SICK ICR890 User manual

Camera System for Reading 1-D and 2-D Codes with Superb
Image Quality suitable for OCR and Video Coding Applications
ICR890
High-end CCD Camera System
OPERATING INSTRUCTIONS

Operating Instructions
ICR890 High-end CCD Camera System
2©SICK AG · Division Auto Ident · Germany · All rights reserved 8011325/0000/2006-10-24
Software Versions
RF interference in case of use in residential areas.
¾ICR890 High-end CCD Camera System is exclusively intended for use in an industrial
environment.
Copyright
Copyright ©2006
SICK AG Waldkirch
Auto Ident, Reute Plant
Nimburger Strasse 11
79276 Reute
Germany
Trademark
Windows98TM, NTTM, METM, 2000TM, XPTM and Internet ExplorerTM are registered trademarks
or trademarks of the Microsoft Corporation in the USA and other countries.
Latest manual version
For the latest version of this manual (PDF), see www.sick.com.
Software/Tool Function Version
ICR890 System SICK Firmware From version
1.0 0000
ICR890 Device
Description
Device-specific software module for SOPAS-ET
Configuration Software
From version
1.00
SOPAS-ET Configuration software From version
2.10

Operating Instructions
ICR890
Quick Finder
8011325/0000/2006-10-24 ©SICK AG · Division Auto Ident · Germany · All rights reserved 3
ICR890 High-end CCD Camera System
Quick Finder …
•Included in the delivery ...
–Chapter 3.1.2 Included in delivery, page 25
•System projection
–Chapter 3.2 System requirements, page 26
•PLEASE NOTE
–Chapter 2 Safety information, page 17
•Installing the device in the reading station
–Chapter 4 Installation, page 45
•Connecting the device to the electricity supply
–Chapter 5 Electrical installation, page 53
•Familiarizing yourself with the device and its functions
–Chapter 3 Product description, page 23
–Chapter 6.3.6 Changing the device password for the user level "Authorized Client",
page 88
–Chapter 9 Technical data, page 103
•Starting up the device with the default setting
–Chapter 6.3 First startup, page 80
•Installing the SOPAS-ET Configuration Software on the PC
–Chapter 6.2.3 Installation of the Configuration Software SOPAS-ET, page 79
•Optimizing the device to the reading conditions
–Chapter 6.3.3 Configuring the ICR890 System/MSC800, page 83
•Assistance in case of problems
–Chapter 8 Troubleshooting, page 97
•Where is everything?
–Chapter Contents, page 5

Operating Instructions
ICR890 High-end CCD Camera System
4©SICK AG · Division Auto Ident · Germany · All rights reserved 8011325/0000/2006-10-24
Quick Finder
Overview of installation sequence
The following list summarizes the most important installation sequences for the ICR890
System as a stand-alone device in combination with the MSC800 for reading from above:
1. Check delivery for completeness.
2. Insert the ICI890 Illumination into two 180° brackets on the frame and screw tight. The front
window of the ICI890 Illumination should face downwards.
3. Remove the yellow and black protective caps from the lens protection tube and from ICD890
Camera lens.
Do not touch the lens!
4. Align the ICD890 Camera from the correct side to the illumination and carefully insert the lens
protection tube into the ICI890 Illumination opening.
5. Attach the ICD890 Camera to the ICI890 Illumination. Align the entire unit parallel to the
conveyor level and screw on the 180° brackets.
6. Connect the control line and the ICI890 Illumination power supply to the ICD890 Camera.
7. Insert and tighten the deflection mirror incl. the protective film on the opposite side to the ICI890
Illumination in two additional 180° brackets, parallel to the conveyor level.
The deflection mirror must be positioned at the same height as and exactly parallel to the
illumination.
8. Install the MSC800 close to the reading location.
9. Install the photoelectric reflex switch on the conveyor system in front of the reading location in
opposite direction of transport.
10. Install the MLG Light Grid on the conveyor system in front of the photoelectric reflex switch in
opposite direction of transport.
11. Install the incremental encoder on the conveyor system at the reading location.
12. Electrically connect the ICR890 System to the MSC800.
13. Connect the photoelectric reflex switch, MLG Light Grid, incremental encoder as well as data
processing host and PC to the MSC800 configuration.
14. Connect the MSC800 to the supply voltage (100 to 264 V AC/50 to 60 Hz).
15. Switch on the MSC800 using the main switch.
The ICR890 System and the MSC800 start up automatically.
16. Switch on the PC and install the SOPAS-ET Configuration Software (minimum requirements:
Windows 98TM).
17. Start the SOPAS-ET Configuration Software and set up the new SOPAS-ET Project by choosing the
appropriate ICR890 and MSC800 Device Descriptions.
18. Establish communication with the MSC800.
19. Configure the ICR890 System via the register tabs in the SOPAS-ET Configuration Software
(position of the ICR890 in relation to conveyor system, focus control, code configuration, reading
pulse, etc.).
20. Trigger the ICR890 System (start reading pulse). To achieve this, move the object into the range
of the photoelectric reflex switch and keep it in this position.
The illumination switches on.
21. Remove the protective film from the deflection mirror and set up the deflection mirror ensuring
that the ICI890 Illumination light hits the stationary object (code) at a 15° angle (skew angle on
the conveyor level).
22. Carry out a test reading with the 1-D/2-D code. Move the object carrying the code several times
across the conveyor level beneath the ICR890 System and display the reading results in the
SOPAS-ET Configuration Software.
23. Repeat the test reading under real conditions and check that the data has been transferred to
the host.
24. Correct or optimize the parameter values where necessary via the SOPAS-ET Configuration
Software.
25. Save the parameter set as an “*.spr” configuration file to the SOPAS-ET Configuration Software.
The ICR890 System is ready for operation once the application-specific setting has been set.
Note Detailed instructions can be found in Chapters 4 „Installation“, 5 „Electrical installation“
and 6 „Operation“.

Operating Instructions
ICR890
Contents
8011325/0000/2006-10-24 ©SICK AG · Division Auto Ident · Germany · All rights reserved 5
Contents
1 Notes on this document.................................................................................................15
1.1 Purpose............................................................................................................15
1.2 Target audience ..............................................................................................15
1.3 Information content ........................................................................................15
1.4 Symbols used ..................................................................................................16
2 Safety information ..........................................................................................................17
2.1 Authorized users .............................................................................................17
2.1.1 Installation and maintenance....................................................................17
2.1.2 Electrical installation and the replacement of system components.......17
2.1.3 Startup, operation and configuration........................................................17
2.2 Intended use ...................................................................................................18
2.3 General safety precautions and protection measures.................................19
2.3.1 Radio interferences....................................................................................19
2.3.2 Installation work .........................................................................................19
2.3.3 Electrical installation work.........................................................................19
2.3.4 LED radiation from the ICI890 Illumination..............................................19
2.4 Quick stop and quick start..............................................................................20
2.4.1 Switch off the ICR890 System...................................................................20
2.4.2 Switch on the ICR890 System ...................................................................20
2.5 Environmental information.............................................................................21
2.5.1 Energy requirements ..................................................................................21
2.5.2 Dispose of the device after decommissioning .........................................21
3 Product description.........................................................................................................23
3.1 Design ..............................................................................................................23
3.1.1 Device view .................................................................................................24
3.1.2 Included in delivery.....................................................................................25
3.1.3 Contents of the CD-ROM ............................................................................26
3.1.4 Device versions...........................................................................................26
3.2 System requirements......................................................................................26
3.2.1 General system requirements ...................................................................26
3.2.2 Installation requirements...........................................................................27
3.2.3 Electrical installation requirements ..........................................................28
3.2.4 Operation requirements.............................................................................28
3.3 Product features and functions (overview) ...................................................29
3.4 Method of operation .......................................................................................31
3.4.1 Reading configuration................................................................................32
3.4.2 Object trigger control..................................................................................33
3.4.3 Focus control ..............................................................................................33
3.4.4 Illumination control.....................................................................................33
3.4.5 Position........................................................................................................35
3.4.6 Increment configuration.............................................................................35
3.4.7 Image requirement.....................................................................................36
3.4.8 Code configuration .....................................................................................37
3.4.9 Data processing.............................................................................................37
3.4.10 Output format .............................................................................................39
3.4.11 Network .......................................................................................................39
3.4.12 Data interfaces ...........................................................................................39
3.4.13 Digital outputs.............................................................................................40
3.4.14 Digital inputs...............................................................................................40
3.5 Indicators and control elements ....................................................................41
3.5.1 User interface .............................................................................................41
3.5.2 LEDs of the ICD890 Camera......................................................................42
3.6 Impacts on the reading quality.......................................................................43
4 Installation .......................................................................................................................45
4.1 Overview of installation sequence.................................................................45
4.2 Installation preparations ................................................................................45

Operating Instructions
ICR890 High-end CCD Camera System
6©SICK AG · Division Auto Ident · Germany · All rights reserved 8011325/0000/2006-10-24
Contents
4.2.1 Layout the components which are to be installed................................... 45
4.2.2 Layout accessories .................................................................................... 45
4.2.3 Selecting the installation location............................................................. 46
4.2.4 Arrangement at the conveyor system....................................................... 47
4.3 Installing and adjusting the device................................................................ 49
4.3.1 Installing the deflection mirror.................................................................. 50
4.3.2 Installing the ICI890 Illumination and the ICD890 Camera.................... 50
4.4 Installing external components ..................................................................... 51
4.4.1 External sensors for triggering .................................................................. 51
4.4.2 Installing the incremental encoder........................................................... 52
4.4.3 Installing the MLG Light Grid..................................................................... 52
4.4.4 Installing the MSC800 Controller.............................................................. 52
4.5 Removing the device...................................................................................... 52
5 Electrical installation...................................................................................................... 53
5.1 Overview of installation sequence................................................................. 53
5.2 Electrical installation preparation ................................................................. 54
5.2.1 Electrical installation of the ICR890 System (without MSC800) ............ 54
5.2.2 Electrical installation of the ICR890 System with MSC800
(single-side reading)................................................................................... 56
5.2.3 Electrical installation of the ICR890 System with MSC800
(multi-side reading) .................................................................................... 58
5.3 Electrical connections and cables................................................................. 60
5.3.1 Electrical connections of the ICD890 Camera......................................... 60
5.3.2 Electrical connections of the ICI890 Illumination.................................... 61
5.3.3 Electrical connections of the MSC800 (overview)................................... 62
5.3.4 Assembled cables (overview) .................................................................... 63
5.4 Performing electrical installation................................................................... 64
5.4.1 Connecting the power supply cable and the ICI890 Illumination
control line.................................................................................................. 64
5.4.2 Power supply of the ICR890 System ........................................................ 64
5.4.3 Data interfaces HOST/AUX........................................................................ 65
5.4.4 Data interface CAN 1-IN/OUT.................................................................... 66
5.4.5 Wiring the Ethernet interface HOST ETHERNET....................................... 68
5.4.6 Wiring the Ethernet interfaces GBIT 1 and GBIT 2 .................................. 69
5.4.7 Wiring the switching inputs IN 1 and IN 2 ............................................... 69
5.4.8 Wiring the switching outputs Result 1 and Result 2 (OUT connection). 70
5.5 Pin assignments and conductor colouring assignment............................... 71
5.5.1 ICD890 Camera connections .................................................................... 71
5.5.2 ICI890 Illumination connections............................................................... 75
5.5.3 Wire colours assignment of assembled cables with open end............... 75
6 Operation ......................................................................................................................... 79
6.1 Overview of the startup procedure................................................................ 79
6.2 Configuration Software SOPAS-ET................................................................. 79
6.2.1 Functions of the SOPAS-ET Configuration Software for the
ICR890 System/MSC800 (overview)........................................................ 79
6.2.2 System requirements for the SOPAS-ET Configuration Software ........... 79
6.2.3 Installation of the Configuration Software SOPAS-ET.............................. 79
6.2.4 Default setting for the SOPAS-ET Configuration Software....................... 80
6.3 First startup..................................................................................................... 80
6.3.1 Overview of the configuration procedure ................................................. 81
6.3.2 Establishing communication with the ICR890 System/MSC800........... 81
6.3.3 Configuring the ICR890 System/MSC800 ............................................... 83
6.3.4 Load changed parameter sets into the device ........................................ 87
6.3.5 Save, display and print the current parameter set.................................. 87
6.3.6 Changing the device password for the user level "Authorized Client".... 88
6.4 Default setting ................................................................................................ 88
6.4.1 Resetting the default setting in the ICR890 System ............................... 88

Operating Instructions
ICR890
Contents
8011325/0000/2006-10-24 ©SICK AG · Division Auto Ident · Germany · All rights reserved 7
6.4.2 Default setting MSC800 ............................................................................88
7 Maintenance ....................................................................................................................89
7.1 Maintenance during operation.......................................................................89
7.2 Cleaning the ICR890 System .........................................................................89
7.2.1 Cleaning the front window .........................................................................89
7.2.2 Cleaning the housing..................................................................................90
7.2.3 Cleaning the deflection mirror...................................................................91
7.2.4 Cleaning further optical effective surfaces...............................................92
7.3 Replacing a system or a component .............................................................93
7.3.1 Replacing the ICD890 Camera or ICI890 Illumination ............................93
7.3.2 Replacing the deflection mirror .................................................................94
7.4 Disposal ...........................................................................................................95
8 Troubleshooting...............................................................................................................97
8.1 Overview of errors and malfunctions which could occur..............................97
8.1.1 Installation error .........................................................................................97
8.1.2 Electrical installation error.........................................................................97
8.1.3 Configuration error .....................................................................................97
8.1.4 Malfunctions during operation ..................................................................97
8.2 Detailed malfunction analysis .......................................................................98
8.2.1 LEDs at the camera....................................................................................98
8.2.2 System information ....................................................................................98
8.2.3 Status protocol ...........................................................................................98
8.3 ST error status in the reading result of a 1-D code (bar code) ................. 101
8.4 SICK support................................................................................................. 102
9 Technical data .............................................................................................................. 103
9.1 Data sheet for ICR890 Camera................................................................... 103
9.2 Data sheet for ICI890 Illumination ............................................................. 105
9.3 Data sheet for deflection mirror.................................................................. 105
9.4 Specification diagram .................................................................................. 106
9.4.1 Reading conditions for the diagram....................................................... 106
9.4.2 Reading areas of the ICR890 System.................................................... 106
9.4.3 Max. resolution across the direction of transport ................................. 107
9.4.4 Max. resolution in the direction of transport ......................................... 107
9.5 System dimensional drawing ICR890......................................................... 108
9.6 Deflection mirror dimensional drawing ...................................................... 110
10 Appendix........................................................................................................................ 111
10.1 Appendix overview ....................................................................................... 111
10.2 Configuring the ICR890 System with command strings............................ 111
10.3 Calculating code length of a bar code ........................................................ 112
10.4 Ordering information.................................................................................... 113
10.4.1 ICR890 High-end CCD Camera System ................................................. 113
10.4.2 Accessories: Controller and object distance detector .......................... 114
10.4.3 Accessories: Cables and connectors ..................................................... 115
10.4.4 Accessories: Incremental encoder ......................................................... 116
10.4.5 Accessories: Cleaning agents for front window of the illumination ..... 116
10.5 Supplementary documentation................................................................... 117
10.6 Glossary ........................................................................................................ 118
10.7 EC Declaration of Conformity ...................................................................... 124
10.8 Code samples (decodeable)........................................................................ 127

Operating Instructions
ICR890 High-end CCD Camera System
8©SICK AG · Division Auto Ident · Germany · All rights reserved 8011325/0000/2006-10-24
Contents

Operating Instructions
ICR890
Figures and tables
8011325/0000/2006-10-24 ©SICK AG · Division Auto Ident · Germany · All rights reserved 9
Abbreviations
BMP Bitmap(pixel-oriented Windows format for saving photos)
CAN Controller Area Network (field bus protocol based on the CAN bus)
CCD Charge Coupled Device
DOF Depth Of Field
dpi dots per inch ( 1 inch = 25.4 mm)
EEPROM Electrically Erasable Programmable Read Only Memory
FTP File Transfer Protocol
HTML Hyper Text Markup Language
IInput
ICD Image Capture Device
ICI Image Capture Illumination
ICR Image Code Reader (High-end CCD Camera System)
JPEG Joint Photographic Expert Group (pixel-oriented file format for saving high compression photos,
compression process for tiff formats)
LED Light Emitting Diode
lpi Lines per inch ( 1 inch = 25.4 mm)
MAC Medium Access Control
MLG Modular Light Grid
MSC Modular System Controller (MSC800)
MTBF Mean Time Between Failure
MTTR Mean Time To Repair
OOutput
RAM Random Access Memory
ROM Read Only Memory
SD Secure Digital Card
SMART SICK Modular Advanced Recognition Technology
SOPAS-ET SICK Open Portal for Application and Systems Engineering Tool (PC software for Windows for
configuration of the ICR890 System and the MSC800)
PLC ProgrammableLogic Controllers
TCP/IP Transmission Control Protocol/Internet Protocol
UDP User Datagram Protocol
VMS Volume Measuring System

Operating Instructions
ICR890 High-end CCD Camera System
10 ©SICK AG · Division Auto Ident · Germany · All rights reserved 8011325/0000/2006-10-24
Figures and tables
Note The ICR890 System components and other components in this document are referred to in
the following simplified terms:
•ICR890 High-end CCD Camera System , simplified: ICR890 System
•ICD890 Image Capture Device, simplified: ICD890 Camera
•ICI890 Image Capture Illumination, simplified: ICI890 Illumination
•MSC800 Modular System Controller, simplified: MSC800
•MLG Light Grid (Modular Light Grid), simplified: MLG Light Grid
•VMS4xx/5xx Volume Measuring System, simplified: VMS4xx/5xx
•SICK Open Portal for Application and Systems Engineering Tool, simplified:
SOPAS-ET Configuration Software
The register tabs for configuration of the ICR890 System are referred to in the SOPAS-ET
Configuration Software online help as "device pages".

Operating Instructions
ICR890
Figures and tables
8011325/0000/2006-10-24 ©SICK AG · Division Auto Ident · Germany · All rights reserved 11
Tables
Tab. 1-1: Target audience ................................................................................................ 15
Tab. 3-1: Included in the delivery of the ICR890 High-end CCD Camera System........ 25
Tab. 3-2: System component versions............................................................................ 26
Tab. 3-3: General system requirements (standard device) ........................................... 27
Tab. 3-4: Data interface function..................................................................................... 39
Tab. 3-5: LED indications ................................................................................................. 42
Tab. 5-1: ICR890 System (stand-alone device) without MSC800: Overview of
the ICD890 Camera connections which have to be established .................. 55
Tab. 5-2: ICR890 System (stand-alone device) with MSC800: Overview of
the ICD890 Camera connections which have to be established .................. 56
Tab. 5-3: ICR890 System (stand-alone device) with MSC800: Overview of
the MSC800 connections which have to be established............................... 57
Tab. 5-4: ICR890 System with MSC800 (multi-side reading): Overview of
the ICD890 Camera connections which have to be established .................. 58
Tab. 5-5: ICR890 System with MSC800 (multi-side reading): Overview of
the MSC800 connections which have to be established............................... 59
Tab. 5-6: ICR890 System with MSC800 (multi-side reading): Overview of
the VMS4xx/5xx connections which have to be established......................... 59
Tab. 5-7: ICD890 Camera: Function of the electrical connections ............................... 61
Tab. 5-8: ICI890 Illumination: Function of the electrical connections .......................... 61
Tab. 5-9: MSC800-0000 logic controller: Function of the electrical
connections (overview)..................................................................................... 62
Tab. 5-10: Cables for connecting the ICR890 System ..................................................... 63
Tab. 5-11: Maximum cable lengths between ICR890 and the host................................ 65
Tab. 5-12: CAN bus: Maximum cable lengths, depending on the data transfer rate..... 66
Tab. 5-13: CAN bus: Maximum stub cable lengths, depending on the data
transfer rate ...................................................................................................... 66
Tab. 5-14: CAN bus: Required wire cross section, depending on the data
cable length....................................................................................................... 67
Tab. 5-15: Ratings of the switching inputs IN1 and IN 2 ................................................. 69
Tab. 5-16: Ratings of the switching outputs Result 1 and Result 2................................ 70
Tab. 5-17: ICD890 Camera: Pin assignment of the 8-pole RJ-45 sockets
“GBIT1“ and “GBIT2“........................................................................................ 71
Tab. 5-18: ICD890 Camera: Pin assignment of the 5-pole M12 sockets
“CAN 1-OUT“/“CAN 2-OUT“ .............................................................................. 71
Tab. 5-19: ICD890 Camera: Pin assignment of the 5-pole M12 plugs
“CAN 1-IN“/“CAN 2-IN“..................................................................................... 72
Tab. 5-20: ICD890 Camera: Pin assignment of the 8-pole M12
socket “ILLUMINATION“.................................................................................... 72
Tab. 5-21: ICD890 Camera: Pin assignment of the 8-pole M12 plug “AUX“ .................. 72
Tab. 5-22: ICD890 Camera: Pin assignment of the 8-pole M12 plug “HOST“ ............... 72
Tab. 5-23: ICD890 Camera: Pin assignment of the 4-pole M12 plug “OUT“.................. 73
Tab. 5-24: ICD890 Camera: Pin assignment of the 5-pole M12 socket “IN 1“.............. 73
Tab. 5-25: ICD890 Camera: Pin assignment of the 5-pole M12 socket “IN 2“.............. 73
Tab. 5-26: ICD890 Camera: Pin assignment of the 4-pole M12 socket
“HOST ETHERNET“............................................................................................ 73
Tab. 5-27: ICD890 Camera: Pin assignment of the 8-pole Harting HanQ8 plug
“POWER IN“ ....................................................................................................... 74
Tab. 5-28: ICD890 Camera: Pin assignment of the 8-pole Harting HanQ8 socket
“POWER OUT“.................................................................................................... 74
Tab. 5-29: ICI890 Illumination: Pin assignment of the 8-pole Harting HanQ8 plug
“POWER IN“ ....................................................................................................... 75
Tab. 5-30: ICI890 Illumination: Pin assignment of the 8-pole M12 plug
“ILLUMINATION“................................................................................................ 75
Tab. 5-31: Wire colours assignment: Cable no. 6028420 (HOST/AUX), standard ........ 75
Tab. 5-32: Wire colours assignment: Cables no. 6021166/no. 6021175

Operating Instructions
ICR890 High-end CCD Camera System
12 ©SICK AG · Division Auto Ident · Germany · All rights reserved 8011325/0000/2006-10-24
Figures and tables
(CAN 1-IN), PVC-free ..........................................................................................76
Tab. 5-33: Wire colours assignment: Cable no.6024861 (IN 1/IN 2), standard ............76
Tab. 5-34: Wire colours assignment: Cable no. 6027559 (OUT), standard....................76
Tab. 5-35: Wire colours assignment: Cable no. 2039398 (ICD890 Camera
power supply), standard....................................................................................77
Tab. 5-36: Wire colours assignment: Cable no. 2032926 (ICD890 Camera
power supply), PVC-free ....................................................................................77
Tab. 6-1: Default setting for the SOPAS-ET Configuration Software (excerpt) ..............80
Tab. 6-2: Connection between the PC with the SOPAS-ET Configuration
Software and the ICR890 System/MSC800 ...................................................81
Tab. 6-3: ICR890 System (stand-alone device) with MSC800: Overview
of parameters which have to be set.................................................................83
Tab. 6-4: ICR890 System (stand-alone device) with MSC800: Overview
of parameters which have to be set.................................................................85
Tab. 6-5: ICR890 System (stand-alone device) without MSC800: Overview
of parameters which have to be set.................................................................86
Tab. 8-1: Request “Query warnings“................................................................................99
Tab. 8-2: Answer to the request “Query warnings“.........................................................99
Tab. 8-3: Request “Query errors“.................................................................................. 100
Tab. 8-4: Answer to the request “Query errors“ ........................................................... 100
Tab. 8-5: Request “Query fatal errors“ ......................................................................... 100
Tab. 8-6: Answer to the request “Query fatal errors“................................................... 100
Tab. 8-7: Meaning of the ST error status in the reading result................................... 101
Tab. 9-1: Technical specifications for the ICR890 Camera......................................... 103
Tab. 9-2: Technical specifications for the ICI890 Illumination ................................... 105
Tab. 9-3: Technical specifications for deflection mirror .............................................. 105
Tab. 9-4: Reading conditions for the specification diagram ....................................... 106
Tab. 10-1: Help table for calculating code length of a bar code ................................... 112
Tab. 10-2: Ordering information: ICR890 High-end CCD Camera System ................... 113
Tab. 10-3: In stock accessories: Controller and object distance detector ................... 114
Tab. 10-4: In stock accessories: Cables and connectors .............................................. 115
Tab. 10-5: In stock accessories: Incremental encoder.................................................. 116
Tab. 10-6: In stock accessories: Cleaning agents for front window of the
illumination ..................................................................................................... 116
Tab. 10-7: Supplementary documentation for the ICR890 System.............................. 117

Operating Instructions
ICR890
Figures and tables
8011325/0000/2006-10-24 ©SICK AG · Division Auto Ident · Germany · All rights reserved 13
Figures
Fig. 2-1: LED radiation outlet opening ........................................................................... 19
Fig. 3-1: ICR890 System in combination with the MSC800 (single-side reading)...... 23
Fig. 3-2: View of the ICD890 camera and the ICI890 Illumination .............................. 24
Fig. 3-3: Work area of the ICR890 System (standard device)...................................... 26
Fig. 3-4: Example of simple system installation on the installation frame.................. 27
Fig. 3-5: The ICR890 System at a conveyor system, single-side reading from above 31
Fig. 3-6: System diagram for single-side reading from above...................................... 32
Fig. 3-7: Diagram of the illumination with illuminated area ......................................... 33
Fig. 3-8: ICR890 System with deflection mirror for reading from above ..................... 34
Fig. 3-9: Position of the ICR890 System and the tilt angle........................................... 35
Fig. 3-10: Example of an image recording for analysis ................................................... 36
Fig. 3-11: Image analysis (blue rectangle: Regions of interest; green rectangle:
Successful decoding; green line: Decoder runtime at end of the
reading pulse) ................................................................................................... 36
Fig. 3-12: Reading operation modi of the ICR890 System in stand-alone operation... 38
Fig. 3-13: SD memory card for parameter set ................................................................. 41
Fig. 3-14: LEDs at the ICD890 Camera............................................................................ 42
Fig. 3-15: Pixel resolution across the direction of transport (standard device,
135 mm (5.32 in) lens) .................................................................................... 43
Fig. 3-16: Line resolution in the direction of transport (standard device,
8,192 pixels CCD sensor)................................................................................. 43
Abb. 4-1: Example of a project-specific dimensional sheet for installation.................. 46
Abb. 4-2: Free space required for connecting the camera and the illumination.......... 47
Abb. 4-3: Arrangement above the conveyor system for single-side reading
from above ........................................................................................................ 47
Abb. 4-4: Arrangement at the conveyor system for multi-side reading with
VMS4xx/5xx....................................................................................................... 48
Abb. 4-5: Arrangement at the conveyor system.............................................................. 48
Abb. 4-6: Position of the components ............................................................................. 49
Abb. 4-7: 180° bracket for the deflection mirror and the illumination......................... 49
Abb. 4-8: Removeable protective camera caps.............................................................. 51
Abb. 4-9: Position of the external components............................................................... 51
Abb. 5-1: Block diagram: connection principle of the ICR890 (standard system) ....... 54
Abb. 5-2: Block diagram: Connection principle of a ICR890 (standard system)
with MSC800..................................................................................................... 56
Abb. 5-3: Block diagram: Connection principle of several ICR890
(standard systems) with MSC800 ................................................................... 58
Abb. 5-4: ICD890 Camera: Position of the electrical connections
(standard system) ............................................................................................. 60
Abb. 5-5: MSC800-0000 logic controller: Position of the electrical connections ........ 62
Abb. 5-6: ICD890 Camera: Wiring of the HOST/AUX data interfaces............................ 66
Abb. 5-7: Block diagram: Function of the Ethernet interface......................................... 68
Abb. 5-8: Wiring of the switching inputs IN 1 and IN 2................................................... 69
Abb. 5-9: Wiring of the switching outputs Result 1 and Result 2.................................. 70
Abb. 5-10: ICD890 Camera: Electrical connections (standard system).......................... 71
Abb. 6-1: Configuration with SOPAS-ET ........................................................................... 80
Abb. 7-1: Cleaning the front window................................................................................ 90
Abb. 7-2: Cleaning the air inlet and outlet openings at the system's
illumination ICR890.......................................................................................... 90
Abb. 7-3: Cleaning of the external optical sensors (reading pulse generator,
detector for object distance)............................................................................ 92
Abb. 7-4: 180° bracket: Loosening clamping screws .................................................... 93
Abb. 7-5: ICD890 Camera: Position of the battery on the internal PC card.................. 95
Abb. 9-1: Reading areas of the ICR890 System (standard).........................................106
Abb. 9-2: Pixel resolution across the direction of transport (standard device,
135 mm (5.32 in) lens) ..................................................................................107

Operating Instructions
ICR890 High-end CCD Camera System
14 ©SICK AG · Division Auto Ident · Germany · All rights reserved 8011325/0000/2006-10-24
Figures and tables
Abb. 9-3: Line resolution in the direction of transport (standard device,
8,192 pixels CCD sensor) .............................................................................. 107
Abb. 9-4: Dimensions of the ICR890 System ............................................................... 108
Abb. 9-5: Total dimensions of the ICR890 System and the free space
required for connecting.................................................................................. 109
Abb. 9-6: Dimensions of the deflection mirror ............................................................. 110
Abb. 10-1: EC Declaration of Conformity for the ICD890 Camera
(page 1, scaled down version)....................................................................... 124
Abb. 10-2: EC Declaration of Conformity for the ICI890 Illumination
(page 1, scaled down version)....................................................................... 125
Abb. 10-3: Code samples of 1-D codes of various module widths
(print ratio 2:1) and 2-D code of various cell sizes ...................................... 127

Operating Instructions Chapter 1
ICR890
Notes on this document
8011325/0000/2006-10-24 ©SICK AG · Division Auto Ident · Germany · All rights reserved 15
1Notes on this document
1.1 Purpose
This document provides instructions for technical staff on the installation and operation of
the following ICR890 System models:
•The ICR890 System equipped with focus control, CCD sensor 8,192 pixels, standard
lens (focal distance 135 mm (5.32 in))
This document contains the following information:
•Installation and electrical installation
•Startup
•Operation and configuration
•Maintenance
•Troubleshooting
•Replacing system components
A step-by-step approach is taken for all tasks.
1.2 Target audience
The target audience of this document is persons assigned the following tasks:
1.3 Information content
This document contains all the required information for installation, electrical installation
and operation of the ICR890 System at the installation location. The factory configuration
(default setting) of the ICR890 System as a stand-alone device is optimized to a
single-side reading (from above or from the side).
Configuration of the ICR890 System for the application-specific reading conditions and
operation is carried out via the SOPAS-ET Configuration Software at a WindowsTM-PC. The
SOPAS-ET Configuration Software contains an online help system to facilitate configuration.
Electrical installation of the MSC800 controller for a ICR890 System as stand-alone device
and its configuration is detailed in the MSC800 Operating Instructions (no. 8011540).
These instructions also described use of the MSC800 as a controller for a multi-side
reading.
Note Further information on High End CCD Camera Systems, Volume Measurement Systems and
Bar Code Scanners is available from SICK AG, Auto Ident division.
On the Internet at www.sick.com.
Tasks Target audience
Installation, electrical installation,
maintenance, replacing system
components
Qualified staff, e. g. service technicians and factory
electricians
Startup, operation and configuration Qualified staff, e. g. technicians and engineers
Operation of the conveyor system Qualified staff for startup and operation of the conveyor
system
Tab. 1-1: Target audience

Chapter 1 Operating Instructions
ICR890 High-end CCD Camera System
16 ©SICK AG · Division Auto Ident · Germany · All rights reserved 8011325/0000/2006-10-24
Notes on this document
1.4 Symbols used
Some of the information in this document is marked specially so that you can access it
quickly:
Warning!
Warnings are provided to prevent injury to operating personnel or serious damage to the
ICR890 System.
¾Always read warnings carefully and observe them at all times.
Reference Italics are used to refer to more detailed information elsewhere.
Note Notes indicate special features or characteristics.
Explanation Explanations provide background information on technical correlations.
Recommendation Recommendations help you carry out certain procedures more effectively.
TIP Tips explain settings in the SOPAS-ET Configuration Software.
PROJECT This font indicates a term in the user interface of the SOPAS-ET Configuration Software.
Icons refer to buttons in the user interface of the SOPAS-ET Configuration Software.
“0x0“ This font indicates messages output by the ICR890 System.
This symbol identifies sections that describe steps carried out with the SOPAS-ET
Configuration Software.
This symbol refers to additional technical documentation.
¾There is a procedure which needs to be carried out. This symbol indicates operational
instructions which only contain one operational step or operational steps in warning notices
which do not have to be followed in any particular order.
Operational instructions comprising several steps are denoted using consecutive numbers.
ÖThis symbol indicates a glossary entry.

Operating Instructions Chapter 2
ICR890
Safety information
8011325/0000/2006-10-24 ©SICK AG · Division Auto Ident · Germany · All rights reserved 17
2Safety information
This chapter deals with your safety and operator safety.
¾Read this chapter carefully before using the ICR890 System.
2.1 Authorized users
For correct and safe functioning, the ICR890 System must be installed, operated and
maintained by sufficiently qualified staff.
Repairs to the ICR890 System should only be carried out by qualified and authorized SICK
AG service staff.
¾The operating instructions should be made available to the end user.
¾The end user should be briefed and urged to read the operating instructions by the
technicians.
The following chapters summarize the required qualifications for the various tasks.
2.1.1 Installation and maintenance
•Practical technical training
•Knowledge of current health and safety regulations at the workplace
2.1.2 Electrical installation and the replacement of system components
•Practical electrical training
•Knowledge of current electrical safety regulations
•Knowledge of startup and operation of the device in each operational area
(e. g. conveyor system)
2.1.3 Startup, operation and configuration
•Knowledge of the mechanical and electrical parameters of the conveyor system and
the characteristics of the conveyor system regarding startup and operation
•Basic knowledge of the WindowsTM operating system
•Basic knowledge of data transfer
•Basic knowledge of designing and setting up (addressing) Ethernet connections for
connecting the ICR890 System to the Ethernet
•Basic knowledge of working with an HTML browser (e.g. Internet Explorer) for using the
online help
•Basic knowledge of 1-D/2-D code technology

Chapter 2 Operating Instructions
ICR890 High-end CCD Camera System
18 ©SICK AG · Division Auto Ident · Germany · All rights reserved 8011325/0000/2006-10-24
Safety information
2.2 Intended use
The ICR890 High-end CCD Camera System is an intelligent sensor for the automatic
recognition and decoding of 1-D/2-D codes on moving objects in a reading station.
In combination with the MSC800 modular system controller, the ICR890 System is used as
a stand-alone device for single-side reading, e.g. from above or from the side. For a similarly
possible multi-side reading on the conveyor system, the corresponding number of systems
is combined with other SICK bar code scanners and with the co-coordinating MSC800.
The intended use of the system results from the following description of the system
components and their functions:
•The system consists of the ICD890 Camera, the ICI890 Illumination and a deflection
mirror. The ICD890 Camera is installed in a frame together with the ICI890 Illumination
as a unit parallel to the deflection mirror, either above the conveyor system (reading
from above) or at the side (side reading).
•The necessary object distance information is contained in the ICR890 System either by
an MLG Light Grid (in the case of readings from above) or by a VMS4xx/5xx Volume
Measurement System for focus control during Single or multi-side reading.
•The ICR890 System transfers the reading data via its HOST main data interface (serial
RS 232, RS 422/485, Ethernet or CAN), with optionally selectable diagnosis data, to a
superordinate host processor for further processing.
The ICR890 System transfers its data via the CAN interface to the MSC800, in
combination with the MSC800. The data can then be accessed from the HOST data
interface.
•The processed image information of the ICD890 Camera is located on two fast GBit
Ethernet channels. The image information can be transferred to the client display at
extremely high data transfer rates on a special PC with compatible GBit Ethernet
interface cards and GigE Vision Standard licence (real time image data transfer). The
high image quality also allows use in OCR and video coding applications.
•Configuration/Operation of the ICR890 System is carried out as standard via the AUX
auxiliary data interface (serial RS 232 or Ethernet) using the SOPAS-ET Configuration
Software, which runs on a standard client PC. Alternatively, the configuration can also
be carried out via the PC connection to the MSC800 (serial RS 232 or Ethernet).
Any warranty claims against SICK AG shall be deemed invalid in the case of other system
use or system modifications, this includes modifications during installation and electrical
installation or changes to the SICK software.
Note The ICD890 Camera and ICI890 Illumination must not be opened. If the devices are
opened, the manufacturer's warranty shall not apply.

Operating Instructions Chapter 2
ICR890
Safety information
8011325/0000/2006-10-24 ©SICK AG · Division Auto Ident · Germany · All rights reserved 19
2.3 General safety precautions and protection measures
¾Read the general safety precautions thoroughly and observe them during all ICR890
System activities. Also observe the warning notices above the operational instructions
of each chapter.
2.3.1 Radio interferences
RF interference in case of use in residential areas.
¾ICR890 High-end CCD Camera System is exclusively intended for use in an industrial
environment.
2.3.2 Installation work
Risk of injuries due to falling components!
The combined weight of the ICD890 Camera and the ICI890 Illumination is approx. 37 kg
(81.6 lb) without installation accessories.
¾Do not carry out installation work alone.
¾A second person should always secure components during installation.
2.3.3 Electrical installation work
Risk of injuries due to electrical current!
Connect the MSC800 Controller to the mains power supply (100 to 264 V AC/50 to 60 Hz).
¾Observe current safety regulations when working with electrical equipment.
2.3.4 LED radiation from the ICI890 Illumination
LED radiation escapes from the entire front window of the ICI890 Illumination.
Fig. 2-1: LED radiation outlet opening
Output opening

Chapter 2 Operating Instructions
ICR890 High-end CCD Camera System
20 ©SICK AG · Division Auto Ident · Germany · All rights reserved 8011325/0000/2006-10-24
Safety information
Class 1M LED radiation (in accordance with EN/IEC 60825-1)!
Incorrect use can result in hazardous radiation exposure and the LED class being
exceeded!
The accessible radiation of the ICI890 Illumination is not hazardous under reasonably
foreseeable conditions, provided that the beam width is not reduced by optical instruments,
e.g. magnifying glass, lenses or telescopes. Visual glare, loss of colour vision and eye
injuries cannot be ruled out.
The entire window surface is the LED radiation outlet opening.
¾Do not look directly into the radiation source with optical instruments.
¾Do not open the housing. (The illumination is not switched off if the housing is opened).
¾Always observe the latest valid version of laser protection regulations.
Note The ICI890 Illumination works with LEDs on the λ = 620 nm (red light) wavelength.
The radiation emitted is not harmful to human skin.
Regular maintenance is not required to ensure compliance with laser class 1M.
The ICI890 Illumination operates as follows:
•The reading pulse (pulse source) controls the on and off mechanism of the LED
illumination during the reading process. The LEDs are switched on in pulsed mode
during the reading operation depending on the reading gate duration.
•A time stage (illumination timeout) automatically switches off the illumination during
the reading operation after 3 seconds (default setting) following the start of a
continuous reading pulse. This, however, does not switch off the reading pulse. The
reading pulse should be stopped via a relevant pulse signal. The next reading pulse
switches the illumination back on.
•The illumination timeout can be set or switched off within a range of 3 s to 25 h. For
safety reasons, the minimum illumination power on time is 3 seconds.
2.4 Quick stop and quick start
The ICR890 System is operated via the MSC800 Controller as standard and can be
switched on and off using the controller main switch.
2.4.1 Switch off the ICR890 System
¾Switch off the power supply of the MSC800.
When the system is switched off the following data is lost:
•Application-specific parameter sets in the ICR890 System and in the MSC800
Controller which were only temporarily saved in the devices
•The last reading result of the ICR890 System
•Daily operating hours counter of the ICR890 System
2.4.2 Switch on the ICR890 System
¾Switch on the power supply of the MSC800 again.
The ICR890 System starts up using the most recent permanently saved configuration.
The daily operating hours counter is reset.