SICK VMS6200 User manual

OPERATING INSTRUCTIONS
VMS6200
Track and trace systems

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Product described
VMS6200
Document No.
8025140
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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Contents
1About this document ........................................................................................................5
1.1 Limitation of liability .............................................................................................5
1.2 Purpose of this document....................................................................................5
1.3 Target groups........................................................................................................5
1.4 Further information ..............................................................................................6
1.5 Other relevant technical documentation/information .......................................6
1.6 Document conventions ........................................................................................6
2Safety information ............................................................................................................7
2.1 Intended use.........................................................................................................7
2.2 General safety notes ............................................................................................7
2.3 Requirements for the qualification of personnel................................................8
2.4 Protective devices ................................................................................................8
2.5 System warranty...................................................................................................8
2.6 RoHS Directive......................................................................................................8
2.7 Safety conventions...............................................................................................9
2.8 Warning symbols on the system components................................................. 10
2.9 Mandatory symbols ........................................................................................... 10
2.10 Safety notes....................................................................................................... 11
3System description ........................................................................................................ 12
3.1 Scope of delivery ............................................................................................... 12
3.2 System components.......................................................................................... 13
3.2.1 LMS500 2D LiDAR sensors............................................................... 14
3.2.2Trigger photoelectric sensor.............................................................. 15
3.2.3 Incremental encoder.......................................................................... 16
3.2.4 Cabinet ............................................................................................... 17
3.3 Operating principle............................................................................................ 18
3.3.1 Automated operating mode............................................................... 18
3.3.2 Recording of measured values and data processing ...................... 20
3.3.3 Data output ........................................................................................ 21
3.3.4 Expanding the system with a reading and weighing station............ 22
3.4 System requirements........................................................................................ 23
3.4.1 Requirements on the ambient conditions ........................................ 23
3.4.2 Requirements on the conveying equipment..................................... 23
3.4.3 Object requirements .......................................................................... 24
3.4.4 Mounting requirements ..................................................................... 25
4Mounting ........................................................................................................................ 27
4.1 Mounting volume measurement devices ........................................................ 27
4.1.1 Mounting components....................................................................... 28
4.1.2 Fastening the mounting plate to the frame...................................... 29
4.1.3 Screwing the volume measurement device plus adapter plate
to the mounting plate ........................................................................ 29
4.2 Mounting the photoelectric retro-reflective sensor......................................... 30
4.3 Mounting the incremental encoder.................................................................. 30
4.4 Mounting the cabinet........................................................................................ 31
5Electrical installation .................................................................................................... 32
5.1 Connection overview ......................................................................................... 33
5.2 Connection to the voltage supply ..................................................................... 34
5.3 Factory connections .......................................................................................... 35

CONTENTS
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5.4 Connecting the volume measurement devices................................................36
5.5 Connection for the photoelectric retro-reflective sensor .................................37
5.6 Connecting the incremental encoder ...............................................................38
5.7 Connecting to the customer interface ..............................................................39
6Commissioning ...............................................................................................................40
6.1 Switching on the system....................................................................................40
6.2 Checking the operational readiness of the system components....................41
6.3 Configuring the system with SOPAS..................................................................42
6.3.1 Installing SOPAS ET ............................................................................42
6.3.2 Installing SOPAS .................................................................................43
6.3.3 Assigning IP addresses.......................................................................44
6.3.4Opening the configuration interface ..................................................50
6.3.5 Configuring the LMS500 and VMC800 .............................................51
6.3.6 Configuring basic settings for the MSC800 ......................................52
6.4 Checking system readiness...............................................................................52
6.5 Testing the configuration...................................................................................53
6.6 Optimizing the measurement results ...............................................................55
6.7 Saving the configuration....................................................................................56
7Maintenance and repair ................................................................................................57
7.1 Monitoring and cleaning work ...........................................................................58
7.1.1 Control measurements.......................................................................58
7.1.2 Visual control ......................................................................................58
7.1.3 Cleaning the volume measurement devices .....................................59
7.1.4 Cleaning the photoelectric retro-reflective sensor............................60
7.1.5 Cleaning the components of the incremental encoder ....................60
7.1.6 Cleaning the cabinet...........................................................................61
7.2 Replacing components ......................................................................................62
7.2.1 General notes......................................................................................62
7.2.2 Replacing the volume measuring device ..........................................63
7.2.3 Replacing the MSC800 ......................................................................65
7.2.4 Replacing the VMC800.......................................................................67
7.2.5 Replacing the photoelectric retro-reflective sensor..........................69
7.2.6 Replacing the components of the incremental encoder ..................70
8Fault diagnosis ...............................................................................................................71
8.1 Fault indications of the components ................................................................71
8.1.1 Fault indication on the LMS500 ........................................................71
8.1.2 Fault indication on the MSC800........................................................72
8.1.3 Fault indication on the photoelectric retro-reflective sensor ...........73
8.2 Fault indication during operation......................................................................74
8.2.1 Checking the triggering.......................................................................74
8.2.2 Checking the incremental encoder....................................................75
8.2.3 Checking the CAN cabling ..................................................................76
8.3 Detailed fault analysis .......................................................................................77
9Technical data ................................................................................................................78
10 Disposal ...........................................................................................................................80

ABOUT THIS DOCUMENT 1
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1About this document
This document regarding the VMS6200 volume measurement system:
•contains information that is required during the life cycle of the system.
•must be made 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 VMS6200 volume measurement system.
1.3 Target groups
This document is intended for qualified persons who operate the VMS6200.

1ABOUT THIS DOCUMENT
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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
–EPLAN E258279
Technical data
Connection diagram
Terminal diagram
•Operating instructions for the following system components:
Operating instructions Manufacturer
LMS5xx LASER MEASUREMENT SENSORS SICK
MSC800 modular system controller SICK
WL(F)18-3 compact photoelectric sensors (optional) SICK
DFV60 (optional) SICK
1.6 Document conventions
Required tools
▸Instructions
 Result of action
Reference to another document.
All measurement units used in this document are metric.
Subject to change without notice.
NOTE! Illustrations may differ from the actual design.

SAFETY INFORMATION 2
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2Safety information
2.1 Intended use
The VMS6200 track and trace system is used to solve demanding applications in the area
of object measurement and position determination.
Not only large objects, but also black, foiled or highly reflective objects can be dynamically
and reliably measured on a wide range of conveyor systems (conveyor belts, roller
conveyors).
Two 2D LiDAR sensors determine the smallest rectangular box that fully encloses an
object regardless of its shape, and then use this to derive the length, width and height of
the object.
The VMS6200 may only be operated in an industrial environment. Applications include,
for example, measuring baggage and freight items on conveyor systems in airports,
measuring objects in the incoming and outgoing goods areas in retail and warehousing,
as well as for storage and conveyor systems.
The objects can be measured with or without object carriers, for example pallets.
The modular system construction of the VMS6200 ensures compatibility with existing
solutions from SICK and enables adaptations to customer-specific applications.
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 VMS6200.
▸Only qualified persons from the relevant departments are permitted to work on the
VMS6200.
▸Follow operating processes.
▸Follow local regulations.
▸Follow all local regulations relating to working with electrical components.
•Only authorized persons are permitted to access the VMS6200.
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.

2SAFETY INFORMATION
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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 Protective devices
The volume measurement system is designed in a way that allows for safe operation.
Protective devices reduce potential risks to the maximum possible extent.
2.5 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 VMS6200 have been installed, mounted or modified
without authorization.
▸The VMS6200 has been altered or modified.
▸The software has been modified, customized, and/or tampered with without
authorization.
2.6 RoHS Directive
This product has been designed for specific applications in large industrial plants
according to Article 2 (4) e, RoHS 2011/65 / EU, and must therefore only be used in such
plants.
The product is neither suitable nor approved for use outside of these plants. SICK
therefore cannot provide any warranty or accept any liability whatsoever for such use.

SAFETY INFORMATION 2
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2.7 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 situation presenting danger, which may lead to minor or moderate
injuries if not prevented.
WARNING
Identifies a situation that may lead to property damage to the system or products in its
vicinity if not observed.
Note
Important information and useful tips.

2SAFETY INFORMATION
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2.8 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
2.9 Mandatory symbols
Symbol Meaning
Read document
Use head protection
Use foot protection
Disconnect before maintenance or repairs

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2.10 Safety notes
DANGER!
HAZARDOUS ELECTRICAL VOLTAGE
Touching live devices 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.
WARNING!
HAZARDOUS LASER RADIATION
The 2D LiDAR sensor of the volume measurement system works with an eye-safe
infrared class 1 laser (IEC 60825-1:2014, EN 60825-1:2014). The laser beam is not
visible to the human eye.
▸Do not open the housing.
▸
Observe laser safety regulations.
DANGER!
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).

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
•Cabinet with MSC800, VMC800, power supply module, and Ethernet switch
•Two LMS500 2D LiDAR sensors with connecting cables
Optional
•DFV60 incremental encoder (optional)
•WL18 photoelectric retro-reflective sensor (optional)
•Aluminum profiles for setting up the frame (application-dependent as per the order)
•Mounting kits for the cabinet and sensors

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3.2 System components
Fig. 1: Components of the VMS6200
Legend
1 2D LiDAR sensor
2 Photoelectric retro-reflective sensor (optional)
3 Incremental encoder (optional)
4 Cabinet with MSC800, VMC800, power supply unit, and Ethernet switch
•The system components are mounted on a customer-specific frame as per the
technical drawing.
NOTE! To avoid dazzling of multiple parallel systems, the field of view in the 2D LiDAR
sensor can be adjusted.
Devices
Mounting

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3.2.1 LMS500 2D LiDAR sensors
Fig. 2: LMS500 with adapter plate and mounting plate
Legend
1 Mounting plate for mounting on a frame
2 Adapter plate with adjustment unit for attaching the LMS500
3 System plug with parameter set
4 Status indicators
5 Beam exit
•Two LMS500 2D LiDAR sensors are mounted on the right and left above the conveyor
on a profile.
•The 2D LiDAR sensors have been pre-mounted on an adapter plate with adjustment
unit, and aligned at the factory.
NOTE! The fixing screws must not be loosened by the customer. Otherwise
measurements with the specified accuracy cannot be guaranteed.
•The unit comprising LMS500 and adapter plate is attached to a frame provided by the
customer using a mounting plate.
•The device parameters are permanently stored in the system plug. This makes it easier
to replace components.
•The two LMS500 sensors span a measuring field and detect the contours of objects
transported into the field.
•The acquired measuring points are transmitted to the VMC800 volume measurement
controller for further processing.
Features
Function

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3.2.2 Trigger photoelectric sensor
Fig.3: Photoelectric retro-reflective sensor with reflector (e.g., WL18-3)
Legend
1 Photoelectric retro-reflective sensor (e.g., WL18-3)
2 Reflector
•Photoelectric retro-reflective sensor trigger available as an option.
•The emitted light band 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.
NOTE! Alternatively, the trigger signal can also be supplied by the customer via the PLC.
Features
Function

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3.2.3 Incremental encoder
Fig. 4: DFV60 incremental encoder
Legend
1 Measuring wheel
2 Spring-loaded mounting arm
•Optionally available measuring wheel system mounted below the conveying equipment.
•Large spring travel and pivot range of the spring arm compensates for unevenness on
measurement surface.
•Measurement of linear movements.
•Detection of position and speed directly on the running surface of the conveyor using
a precision measuring wheel.
NOTE! Alternatively, the speed signal can also be supplied by the customer via the PLC.
Properties
Function

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3.2.4 Cabinet
Fig. 5: Components in the cabinet
Legend
1 Air inlet for cooling (with filter mat and cooler)
2 Ethernet switch for connecting the system components
3 VMC800 volume measurement controller
4 Air outlet for cooling (with filter mat)
5 Terminals (24 V DC) and fuse module OUT
6 Power supply unit for supplying voltage to the system components
7 Terminals for voltage supply IN (100–264 V AC / 50–60 Hz)
8 MSC800 system controller
•The power supply unit supplies the voltage to the controllers and connected sensors.
•The VMC800 volume measurement controller receives the measuring points from the
volume measurement devices and uses the 2D sections to calculate a three-
dimensional model. Based on this model, it determines the dimensional values and
transmits these to the MSC800 system controller via CAN bus.
•The MSC800 system controller coordinates all the connected sensors. It processes
the trigger and encoder signals and, via its digital inputs and outputs, provides all the
relevant information for calculating the object dimensions.
The MSC800 receives the measurement results from the VMC800 and outputs these
to the customer system in a defined host telegram.
Function

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3.3 Operating principle
3.3.1 Automated operating mode
The VMS6200 runs fully automatically after startup. No manual intervention by the
operator is required.
Fig. 6: Transport conditions – singulated measurement
•The VMS6200 measurement system is capable of identifying singulated box shaped
objects as well as singulated objects of virtually any other shape on flat conveying
systems such as conveyor belts or roller conveyors.
•The objects must pass the VMS6200 with a defined separation distance of 200 mm
(distance between rear edge and leading edge).
•Only one object can be in the measuring range at any given time.
•The VMS6200 can detect the rotation and position of the objects.
Fig. 7: Minimum separation calculation for baggage items with IATA codes
•When measuring baggage items, the IATA code counts as part of the baggage item.
•They must therefore be taken into account when determining the minimum separation.
Transport conditions/
measurement principle
IATA codes

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Fig. 8: Minimum separation calculation for palletized freight with straps/wrapping
•Similarly, pallet wrapping or straps need to be taken into consideration when
calculating the separation for objects on pallets.
Fig. 9: No touching, no side-by-side
•The objects must not be located side-by-side*.
•The objects must not be touching*.
NOTE! Objects are also deemed to be touching if the IATA codes are in contact with one
another.
Pallet wrap/straps
Not allowed!

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3.3.2 Recording of measured values and data processing
Fig. 10: Measuring point determination of the VMS6200
•The measurement process is activated via the trigger signal.
•The volume measurement devices span a two-dimensional measuring range and scan
the surfaces of the object located within this range on the conveying equipment,
without making contact.
•The volume measurement devices transmit the acquired measuring points to the
VMC800 volume measurement controller.
Fig. 11: 3D model generation in the VMC800 volume measurement controller
•There, a spatial model is created taking into consideration the detected conveyor
speed and the specific position of the object on the conveying equipment.
•The VMC800 calculates the volume of the smallest rectangular box that fully encloses
the object and uses this to derive the length, width and height.
•The rotation and position of the object on the conveying equipment is also determined.
•The measurement results are transmitted to the MSC800 system controller for further
processing.