SICK TTC100-2 Operating instructions

A D D E N D U M T O O P E R A T I N G I N S T R U C T I O N S
Track and trace cabinet
TTC100-2

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Described product
TTC100-2 track and trace cabinet
Document no.
8027439
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 Abbreviations............................................................................................ 7
1.5 Further information .................................................................................. 7
1.6 Other relevant technical documentation/information ........................... 7
1.7 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 Warranty ................................................................................................... 9
2.5 RoHS Directive.......................................................................................... 9
2.6 Safe network environment ...................................................................... 9
2.7 Safety conventions................................................................................. 10
2.8 Sources of danger .................................................................................. 10
2.9 Warning symbols on the system components...................................... 11
2.10 Mandatory symbols................................................................................ 11
3Product description ......................................................................................... 12
3.1 Scope of delivery .................................................................................... 12
3.2 Components ........................................................................................... 13
3.2.1 Cabinet layout ......................................................................... 13
3.2.2 Controller ................................................................................. 15
3.2.3 Components for voltage supply.............................................. 16
3.2.4 Ethernet switches ................................................................... 17
3.3 Interfaces................................................................................................ 18
3.3.1 Overview .................................................................................. 18
3.3.2 Data interfaces for setting up an internal sensor
network.................................................................................... 19
3.3.3 Digital inputs and outputs ...................................................... 19
3.3.4 Interfaces for data and image output to the customer
system ..................................................................................... 20
3.4 Operating principle................................................................................. 22
3.4.1 Basic principle of the measuring and reading process ........ 22
3.4.2 Triggering and tracking ........................................................... 23
3.4.3 Data processing and data output .......................................... 24
3.5 Configuration with SOPAS...................................................................... 26
3.6 System requirements............................................................................. 28
3.7 Status indicators .................................................................................... 29
3.7.1 Status indicators on SIM2000-2 Prime controller ................ 29
3.7.2 Status indicators on the power supply modules ................... 33
3.7.3 LEDs on the fuse modules...................................................... 33
4Mounting .......................................................................................................... 34
5Electrical installation ...................................................................................... 36
5.1 Overview ................................................................................................. 37
5.1.1 Connection areas .................................................................... 37
5.1.2 Cable entries ........................................................................... 38

Contents
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5.2 Notes on electrical installation.............................................................. 39
5.2.1 Required wire cross-sections ................................................. 39
5.2.2 Recommended lengths of cable ............................................ 39
5.2.3 Shield....................................................................................... 40
5.2.4 Terminal blocks....................................................................... 41
5.2.5 RCD and fuse module............................................................. 42
5.3 Connecting the voltage supply .............................................................. 43
5.3.1 Mains voltage.......................................................................... 43
5.3.2 24 V power supply to the controllers and sensors ............... 44
5.4 Connections on the controller ............................................................... 46
5.4.1 SIM2000-2 Prime connection overview ................................ 46
5.4.2 Connection examples ............................................................. 53
6Commissioning .................................................................................................55
6.1 Starting up the cabinet .......................................................................... 55
6.1.1 Establishing the voltage supply ............................................. 55
6.1.2 Checking the operational readiness of the controllers......... 55
6.2 Connecting the configuration PC........................................................... 56
6.2.1 Establishing a connection with the configuration PC ........... 56
6.2.2 Installing SOPAS ..................................................................... 57
6.2.3 Launching SOPAS ................................................................... 58
6.2.4 Starting the device search ..................................................... 58
6.2.5 Transferring the controller to a SOPAS project ..................... 60
6.2.6 Loading device drivers into the SOPAS project..................... 60
6.2.7 Changing the IP address ........................................................ 61
6.2.8Opening the configuration interface...................................... 62
6.3 Configuration in SOPAS ......................................................................... 63
6.3.1 Configuration interface........................................................... 63
6.3.2 Logging into the controller...................................................... 64
6.3.3 Configuring the parameters ................................................... 65
6.3.4 Saving the parameters permanently ..................................... 66
6.3.5 Restarting the controller......................................................... 66
6.4 Restoring the default ............................................................................. 67
6.5 Deactivating TCP/IP CoLa protocol server............................................ 68
6.6 Changing password................................................................................ 69
7Maintenance and repair...................................................................................70
7.1 Monitoring and cleaning work............................................................... 70
7.2 Replacing the controller ........................................................................ 71
7.2.1 Removing connecting cables ................................................. 71
7.2.2 Removing device..................................................................... 72
7.2.3 Putting the replacement device into operation..................... 73
7.3 Replacing the battery in the controller ................................................. 73
7.4 Replacing the power supply unit ........................................................... 74
8Fault diagnosis .................................................................................................76
8.1 Displays on the controller...................................................................... 76
8.1.1 Checking system readiness ................................................... 76
8.1.2 Checking the triggering........................................................... 77
8.1.3Checking the incremental encoder........................................ 78
8.1.4 Checking the CAN cabling ...................................................... 79
8.2 Detailed fault analysis ........................................................................... 80

CONTENTS
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9Technical data.................................................................................................. 81
9.1 Data sheet .............................................................................................. 81
9.2 Dimensional drawings............................................................................ 82
9.3 Compliance with EU directives .............................................................. 83
10 Disposal ............................................................................................................ 84

1ABOUT THIS DOCUMENT
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1About this document
This document about the track and trace cabinet:
•contains information that is required during the life cycle of the track and trace cabinet.
•must be made available to all those who work with the track and trace cabinet.
•should be read through carefully, and the contents fully understood before working with
the track and trace cabinet.
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
These operating instructions are intended to allow the technical personnel to perform
mounting, electrical installation, commissioning and maintenance on the track and trace
cabinet in a safe manner.
Further information on high-end CCD camera systems, volume measurement systems,
and fixed mount bar code scanners is available at www.sick.com.
1.3 Target groups
This document is intended for qualified persons who perform the following tasks with
the track and trace cabinet:
These operating instructions are intended for people that mount, commission, and
maintain the track and trace cabinet.
NOTE! This document does not provide information on operating the track and trace
systems into which the track and trace cabinet has been or is going to be integrated.

ABOUT THIS DOCUMENT 1
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1.4 Abbreviations
Controller area network (fieldbus log based on the CAN bus)
Electrically erasable programmable read-only memory (electrically erasable and
programmable nonvolatile memory)
File transfer protocol
Image code reader (high-end CCD camera system)
Programmable read-only memory (electrically programmable non-volatile memory)
Random access memory (direct-access volatile memory)
Residual current device (FI circuit protection)
Read-only memory (read-only, nonvolatile memory)
Secure digital card (digital, replaceable memory card)
Sensor Integration Machine (SIM2000-2 Prime)
SICK Open Portal for Application and Systems Engineering Tool (PC software for
Windows for configuring the controllers and connected sensors)
Programmable logic controller
Transmission control protocol/Internet protocol
1.5 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.
1.6 Other relevant technical documentation/information
•Technical system documentation
Technical data
Connection diagram
•Operating instructions for the following system components:
Component
Manufacturer
SIM2000-2 Prime Sensor Integration Machine operating
instructions
SICK
1.7 Document conventions
▸Instructions
•All measurement units used in this document are metric.
•Subject to change without notice.
•Figures may differ from the actual design.
CAN
EEPROM
FTP
ICR
PROM
RAM
RCD
ROM
SD
SIM
SOPAS ET
PLC
TCP/IP

2FOR YOUR SAFETY
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2For your safety
2.1 Intended use
The TTC100-2 track and trace cabinet is used in conjunction with SICK sensors.
The SIM2000-2 Prime controller installed in the TTC100-21xxxx cabinet performs the
tasks of coordinating all connected sensors, processing the received measured values
and reading results, as well as outputting the data and camera images to the higher-level
customer system.
The data is communicated via a CAN or Ethernet network. Various data output formats
are available at the controller interfaces.
The configuration of the track and trace cabinet is carried out as standard via the
Ethernet interface using the SOPAS ET configuration software, which is installed on a
standard PC provided by the customer.
The track and trace cabinet is intended exclusively for use in industrial environments.
NOTE! Intended use also includes observance of this system description, in particular
the safety notes as well as the repair and maintenance requirements.
2.2 General safety notes
▸Please read this document and the related documents through carefully and observe
all the safety notes and information before working with the track and trace cabinet.
▸Only qualified persons from the relevant departments are permitted to work on the
track and trace cabinet.
▸Follow operating processes.
▸National and regional regulations must be complied with.
▸Observe all national and local regulations relating to working with electrical
components.
•Only authorized persons are permitted access to the track and trace cabinet.
System damage/transport damage
Damage to the individual components can lead to malfunctions of the track and trace
cabinet.
▸Do not ignore any damage caused to components during transport.
▸In case of damage, contact SICK Service.

FOR YOUR SAFETY 2
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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 track and trace cabinet.
•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 Warranty
No warranty claims will be accepted if:
▸The safety notes and measures in this document are not observed.
▸Parts or components of the track and trace cabinet have been installed, mounted
or modified without authorization.
▸The software has been modified, customized, and/or tampered with without
authorization.
2.5 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.
2.6 Safe network environment
SICK uses standard IP technology in its products. The focus is on availability of products
and services.
SICK always assumes the following prerequisites:
•The customer ensures the integrity and confidentiality of the data and rights affected
by its own use of the aforementioned products.
•In all cases, the customer implements the appropriate security measures, such as
network separation, firewalls, virus protection, and patch management.

2FOR YOUR SAFETY
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2.7 Safety conventions
The warnings used in these operating instructions 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.
2.8 Sources of danger
DANGER!
RISK OF INJURY DUE TO ELECTRICAL CURRENT
The cabinet is connected to the local mains supply.
Touching live devices, which may still be energized, can lead to death, burns or
electrical shock.
▸Ensure the nominal current/voltage/power ratings of the mains supply are
compatible with the system-specific requirements.
▸Only qualified specialist personnel are permitted to perform electrical work on the
cabinet.
▸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 disconnect or remove any protective conductors in the system or in the mains
cable.
WARNING!
RISK OF INJURY DUE TO EQUIPOTENTIAL BONDING CURRENTS
Due to equipotential bonding currents, incorrect earthing can lead to the following
dangers and faults: Voltage is applied to the metal housing, cable fires due to cable
shields heating up, the product and other devices become damaged.
▸Generate the same ground potential at all grounding points.
▸Ground the equipotential bonding via the functional ground connection with a low
impedance.

FOR YOUR SAFETY 2
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DANGER!
RISK OF INJURY FROM SUSPENDED LOADS
The track and trace cabinet can weigh up to 36 kg depending on the variant.
Severe injury or death.
▸Never stand under suspended loads.
▸Pay close attention when lifting loads.
▸Comply with lifting instructions to prevent injuries and accidents.
▸Use suitable, undamaged lifting tools.
▸Prevent the cabinet from tipping over during transport.
▸Wear personal protective equipment (safety helmet, safety shoes).
▸Obtain the assistance of at least one other person during mounting.
▸Use the mounting accessories included with delivery.
WARNING!
RISK OF INJURY FROM HOT SURFACES
Risk of burns due to hot surfaces on the controller on the power supply units during
operation.
▸Do not touch hot surfaces.
▸Wear suitable safety gloves.
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
Suspended load warning
2.10 Mandatory symbols
Symbol
Meaning
Read document
Disconnect before maintenance or repairs

3PRODUCT DESCRIPTION
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3Product description
3.1 Scope of delivery
NOTE!
▸After delivery, inspect the track and trace cabinet for transport damage and report any
such damage immediately.
▸Check that the delivery includes all components listed on the delivery note.
System components
•Cabinet
•SIM2000-2 Prime controller
•Power supply modules
•Ethernet switches
•Mounting material
Depending on the customer system, the components installed in the cabinet can deviate
from the configuration described here.
NOTES
•A device information sheet with initial information is enclosed with the delivery.
•The current version of the SOPAS ET configuration software required to configure the
cabinet can be downloaded from www.sick.com.

PRODUCT DESCRIPTION 3
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3.2 Components
3.2.1 Cabinet layout
Fig. 1: External view of the cabinet
Legend
1
Cable entries on the bottom of the device
2
Lower perforated plate for mounting
3
Air inlet for cooling (with fan and filter mat)
4
Left door
5
Air outlet for cooling (with filter mat)
6
Upper perforated plate for mounting
7
Air outlet for cooling (with filter mat)
8
Right door
9
“Hazardous electrical voltage” warning symbol
10
Air inlet for cooling (with fan and filter mat)
External view
of the cabinet

3PRODUCT DESCRIPTION
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NOTE! The following figure shows the fully-equipped cabinet. Depending on the
application, individual components may be missing or additional components, such as
optocouplers, may be included.
Fig. 2: Internal view of the TTC100-2 cabinet (example)
Legend
1
SIM2000-2 Prime controller with connections and SD memory card for
parameter cloning and optionally with alibi memory for legal-for-trade
systems
2
Terminals for mains voltage IN (AC 100 ... 264 V / 50 ... 60 Hz)
3
Circuit breaker for power supply modules
4
RCD (residual current device) for protective contact plug
5
Protective contact socket (mains voltage)
6
Power supply module(s) for supplying voltage to the controller as well as
the connected sensors and ICR camera systems
7
Thermostat for the fan controller
8
Circuit breaker for the connected ICR cameras
(2 circuit breakers per ICR camera)
9
24 V terminals with fuse modules for supplying voltage to the controller,
sensors and internal fans
10
Optional LFT Ethernet switch for connecting legal-for-trade system
components
11
Optional Ethernet switches for setting up an internal sensor network as
well as for outputting data and camera images
12
24 V terminals for supplying voltage to the ICR cameras
Internal view
of the cabinet

PRODUCT DESCRIPTION 3
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3.2.2 Controller
Fig. 3: SIM2000-2 Prime controller
Legend
1
Terminal blocks for connecting sensors and peripheral devices
2
USB connection
3
2 MicroSD card shafts
4
Function selector switch (used as calibration switch for legal-for-trade
systems)
5
Battery compartment
6
Ethernet connections
7
Connections for Ethernet-based fieldbuses
8
Mounting strap (both sides)
•In addition to the SIM2000-2 Prime controller, the cabinet contains the central control
and evaluation unit for sensors and image processing devices.
•It acts as a link between system and plant controls, and the connected sensors for
measured value acquisition.
•The controller processes the signals from the connected sensors and delivers the
recorded data to the higher-level system controller. The data is delivered via a
customer-specific interface.
•In volume measurement devices, the controller receives the measuring points from the
multi-dimensional measurement devices and uses the 2D sections to calculate a three-
dimensional model with respective dimension values.
Properties

3PRODUCT DESCRIPTION
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3.2.3 Components for voltage supply
Fig. 4: Power supply units
Legend
1
Connection to the local mains voltage (AC 100 ... 264 V / 50 ... 60 Hz)
2
Input voltage connection (wired at the factory)
3
Potentiometer for the output voltage
4
Connection for 24 V output voltage
5
Mounting strap
•The power supply units of the cabinet deliver the 24 V supply voltage for all
components installed in the cabinet as well as the connected sensors.
•The cabinet does not have a master switch for the incoming supply voltage.
Fig. 5: Terminal blocks for connecting to a 24 V voltage supply
Legend
A
24 V terminals for connecting ICR cameras to the voltage supply
(each protected via 2 circuit breakers)
B
24 V terminals with fuse modules for connecting internal components
and external sensors to the voltage supply
1
Terminals
2
Fuse module
3
LED display
Power supply units
Connection to 24 V
voltage supply

PRODUCT DESCRIPTION 3
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3.2.4 Ethernet switches
Fig. 6: Cabinet with 8 port Ethernet switches (application-dependent)
•Connection of multi-dimensional volume measurement devices or image-based reading
systems to the SIM2000-2 Prime controller via Ethernet network for transmission of
the measured values.
•Transfers camera images to an image server.
•Outputs data to the customer system via the TCP/IP interface.
•Access to the controller with the SOPAS ET configuration software.
•Connects to an analytics software client (e.g., Package Analytics, Baggage Analytics,
RDT400).
Ethernet
switches

3PRODUCT DESCRIPTION
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3.3 Interfaces
3.3.1 Overview
The cabinet has interfaces for connecting to different sensor types.
Fig. 7: Connection of sensors to the cabinet
Legend
1
Sensors for triggering and position determination
2
Sensors for data acquisition
•Sensors such as laser scanners, bar code readers, or camera systems are used for
data acquisition.
•They are connected to the controller via a CAN or Ethernet network.
•The number of connected sensors depends on the application.
•The acquired data can also be used by other sensors, e.g., by camera systems for focus
control.
•Sensors such as photoelectric sensors or incremental encoders are used for triggering
and position determination.
•They are generally connected to the SIM2000-2 Prime controller via digital inputs.
•A photoelectric sensor supplies the controller with the trigger signal for activating the
connected sensors.
•The controller requires this information, together with the signals from an incremental
encoder, to identify the exact position of the object on the conveyor belt and for the
object allocation of the recorded data.
Sensors for data
acquisition
Sensors for triggering
and position
determination

PRODUCT DESCRIPTION 3
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3.3.2 Data interfaces for setting up an internal sensor network
Fig. 8: Connection of data interfaces for setting up an internal sensor network
Legend
1
CAN network
2
Ethernet network via Ethernet switches
•The internal sensor network is set up via the SIM2000-2 Prime controller using
CAN bus and Ethernet.
•All sensors for data collection are connected to the SIM2000-2 Prime controller with
their own supply voltage in a linear bus structure via CAN bus.
•The end of the structure is closed with a resistor (terminated).
•The signals for the read cycle and increment are typically transmitted by the controller
to the connected sensors via the CAN bus.
•Image-based sensors are also connected to the SIM2000-2 Prime controller via an
Ethernet switch.
3.3.3 Digital inputs and outputs
•The digital switching inputs of the SIM2000-2 Prime controller are used, amongst
other things, to connect the read cycle sensor and the incremental encoder.
•Digital switching outputs can be used, for example, to output system statuses.
•For the System Ready system status, the output provides a static signal when the
entire system composed of the controllers and all connected sensors is ready for
operation.
CAN and
Ethernet network
Inputs
Outputs

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3.3.4 Interfaces for data and image output to the customer system
The data and image are output to the customer system via interfaces located directly on
the SIM2000-2 Prime controller or via the Ethernet switches.
Fig. 9: Interfaces for data and image output to the customer system
Legend
1
Data output via the TCP/IP interface of the SIM2000-2 Prime controllers
to the customer system (host telegram)
2
Output of camera images to an image server via an Ethernet switch
3
Output of measurement data and image information as well as operating
data to the Package Analytics server in real time
•The SIM2000-2 Prime supports data output in output format RS-232 / RS-422,
Profinet or Ethernet.
NOTE! Due to the use of an external fieldbus module, other fieldbus connections are
possible.
•The image information processed by the image-based code readers can be transmitted
through an Ethernet switch to an image server via a separate Ethernet or Gbit
interface.
•Optional connection of the track and trace system to the Package Analytics analysis
platform. Package Analytics is a diagnostic and data management platform which,
in addition to the recorded measurement data such as volume, bar code and weight,
also stores and visualizes image information as well as the operating data of the
measurement system in real time.