SICK VMS4200 Operating instructions

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

VMS4200 / VMS5200

Track and trace systems

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Product described

Product name: VMS4200 / VMS5200

Document identification

Title: VMS4200 / VMS5200 operating instructions

Part number: 8022965

Status: 2018-08-16

Manufacturer

SICK AG

Erwin-Sick-Str. 1 · 79183 Waldkirch · Germany

Trademarks

IBM is a trademark of the International Business Machine Corporation.

MS-DOS is a trademark of the Microsoft Corporation.

Windows is a trademark of the Microsoft Corporation.

Other product names in this document may also be trademarks and are only

used here for identification purposes.

Original documents

The German version 8022964 of this document is an original SICK AG

document.

SICK AG does not assume liability for the correctness of any unauthorized

translation.

In case of doubt, contact SICK AG or your local agency.

Legal notes

Subject to change without notice

CONTENTS 
 

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Content 
About this document ............................................................................................ 6 
1  Purpose of this document ........................................................................ 6 
2  Abbreviations used................................................................................... 6 
3  Symbols used ........................................................................................... 6 
On safety ................................................................................................................ 7 
1  Qualified safety personnel ....................................................................... 7 
2  Intended use ............................................................................................. 7 
3  General safety notes and protective measures ..................................... 8 
3.1  Safety notes and symbols ........................................................ 8 
3.2  General safety notes ................................................................. 9 
3.3  Additional operating instructions ............................................. 9 
3.4  Dangers connected with handling of the system .................. 10 
4  RoHS Directive........................................................................................ 14 
System description ............................................................................................. 15 
1  Scope of delivery .................................................................................... 15 
2  Structure of the volume measurement system .................................... 16 
2.1  System components ............................................................... 16 
2.2  Expanding the system with a reading station ........................ 19 
3  Operating principle of the volume measurement system .................... 20 
3.1  Operating modes ..................................................................... 20 
3.2  Calculating the volume ........................................................... 22 
3.3  Data processing and data output .......................................... 24 
4  Nominal value conditions ...................................................................... 26 
4.1  Fixed scale values ................................................................... 26 
4.2  Dynamic scale value switchover ............................................ 29 
5  System requirements ............................................................................. 30 
5.1  Required interfaces ................................................................ 30 
5.2  Requirements at the operation site ....................................... 30 
5.3  Object requirements ............................................................... 30 
5.4  Conveying equipment requirements ...................................... 30 
5.5  Mounting requirements .......................................................... 31 
6  Officially verifiable operation ................................................................. 34 
6.1  Information labels ................................................................... 34 
6.2  Security seal ............................................................................ 38 
6.3  SD card with alibi memory ...................................................... 41 
6.4  LFT display ............................................................................... 43 
6.5  Test instructions for market surveillance .............................. 46 
7  Status indicators .................................................................................... 50 
7.1  LMS4xxx volume measurement devices ............................... 50 
7.2  Status indicators on the SIM2000 controller ........................ 50 
8  Interfaces ................................................................................................ 51 
Mounting ............................................................................................................. 52 
1  Mounting volume measurement devices ............................................. 52 
1.1  Assembling the profiles of the telescopic tube ..................... 53 
1.2  Mounting telescopic tube to the frame ................................. 53 
1.3  Mounting the volume measurement devices to the retaining 
plates ....................................................................................... 53 
2  Mounting the measuring wheel encoder .............................................. 55 

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3  Mounting the photoelectric retro-reflective sensor and reflector 
(optional) ................................................................................................ 56 
4  Mounting the cabinet ............................................................................. 57 
5  Dismantling the measurement system ................................................. 58 
Electrical installation ......................................................................................... 59 
1  Connection overview .............................................................................. 61 
2  Connecting to the voltage supply .......................................................... 62 
3  Connection for the Ethernet switch (set up at the factory) .................. 63 
4  Connecting the volume measurement devices .................................... 64 
5  Connecting the LFT display ................................................................... 65 
6  Connection for the measuring wheel encoder ..................................... 66 
7  Connection for the photoelectric retro-reflective sensor (optional) .... 67 
8  Connecting to the customer interface .................................................. 68 
Commissioning ................................................................................................... 69 
1  Switching on the system ........................................................................ 69 
2  Configuring the system with SOPAS ...................................................... 70 
2.1  Installing SOPAS ET ................................................................ 70 
2.2  Allocating IP addresses .......................................................... 72 
2.3  Opening the configuration interface ...................................... 78 
2.4  Logging into the device ........................................................... 80 
2.5  Saving the parameters permanently ..................................... 80 
Maintenance and repairs .................................................................................. 81 
1  Monitoring and cleaning work ............................................................... 82 
1.1  Control measurements ........................................................... 82 
1.2  Visual inspection ..................................................................... 83 
1.3  Cleaning the volume measurement devices ......................... 84 
1.4  Checking the measuring wheel encoder components ......... 85 
1.5  Cleaning the photoelectric retro-reflective sensor ................ 86 
1.6  Keeping the cabinets cool ...................................................... 86 
2  Replacing components .......................................................................... 88 
2.1  Replacing the volume measuring device .............................. 88 
2.2  Replacing the measuring wheel encoder .............................. 90 
2.3  Replacing the photoelectric retro-reflective sensor .............. 91 
Fault diagnosis ................................................................................................... 92 
1  Response to errors................................................................................. 92 
2  SICK Support .......................................................................................... 92 
3  Fault indicators of the components ...................................................... 92 
4  Troubleshooting for the SIC2000.......................................................... 93 
4.1  Checking the trigger ................................................................ 93 
4.2  Checking the incremental encoder ........................................ 94 
4.3  Checking CAN cabling ............................................................. 95 
5  Faults during operation ......................................................................... 96 
6  Detailed fault analysis ........................................................................... 97 
6.1  The status log .......................................................................... 97 
6.2  Checking the status log with SOPAS ...................................... 97 
Appendix .............................................................................................................. 98 
1  Technical data ........................................................................................ 98 
1.1  Data sheet ............................................................................... 98 

CONTENTS

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9.1.2 Dimensional drawings of the volume measurement

devices ..................................................................................... 99

9.2 Compliance with EU directives ............................................................ 100

10 Disposal ............................................................................................................. 101

1 ABOUT THIS DOCUMENT

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1 About this document

Please read this chapter carefully before you begin working with this documentation and

the VMS4200 / VMS5200.

1.1 Purpose of this document

These operating instructions guide technical personnel in the safe mounting,

parameterization, electrical installation, commissioning, operation, and maintenance of

the VMS4200 / VMS5200 volume measurement system.

1.2 Abbreviations used

Controller Area Network = standardized fieldbus system that uses a message-based

data exchange protocol

Light emitting diode

Laser measurement scanner = 2D LiDAR sensor from SICK AG

Random Access Memory = direct-access volatile memory

SICK OPEN PORTAL for APPLICATION and SYSTEMS Engineering Tool = software for

configuring the VMS4200 / VMS5200

Volume Measurement System from SICK AG

1.3 Symbols used

Recommendations are designed to assist you in the decision-making process with respect

to the use of a certain function or technical measure.

Notes provide information about the features of a device, application tips, or other useful

information.

Instructions requiring specific action are indicated by an arrow. Carefully read and follow

the instructions for action.

LED icons describe the status of a diagnostics LED. Examples:

 The LED is illuminated continuously.

 The LED is flashing.

 The LED is off.

CAN

LED

LMS

RAM

SOPAS ET

VMS

Recommendation

Note



  , 

ON SAFETY 2

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2 On safety

This chapter concerns your own safety and the safety of the system operator.

▸

Please read this chapter carefully before you begin working with the volume

measurement system.

2.1 Qualified safety personnel

The volume measurement system must only be mounted, commissioned, and maintained

by properly qualified safety personnel.

The following qualifications are necessary for the various tasks:

Activities

Qualification

Mounting and

maintenance

 Practical technical training

 Knowledge of the current safety regulations in the workplace

Electrical installation

and device replacement

 Practical electrical training

 Knowledge of current electrical safety regulations

 Knowledge of device control and operation in the particular

application concerned (e.g., conveying system, etc.)

Commissioning,

operation, and

configuration

 Knowledge of the operation and control of the devices in their

particular application (e.g., conveying system)

 Knowledge concerning the software and hardware environment of

the particular application concerned (e.g., conveying system)

 Basic knowledge of the Windows operating system used

 Basic knowledge of data transmission

 Basic knowledge of the design and setup (addressing) of Ethernet

connections when connecting the system to the Ethernet

Table 1Qualified safety personnel

2.2 Intended use

The VMS4200 / VMS5200 volume measurement system is used to measure cubic and

non-cubic objects on flat conveying systems in industrial environments.

The objects must be dimensionally stable, opaque, and non-reflective.

The VMS4200 / VMS5200 determines length, width, and height, and can calculate the

volume of the smallest enveloping cuboid (box volume) using these values.

All measurement results are transferred to the customer network via the data interface of

the SIM2000 control unit.

The VMS5200 volume measurement system is verified as legal for trade and can be used

for billing purposes.

WARNING

Danger due to intended use

Intended use of the system can lead to danger to the life and limb of persons and damage

to the plant in which the system is integrated.

▸

The system should only be used in line with the intended use.

▸

The system should not be used outdoors or in an explosion-protected environment.

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2.3 General safety notes and protective measures

2.3.1 Safety notes and symbols

The following safety and hazard information is for your own safety, for the safety of third

parties, and for the protection of the volume measurement system. You should therefore

observe them at all times.

DANGER

Denotes an immediate hazard that may result in severe to fatal injuries.

The symbol shown on the left-hand side of the note refers to the type of hazard in

question (the example here shows a risk of injury resulting from electrical current).

WARNING

Denotes a potentially dangerous situation that may result in severe to fatal injuries.

The symbol shown on the left-hand side of the note refers to the type of hazard in

question (the example here shows a risk of injury resulting from falling components).

CAUTION

Caution note

Denotes a potentially dangerous situation that may result in minor personal injury or

possible material damage.

The symbol shown on the left-hand side of the note refers to the type of hazard in

question (the example here shows a risk of damage to the eye by laser beams).

NOTE

Denotes a potential risk of damage or functional impairment of the device or the devices

connected to it.

This symbol refers to supplementary technical documentation.

ON SAFETY 2

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2.3.2 General safety notes

General, recognized safety-related rules and regulations were taken into account in the

design and manufacture of the volume measurement system. However, risks for the user

resulting from the system cannot be completely ruled out. The safety notes below must

therefore be observed.

WARNING

Observe the following to ensure the safe use of the system as intended.

 The notes in this documentation must be complied with.

 All official and statutory regulations governing the operation of the system must be

complied with.

 The national and international legal specifications apply to the installation and use of

the system, to its commissioning, and to recurring technical inspections, in particular:

– The accident prevention regulations and work safety regulations

– Any other relevant safety regulations

 The manufacturer and user of the system are responsible for coordinating and

complying with all applicable safety specifications and regulations in cooperation with

the relevant authorities.

 The checks must be carried out by qualified safety personnel or specially qualified and

authorized personnel, and must be recorded and documented to ensure that the tests

can be reconstructed and retraced at any time.

 These operating instructions must be made available to the operator of the system.

The system operator must be instructed by qualified safety personnel and must read

the operating instructions.

 Maintenance and repair work may only be performed by trained and authorized SICK

AG service technicians or qualified safety personnel of the customer.

2.3.3 Additional operating instructions

Other operating instructions of the individual components are enclosed along with this

system description.

▸

When working on or with the system components, please observe the notes in the

relevant operating instructions.

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2.3.4 Dangers connected with handling of the system

Awareness of potential hazardous points in the system will help you to work in a safer

manner and thus prevent accidents.

Dangers due to electrical current

DANGER

Risk of injury due to electrical current

Electrical voltage can cause severe personal injury or death by electric shock.

▸

Electrical installation work may only be carried out by electrically qualified persons.

▸

Be sure to disconnect the voltage supply before attaching or detaching any electrical

connections.

▸

Only connect the system to a voltage source that meets the technical requirements.

▸

National and regional regulations must be complied with.

▸

Safety requirements relating to work on electrical systems must be complied with.

DANGER

Dangerous equipotential bonding currents

As a result of possible equipotential bonding currents between the device and other

earthing devices in the system, faulty earthing of the device can give rise to the following

dangers and faults:

 Dangerous voltages on the metal housing, e.g., of the laser scanner.

 Incorrect functioning of or irreparable damage to the devices

 Damage/irreparable damage to the cable shields due to heating and cable fires.

Measures

▸

Only skilled electricians should be permitted to carry out work on the electrical system.

▸

Ensure that the ground potential is the same at all grounding points.

▸

If the cable insulation is damaged, disconnect the voltage supply immediately and have

the damage repaired.

▸

Where local conditions are unfavorable and thus do not meet conditions for a safe

earthing method (same ground potential at all grounding points), take measures in

accordance with the following explanations.

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Danger due to laser light

WARNING

Damage to the eye by laser beams

The LMS4xxx volume measurement devices work with red, class-2 lasers.

The human eye is not at risk when briefly exposed to the radiation for up to 0.25 seconds.

Exposure to the laser beam for longer periods of time may cause damage to the retina.

The laser radiation is harmless to human skin.

The laser output aperture is the front screen of the devices.

Fig.1: Laser output aperture of the laser scanner

▸

Do not look into the laser beam intentionally.

▸

Never point the laser beam at people’s eyes.

▸

If it is not possible to avoid looking directly into the laser beam, e.g., during

commissioning and maintenance work, suitable eye protection must be worn.

▸

Avoid laser beam reflections caused by reflective surfaces. Be particularly careful

during mounting and alignment work.

▸

Do not open the housing. Opening the housing will not switch off the laser. Opening the

housing may increase the level of risk.

▸

Applicable national regulations regarding laser protection must be observed.

Measures

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The laser warning labels are located on the respective devices.

Fig.2: Laser warning labels

No.

Meaning

1

Avoid exposure – Laser radiation is emitted from this aperture.

Laser output aperture corresponds to the front screen at the height of the position

shown.

2

Caution – Laser radiation when open. Do not stare into beam.

3

Laser radiation – Do not stare into beam. Class 2 laser product

Average output radiation: 13.5 mW

Maximum output radiation: 27 mW

Wavelength: 660 nm

IEC60825-1:2014

Complies with 21CFR 1040.10 and 1040.11 except for deviations pursuant to Laser

Notice No. 50, dated June 24, 2007.

4

Warning symbol: Laser radiation

5

Do not remove – Laser radiation hazard and danger of personal injury in case of

removal.

 “RADIATION – DO NOT STARE INTO BEAM” is to be replaced with a warning label in a

language that the operators of the system understand. Laser warning labels in German

and French are included in the scope of delivery.

 If the device is installed in a system/casing in way that means that the warning labels

are covered, other warning labels (not included with delivery) must be attached to the

system/casing next to the laser output aperture.

 When operating with the trigger, the laser diode is switched on by the switch-on signal

and switched off again by the deactivation signal. When free output of measured

values is set, the laser diode is continuously on.

 The device automatically monitors beam generation and automatically shuts down the

laser diode in the event of irregularities. If this happens, the red “Status” LED lights up.

The device stops sending measured values and an entry is added to the error memory.

Laser warning labels

Notes

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Dangers when mounting

WARNING

Risk of injury due to components tipping over

If profiles of the mounting frame have been upended, they could possibly tip over during

disassembly.

▸

Do not do mounting work alone.

▸

Ask a second person to assist you. during mounting where necessary.

▸

Wear safety shoes.

Risks during operation

WARNING

Risk of injury and/or material damage caused by incorrect operation.

Risk of injury and/or material damage due to absence of qualification and/or incorrect

and non-intended use.

▸

Observe the notes on intended use.

▸

Only use the plant in perfect working order and for its intended purpose, keeping safety

and potential dangers in mind, and in compliance with the system documentation.

WARNING

Danger due to malfunction!

Cease operation if the cause of the malfunction has not been clearly identified.

▸

Take the system out of operation if an error cannot be clearly identified and safely

remedied.

Risks during maintenance

and repair work

NOTE

Repair work on the individual components may only be performed by qualified and

authorized service personnel.

NOTE

Claims under the warranty rendered void

If the device is opened, any warranty claims against SICK AG will be void.

▸

Do not open the device housing.

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2.4 RoHS Directive

This system has been designed for specific applications in 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 suited for nor certified for use outside of these plants. SICK

therefore cannot assume any type of warranty or liability for such use.

SYSTEM DESCRIPTION 3

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3 System description

This chapter describes the design and operating principle of the system.

3.1 Scope of delivery

NOTE

▸

It is recommended that you carefully check for and report transport damage of any kind

as soon as possible after receiving the system.

▸

Also verify that the delivery includes all components listed on the delivery note.

System components

 2 LMS4421R-16000 volume measurement devices with laser protective cover

(VMS4200) or

2 LMS4521R-16000 volume measurement devices with laser protective cover

(VMS5200 MID)

 1 LFT display (only VMS5200)

 1 SIC2000 cabinet with SIM2000 controller, voltage supply module, and Ethernet

switch

 1 measuring wheel encoder with mounting kit (e.g., DFV60, DBS36)

 1 modular mounting set

 2 beam blockers

 Connecting cables

Optional

 1 photoelectric retro-reflective sensor for triggered systems (e.g., WL18-3 or WL27-3)

3 SYSTEM DESCRIPTION

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3.2 Structure of the volume measurement system

3.2.1 System components

The VMS4200 / VMS5200 volume measurement system consists of two LMS4xxx volume

measurement devices, an LFT display, a measuring wheel encoder, and a cabinet

containing the SIM2000 control unit.

Systems for which measuring is triggered via a signal also have a photoelectric retro-

reflective sensor as an accessory.

Fig.3: System components

No.

Meaning

1

LMS4xxx volume measurement devices with laser protective cover

2

LFT display

3

Cabinet with SIM2000 control, voltage supply unit, and Ethernet switch

4

Measuring wheel encoder (e.g., DFV60)

5

Photoelectric retro-reflective sensor for triggered systems (e.g., WL-18-3)

All system components are mounted on a frame provided by the customer according to

the technical drawing. The volume measurement devices are mounted using a mounting

system included in the scope of delivery, which is attached to the frame.

Additional glare protection on the frame (beam blocker) prevents objects located outside

of the measuring range from being taken into account when calculating the measured

values.

The figures in these operating instructions show the mounting set consisting of a width-

adjustable telescopic tube with pre-mounted attachment mechanism for the volume

measurement devices and for mounting to a frame provided by the customer.

Note

SYSTEM DESCRIPTION 3

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The VMS4200 / VMS5200 volume measurement system consists of two LMS4xxx volume

measurement devices, which are mounted on the left and right above the conveying

equipment. The volume measurement devices configured as master and slave scan the

object and transmit the detected measuring points to the SIM2000 control unit.

Fig.4: Volume measurement devices

No.

Meaning

1

LMS4xxx master

2

LMS4xxx slave

3

Modular mounting set

The officially verifiable VMS5200 volume measurement system also has a separate LFT

display to show the measurement results, status information, the firmware version, and

the logbook (version history).

The measuring wheel encoder mounted below the conveyor belt is needed for position

determination of the object on the conveyor belt and for the calculation of the 3D model.

As part of this process, the encoder sends two incremental signals to the controller –

there is a 90-degree phase shift between the signals.

Measurement is performed directly on the running surface of the conveyor belt using a

precise measuring wheel, which is mounted on a spring-loaded arm.

Fig.5: Measuring wheel encoder (e.g., DFV60)

No.

Meaning

1

Running surface of the conveyor belt

2

Measuring wheel

3

Spring-loaded mounting arm

Volume measurement

devices

LFT display

Measuring wheel

encoder

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In the case of systems for which measuring is triggered, an additional photoelectric retro-

reflective sensor with reflector attached before the measuring field also provides a trigger

signal. The trigger signal activates the sensors and opens the internal reading gate. The

photoelectric sensor trigger is optionally available.

Fig.6: Photoelectric retro-reflective sensor with reflector (e.g., WL18-3)

No.

Meaning

1

Photoelectric retro-reflective sensor (e.g., WL18-3)

2

Reflector

The cabinet contains the SIM2000, which is the central control unit of the volume

measurement system, the voltage supply unit with fuse module for supplying voltage to

the components, and an Ethernet switch as the central interface for the sensor network.

In the case of the officially verifiable VMS5200, the SIM2000 also contains the legally

relevant memory (alibi memory) for the entire system.

Fig.7: SIC2000 cabinet

No.

Meaning

1

SIM2000 controller (for the VMS5200 with alibi memory)

2

Voltage supply unit with fuse modules

3

Ethernet switch

Photoelectric sensor

trigger

Cabinet

SYSTEM DESCRIPTION 3

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3.2.2 Expanding the system with a reading station

The VMS4200 / VMS5200 volume measurement system can be expanded to include a

reading station. The reading station allows automated identification of objects by reading

their bar codes, which in turn enables faster process automation. Depending on the

application case, this station can consist of scanners, cameras and/or a combination of

both in any desired arrangement.

The devices are connected to the volume measurement system via the CAN bus of the

SIM2000 controller. The controller links the acquired identification data with the

dimensional values calculated by the VMS4200 / VMS5200 and outputs both data types

to the higher-level system.

Fig.8: Expanding the system with a reading station

The volume measurement system can also supply the focus information for the connected

camera systems.

Note

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3.3 Operating principle of the volume measurement system

The VMS4200 / VMS5200 volume measurement system measures cubic and irregularly

shaped objects that are moved past the measuring station on flat conveying systems.

3.3.1 Operating modes

The volume measurement system can either be in free-running or triggered operating

mode.

In free-running mode, the volume measurement system detects the objects to be

measured itself. The measurement starts when an object enters the scanning line of the

volume measurement devices. It ends when the object leaves the scanning line.

Fig. 9: Free-running operating mode

In triggered mode, the object is detected via a trigger signal, not automatically. The trigger

signal can be triggered by the entry of the object into the path of a photoelectric retro-

reflective sensor or via a customer-controlled digital signal.

The trigger signal activates the volume measurement devices and opens the internal

reading gate. The reading gate determines the start and the end of the measuring

process. It corresponds to the trigger length in the conveying direction. The measuring

process lasts for as long as the reading gate is open, regardless of whether the object is

entering the scanning line or leaving it.

Fig. 10: Triggered operating mode

Object detection via a trigger signal also reliably detects very flat objects.

Free-running operating

mode

Triggered operating

mode

Note

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