
and uses the 2D sections to calculate a three-dimensional model.
•Based on this calculated 3D model, the dimensioning controller determines the
dimension values and the so-called box volume.
•The measurement results are transmitted to the SIM2000 system controller via
CAN bus.
SIM2000
system controller
APU8520
dimensioning
controller

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 VMS4300/5300
2 Laser- or image-based reading systems
3 CAN bus
•Expansion of the VMS4300/5300 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 automated 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 system controller.
•The SIM2000 system controller links the acquired identification data with the
dimension values calculated by the VMS4300/5300.
•Identification data and dimension values are output together to the higher-level
system.
Properties
Function
Connection