SICK ALIS User manual

MMMI MMMSYSTEM DESCRIPTION
S Y S T E M D E S C R I P T I O N
ALIS
Airport Luggage Identification System
Track and Trace Systems

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Subject to change without notice
Described Product
ALIS
Airport Luggage Identification System
Manufacturer
SICK AG
Erwin-Sick-Str. 1
D-79183 Waldkirch
Germany
Production Location
SICK AG AG
Gisela-Sick-Str. 1
D-79276 Reute
Germany
Legal Information
This work is protected by copyright. Any rights derived from the copyright shall be reserved
for SICK AG. Reproduction of this document or parts of this document is only permissible
within the limits of the legal determination of Copyright Law. Any modification, reduction or
translation of this document is prohibited without the express written permission of SICK
AG.
The trademarks stated in this document are the property of their respective owner.
© SICK AG. All rights reserved
Original Document
This document is an original document of SICK AG.

CONTENT
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1 About this Document ................................................................................ 7
1.2 Purpose of this Document .............................................................................. 7
1.3 Target Group.................................................................................................... 7
1.4 Further Information......................................................................................... 7
1.5 Additional Technical Documentation/Information ........................................ 8
1.6 Document Conventions................................................................................... 9
2 Important Safety Instructions ................................................................11
2.1 Intended Use .................................................................................................11
2.2 Supplemental Directives...............................................................................11
2.3 Requirements for the Qualification of Personnel ........................................11
2.4 Potential Hazards..........................................................................................12
2.5 Protective Devices.........................................................................................14
2.6 System Warranty ...........................................................................................14
2.7 RoHS-Directive ..............................................................................................14
2.8 Safety Conventions .......................................................................................15
2.9 Warning Signs on System Components .......................................................15
2.10 Mandatory Signs ...........................................................................................16
3 Systems Description................................................................................17
3.1 ALIS Laser - Laser Based Bar Code Reading System ..................................18
3.2 ALIS - Matrix Camera based Bar Code Reading System .............................19
3.2.1 ALIS Camera - Camera System with 8 Matrix Cameras and 2 Laser
Scanners .......................................................................................19
3.2.2 ALIS Camera - Camera System with 10 Matrix Cameras ............20
3.2.3 ALIS Vision - Camera System with OCR&VC.................................20
3.3 ALIS RFID - Radio Frequency Identification System ....................................21
3.4 ALIS - Hybrid ..................................................................................................22
3.4.1 RFID and Laser Scanner Reading System ...................................22
3.4.2 RFID Camera and Laser Reading System....................................23
3.5 General Information ......................................................................................24
3.5.1 Integration Into Customer System ...............................................24
3.5.2 Bar Code/RFID tag Specification .................................................25
3.5.3 System Ambient Data ...................................................................25
3.5.4 System Redundancy .....................................................................25
4 System Components ...............................................................................27
4.1 Laser Bar Code Scanner ...............................................................................27
4.1.1 CLV691 Laser Bar Code Scanner ................................................27
4.1.2 CLV691 Laser Bar Code Scanner with Mirror Hood ....................28
4.1.3 CLV691 Laser Bar Code Scanner with Cleaning Unit..................29
4.1.4 CLV651 Laser Bar Code Scanner (Option) ..................................30
4.2 Image-Based Code Reader ...........................................................................31
4.2.1 Lector654 Image-Based Code Reader ........................................31
4.2.2 Lector654 Image-Based Code reader with Mirror.......................32
Content

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4.3 RFID............................................................................................................... 33
4.3.1 RFU630 - RFID Read Device ........................................................ 33
4.3.2 Modules with/without Antenna ................................................... 34
4.4 Cabinet incl. Controller ................................................................................. 35
4.5 Reflection Light Barrier - Trigger Signal ...................................................... 36
4.6 Incremental-Encoder DFV60 ........................................................................ 37
4.7 Accessories (option) ..................................................................................... 38
4.7.1 CDF600-2200 Field Bus Module (Option)................................... 38
4.7.2 Network Camera........................................................................... 39
4.7.3 Signal Lamp.................................................................................. 39
5 Transport, Setup and Mounting............................................................. 41
5.1 Check Delivery .............................................................................................. 41
5.2 Transport and Setup..................................................................................... 41
6 Electrical Installation............................................................................... 43
6.1 Connection Overview CLV691 - ALIS Laser ................................................. 44
6.2 Connection Overview Lector654 - ALIS Camera.......................................... 45
6.3 Connection Overview - ALIS RFID ................................................................. 46
7 Commissioning ........................................................................................ 47
8 Operation .................................................................................................. 49
8.1 System Start ................................................................................................. 49
8.2 Check operational readiness ....................................................................... 49
8.2.1 CLV691 Bar Code Scanner .......................................................... 49
8.2.2 CLV651 Bar Code Scanner .......................................................... 49
8.2.3 Lector654 Code Reader............................................................... 50
8.2.4 RFU630......................................................................................... 50
8.2.5 MSC800 System Controller ......................................................... 50
8.2.6 System Readiness........................................................................ 50
8.2.7 Automated Operating Mode......................................................... 51
8.3 System End ................................................................................................... 52
8.3.1 Stopping the Conveying Syste, .................................................... 52
8.3.2 Interrupting the Voltage Supply ................................................... 53
9 Maintenance and Repair ........................................................................ 55
9.1 Regular Control Measurement ..................................................................... 56
9.2 Visual Control................................................................................................ 56
9.3 Cleaning Instructions.................................................................................... 56
9.3.1 Cleaning the CLV691/CLV651 .................................................... 56
9.3.2 Cleaning the Cleaning Unit for CLV691....................................... 57
9.3.3 Cleaning the Lector654 ............................................................... 58
9.3.4 Cleaning the Cabinet .................................................................... 59
9.3.5 Cleaning the Trigger ..................................................................... 59
9.3.6 Cleaning the Encoder ................................................................... 60

CONTENT
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9.4 Components Replacing.................................................................................61
9.4.1 CLV691 Replacing ........................................................................61
9.4.2 CLV651 Replacing ........................................................................63
9.4.3 Lector654 Replacing ....................................................................65
9.4.4 MSC800 System Controller Replacing.........................................67
9.4.5 MSC800 Battery Replacing ..........................................................68
9.4.6 Power Supply Unit Replacing........................................................69
9.4.7 Photoelectric Retro-Refelctive Sensor Replacing........................70
9.4.8 Incremental Encoder Replacing ...................................................71
10 Fault Diagnosis.........................................................................................73
10.1 Lector654 ......................................................................................................73
10.2 CLV691 ..........................................................................................................73
10.3 CLV651 ..........................................................................................................74
10.4 MSC800 System Controller ..........................................................................74
10.4.1 MSC800 System Controller Check...............................................75
10.4.2 Detailed Fault Analysis .................................................................76
11 Dimensional Drawings ............................................................................77
11.1 ALIS Laser- Laser Based Bar Code Reading System ...................................77
11.2 ALIS Camera - Camera Based Bar Code Reading System...........................79
11.2.1 ALIS Camera - Camera System with 8 Matrix Cameras and 2 Laser
Scanner .........................................................................................79
11.2.2 ALIS Camera - Camera System with 10 Matrix Cameras ............81
11.3 ALIS RFID - Radio Frequency Identification System ....................................83
11.4 ALIS - Hybrid ..................................................................................................85
11.4.1 RFID and Laser Scanner Reading System ...................................85
11.4.2 RFID Camera and Laser Scanner Reading System .....................87
12 Disposal.....................................................................................................89

CONTENT
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ABOUT THIS DOCUMENT 1
1 About this Document
1.1 Limitation of Liability
1.2 Purpose of this Document
This document describes the ALIS - Airport Luggage Identification Systems.
1.3 Target Group
This document is intended for qualified personnel which are authorized to work on the ALIS.
1.4 Further Information
Special local conditions
Follow all local laws, technical rules, and company-internal operating directives applicable
at the respective installation site of the ALIS.
Preserving the documents
This document and the additional technical documentation and information must be:
●Available for reference.
●Passed on to new system operator or new employees.
Note
This document regarding the ALIS - Airport Luggage Identification System:
●contains information required during the life cycle of the system.
●is available to all those people who work with the system.
●read this document carefully and make sure that you understand the content fully
before working with the system.
Note
All information and notes in this document have been compiled in accordance with the
applicable standards and regulations, the state of the art and the manufacturer's many
years of knowledge and experience.
It is therefore pointed out that the manufacturer assumes no liability, particularly in the
following cases:
●Non-compliance with this document.
●Failure to comply with instructions and regulations.
●Unauthorized assembly and installation.
●Unauthorized technical and other modifications.
●Use of spare parts, wearing parts and accessories not approved by the manufacturer.
●Unauthorized changes, adjustments and/or manipulations of software.
●Non-performance of regular maintenance work and its documentation.
The actual scope of delivery may deviate from the features and illustrations described
here in the case of special designs, the use of additional ordering options or due to the
latest technical changes.

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1ABOUT THIS DOCUMENT
1.5 Additional Technical Documentation/Information
●Technical System-Documentation:
– Wiring diagram
– Technical drawings
●Original SICK operating instructions for optional products and components can be found
at www.sick.com
ID-Number Components Manufacturer
8016185 Lector64x/65x - Image-Based Code Readers SICK
8014335 RFU63x - RFID read/write device (UHF) SICK
8014396 CLV69x - Bar Code Scanners SICK
8019588 CLV65x - Bar Code Scanners SICK
8015922 CDF600-2200 - PROFINET IO (Option) SICK
8013709 DFV60 - Incremental Encoder SICK
8011540 MSC800 - Modular System Controller SICK

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ABOUT THIS DOCUMENT 1
1.6 Document Conventions
Required tools
▸Instruction
Instruction result
All units of measurement in this document are originally metric units.
Subject to change without notice.
Images might differ from actual design.
Refer to another document.

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1ABOUT THIS DOCUMENT

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IMPORTANT SAFETY INSTRUCTIONS 2
2 Important Safety Instructions
2.1 Intended Use
With the ALIS (Airport Luggage Identification System) track and trace system, luggage can
be clearly identified as it is transported quickly and reliably through the airport and thus
reaches the right sorting zone.
Designed like a reading interval gate, SICK has developed ALIS specifically with luggage
handling services in mind.
The system is extremely reliable when it comes to reading luggage information on IATA bar
codes and/or RFID tagged labels.
With ALIS, SICK has created a modular system which can be specially adapted to suit the
various requirements of airport luggage identification and handling processes, whether this
involves sensors, visualization software, or even the commissioning process.
Intended use also includes compliance with this system information, especially the sources
of danger.
2.2 Supplemental Directives
▸Before working on the ALIS, read this document carefully and follow all safety instruc-
tions and information.
▸Only qualified persons from the respective areas are permitted to work on the ALIS.
▸Follow operating procedures.
▸Follow local regulations.
▸Observe local regulations for working with gas and electrical components.
▸Access to the ALIS is restricted to authorized personnel only.
System damage/transport damage
▸Damage to individual components can lead to malfunctions of the entire system.
▸Do not ignore system components damaged during transport.
▸In the event of damage, contact SICK Service.
2.3 Requirements for the Qualification of Personnel
Only qualified personnel from the respective field are permitted to work on the system.
●Qualified personnel have the specialist training, skills, and experience, as well as know-
ledge of the relevant regulations and standards, to be able to perform tasks delegated to
them and to detect and to avoid any potential dangers independently.
●Electricians have the specialist training, skills, and experience, as well as knowledge of
the relevant standards and provisions to be able to carry out work on electrical systems
and to detect and avoid any potential dangers independently.

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2IMPORTANT SAFETY INSTRUCTIONS
2.4 Potential Hazards
Optical radiation Laser class 1
The Lector65x camera-based code readers have a targeting laser as a setup aid.
The accessible radiation does not pose a hazard even when viewed directly for long periods
of time, (time base 100 seconds). In the case of visible lasers (red), temporary irritating
optical effects on the human eye (e.g. glare, flash blindness, afterimages, impairment of
color vision) cannot be completely ruled out, especially at low ambient brightness.
▸Do not look into the switched-on light source.
▸Do not look directly at the laser with optical instruments (magnifying glasses, micro-
scopes).
▸Observe current national regulations on laser protection.
Optical radiation Laser class 2
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.
▸Do not look into the laser beam intentionally.
▸Never point the laser beam at people's eyes.
▸If it is not possible to avoid looking directly into the laser beam, e.g., during commission-
ing and maintenance work, suitable eye protection must be worn.
▸Avoid laser beam reflections caused by reflective surfaces. Be particularly careful during
mounting and alignment work.
▸Do not open the housing. Opening the housing may increase the level of risk.
▸Current national regulations regarding laser protection must be observed.
Optical radiation LED light (RG2)
Camera system and the integrated LED illumination of the Lector65x use LEDs of the RG2
risk group.
The optical radiation can cause serious eye injuries if the following points are not observed:
▸Do not look into the light source for extended periods of time.
▸Do not point the light source at people and prevent reflections of the light source from
reflective surfaces onto people.
▸During commissioning or maintenance work, suitable eye protection must be worn.
▸Do not open the housing.
▸Comply with the recent national version of the applicable standards on photobiological
safety of lamps and lamp systems.
Electric voltage
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.

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IMPORTANT SAFETY INSTRUCTIONS 2
Hot surfaces
Components can be hot. Contact may cause burn and serious injuries.
▸Do not touch hot surfaces.
▸Use appropriate safety gloves.
Suspended loads
▸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).

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2IMPORTANT SAFETY INSTRUCTIONS
2.5 Protective Devices
The ALIS systems are designed in a way that allows for safe operation. Protective devices
reduce potential risks to the maximum possible extent.
Side panels prevent the bags from falling.
2.6 System Warranty
Any warranty claim expires if:
▸Safety instructions and measures in this document are not observed.
▸Parts or components of the Continuous Emission Monitoring System are installed,
assembled or modified without authorization.
▸The ALIS is changed or modified.
▸Software is changed, adapted and/or manipulated without authorization.
2.7 RoHS-Directive
This product is designed for applications in large industrial plants according to
Article 2 (4) e, RoHS 2011/65/EU and can therefore only be used in such systems.
The product is neither suitable nor approved for use outside of these systems.
SICK cannot assume any kind of warranty or liability for use outside of these systems..

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IMPORTANT SAFETY INSTRUCTIONS 2
2.8 Safety Conventions
The warnings used in this manual have the following meanings:
2.9 Warning Signs on System Components
Do not remove or cover warning stickers. Damaged or missing stickers must be replaced.
DANGER
Indicates a hazardous situation which, if not avoided, will result in death or serious
injury.
WARNING
Indicates a hazardous situation which, if not avoided, could result in death or serious
injury.
CAUTION
indicates a hazardous situation which, if not avoided, could result in minor or moder-
ate injuries.
NOTICE
Indicates a situation which that can lead to material damage if not avoided.
Sign Significance
Warning of a danger point
Warning of dangerous electrical voltage
Warning of laser light / LED light
Warning of hot surfaces
Warning of suspended loads

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2IMPORTANT SAFETY INSTRUCTIONS
2.10 Mandatory Signs
Mandatory signs indicate a measure that is required to protect personal health and / or
avoid the risk of personal injury.
Mandatory signs on the system must not be removed or covered. Damaged or missing
mandatory signs (stickers) must be replaced.
Sign Significance
Read instructions manual
Wear safety gloves
Wear eye protection
Wear hard hat
Wear safety boots
Disconnect before maintenance or repair

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SYSTEMS DESCRIPTION 3
3 Systems Description
The ALIS is a fully automatic reading gate including frame, scan heads with on-board
decoder, local network controller and host communication for reading bar codes on flight
baggage, which in turn is located e.g. on conveyor belts, cross belts or tilt tray sorter sys-
tems.
The local network-controller incorporates a controller for the local scanner-network, opto-
isolated digital diagnostic software, flexible HOST-Interface and an interface supplying diag-
nostic data to the Diagnostic Tool “Baggage Analytics” or "Logistics Diagnostic Analytics".
More information about the diagnostic software can be found on SICK.com.
The HOST-interface can be adapted to customers specific requirements in terms of HOST-
Protocol and physical interface.
The complete system consists of a certain amount of bar code readers or/and RFID reader
and antennas - depending on the application -, the control unit MSC800 unit, photoelectric
switches for object-trigger, cables and an increment encoder for measuring the conveyor
speed.
System Types
●ALIS Laser - Laser based bar code reading
●ALIS Cam - Matrix cameras based bar code reading, two versions:
– with 10 matrix cameras, 2 of them for bottom reading
– with 8 matrix cameras and 2 laser scanners for bottom reading
●ALIS RFID - Reading and assignment of RFID tags
●ALIS Hybrid - combination of RFID and further identification readers, two versions:
– with RFID and laser scanners
– with RFID and matrix cameras

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3SYSTEMS DESCRIPTION
3.1 ALIS Laser - Laser Based Bar Code Reading System
Fig. 1: Components of the 6 side ALIS reading gate based on laser scanners
Legend
1Eight CLV691 fixed mount bar code scanner
2Cabinet with controller and power supply unit
3Field bus module for PROFINET (optionally)
4Two CLV691 fixed mount bar code scanner with cleaning unit
optionally 3 - 4 CLV651 fixed mount bar code scanners with
cleaning unit and connection unit
5Incremental signal
6Trigger signal

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SYSTEMS DESCRIPTION 3
3.2 ALIS - Matrix Camera based Bar Code Reading System
3.2.1 ALIS Camera - Camera System with 8 Matrix Cameras and 2 Laser Scanners
Fig. 2: Components of the 6 side ALIS reading gate based on Lectors654 and 2 CLV691
Legend
1Eight Lector654 image based code reader
2Cabinet with controller, power supply and Ethernet switch
3Field bus module for PROFINET (optionally)
4Two CLV691 fixed mount bar code scanner with cleaning unit
optionally 3 - 4 CLV651 fixed mount bar code scanners with
cleaning unit and connection unit
5Incremental signal
6Trigger signal

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3SYSTEMS DESCRIPTION
3.2.2 ALIS Camera - Camera System with 10 Matrix Cameras
Fig. 3: Components of the 6 side ALIS reading gate based on Lector654
3.2.3 ALIS Vision - Camera System with OCR&VC
The ALIS camera can be supplemented with optical character recognition and/or video
coding.
This makes up the ALIS Vision. In the event that the baggage source message is missing,
the data (flight number, destination code, license plate number) that is relevant to sorting
can be read on the baggage tag in conjunction with OCR or VC. Less manual reprocessing
of the baggage item is required.
The number of bags going to the manual encoding station is further reduced. This results in
a higher sorting rate and optimizes the process time of transfer bags.
Legend
1Eight Lector654 image based code reader
2Cabinet with controller, power supply and Ethernet switch
3Field bus module for PROFINET (optionally)
4Two Lector654 with cleaning unit
5Incremental signal
6Trigger signal