SICK Master Data Analyzer User manual

OPERATING INSTRUCTIONS
MASTER DATA ANALYZER
Track and trace systems

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OPERATING INSTRUCTIONS | Master Data Analyzer
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Product described
Product name: Master Data Analyzer
Document identification
Title: Operating instructions for Master Data Analyzer
Part number: 8020065-ZSP4
Status: 2017-08-10
Manufacturer
SICK AG
Erwin-Sick-Str. 1 · 79183 Waldkirch · Germany
Trademarks
IBM is a trademark of the International Business Machine Corporation.
MS-DOS is a trademark of the Microsoft Corporation.
Windows is a trademark of the Microsoft Corporation.
Other product names in this document may also be trademarks and are
only used here for identification purposes.
Original documents
The German issue 8020064-ZSP4 of this document is an original SICK AG
document.
SICK AG does not assume liability for the correctness of a non-authorized
translation.
In case of doubt, contact SICK AG or your local dealer.
Legal notes
Subject to change without notice
© SICK AG. All rights reserved

CONTENTS
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Contents
1About these operating instructions ..............................................................................7
1.1 Purpose of this document....................................................................................7
1.2 Information depth ................................................................................................7
1.3 Abbreviations used...............................................................................................7
1.4 Symbols used .......................................................................................................8
2Safety ..............................................................................................................................9
2.1 Qualified safety personnel...................................................................................9
2.2 Applications of the system...................................................................................9
2.3 Intended use...................................................................................................... 10
2.4 General safety notes and protective measures .............................................. 11
2.4.1 Safety notes and symbols ................................................................. 11
2.4.2 General safety notes.......................................................................... 12
2.4.3 Additional operating instructions ...................................................... 12
2.4.4 Dangers connected with handling of the device.............................. 13
2.4.4.1 Danger due to electrical current ...................................... 13
2.4.4.2 Risks during transport and installation............................ 14
2.4.4.3 Risks during operation...................................................... 15
2.4.5 Protective devices .............................................................................. 17
2.4.6 Work station ....................................................................................... 18
2.4.7 Protective equipment......................................................................... 18
2.4.8 The operating entity’s responsibilities .............................................. 18
2.5 Protecting the environment .............................................................................. 19
2.5.1 Power consumption ........................................................................... 19
2.5.2 Disposal after final decommissioning............................................... 19
3System description ..................................................................................................... 20
3.1 Scope of delivery ............................................................................................... 20
3.2 System components ......................................................................................... 21
3.3 The system’s operating principle...................................................................... 26
3.4 Project planning ................................................................................................ 31
3.5 Status indicators ............................................................................................... 32
3.5.1 Status indicators – Light grids .......................................................... 32
3.5.2 Status indicators – Hand-held scanner (only in operating
mode with bar code scanning) .......................................................... 33
3.5.3 Status indicators – IP camera ........................................................... 34
3.5.4 Status indicators – Display................................................................ 34
3.5.5 Status indicators – Electronic scales................................................ 35
3.5.6 Status indicators – WLAN module .................................................... 35
3.6 Interfaces........................................................................................................... 36
4Transport, assembly, and mounting .......................................................................... 37
4.1 Accepting the delivery....................................................................................... 37
4.1.1 Packaging ........................................................................................... 37
4.1.2 Checking delivery for visible transport damage ............................... 37
4.2 Transporting the MDA to its location of use .................................................... 38
4.3 Unpacking and setting up the device............................................................... 39
4.3.1 Unpacking the MDA ........................................................................... 39
4.3.2 Checking delivery for hidden transport damage .............................. 40
4.3.3 Setting up the MDA............................................................................ 41
4.4 Removing the transport locks........................................................................... 43

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4.5 Mounting ............................................................................................................44
4.5.1 Ready to go .........................................................................................44
4.5.2 Mounting the WLAN module ..............................................................44
5Electrical installation ..................................................................................................45
5.1 Connections on the MDA...................................................................................46
5.1.1 Components connected as standard ................................................46
5.1.2 Connections on the controller housing..............................................46
5.2 Connecting the MDA to the supply voltage ......................................................47
5.3 Connecting the MDA to the target network ......................................................48
5.4 Connecting the sliding table with rechargeable battery ..................................48
5.5 Connecting the WLAN adapter ..........................................................................49
6Commissioning ............................................................................................................50
6.1 Starting the MDA................................................................................................50
6.1.1 Starting up the MDA ...........................................................................50
6.1.2 Checking operational readiness ........................................................50
6.2 Preparing the configuration PC .........................................................................52
6.2.1 Establishing a connection with the configuration PC .......................52
6.2.2 Service and data interface .................................................................52
6.2.3 Installing SOPAS .................................................................................53
6.2.4 Launching SOPAS ...............................................................................54
6.3 Adding the MDA to the SOPAS project..............................................................55
6.3.1 Starting the device search .................................................................55
6.3.2 Transferring the controller to a SOPAS project .................................57
6.3.3 Loading device drivers into the SOPAS project.................................57
6.3.4 Setting the controller to online...........................................................59
6.4 Configuring the MDA in SOPAS .........................................................................60
6.4.1 Incorporating the MDA controller into the customer’s network.......61
6.4.1.1 Issuing the Data interface IP address ..............................61
6.4.1.2 Testing the server connection...........................................62
6.4.2 Storing connection data for the customer server .............................63
6.5 Saving data permanently...................................................................................64
6.6 Performing a test run.........................................................................................65
6.7 Setting up the IP camera ...................................................................................66
6.8 Configuring the WLAN module ..........................................................................67
7Operation...................................................................................................................... 68
7.1 Safety information .............................................................................................68
7.2 Steps for preparing for your first measurement...............................................70
7.2.1 Adjusting the display and operating position ....................................70
7.2.2 Starting up the MDA ...........................................................................71
7.2.3 Structure of the measurement window.............................................72
7.2.4 Moving the measurement gantry to a start position ........................74
7.2.5 Positioning a measuring object..........................................................75
7.3 Performing measurements................................................................................76
7.3.1 Starting the measurement process ...................................................76
7.3.1.1 Scanning the bar code (only for the operating mode
with bar code scanning) ....................................................76
7.3.1.2 Weighing the object (only for the operating mode
without bar code scanning)...............................................78
7.3.2 Measuring the volume........................................................................79

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7.3.3 Checking the measurement results.................................................. 80
7.3.3.1 Reading measurement data............................................. 80
7.3.3.2 Checking measurements with the 2D display ................. 81
7.3.3.3 Displaying the measuring object in a live view................ 81
7.4 Transmitting measurement results.................................................................. 82
7.4.1.1 Direct data output if the device is connected
to a server.......................................................................... 82
7.4.1.2 Saving measurement data internally (only for
operating mode with bar code scanning) ........................ 82
7.4.1.3 Displaying the transmission status (only for
operating mode without bar code scanning).................. 84
7.4.1.4 Restoring a server connection manually ......................... 85
7.5 Performing new measurements ....................................................................... 86
7.6 Repeating incorrect measurements................................................................. 88
7.6.1 Object was positioned incorrectly ..................................................... 88
7.6.2 Volume measurement without bar code (only for operating
mode with bar code scanning) .......................................................... 89
7.6.3 Volume measurement without a stable weight (only for
operating mode without bar code scanning).................................... 90
7.7 Performing mobile measurements................................................................... 91
7.8 Using the sliding table with rechargeable battery ........................................... 91
7.9 Configuration ..................................................................................................... 92
7.9.1 Logging into the configuration area .................................................. 92
7.9.2 General settings ................................................................................. 93
7.9.2.1 Selecting a language......................................................... 93
7.9.2.2 Correcting the zero point .................................................. 93
7.9.2.3 Performing teach-in........................................................... 93
7.9.3 Display settings .................................................................................. 95
8Maintenance and repairs ........................................................................................... 96
8.1 Maintenance and repairs.................................................................................. 97
8.1.1 Visual inspection for mechanical and electrical damage ................ 98
8.1.2 Cleaning the light grids ...................................................................... 99
8.1.3 Cleaning the display......................................................................... 100
8.1.4 Cleaning the glass panel ................................................................. 101
8.1.5 Cleaning the internal housing area................................................. 101
8.1.6 Cleaning the IP camera’s dust shield housing ............................... 103
8.2 Replacing components ................................................................................... 104
8.2.1 Replacing the hand-held scanner (only in operating mode
with bar code scanning)................................................................... 105
8.2.2 Replacing the display.......................................................................105
8.2.3 Replacing the glass panel ............................................................... 106
8.2.4 Replacing the IP camera..................................................................108
8.2.5 Replacing the WLAN module........................................................... 109
9Fault diagnosis.......................................................................................................... 110
9.1 Response to faults .......................................................................................... 110
9.2 Fault indicators................................................................................................ 110
9.2.1 Status indicator on the display........................................................ 110
9.2.1.1 Dealing with status messages........................................110
9.2.1.2 Overview of status messages.........................................111
9.2.2 Status indicators for components................................................... 114
9.3 SICK support....................................................................................................115

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10 Technical specifications .......................................................................................... 116
10.1 Data sheets ..................................................................................................... 116
10.1.1 System data sheet........................................................................... 116
10.1.2 Data sheet for the IDM26x hand-held scanner (wired) ................. 116
10.1.3 IP camera Axis M3005-V ................................................................. 117
10.1.4 WLAN Ethernet port adapter FL WLAN EPA.................................... 117
10.2 Dimensional drawings .................................................................................... 118
10.3 Spare parts list ................................................................................................ 118
10.4 Data interface ................................................................................................. 119
11 Appendix.................................................................................................................... 120
11.1 List of tables.................................................................................................... 120
11.2 List of figures................................................................................................... 121
11.3 Keywords index ............................................................................................... 123

ABOUT THESE OPERATING INSTRUCTIONS 1
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1About these operating instructions
Please read through this chapter carefully before you use the documentation and work
with the Master Data Analyzer (also abbreviated to MDA in these operating instructions).
1.1 Purpose of this document
These operating instructions are intended for people who install, connect, commission,
operate, and maintain the Master Data Analyzer.
Tasks
Target group
Mounting, electrical installation,
maintenance, and replacement of
components
Qualified personnel, such as service technicians or
industrial electricians
Commissioning
Qualified personnel, such as service technicians or
industrial electricians
Operation
Qualified personnel
Tab. 1: Target group
1.2 Information depth
These operating instructions contain information on the Master Data Analyzer relating to
the following topics:
•Safety
•System description
•Transport, assembly, and mounting
•Electrical installation
•Commissioning
•Operation
•Maintenance and repairs
•Fault diagnosis and troubleshooting
•Technical data and dimensional drawings
1.3 Abbreviations used
File Transfer Protocol
Light emitting diode
Master Data Analyzer
Modular light grid
Modular system controller (MSC800)
Note
FTP
LED
MDA
MLG
MSC

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1.4 Symbols used
Recommendations are designed to assist you in the decision-making process with respect
to the use of a certain function or technical measure.
Notes provide information about the features of a device, application tips, or other useful
information.
Instructions that must be carried out in the described order are referred to as step-by-step
instructions and are indicated by numbered lists. Carefully read and follow the
instructions for action.
Instructions for taking action are indicated by an arrow. Carefully read and follow the
instructions for action.
LED symbols describe the status of a diagnostics LED. Examples:
The LED is illuminated continuously.
The LED is flashing.
The LED is off.
Recommendation
Note
1. / 2. ...

, 

SAFETY 2
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2Safety
This chapter concerns your own safety and the safety of the system operator.
▸Please read this chapter carefully before you begin working with the Master Data
Analyzer.
2.1 Qualified safety personnel
The Master Data Analyzer must only be set up, commissioned, operated, and maintained
by adequately qualified personnel.
The following qualifications are necessary for the various tasks:
Tasks
Qualification
Mounting and maintenance
Practical technical training
Knowledge of the current safety regulations in the workplace
Electrical installation and
device replacement
Practical electrical training
Knowledge of current electrical safety regulations
Commissioning, operation,
and configuration

Basic knowledge of data transmission
Basic knowledge of the design and setup (addressing)
of Ethernet connections when connecting the system to
the Ethernet
Basic knowledge of how to use an HTML browser
(e.g., Internet Explorer) to access the online help
Basic knowledge of 1D/2D code technology
Basic knowledge of the Windows operating system used
Tab. 2: Qualified safety personnel
2.2 Applications of the system
The Master Data Analyzer is a stationary DWS system (Dimensioning-Weighing-Scanning).
It enables master data for products to be logged in a standardized manner for goods entry
or shipping. The products are measured, weighed, identified, and visualized in a single
operation. Data are processed in real time, regardless of their shape, surface, and
material properties.
Operating modes
The Master Data Analyzer is set up at the factory to support two operating modes:
•Operating mode with bar code scanning: The object is identified using its bar code
and is then measured. In this case, the Master Data Analyzer supplies the complete set
of master data with bar code, weight, and dimensions.
•Operating mode without bar code scanning. This variant assumes that the bar code
for the object is already available, meaning that only the weights and dimensions have
to be logged. The measurement results are assigned to an existing bar code in the
customer’s system.

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Brief description
•The object is placed on a rugged glass plate. The object does not need to be aligned.
•In the operating mode with bar code scanning, the object is identified using a wired bar
code scanner. Electronic scales measure the weight of the object.
In the operating mode without bar code scanning, the measuring process starts with
the system detecting a stable weight value. There is no hand-held scanner.
•To measure the dimensions, a gantry with two pairs of light grids is moved manually
over the object using two linear guides. Measurements can be taken in both directions.
The object’s dimensions and volume are measured.
•The data are sent to the warehouse management system in a stationary solution via
Ethernet. An external PC or screen is not required. In the mobile variant of the Master
Data Analyzer, the data are sent via a WLAN access point.
•All system components are pre-assembled in a rugged industrial design and are ready
for operation immediately after commissioning.
The majority of the images and screenshots in these operating instructions visualize the
Master Data Analyzer in the operating mode with bar code scanning.
2.3 Intended use
The Master Data Analyzer may only be used as described in 2.2 Applications of the
system.It may only be used by qualified personnel in the environment in which it was
mounted and initially commissioned by qualified safety personnel in accordance with
these operating instructions.
The equipment may only be operated in an industrial environment. Operation of the
system is not allowed outdoors or in an explosion-protected environment.
If used in any other way or if alterations are made to the system or the devices are
opened – including in the context of mounting and installation – this will void any warranty
claims directed to SICK AG.
Examples of non-intended use:
•Measurement of products not defined in the contract or in these operating instructions.
•Non-observance of the permitted parameters for measuring objects.
•Failure to observe the operating instructions.
•Use of parts other than original spare parts.
WARNING
Danger due to improper use
Non-intended use of the device can lead to danger to the life and limb of persons and
damage to the plant.
The device must only be used for the intended use.
Note