SICK TRACK-AND-TRACE-CABINET TTC100-2 Operating instructions

O P E R A T I N G I N S T R U C T IO N S

Track and trace cabinet

TTC100-2

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Product described

TTC100-2 track and trace cabinet

Document No.

8025175

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.

Original documents

This document is the translation of the original document from SICK AG.

CONTENTS 
 

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T RA N S L A T I O N  OF   T H E   O RI G IN A L   O P ER A T I N G  I NS T RU C T IO N S  TTC100-2 track and trace cabinet 
Contents 
About this document ............................................................................................................ 6 
1  Limitation of liability ................................................................................................. 6 
2  Purpose of this document ....................................................................................... 6 
3  Target groups ............................................................................................................ 7 
4  Abbreviations ............................................................................................................ 7 
5  Further information .................................................................................................. 8 
6  Other relevant technical documentation/information......................................... 8 
7  Document conventions ............................................................................................ 8 
Safety information................................................................................................................. 9 
1  Intended use ............................................................................................................. 9 
2  General safety notes ................................................................................................ 9 
3  Requirements for the qualification of personnel ...............................................10 
4  System warranty .....................................................................................................10 
5  RoHS Directive ........................................................................................................10 
6  Standard IP technology..........................................................................................10 
7  Cybersecurity...........................................................................................................11 
8  Safety conventions .................................................................................................11 
9  Sources of hazard...................................................................................................12 
10  Warning symbols on the system components ....................................................13 
11  Mandatory symbols ................................................................................................13 
Product description.............................................................................................................14 
1  Scope of delivery ....................................................................................................14 
2  Components ............................................................................................................15 
2.1  Cabinet layouts .......................................................................................15 
2.2  Controller .................................................................................................19 
2.3  Components for voltage supply ............................................................20 
2.4  Ethernet switches ...................................................................................21 
3  Interfaces.................................................................................................................22 
3.1  Overview...................................................................................................22 
3.2  Data interfaces for setting up an internal sensor network ...............23 
3.3  Digital inputs and outputs .....................................................................24 
3.4  Interfaces for data and image output to the customer system........24 
4  Operating principle .................................................................................................26 
4.1  Basic principle of the measuring and reading process .....................26 
4.2  Triggering and tracking ..........................................................................27 
4.3  Data processing and data output.........................................................28 
5  Configuration with SOPAS .....................................................................................30 
6  Alibi saving...............................................................................................................31 
7  System requirements .............................................................................................32 
8  Status indicators.....................................................................................................33 
8.1  Status indicators on the MSC800 ........................................................33 
8.2  Status indicators on the SIM2000 .......................................................36 
8.3  Status indicators on the power supply modules ................................38 
8.4  LEDs on the fuse modules ....................................................................40 
Mounting...............................................................................................................................41 

CONTENTS 
 

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Electrical installation .........................................................................................................43 
1  Overview...................................................................................................................44 
1.1  Connection areas....................................................................................44 
1.2  Cable entries ...........................................................................................46 
2  Notes on electrical installation .............................................................................47 
2.1  Required wire cross-sections ................................................................47 
2.2  Recommended cable lengths ...............................................................47 
2.3  Shield .......................................................................................................48 
2.4  Terminal blocks.......................................................................................49 
2.5  RCD and fuse module ............................................................................51 
3  Voltage supply connection ....................................................................................53 
3.1  Mains voltage ..........................................................................................53 
3.2  24 V power supply to the controllers and sensors.............................54 
4  Connections on the controller...............................................................................57 
4.1  MSC800 connection overview ..............................................................57 
4.2  SIM2000 connection overview .............................................................63 
4.3  Connection examples.............................................................................68 
Commissioning ....................................................................................................................70 
1  Starting up the cabinet ..........................................................................................70 
1.1  Establishing the voltage supply ............................................................70 
1.2  Checking the operational readiness of the controllers .....................70 
2  Connecting the configuration PC ..........................................................................71 
2.1  Establishing a connection with the configuration PC ........................71 
2.2  Installing SOPAS .....................................................................................72 
2.3  Launching SOPAS ...................................................................................73 
2.4  Starting the device search.....................................................................73 
2.5  Transferring the controller to a SOPAS project...................................75 
2.6  Loading device drivers into the SOPAS project ..................................75 
2.7  Changing the IP address........................................................................76 
2.8  Opening the configuration interface ....................................................77 
3  Configuration in SOPAS .........................................................................................78 
3.1  Configuration interface ..........................................................................78 
3.2  Logging into the controller.....................................................................78 
3.3  Configuring the parameters ..................................................................79 
3.4  Saving the parameters permanently ...................................................80 
3.5  Restart the system controller................................................................80 
4  Restoring the default .............................................................................................80 
5  Deactivating TCP/IP CoLa protocol server ..........................................................81 
6  Changing password ................................................................................................83 
Maintenance and repair.....................................................................................................84 
1  Monitoring and cleaning work ..............................................................................84 
2  Replacing the controller.........................................................................................85 
2.1  Removing connecting cables ................................................................85 
2.2  Replacing the MSC800..........................................................................86 
2.3  Replacing the SIM2000.........................................................................87 
2.4  Putting the replacement device into operation ..................................88 
3  Replacing the battery in the MSC800 system controller ..................................89 
4  Replacing the power supply unit ..........................................................................90 

CONTENTS

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8 Fault diagnosis ....................................................................................................................92

8.1 Displays on the system controller ........................................................................92

8.1.1 Checking system readiness ..................................................................92

8.1.2 Checking the triggering ..........................................................................93

8.1.3 Checking the incremental encoder ......................................................94

8.1.4 Checking the CAN cabling .....................................................................95

8.2 Detailed fault analysis ...........................................................................................96

9 Technical data......................................................................................................................97

9.1 Data sheet ...............................................................................................................97

9.2 Dimensional drawings............................................................................................98

9.3 Compliance with EU directives..............................................................................99

10 Disposal.............................................................................................................................. 100

1 ABOUT THIS DOCUMENT

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1 About 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

This document describes the following topics relating to the track and trace cabinet:

 Product description

 Mounting

 Electrical installation

 Commissioning and configuration with the SOPAS ET configuration tool

 Maintenance and repair

 Fault diagnosis and troubleshooting

 Technical data and dimensional drawings

Further information on high-end CCD camera systems, volume measurement systems,

and bar code scanners is available at www.sick.com.

ABOUT THIS DOCUMENT 1

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1.3 Target groups

This document is intended for qualified persons who perform the following tasks with the

track and trace cabinet:

 Mounting

 Installation

 Commissioning

 Operation, and

 Repairing

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.

For more information, see the customer documentation.

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

Hypertext markup language (page description language used on the Internet)

Image code reader (high-end CCD camera system)

Light emitting diode

Modular system controller (MSC800)

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)

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

CAN

EEPROM

FTP

HTML

ICR

LED

MSC

PROM

RAM

RCD

ROM

SD

SIM

SOPAS ET

PLC

TCP/IP

1 ABOUT THIS DOCUMENT

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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

Terminal diagram

 Operating instructions for the following system components:

Component

Manufacturer

SIM2000ST Sensor Integration Machine operating

instructions

SICK

MSC800 Modular System Controller operating

instructions

SICK

1.7 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 are examples only and may differ from the actual design.

SAFETY INFORMATION 2

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2 Safety information

2.1 Intended use

The TTC100-21xxxx track and trace cabinet is used in conjunction with SICK sensors.

The controllers installed in the TTC100-21xxxx cabinet perform the tasks of coordinating

all connected sensors, processing the received measured values and read 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 controller cabinet can be supplemented with a TTC100-21xxx0 power cabinet.

The power cabinet allows more sensors to be connected.

Both cabinet variants are 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 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 cabinet.

▸

Do not ignore any damage caused to components during transport.

▸

In case of damage, contact SICK Service.

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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 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 track and trace cabinet have been installed, mounted

or modified without authorization.

▸

The track and trace cabinet has been altered or modified.

▸

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 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.

2.6 Standard IP technology

NOTE!

SECURE 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.

SAFETY INFORMATION 2

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2.7 Cybersecurity

NOTE!

CYBERSECURITY CONTACTS FOR SICK PRODUCTS

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.

2.8 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.

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2.9 Sources of hazard

WARNING!

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 POTENTIAL EQUALIZATION 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.

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 controllers and power supply units during

operation.

▸

Do not touch hot surfaces.

▸

Wear suitable safety gloves.

SAFETY INFORMATION 2

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2.10 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

Warning of LED light

Suspended load warning

2.11 Mandatory symbols

Symbol

Meaning

Read document

Use head protection

Use foot protection

Disconnect before maintenance or repairs

Further information to note

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3 Product 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.

Two cabinet variants with different controllers are available depending on the customer

system and the host protocols defined for data output.

Variant

Explanation

TTC100-21xxx3

Cabinet with MSC800 system controller and SIM2000

dimensioning controller plus power supply units and Ethernet

switch

TTC100-21xxx5

Cabinet with SIM2000 system controllers and SIM2000

dimensioning controller plus power supply units and Ethernet

switch

TTC100-21xxx2

Cabinet with SIM2000 system controller plus power supply units

and Ethernet switch

TTC100-21xxx0

Cabinet with power supply units for connecting additional ICR

cameras

NOTE!

 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 layouts

Fig. 1: External view of the TTC100-21xxxx 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

TTC100-21xxxx cabinet

3 PRODUCT DESCRIPTION

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NOTE! The following figure shows the fully-equipped controller cabinet. Some components

may not be present depending on the application.

Fig. 2: Internal view of the TTC100-2 cabinet (in this case TTC100-21xxx5)

Legend

1

System controller (SIM2000 or MSC800) with connections and

SD memory card for parameter cloning

2

Terminals for mains voltage IN (AC 100 ... 240 V / 50 ... 60 Hz)

3

Power supply module(s) for supplying voltage to the controller as well as

the connected sensors and ICR cameras

4

Power supply module for the LFT display (legal for trade systems only)

5

RCD (residual current device) for protective contact plug

6

Circuit breaker for power supply unit modules

7

Protective contact socket (mains voltage)

8

Thermostat for the fan controller

9

Circuit breaker for the connected ICR cameras

(2 circuit breakers per ICR camera)

10

Optional Ethernet switch for connecting legal for trade system

components or setting up an internal sensor network

11

24 V terminals with fuse modules for supplying voltage to the controller,

sensors and internal fans

12

SIM2000 dimensioning controller with connections and SD memory card

for parameter cloning NOTE! May not be included depending on the

application.

13

Optional Ethernet switches for setting up an internal sensor network as

well as for outputting data and camera images

14

24 V terminals for supplying voltage to the ICR cameras

Internal view of the

TTC100-21xxxx cabinet

PRODUCT DESCRIPTION 3

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Fig. 3: External view of the TTC100-21xxx0 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

TTC100-21xxx0 cabinet

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NOTE! The following figure shows the fully-equipped power cabinet. Some components

may not be present depending on the application.

Fig. 4: Internal view of the TTC100-21xxx0 cabinet

Legend

1

Terminals for mains voltage IN (AC 100 ... 240 V / 50 ... 60 Hz)

2

Circuit breaker for power supply unit modules

3

Power supply module(s) for supplying voltage to the connected

ICR cameras

4

Thermostat for the fan controller

5

Circuit breaker for the connected ICR cameras

(2 circuit breakers per ICR camera)

6

24 V terminals for supplying voltage to the ICR cameras

Internal view of the

TTC100-21xxx0 cabinet

PRODUCT DESCRIPTION 3

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3.2.2 Controller

Fig. 5: TC100-21xxxx cabinet with system controller and dimensioning controller

Legend

1

Cabinet with MSC800 system controller and SIM2000 dimensioning controller

2

Cabinet with SIM2000 system controller and SIM2000 dimensioning

controller

 The cabinet contains a system controller and a dimensioning controller.

 Either an MSC800 or SIM2000 can be used as the system controller.

 A SIM2000 is always used as the dimensioning controller.

NOTE! Only a SIM2000 system controller is installed in the TTC100-21xxx2 cabinet

variant.

 The system controller is a 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 system controller processes the signals from the connected sensors and delivers

the acquired data to the higher-level system controller. The data is delivered via a

customer-specific interface.

 The dimensioning controller increases the computing power of the SICK system when

using volume measurement systems, thereby allowing a higher throughput.

 The dimensioning controller receives the measuring points from the multi-dimensional

measurement devices and uses the 2D sections to calculate a three-dimensional

model.

 Based on this calculated 3D model, the dimensioning controller determines the

dimensional values and transmits the measurement results to the system controller via

CAN bus.

Properties

Function of the system

controller

Function of the

dimensioning controller

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3.2.3 Components for voltage supply

Fig. 6: Connection to the mains voltage and power supply units

Legend

1

Connection to the local mains voltage (AC 100 ... 240 V / 50 ... 60 Hz)

2

Power supply units for the 24 V voltage supply to the sensors and

ICR cameras

3

Power supply unit for the LFT display (legal for trade systems only)

 The cabinets do not have a master switch for the incoming supply voltage.

 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.

 For legal for trade SICK systems, a separate power supply unit in the TTC100 -21xxxx

delivers the supply voltage to the LFT display.

Fig. 7: Terminal blocks for connecting to a 24 V voltage supply

Legend

1

24 V terminals for connecting ICR cameras to the voltage supply (each

protected via 2 circuit breakers)

2

24 V terminals with fuse modules for connecting internal components

and external sensors to the voltage supply

Power supply units

Connection to 24 V

power supply

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