MMMI MMMSYSTEM DESCRIPTION - SICK Germany

MMMIMMMSYSTEM DESCRIPTIONS Y S T E M D E S C R I P T I O N

ALISAirport Luggage Identification System

Track and Trace Systems

2 8027605/V1-0/2022-03| SICKS Y S T E M D E S C R I P T I O N | ALISSubject to change without notice

Described Product

ALISAirport Luggage Identification System

Manufacturer

SICK AGErwin-Sick-Str. 1D-79183 WaldkirchGermany

Production Location

SICK AG AGGisela-Sick-Str. 1D-79276 ReuteGermany

Legal Information

This work is protected by copyright. Any rights derived from the copyright shall be reserved for SICK AG. Reproduction of this document or parts of this document is only permissible within the limits of the legal determination of Copyright Law. Any modification, reduction or translation of this document is prohibited without the express written permission of SICK AG.

The trademarks stated in this document are the property of their respective owner.

© SICK AG. All rights reserved

Original Document

This document is an original document of SICK AG.

CONTENT

38027605/V1-0/2022-03| SICK S Y S T E M D E S C R I P T I O N | ALISSubject to change without notice

1 About this Document ................................................................................ 71.2 Purpose of this Document ..............................................................................71.3 Target Group....................................................................................................71.4 Further Information.........................................................................................71.5 Additional Technical Documentation/Information ........................................81.6 Document Conventions...................................................................................9

2 Important Safety Instructions ................................................................112.1 Intended Use .................................................................................................112.2 Supplemental Directives...............................................................................112.3 Requirements for the Qualification of Personnel ........................................112.4 Potential Hazards..........................................................................................122.5 Protective Devices.........................................................................................142.6 System Warranty ...........................................................................................142.7 RoHS-Directive ..............................................................................................142.8 Safety Conventions .......................................................................................152.9 Warning Signs on System Components .......................................................152.10 Mandatory Signs ...........................................................................................16

3 Systems Description................................................................................173.1 ALIS Laser - Laser Based Bar Code Reading System ..................................183.2 ALIS - Matrix Camera based Bar Code Reading System .............................19

3.2.1 ALIS Camera - Camera System with 8 Matrix Cameras and 2 Laser Scanners .......................................................................................19

3.2.2 ALIS Camera - Camera System with 10 Matrix Cameras ............203.2.3 ALIS Vision - Camera System with OCR&VC.................................20

3.3 ALIS RFID - Radio Frequency Identification System ....................................213.4 ALIS - Hybrid ..................................................................................................22

3.4.1 RFID and Laser Scanner Reading System...................................223.4.2 RFID Camera and Laser Reading System....................................23

3.5 General Information ......................................................................................243.5.1 Integration Into Customer System ...............................................243.5.2 Bar Code/RFID tag Specification .................................................253.5.3 System Ambient Data ...................................................................253.5.4 System Redundancy .....................................................................25

4 System Components ...............................................................................274.1 Laser Bar Code Scanner ...............................................................................27

4.1.1 CLV691 Laser Bar Code Scanner ................................................274.1.2 CLV691 Laser Bar Code Scanner with Mirror Hood ....................284.1.3 CLV691 Laser Bar Code Scanner with Cleaning Unit..................294.1.4 CLV651 Laser Bar Code Scanner (Option) ..................................30

4.2 Image-Based Code Reader ...........................................................................314.2.1 Lector654 Image-Based Code Reader ........................................314.2.2 Lector654 Image-Based Code reader with Mirror.......................32

Content

CONTENT


4.3 RFID............................................................................................................... 334.3.1 RFU630 - RFID Read Device ........................................................ 334.3.2 Modules with/without Antenna ................................................... 34

4.4 Cabinet incl. Controller ................................................................................. 354.5 Reflection Light Barrier - Trigger Signal ...................................................... 364.6 Incremental-Encoder DFV60 ........................................................................ 374.7 Accessories (option) ..................................................................................... 38

4.7.1 CDF600-2200 Field Bus Module (Option)................................... 384.7.2 Network Camera........................................................................... 394.7.3 Signal Lamp.................................................................................. 39

5 Transport, Setup and Mounting.............................................................415.1 Check Delivery .............................................................................................. 415.2 Transport and Setup..................................................................................... 41

6 Electrical Installation...............................................................................436.1 Connection Overview CLV691 - ALIS Laser ................................................. 446.2 Connection Overview Lector654 - ALIS Camera.......................................... 456.3 Connection Overview - ALIS RFID................................................................. 46

7 Commissioning ........................................................................................47

8 Operation ..................................................................................................498.1 System Start ................................................................................................. 498.2 Check operational readiness ....................................................................... 49

8.2.1 CLV691 Bar Code Scanner .......................................................... 498.2.2 CLV651 Bar Code Scanner .......................................................... 498.2.3 Lector654 Code Reader............................................................... 508.2.4 RFU630......................................................................................... 508.2.5 MSC800 System Controller ......................................................... 508.2.6 System Readiness........................................................................ 508.2.7 Automated Operating Mode......................................................... 51

8.3 System End ................................................................................................... 528.3.1 Stopping the Conveying Syste, .................................................... 528.3.2 Interrupting the Voltage Supply ................................................... 53

9 Maintenance and Repair ........................................................................559.1 Regular Control Measurement ..................................................................... 569.2 Visual Control ................................................................................................ 569.3 Cleaning Instructions.................................................................................... 56

9.3.1 Cleaning the CLV691/CLV651 .................................................... 569.3.2 Cleaning the Cleaning Unit for CLV691....................................... 579.3.3 Cleaning the Lector654 ............................................................... 589.3.4 Cleaning the Cabinet.................................................................... 599.3.5 Cleaning the Trigger ..................................................................... 599.3.6 Cleaning the Encoder ................................................................... 60

CONTENT


9.4 Components Replacing.................................................................................619.4.1 CLV691 Replacing ........................................................................619.4.2 CLV651 Replacing ........................................................................639.4.3 Lector654 Replacing ....................................................................659.4.4 MSC800 System Controller Replacing.........................................679.4.5 MSC800 Battery Replacing ..........................................................689.4.6 Power Supply Unit Replacing........................................................699.4.7 Photoelectric Retro-Refelctive Sensor Replacing........................709.4.8 Incremental Encoder Replacing ...................................................71

10 Fault Diagnosis.........................................................................................7310.1 Lector654......................................................................................................7310.2 CLV691 ..........................................................................................................7310.3 CLV651 ..........................................................................................................7410.4 MSC800 System Controller ..........................................................................74

10.4.1 MSC800 System Controller Check...............................................7510.4.2 Detailed Fault Analysis .................................................................76

11 Dimensional Drawings............................................................................7711.1 ALIS Laser- Laser Based Bar Code Reading System ...................................7711.2 ALIS Camera - Camera Based Bar Code Reading System...........................79

11.2.1 ALIS Camera - Camera System with 8 Matrix Cameras and 2 Laser Scanner .........................................................................................79

11.2.2 ALIS Camera - Camera System with 10 Matrix Cameras ............8111.3 ALIS RFID - Radio Frequency Identification System ....................................8311.4 ALIS - Hybrid ..................................................................................................85

11.4.1 RFID and Laser Scanner Reading System...................................8511.4.2 RFID Camera and Laser Scanner Reading System .....................87

12 Disposal.....................................................................................................89

CONTENT


78027605/V1-0/2022-03| SICK AG S Y S T E M D E S C R I P T I O N | ALISSubject to change without notice

ABOUT THIS DOCUMENT 1

1 About this Document

1.1 Limitation of Liability

1.2 Purpose of this Document

This document describes the ALIS - Airport Luggage Identification Systems.

1.3 Target Group

This document is intended for qualified personnel which are authorized to work on the ALIS.

1.4 Further Information

Special local conditions

Follow all local laws, technical rules, and company-internal operating directives applicable at the respective installation site of the ALIS.

Preserving the documents

This document and the additional technical documentation and information must be:

● Available for reference.● Passed on to new system operator or new employees.

NoteThis document regarding the ALIS - Airport Luggage Identification System:

● contains information required during the life cycle of the system.● is available to all those people who work with the system.● read this document carefully and make sure that you understand the content fully

before working with the system.

NoteAll information and notes in this document have been compiled in accordance with the applicable standards and regulations, the state of the art and the manufacturer's many years of knowledge and experience.

It is therefore pointed out that the manufacturer assumes no liability, particularly in the following cases:

● Non-compliance with this document.● Failure to comply with instructions and regulations.● Unauthorized assembly and installation.● Unauthorized technical and other modifications.● Use of spare parts, wearing parts and accessories not approved by the manufacturer.● Unauthorized changes, adjustments and/or manipulations of software.● Non-performance of regular maintenance work and its documentation.

The actual scope of delivery may deviate from the features and illustrations described here in the case of special designs, the use of additional ordering options or due to the latest technical changes.


1 ABOUT THIS DOCUMENT

1.5 Additional Technical Documentation/Information

● Technical System-Documentation:– Wiring diagram– Technical drawings

● Original SICK operating instructions for optional products and components can be found at www.sick.com

ID-Number Components Manufacturer8016185 Lector64x/65x - Image-Based Code Readers SICK8014335 RFU63x - RFID read/write device (UHF) SICK8014396 CLV69x - Bar Code Scanners SICK8019588 CLV65x - Bar Code Scanners SICK8015922 CDF600-2200 - PROFINET IO (Option) SICK8013709 DFV60 - Incremental Encoder SICK8011540 MSC800 - Modular System Controller SICK

98027605/V1-0/2022-03| SICK AG S Y S T E M D E S C R I P T I O N | ALISSubject to change without notice

ABOUT THIS DOCUMENT 1

1.6 Document Conventions

Required tools▸ InstructionInstruction result

All units of measurement in this document are originally metric units.

Subject to change without notice.

Images might differ from actual design.

Refer to another document.


1 ABOUT THIS DOCUMENT


IMPORTANT SAFETY INSTRUCTIONS 2

2 Important Safety Instructions

2.1 Intended Use

With the ALIS (Airport Luggage Identification System) track and trace system, luggage can be clearly identified as it is transported quickly and reliably through the airport and thus reaches the right sorting zone.

Designed like a reading interval gate, SICK has developed ALIS specifically with luggage handling services in mind. The system is extremely reliable when it comes to reading luggage information on IATA bar codes and/or RFID tagged labels.

With ALIS, SICK has created a modular system which can be specially adapted to suit the various requirements of airport luggage identification and handling processes, whether this involves sensors, visualization software, or even the commissioning process.

Intended use also includes compliance with this system information, especially the sources of danger.

2.2 Supplemental Directives

▸ Before working on the ALIS, read this document carefully and follow all safety instruc-tions and information.

▸ Only qualified persons from the respective areas are permitted to work on the ALIS.▸ Follow operating procedures.▸ Follow local regulations.▸ Observe local regulations for working with gas and electrical components.▸ Access to the ALIS is restricted to authorized personnel only.

System damage/transport damage

▸ Damage to individual components can lead to malfunctions of the entire system.▸ Do not ignore system components damaged during transport.▸ In the event of damage, contact SICK Service.

2.3 Requirements for the Qualification of Personnel

Only qualified personnel from the respective field are permitted to work on the system.

● Qualified personnel have the specialist training, skills, and experience, as well as know-ledge of the relevant regulations and standards, to be able to perform tasks delegated to them and to detect and to avoid any potential dangers independently.

● Electricians have the specialist training, skills, and experience, as well as knowledge of the relevant standards and provisions to be able to carry out work on electrical systems and to detect and avoid any potential dangers independently.


2 IMPORTANT SAFETY INSTRUCTIONS

2.4 Potential Hazards

Optical radiation Laser class 1

The Lector65x camera-based code readers have a targeting laser as a setup aid.

The accessible radiation does not pose a hazard even when viewed directly for long periods of time, (time base 100 seconds). In the case of visible lasers (red), temporary irritating optical effects on the human eye (e.g. glare, flash blindness, afterimages, impairment of color vision) cannot be completely ruled out, especially at low ambient brightness.

▸ Do not look into the switched-on light source. ▸ Do not look directly at the laser with optical instruments (magnifying glasses, micro-

scopes). ▸ Observe current national regulations on laser protection.

Optical radiation Laser class 2

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.

▸ 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 commission-

ing 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 may increase the level of risk.▸ Current national regulations regarding laser protection must be observed.

Optical radiation LED light (RG2)

Camera system and the integrated LED illumination of the Lector65x use LEDs of the RG2 risk group.

The optical radiation can cause serious eye injuries if the following points are not observed:

▸ Do not look into the light source for extended periods of time.▸ Do not point the light source at people and prevent reflections of the light source from

reflective surfaces onto people.▸ During commissioning or maintenance work, suitable eye protection must be worn.▸ Do not open the housing.▸ Comply with the recent national version of the applicable standards on photobiological

safety of lamps and lamp systems.

Electric voltage

Touching live devices, which may still be energized, can lead to death, burns or electrical shock.▸ Electrical work may only be performed on the system by qualified specialist personnel.▸ Before working on electrical components, observe the five safety rules:

▸ Disconnect.▸ Secure against being switched back on.▸ Ensure that there is no voltage.▸ Ground and short-circuit.▸ Cover or enclose live parts in the vicinity.



Hot surfaces

Components can be hot. Contact may cause burn and serious injuries.▸ Do not touch hot surfaces.▸ Use appropriate safety gloves.

Suspended loads

▸ Never enter the area under suspended loads.▸ Pay close attention when lifting loads.▸ Comply with lifting instructions to prevent injuries and accidents.▸ Use suitable, undamaged lifting tools.▸ Wear personal protective equipment (safety helmet, safety shoes).



2.5 Protective Devices

The ALIS systems are designed in a way that allows for safe operation. Protective devices reduce potential risks to the maximum possible extent.

Side panels prevent the bags from falling.

2.6 System Warranty

Any warranty claim expires if:

▸ Safety instructions and measures in this document are not observed.▸ Parts or components of the Continuous Emission Monitoring System are installed,

assembled or modified without authorization.▸ The ALIS is changed or modified.▸ Software is changed, adapted and/or manipulated without authorization.

2.7 RoHS-Directive

This product is designed for applications in large industrial plants according toArticle 2 (4) e, RoHS 2011/65/EU and can therefore only be used in such systems.

The product is neither suitable nor approved for use outside of these systems.SICK cannot assume any kind of warranty or liability for use outside of these systems..



2.8 Safety Conventions

The warnings used in this manual have the following meanings:

2.9 Warning Signs on System Components

Do not remove or cover warning stickers. Damaged or missing stickers must be replaced.

DANGERIndicates a hazardous situation which, if not avoided, will result in death or serious injury.

WARNINGIndicates a hazardous situation which, if not avoided, could result in death or serious injury.

CAUTIONindicates a hazardous situation which, if not avoided, could result in minor or moder-ate injuries.

NOTICEIndicates a situation which that can lead to material damage if not avoided.

Sign Significance

Warning of a danger point

Warning of dangerous electrical voltage

Warning of laser light / LED light

Warning of hot surfaces

Warning of suspended loads



2.10 Mandatory Signs

Mandatory signs indicate a measure that is required to protect personal health and / or avoid the risk of personal injury.

Mandatory signs on the system must not be removed or covered. Damaged or missing mandatory signs (stickers) must be replaced.

Sign SignificanceRead instructions manual

Wear safety gloves

Wear eye protection

Wear hard hat

Wear safety boots

Disconnect before maintenance or repair


SYSTEMS DESCRIPTION 3

3 Systems Description

The ALIS is a fully automatic reading gate including frame, scan heads with on-board decoder, local network controller and host communication for reading bar codes on flight baggage, which in turn is located e.g. on conveyor belts, cross belts or tilt tray sorter sys-tems.

The local network-controller incorporates a controller for the local scanner-network, opto-isolated digital diagnostic software, flexible HOST-Interface and an interface supplying diag-nostic data to the Diagnostic Tool “Baggage Analytics” or "Logistics Diagnostic Analytics". More information about the diagnostic software can be found on SICK.com.

The HOST-interface can be adapted to customers specific requirements in terms of HOST-Protocol and physical interface.

The complete system consists of a certain amount of bar code readers or/and RFID reader and antennas - depending on the application -, the control unit MSC800 unit, photoelectric switches for object-trigger, cables and an increment encoder for measuring the conveyor speed.

System Types

● ALIS Laser - Laser based bar code reading● ALIS Cam - Matrix cameras based bar code reading, two versions:

– with 10 matrix cameras, 2 of them for bottom reading– with 8 matrix cameras and 2 laser scanners for bottom reading

● ALIS RFID - Reading and assignment of RFID tags● ALIS Hybrid - combination of RFID and further identification readers, two versions:

– with RFID and laser scanners– with RFID and matrix cameras


3 SYSTEMS DESCRIPTION

3.1 ALIS Laser - Laser Based Bar Code Reading System

Fig. 1: Components of the 6 side ALIS reading gate based on laser scanners

Legend1 Eight CLV691 fixed mount bar code scanner2 Cabinet with controller and power supply unit3 Field bus module for PROFINET (optionally)4 Two CLV691 fixed mount bar code scanner with cleaning unit

optionally 3 - 4 CLV651 fixed mount bar code scanners with cleaning unit and connection unit

5 Incremental signal6 Trigger signal



3.2 ALIS - Matrix Camera based Bar Code Reading System

3.2.1 ALIS Camera - Camera System with 8 Matrix Cameras and 2 Laser Scanners

Fig. 2: Components of the 6 side ALIS reading gate based on Lectors654 and 2 CLV691

Legend1 Eight Lector654 image based code reader2 Cabinet with controller, power supply and Ethernet switch3 Field bus module for PROFINET (optionally)4 Two CLV691 fixed mount bar code scanner with cleaning unit

optionally 3 - 4 CLV651 fixed mount bar code scanners with cleaning unit and connection unit

5 Incremental signal6 Trigger signal



3.2.2 ALIS Camera - Camera System with 10 Matrix Cameras

Fig. 3: Components of the 6 side ALIS reading gate based on Lector654

3.2.3 ALIS Vision - Camera System with OCR&VC

The ALIS camera can be supplemented with optical character recognition and/or video coding.This makes up the ALIS Vision. In the event that the baggage source message is missing, the data (flight number, destination code, license plate number) that is relevant to sorting can be read on the baggage tag in conjunction with OCR or VC. Less manual reprocessing of the baggage item is required.The number of bags going to the manual encoding station is further reduced. This results in a higher sorting rate and optimizes the process time of transfer bags.

Legend1 Eight Lector654 image based code reader2 Cabinet with controller, power supply and Ethernet switch3 Field bus module for PROFINET (optionally)4 Two Lector654 with cleaning unit5 Incremental signal6 Trigger signal



3.3 ALIS RFID - Radio Frequency Identification System

Fig. 4: Components of the ALIS RFID

Legend1 Absorber modules with integrated antenna.

The remaining modules are without antennas 2 Bottom antenna mounted between conveyor bed and conveyor belt3 RFU630 read/write device4 Cabinet with controller and power supply unit5 Incremental signal6 Trigger signal



3.4 ALIS - Hybrid

3.4.1 RFID and Laser Scanner Reading System

Fig. 5: Components of the ALIS RFID - Laser combination


The remaining modules are without antennas.2 Bottom antenna mounted between conveyor bed and conveyor belt3 Side guards must not be made of metal

(not included in SICK scope of delivery)4 Eight CLV691 fixed mount bar code scanner5 Cabinet with controller and power supply unit6 RFU630 read/write device7 Two CLV691 fixed mount bar code scanner with cleaning unit 8 Incremental signal9 Trigger signal



3.4.2 RFID Camera and Laser Reading System

Fig. 6: Components of the ALIS RFID, camera and Laser combination


The remaining modules are without antennas.2 Bottom antenna mounted between conveyor bed and conveyor belt3 Side guards must not be made of metal

(not included in SICK scope of delivery)4 Eight Lector654 image based code reader5 Cabinet with controller and power supply unit6 RFU630 read/write device7 Two CLV691 fixed mount bar code scanner with cleaning unit 8 Incremental signal9 Trigger signal



3.5 General Information

3.5.1 Integration Into Customer System

Fig. 7: Integration in customer system

Conveyor Systems

A conveyor system provided by the system integrator conveys the objects to the reading sta-tion of the track and trace system.

The bar code reading can be realized by top, front, rear, side and underbelt mounted scan-ners or cameras.

For underbelt reading the recommended belt gap is:

– with laser scanners of 50mm– with cameras of 80mm

Legend1 Track and trace system (example)2 Conveyor technology provided by customer3 Inbound conveyor4 Outbound conveyor

NoteFor standard systems, the conveyor must be straight. However, it is also possible to install systems in curves, but these are then customized.



3.5.2 Bar Code/RFID tag Specification

Bar Code

● Bar code must be according to IATA Resolution 740, Attachment ‘B’ / chapter 2.Large Sortation Bar Code Specification

● Symbology: interleaved 2 of 5● Module width: 0,508mm / Tolerance: +/- 5%● Bar height: min. 48mm● Quiet zone: min. 7 times module width / preferred: 10 times module width● Orientation: horizontal, vertical or orthogonal. Preferred: orthogonal● Print contrast signal: not less then 80% at wavelength of 633nm

RFID tag

● The RFID tag must be compliant with the requirements of IATA RP 1740C

3.5.3 System Ambient Data

● Ambient operating temperature from 0° to 40°C / upon request 50° C possible● Permissible relative humidity max. 90%, non-condensing● Ambient light immunity 2000 lx on bar code

3.5.4 System Redundancy

In a redundant system two controllers MSC800 are running simultaneously. One MSC is parameterized as "Primary controller" and the other one as "Secondary controller".

This assignment is static and will never change during operation. The controller can be in the operation mode ACTIVE or STANDBY. In normal operation mode the primary controller is in ACTIVE mode and the secondary controller is in STANDBY mode.

The assignment of the reading results to the object is done by the controller which receives the data of the connected sensors. The reading data is then transferred inside a XML for-mat to the remote controller via CAN2 connection.

This mirroring of the data is done from the ACTIVE to the STANDBY controller and vice versa. To ensure that both controllers will output the identical reading data, all relevant settings have to be identical. Redundant operation is only possible in tracking mode of the system.

The primary controller checks periodically the system state and compares it with the sec-ondary system state. If the readiness of the primary controller is less than the secondary, the primary controller will change to mode STANDBY and the secondary controller will change to mode ACTIVE.




SYSTEM COMPONENTS 4

4 System Components

4.1 Laser Bar Code Scanner

4.1.1 CLV691 Laser Bar Code Scanner

Fig. 8: CLV691 laser bar code scanner

Features

● Optical sensor for scanning bar codes● Comprises a laser diode with optics, as well as an electronics unit with integrated

decoder. Both components are installed in a housing● Light is emitted and received through the viewing window in the housing

Fig. 9: CLV691 aperture angle

Function

● Automated and non-contact detection and decoding of bar codes on a conveying line after triggering

● A scan line is generated on the object in order to detect the bar code● Auto focusing when the light beam hits the object● The line pattern reflected from the bar code is recorded, processed, and decoded by the

CLV691● The read result is transmitted to the MSC800 system controller

Legend1 Viewing window2 Mounting points3 Connector for parameter storage


4 SYSTEM COMPONENTS

4.1.2 CLV691 Laser Bar Code Scanner with Mirror Hood

If the CLV691 bar code scanner cannot be installed at the prescribed minimum distance to the conveyor, the bar code reading can be done via a mirror. The mirrors can be installed on either one or both sides of the system, depending on where the space restriction occurs.

Fig. 10: Bar code scanner CLV691 with mirror hoods

Function

● Reduced reading distance by extending the light path and thus greater reading field height through the use of mirror hoods.

● Adjustable exit angle of the laser beam via the deflection mirror.

Legend1 Bar code scanner placed on the mirror cover2 Light beam exit through the glass front panel

For further information about the CLV691, refer to the respective SICK operating instruc-tions.


SYSTEM COMPONENTS 4

4.1.3 CLV691 Laser Bar Code Scanner with Cleaning Unit

Fig. 11: CLV691 with cleaning unit

Function

● The fixed mount bar code scanners mounted underneath the conveying equipment fea-ture an integrated cleaning unit

● This prevents an increased risk of contamination of the viewing window underneath the belt

● The bar code is read through a belt gap. Recommended gap: 50mm● The air is blown over the viewing window of the fixed mount bar code scanner● This blows off any dirt particles on the viewing window

Legend1 CLV691 / CLV651 bar code scanner2 Blow out nozzle3 Fan housing with radial fan



4 SYSTEM COMPONENTS

4.1.4 CLV651 Laser Bar Code Scanner (Option)

Fig. 12: CLV651 with cleaning unit and connection unit

Function

● CLV651 are used when there is not enough space under the belt. Distance floor to top of belt < 750mm

● The CLV651 operates in the same way as the CLV691 fixed mount bar code scanner● The bar code is read through a gap in the belt. Recommended gap: 50mm● Each fixed mount bar code scanner features a cleaning unit

Connection unit

● The individual readers are connected via a CDB620 connection unit● This allows for central voltage supply of the fixed mount bar code scanners and connec-

tion to one another via CAN bus

Legend1 Viewing window2 Swivel connection3 Cleaning unit4 Cable glands5 Connection type6 Connection card inside the housing with LEDs, terminal strip and switches



SYSTEM COMPONENTS 4

4.2 Image-Based Code Reader

4.2.1 Lector654 Image-Based Code Reader

Fig. 13: Lector 654 image based code reader

Features

● Optical sensor with integrated LED illumination unit and dynamic focus control for bar code detection

● It allows the omni directional reading of bar codes on one side of an object, even with varying object heights and code positions

Function

● Does not scan the code area; instead, takes several photos from the bar codes

● The read process is activated by a trigger signal provided by SICK or customer

● For the image recordings, the reading field is lit up with a powerful LED illumination unit

● The read result is transmitted to the MSC800 system controller

Fig. 14: Operating principle

Legend1 Lector654 code reader2 Lens3 Protective cover for optics4 Integrated LED illumination ring5 Aiming laser


4 SYSTEM COMPONENTS

4.2.2 Lector654 Image-Based Code reader with Mirror

If the Lector654 Image based bar code reader cannot be installed at the prescribed mini-mum distance to the conveyor, the reading can be done by using a mirror.

The mirrors can be installed on either one or both sides and even on top of the system, depending on where the space restriction occurs.

Fig. 15: Lector654 with deflection mirror

Function

● The resulting extension of the light path allows space-saving mounting of the sensors on the conveyor system

● The deflection via the mirror is loss-free due to its special surface vaporization, as this eliminates light refraction

● Figure 15 shows the arrangement of the side camera with mirror

Legend1 Deflection mirror2 Lector654

For further information about the Lector654, refer to the respective SICK operating instructions.


SYSTEM COMPONENTS 4

4.3 RFID

4.3.1 RFU630 - RFID Read Device

The RFU630 read/write devices are intelligent 4Dpro sensors from the SICK RFU6xx (UHF) product family. Version (working range): Long Range.

Thanks to their intelligent process logic, the devices can be used either as a standalone solution or as part of a group in a CAN network. In read mode, the devices transmit the results via a host interface to a higher-level computer (e.g. PLC) for further centralized pro-cessing.

RFU630

● Using up to four external antennas, it processes all common transponders in the fre-quency range of 860 - 960 MHz

● Before a UHF RFID device can be introduced and operated in a particular country or region, radio approvals from the local authorities are required. In most cases, SICK has already received approval. However, this must be checked in advance

For further information about the RFU630, refer to the respective SICK operating instruc-tions.


4 SYSTEM COMPONENTS

4.3.2 Modules with/without Antenna

The RFID system consists of modules that can be freely combined, enabling the tunnel design to be adapted to the relevant on-site conditions quickly and conveniently.

As a result, the RFID system can respond flexibly to the different widths and heights of con-veying systems, as well as to the different positions of tags on the objects passing through it.

For the supporting of the modules a supporting frame is in scope of supply by SICK.

Reader modules

Reader modules feature an integrated antenna and integrated absorber panels. These are covered on the inside by a plastic panel.

Abb. 16: Reader modules

Legend1 Module with integrated antenna2 Integrated absorber panel3 Antenna downlead4 Cutouts for antenna mounting5 Cable channel


SYSTEM COMPONENTS 4

4.4 Cabinet incl. Controller

Fig. 17: Cabinet with system controller MSC800

Function

● The power supply unit supplies the voltage to the sensors in the track and trace system● Contains the MSC800 system controller, the central control unit of the track and trace

system● The MSC800 system controller coordinates all connected sensors, and assigns the

received read results to the respective bags● The read results are output to the higher-level customer system in a host telegram with a

defined format● The track and trace system is connected to the customer’s PROFINET IO network via the

CDF600 fieldbus module (option) (see below)

NOTEA white status LED lights up as soon as voltage is applied to the cabinet.

Legend1 Air inlet cooling (with filter mat and cooler)

– Used only in ALIS camera systems– ALIS Laser and RFID systems are equipped with a smaller cabinet without

air inlet cooling2 MSC800 system controller3 FI/LS switch (RCBO)4 Terminals for voltage supply IN (100-264 V AC/ 50-60 Hz)5 Power supply circuit breaker6 White status LED7 Air outlet for cooling (with filter mat)8 Terminals (24 V DC) and fuse module OUT9 Power supply unit for supplying voltage to the system components

– 10A power supply for a ALIS Laser or RFID system– 20A power supply for a ALIS camera System


4 SYSTEM COMPONENTS

4.5 Reflection Light Barrier - Trigger Signal

Fig. 18: Reflection light barrier

Function

● Used for optical contact less detection of objects● A reflector is required for the function● The emitted light signal is reflected back via a reflector● The emitter and receiver are arranged in parallel in the housing of the retro-reflective

light barrier● If the light beam is interrupted by an object, a switching signal is output to the MSC800

system controller

Trigger signal

● The track and trace system requires a trigger signal● The trigger signal is supplied either SICK or by customer● It is processed by the MSC800 system controller● The trigger signal activates the connected readers and opens the reading gate

Legend1 Reflection light barrier2 Reflector


SYSTEM COMPONENTS 4

4.6 Incremental-Encoder DFV60

Fig. 19: Incremental encoder DFV60

Function

● Measuring wheel system, mounted under the conveyor belt. ● Large spring travel and steer ability of the spring arm to compensate for unevenness of

the measuring surface

Incremental signal

● The track and trace system requires an incremental signal● The incremental signal is supplied either by SICK or by customer● It is processed by the MSC800 system controller ● The belt speed is determined by means of the incremental signal● The incremental signal together with the trigger signal enables definition of the

position of the object within the reading field

Legend1 Wheel2 Spring load mounting arm


4 SYSTEM COMPONENTS

4.7 Accessories (option)

4.7.1 CDF600-2200 Field Bus Module (Option)

Fig. 20: CDF600-2200 field bus module

Function

● Field bus proxy/gateway for connecting the track and trace system to a PROFINET IO net-work

● Connected to the MSC800 data interface and the customer network● Encoding switches that are mounted and protected behind the side cover and easily

accessible from the outside for easy setup of bus address and operating mode

Legend1 Connection to the customer network2 Serial data interface to the MSC800 controller3 Connecting the voltage supply4 Rotary encoding switch behind the side cover

For further information about the CDF600-2200 - Field Bus Module, refer to the respec-tive SICK operating instructions.


SYSTEM COMPONENTS 4

4.7.2 Network Camera

Fig. 21: Network camera from Axis P13 series

Characteristics

● Great image quality with a high level of details

● The P-Iris gives an optimal image clarity in complex lightning

● Flexibility to change lenses

● Additional illumination can be provided upon request

● Up to 5MP resolution

4.7.3 Signal Lamp

Fig. 22: Signal lamp

Signal color SignificanceGreen (flashing) Power supply on. Components ready for operationGreen (permanent) System started conveyor belt is runningYellow (permanent) Maintenance mode activeRed (flashing) System in error modeRed (permanent) System stopped via emergency stop button


4 SYSTEM COMPONENTS


TRANSPORT, SETUP AND MOUNTING 5

5 Transport, Setup and Mounting

All transport, assembly, mounting, and electrical installation work must only be carried outby qualified persons.

● Qualified persons have the specialist training, skills, experience and knowledge of the relevant regulations and standards needed to be able to perform work assigned to them and to identify and avoid any potential dangers independently

● Electricians have the professional training, skills, experience and knowledge of the rele-vant standards and provisions needed to work on electrical systems and to detect and avoid any potential dangers independently

NOTEAssembly, mounting, and electrical installation work is carried out by SICK Service.

5.1 Check Delivery

▸ Completeness▸ Transport damage

5.2 Transport and Setup

The components of the track and trace system are delivered on transport pallets.▸ Transport the transport pallets to the operation site.▸ Use suitable transportation equipment (manned forklift truck). Observe the center of

gravity.▸ The installation side must be clean, level and free from obstacles.


5 TRANSPORT, SETUP AND MOUNTING


ELECTRICAL INSTALLATION 6

6 Electrical Installation

All electrical work may only be performed by qualified persons.● Qualified persons have the specialist training, skills, experience and knowledge of

the relevant regulations and standards needed to be able to perform work assigned to them and to identify and avoid any potential dangers independently


DANGERHAZARDOUS ELECTRICAL VOLTAGETouching live devices, which may still be energized, can lead to death, burns or electri-cal shock.▸ Electrical work may only be performed on the system by qualified specialist person-

nel.▸ 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

WARNINGDEVICE DAMAGE IF CONNECTED INCORECTLYAny incorrect supply voltage may result in damage to the device.▸ Only operate the cabinet with the specified supply voltage.▸ All connected circuits must be designed as SELV circuits (in accordance with

EN 60950 or ES1 EN 60368-1).

NoteAll connection work is performed by the manufacturer.

It is not covered in these system description.


6 ELECTRICAL INSTALLATION

6.1 Connection Overview CLV691 - ALIS Laser

Fig. 23: Connection overview

1 CLV6911a CAN 1 (CAN bus, 24 V voltage supply, incremental signal, terminator)1b CAN 2 (CAN bus, 24 V voltage supply, incremental signal, terminator)2 Cleaning Unit2a Voltage supply3 MSC800 system controller4 Cabinet4a Feed 230 V / 50 Hz5a Trigger signal5b Incremental signal6 Field bus module (option)6a 24 V voltage supply6b RS232 data cable (MSC800 system controller - field bus module6c Data output into PROFINET network7 Customer's system


ELECTRICAL INSTALLATION 6

6.2 Connection Overview Lector654 - ALIS Camera


1 Lector6541a CAN 1 (CAN bus, 24 V voltage supply, incremental signal, terminator)1b CAN 2 (CAN bus, 24 V voltage supply, incremental signal, terminator)1c Gbit Ethernet2 MSC800 system controller2a Ethernet3 Cabinet3a Feed 230 V / 50 Hz4 Ethernet switches4a Gbit Ethernet (image output)5a Trigger signal5b Incremental signal6 Field bus module (option)6a 24 V voltage supply6b RS232 data cable (MSC800 system controller - field bus module6c Data output into PROFINET network7 Customer's system8 Image server (option)


6 ELECTRICAL INSTALLATION

6.3 Connection Overview - ALIS RFID


1 Read device RFU 630-0411a TCP/IP2 Antennas (3x with absorber module included and 1 for bottom reading)2a Coax cabel3 MCC800 system controller4 Cabinet4a Feed 230 V / 50 Hz5a Trigger signal5b Incremental signal6 Field bus module (option)6a 24 V voltage supply6b RS232 data cable (MSC800 system controller - field bus module)6c Data output into PROFINET network7 Customer system


COMMISSIONING 7

7 Commissioning

Commissioning may only be performed by qualified persons.● Qualified persons have the specialist training, skills, experience and knowledge of

the relevant regulations and standards needed to be able to perform work assigned to them and to identify and avoid any potential dangers independently


Initial configuration

The initial commissioning of the track and trace system is carried out by the manufacturer.

All of the system functions are set up by configuring the measuring conditions on-site.

NoteInitial commissioning by the manufacturer is not covered in these operating instructions.


7 COMMISSIONING


OPERATION 8

8 Operation

The track and trace system may only be operated by qualified persons.

Qualified persons have the specialist training, skills, experience and knowledge of the rele-vant regulations and standards needed to be able to perform work assigned to them and to identify and avoid any potential dangers independently.

8.1 System Start

▸ Set up the voltage supply for the cabinet.▸ Connects the voltage supply for the MSC800 system controller and the connected sen-

sors.▸ The sensors and controller are started up and checked for operational readiness in

a self-test.

The track and trace system is ready for use.

8.2 Check operational readiness

8.2.1 CLV691 Bar Code Scanner

Fig. 26: Operational readiness of the CLV691

● The Ready LED lights up.

8.2.2 CLV651 Bar Code Scanner

Fig. 27: Operational readiness of the CLV651

● The Ready LED lights up

NoteThe white status LED on the cabinet lights up as soon as voltage is applied.

see chapter 8.2.5 MSC800 System Controller /page 50 andchapter 8.2.6 System Readiness /page 50

NoteThe conveying system must be started by customer.


8 OPERATION

8.2.3 Lector654 Code Reader

Fig. 28: Operational readiness of the Lector654

● The Ready I Tst LED lights up.

8.2.4 RFU630

Fig. 29: Optical status indicators on the display

● The Ready LED lights up green

8.2.5 MSC800 System Controller

Fig. 30: Operational readiness of the MSC800 system controller

● The DEVIDE READY LED lights up

8.2.6 System Readiness

Fig. 31: System readiness

● In addition to the DEVICE READY LED, the SYSTEM READY LED also lights up on the MSC800 system controller


OPERATION 8

8.2.7 Automated Operating Mode

The track and trace system runs fully automated after startup. No manual intervention by the operator is required

Minimum distance and rotational position

Fig. 32: Minimum distance and rotational position

Legend1 ALIS Laser or Camera:

– minimum distance between bags >150mmALIS RFID:– minimum distance between bags >400mm

2 ALIS Laser or Camera:– minimum distance between two bar codes >50mmALIS RFID:– minimum distance between RFID tags >400mm

3 Rotational position of bag and IATA code as desired

NoteIf the bags rotate, vibrate, roll, or slip on the conveyor system and if the conveying sur-faces are uneven, the read result may be affected.


8 OPERATION

Several bags in reading field

Fig. 33: Several bags in reading field

● Several bags can be in the reading field● The minimum distance must be upheld here

Not allowed

Fig. 34: No touching

● The objects must not be touching● Otherwise the track and trace system will not deliver plausible read results.

8.3 System End

The conveying system is stopped by the customer.

8.3.1 Stopping the Conveying Syste,

▸ Wait until all objects have been processed.

Note

Do not stop the conveyor system if there is still an object in the reading area or if it enters the reading area.


OPERATION 8

8.3.2 Interrupting the Voltage Supply

▸ Interrupt the voltage supply to the cabinet.The connected system components are now free from voltage.

NoteThe white status LED on the cabinet is off.


8 OPERATION


MAINTENANCE AND REPAIR 9

9 Maintenance and Repair

Maintenance and repair measures may only be carried out by qualified persons.● Qualified persons have the specialist training, skills, experience and knowledge of the

relevant regulations and standards needed to be able to perform work assigned to them and to identify and avoid any potential dangers independently


Device Maintenance task Interval[1] Staff

Lector654 Clean the viewing window 1x/month Trained personnel

CLV691 Clean the viewing window 1x/month Trained personnel

CLV651 Clean the viewing window 1x month Trained personnel

Radial fan Check whether the fan is running and if air is coming out of the blow-out nozzle Daily Trained

personnel

CabinetCleaning the air inlets and outletsReplacement of the filter mat in the air inlets and outlets

4x/yearTrained personnel

General

Visual monitoring for contamination Daily Trained personnel

Visual monitoring of conveying equipment for foreign bodies/damage Daily Trained

personnel

Control measurements with test objects to check the measure-ment accuracy of the multi-dimensional measurement system

Whenever the system is started

Trained personnel

Visual inspection of the electrical cabling and wiring for damage 1x/year Trained personnel

Maintenance of the individual components 2x/year Service technicians

Checking the complete system including measurement system/reading performance/image quality/reading range 1x/year Service

technicians[1] The intervals depend on the ambient conditions and degree of contamination.

In addition, the intervals must be defined according to how important they are for the customer process.


9 MAINTENANCE AND REPAIR

9.1 Regular Control Measurement

▸ Fault-free functioning of the track and trace system should be ensured by means of regular monitoring.

▸ Check reading performance while doing so.▸ If any unexpected deviations are found, check the track and trace system for mechanical

damage. ▸ Should the track and trace system show signs of mechanical damage, contact

SICK Service

9.2 Visual Control

Visual inspection of the conveying equipment

▸ Regularly check the conveying equipment for damage or contamination. ▸ Replace any damaged belt elements immediately.

Visual inspection of the cables

▸ Check the electrical installation regularly. ▸ Make sure that all cable connections are secure. ▸ Replace any damaged connecting cables immediately.

9.3 Cleaning Instructions

9.3.1 Cleaning the CLV691/CLV651

Contamination on the viewing window of the fixed mount bar code scanners can impair the scanning performance.

▸ Regularly check the viewing window for contamination.

WARNINGHAZARDOUS LASER RADIATIONCLV691 and CLV651 fixed mount bar code scanners work with a laser class 2 laser.

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.▸ Never look directly into the laser beam.▸ Never point the laser beam at people’s eyes.▸ During commissioning or maintenance work, suitable eye protection must be worn.▸ Avoid laser beam reflections caused by reflective surfaces. In particular during mount-

ing and alignment work.▸ Do not open the housing.▸ Current national regulations regarding laser protection must be observed.

NOTICE

Reduce reading performance due to scratches or streaks on the viewing windowThe viewing window is made of glass. The optical output is weakened by scratches and streaks on the viewing window.▸ Do not use aggressive cleaning agents.▸ Do not use abrasive cleaning agents.▸ Avoid any movements that could cause scratches or abrasions on the viewing window.



Cleaning the viewing window

Fig. 35: CLV651/CLV691 cleaning the viewing window

▸ Switch off the fixed mount bar code scanners during cleaning.▸ Remove dust from the viewing window using a soft, clean brush.Then wipe the viewing window with a clean, damp cloth. Use a mild, anti-static lens clean-

ing fluid if necessary.

9.3.2 Cleaning the Cleaning Unit for CLV691

Filter mat inside the housing. Spare filter mat P/N: 4028998

Fig. 36: Radial fan functional test

▸ Switch off the power supply from the system.▸ Lift the top cover of the blower housing with a screwdriver with thin tip carefully.▸ Remove the filter.▸ Replace or clean the filter (e.g. with a vacuum cleaner).▸ After a maximum of 2 times cleaning , it is recommended, to replace the filter by a new

one.▸ Insert the cleaned or new filter into the blower housing.▸ Press the top cover back onto the blower housing.

Fig. 37: Filter mat replacement

Legend1 Listen if the fan has started and is running2 Check whether air is coming out of the blow out nozzle



9.3.3 Cleaning the Lector654

Contamination of the viewing window can impair the reading behavior.

Cleaning the viewing window

Fig. 38: Lector654 viewing window

▸ Switch off the device during cleaning.▸ Remove dust from the viewing window using a soft, clean brush.Then wipe the viewing window with a clean, damp cloth. Use a mild, anti-static lens clean-

ing fluid if necessary

WARNINGDANGEROUS LED RADIATIONThe Lector65x image-based code readers feature an integrated LED illumination unit. Temporary, irritating optical effects on the human eye.▸ Do not look into the illumination unit for a long period of time.▸ Never point the light source at people.▸ Prevent light source reflections caused by reflective surfaces.▸ Do not open the housing.▸ Comply with the regulations on photo biological safety of lamps and lamp systems

WARNINGDANGEROUS LASER RADIATIONThe Lector654 image-based code readers feature an integrated laser alignment aid. Serious damage to retina.▸ Do not look into the light source when it is switched on.▸ Do not view the laser directly with optical instruments (e.g., magnifying glasses, micro-

scopes).▸ Applicable regulations regarding laser protection must be observed



9.3.4 Cleaning the Cabinet

The cabinet features an integrated fan to ensure that cabinet components are adequately cooled.

Cleaning

▸ Air inlets and outlets on the cabinet should be cleaned regularly with a brush.

Fig. 39: Replacing the cabinet filters

▸ Regularly check and, if necessary, replace the filter mats behind the covers for the air inlets and outlets.

▸ Remove the covers from the air inlets and outlets. To do this, insert your finger into the semi-circular recess in the cover.

▸ Carefully remove the cover from the front.▸ Remove old filter mats and replace them with new ones.▸ Reattach the covers the right way up and press them down until they click into place.The filter mats are replaced.

9.3.5 Cleaning the Trigger

Contamination on the retro-reflective sensor can cause faulty switching behavior.

Fig. 40: Cleaning the optical surfaces of the refection light barrier

NOTICE

Risk of damage to electronic devices.▸ Never use compressed air for cleaning.▸ Only knock the dirt off the ventilation grilles or clean them with a brush.▸ Never wet clean the grilles.



9.3.6 Cleaning the Encoder

The measuring wheel of the incremental encoder must have direct and steady contact with the conveyor belt and must turn without any slipping.

Contamination on the measuring wheel or damaged rubber rings can cause faulty behavior of the incremental encoder.

Fig. 41: Visual inspection of the incremental encoder

▸ Remove any contamination on the measuring wheel of the incremental encoder. ▸ Replace damaged rubber rings. ▸ Check the wear of the measuring wheel.

Note If it is so badly worn that contact with the conveyor belt is impaired, the incremental encoder must be replaced



9.4 Components Replacing

9.4.1 CLV691 Replacing

The CLV691 features a removable cloning connector, on which all parameters of the device are permanently stored. This makes replacing the component very easy.

Removing the cloning connector

Fig. 42: Removing the cloning connector

▸ Undo the hexagonal socket screws of the cloning connector.▸ Remove the cloning connector and connected cables from the CLV691.

Quick release

The fixed mount bar code scanners for top reading are mounted on the main frame using a quick release and a mounting bracket.

Fig. 43: Quick release

Legend1 Clamping profile. Used to accommodate the fixed mount bar

code scanner. 2 Clamp. Is inserted into the clamping profile and screwed in

place after the fixed mount bar code scanner has been mounted



Replacing the components via quick release

Fig. 44: Clamping profile

▸ Remove the M8 setscrew used to fasten the clamp to the clamping profile. ▸ Remove the clamping profile, with the CLV691 mounted on it, from the clamp. ▸ Remove the M6 countersunk screws and detach the CLV691 from the clamping profile.

The mounting bracket remains fastened to the main frame together with the clamp.▸ Fit the clamping profile to the replacement device then fasten the device in place with

the two M6 countersunk screws.▸ Insert the clamp, with the replacement device mounted on it, into the clamping profile.▸ Fasten the clamp to the clamping profile with the M8 setscrew.The component is replaced.

Completing the work

▸ Screw the cloning connector back again.

▸ Switch on the track and trace system. When the voltage supply is connected, the config-uration stored in the parameter memory of the cloning connector is transferred to the fixed mount bar code scanner.

▸ Check that the Ready LED is lit up green. The replacement is complete.

NoteTo correctly mount the connector on the side of the device, note the guide holes on the fixed mount bar code scanner and the notch at the top-left corner of the cloning connec-tor.



9.4.2 CLV651 Replacing

With a CLV651 bar code scanner, the device parameters are saved on a microSD card. This makes it easier to replace components.

Quick release design

Fig. 45: Quick release design

Remove via quick release

Fig. 46: Remove via quick release

▸ Undo the M5 setscrew used to fasten the clamp to the clamping profile and pull it out of the bore hole.

▸ Remove the clamp, with the CLV651 mounted on it, from the clamping profile. ▸ Loosen and remove the M6 countersunk screws.

Legend1 Clamping profile. Screwed onto the mounting bracket2 Clamp. Used to accommodate the fixed mount bar code scanner.

Inserted into the clamping profile and fixed in place.



▸ Remove the clamp from the CLV651. The mounting bracket remains fastened to the main frame together with the clamping profile.

Fig. 47: Removing from the clamp

Swapping over the memory card

Fig. 48: Removing/inserting the memory card

▸ Unscrew the cover for the microSD card slot.▸ Remove the microSD card from the defective device. ▸ Insert the microSD card into the replacement device. ▸ Screw the cover back on.

Mounting the replacement device

▸ Fit the clamp to the replacement device then fasten the device in place with the two M5 countersunk screws.

▸ Place the clamp, with the replacement device mounted on it, on the clamping profile.▸ Fasten the clamp to the clamping profile with the M5 setscrew.

Completing work

▸ Switch on the track and trace system via the cabinet. When the voltage supply is con-nected, the configuration stored on the microSD card is transferred to the bar code scan-ner.

▸ Check that the Ready LED is lit up green. The CLV651 is replaced.



9.4.3 Lector654 Replacing

It is not necessary to replace the lens at the same time as a defective Lector654 if it is not damaged.

The Lector654 has a microSD card on which all parameters of the device are permanently stored. This makes replacing the component very easy.

Removing from the plate adapter

Fig. 49: Removing the plate adapter

Pulling the Lector654 off the plate adapter

Fig. 50: Pulling off

▸ Interrupt the voltage supply.▸ Disconnect and remove all connecting cables from the device.▸ Undo the (captive) fixing screws.▸ Pull the Lector654 off the plate adapter.The Lector654 is pulled of the plate adapter.

Legend1 Connector2 Plate adapter3 Fixing screws4 Frame profile5 Lector654



Removing the microSD card

Fig. 51: Removing the memory card

▸ Undo the two (captive) hexagonal socket screws for the cover using the enclosed socket wrench (WAF 2 mm).

▸ Push the cover away from the device until the card slot can be accessed.▸ Pull the memory card out of the card slot.

Removing the lens from the defective device

Fig. 52: Removing the lens

▸ Place the defective Lector654 on a nonslip base. ▸ Twist off the protective optics cover. ▸ Screw the lens out of the C-mount thread of the defective Lector65x.



9.4.4 MSC800 System Controller Replacing

The system parameters are stored on the microSD card of the MSC800 system controller. This makes it quick and easy to replace components.

Removing connecting cables

▸ Interrupt the supply voltage to the cabinet.Disconnect all plug-in terminal blocks from the controller.

Replacing MSC800 system controller

Fig. 53: Removing

▸ Undo the fixing screw for the controller on the left-hand side. ▸ Pull the controller to the right and remove it from the cabinet.

Transferring the microSD card

Fig. 54: Removing microSD card

▸ Remove the microSD card from the slot in the removed controller.▸ Insert the microSD card that was just removed into Slot SD 1 on the new controller.

Installing the replacement device

▸ Position the new MSC800 system controller inside the cabinet. ▸ Pull the controller to the left and secure it to the cabinet using the fixing screw.▸ Place the terminal blocks, together with the cabling, back inside the designated slots.▸ Plug the Ethernet cables into the designated connectors.▸ Select the same position for the micro switch as in the removed controller.The MSC800 is replaced.

NoteMake sure that no wires are pulled out from the terminal blocks,



9.4.5 MSC800 Battery Replacing

A battery powers the real-time clock of the MSC800 system controller. The battery must be replaced when drained.

Fig. 55: Location of the battery

▸ Remove the black plastic cover on the MSC800.▸ Remove the battery from the bracket and replace it with a new CR2032 battery.▸ Put the black plastic cover back in place.▸ Dispose of the old battery as hazardous waste as per the ROHS directives (Europe).▸ Set the system time again using the SOPAS software

(Project tree MSC800 System REAL-TIME CLOCK area).



9.4.6 Power Supply Unit Replacing

Fig. 56: Power supply unit

DANGERRISK OF INJURY DUE TO ELECTRICAL CURRENTThe 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 compati-

ble 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.

NoteBefore removing the power supply unit, note the assignment of the cables to the connec-tions.

Legend1 Mounting strap2 Input voltage connection3 Output voltage connection4 Potentiometer for output voltage



Replacing the power supply unit

▸ Interrupt the supply voltage to the cabinet.Disconnect and remove the cables from the power supply module.

▸ Remove the defective power supply module from the cabinet. To do this, use a suitable screwdriver to slide the black clip on the rear wall backwards.

▸ Lift the power supply unit and pull it forward and out of the bracket.

Installing the power supply unit

▸ Place the new power supply module on the mounting rail of the cabinet and press back-wards until the power supply module audibly engages.

▸ Reconnect all cables to the power supply unit.▸ Restore the supply voltage to the cabinet.

Setting the output voltage

The power supply modules are factory preset with a 24 V output voltage.

▸ Set the output voltage on the power supply module using the potentiometer.▸ Check that the output voltage is correct.

9.4.7 Photoelectric Retro-Refelctive Sensor Replacing

A defective retro-reflective sensor must be replaced immediately.

Fig. 57: Replacing the photoelectric retro-reflective sensor

▸ Unscrew the M12 plug connector from the male connector on the photoelectric retro-reflective sensor.

▸ Loosen fixing screws. Note Hold the photoelectric retro-reflective sensor firmly with one hand during the proce-dure.

▸ Remove the defective photoelectric sensor from the mounting bracket. ▸ Screw the replacement device onto the mounting bracket. ▸ Screw the M12 plug connector onto the male connector on the photoelectric retro-reflec-

tive sensor. ▸ Align the photoelectric sensor correctly on the reflector. The reflector must be in line with

the beam path of the photoelectric retro-reflective sensor.▸ Check that the photoelectric retro-reflective sensor is operating correctly.



9.4.8 Incremental Encoder Replacing

A defective encoder must be replaced immediately.

Fig. 58: Replacing the incremental encoder

▸ Unscrew the M12 pug connector from the male connector on the incremental encoder.▸ Loosen and remove the fixing screws.▸ Mount the replacement device on the conveyor belt

Note Observe the correct mounting direction.▸ Screw the M12 pug connector onto the male connector on the incremental encoder.




FAULT DIAGNOSIS 10

10 Fault Diagnosis

10.1 Lector654

10.2 CLV691

Fault indication

The READY LED does not light up.Fault cause Possible solution to the problemFuse failure in the voltage supply. ▸ Reconnect voltage supply circuit breaker for

the code readers.Fuse is defective. ▸ Check the fuse block in the cabinet and,

if necessary, replace the defective fuseDevice is defective. ▸ Replace the device.

Fault indication

The READY LED lights up red.Fault cause RemedyHardware or software error. ▸ Check the device status using SOPAS.

▸ Contact SICK Service.

Fault indication

The RESULT LED lights up red.Fault cause RemedyBar code reading unsuccessful. ▸ Check the device status using SOPAS.

▸ Contact SICK Service.

Fault indication

The READY LED does not light up.Fault cause Possible solution to the problemFuse is defective. ▸ Check the fuse block in the cabinet and,

if necessary, replace the defective fuse,

Fault indication

The READY LED lights up red. The scanner no longer sends any measured values.Fault cause Remedy● Error during initialization or self-test.

● Errors arise during operation.Checking voltage supply▸ Interrupt the voltage supply for the sensors.▸ Restore the voltage supply.

If the fault persists or occurs again after the volt-age supply has been restored:▸ Check the device status using SOPAS.▸ If errors are listed there, contact SICK Service.


10 FAULT DIAGNOSIS

10.3 CLV651

10.4 MSC800 System Controller

Fig. 59: MSC800 fault indication

If all of the connected sensors are configured and working properly, the SYSTEM READY LED lights up on the system controller.

This means that the system controller has received a positive response from all of the com-ponents and that the devices are communicating with one another.

Fault indication

The READY LED does not light up.Fault cause Possible solution to the problemFuse is defective. ▸ Check the fuse block in the cabinet and,

if necessary, replace the defective fuse.

Fault indication

The READY LED lights up red. The scanner no longer sends any data.Fault cause Remedy● Error during initialization or self-test.

● Errors arise during operation.Checking voltage supply▸ Interrupt the voltage supply for the sensors.▸ Restore the voltage supply.

If the fault persists or occurs again after the volt-age supply has been restored:▸ Check the device status using SOPAS.▸ If errors are listed there, contact SICK Service.

Fault indication

The DEVICE READY LED does not light up.Fault cause Possible solution to the problemFuse is defective. ▸ Check the fuse block in the cabinet and,

if necessary, replace the defective fuse.Voltage is not switched on, ▸ Establish the correct voltage supply.System controller defective, ▸ Replace the system controller.


FAULT DIAGNOSIS 10

10.4.1 MSC800 System Controller Check

If the CAN is cabled correctly, the LEDs in the CAN1 or CAN2 terminal blocks light up weakly during operation.

If the conveyor belt is switched off, the LED should flicker if the CAN cabling is correct.

Fig. 60: CAN cabling check

Fault indication

The SYSTEM READY LED does not light up.Fault cause Possible solution to the problemCAN cable is attached incorrectly. ▸ Check the CAN cabling and establish connec-

tions in accordance with the electrical dia-gram

Defective Ethernet connection to sen-sor components, ▸ Check the Ethernet connections.

Ethernet cable is defective. ▸ Replace the Ethernet cable.Heavy contamination on the front screen of the 2D LiDAR sensors, ▸ Clean the front screen,

Sensor component is defective. ▸ Replace the sensor component.

Fault indication

The LEDs light up brightly like the others. There is a problem with the CAN connection.Fault cause Possible solution to the problemThe wires have been swapped . ▸ Check the CAN cabling and establish connec-

tions in accordance with the electrical dia-gram.

Wire is not attached correctly in the terminal block, ▸ Check that the wires are attached correctly.


10 FAULT DIAGNOSIS

10.4.2 Detailed Fault Analysis

The MSC800 system controller outputs faults in a staggered manner in messages. This means that a more detailed analysis is always possible.● Communication errors can, for example, occur when transmitting telegrams to the

MSC800 system controller. The MSC800 system controller then returns a fault code.● For faults that occur during measuring or reading, fault codes are written to a status log.

Message types

The status log distinguishes between four message types:● Information● Warning● Error● Critical fault

The system saves only the last five entries for each message type.Information and Warning messages are deleted after a restart.

Calling up the status log

▸ Call up the status log using the SOPAS configuration software.▸ To do this, install SOPAS on a PC and connect the PC to the MSC800 via Ethernet.

NotePlease contact SICK Support for a more detailed analysis of the fault situation.


DIMENSIONAL DRAWINGS 11

11 Dimensional Drawings

11.1 ALIS Laser- Laser Based Bar Code Reading System

Fig. 61: Side view

Fig. 62: Top View B


11 DIMENSIONAL DRAWINGS

Fig. 63: View A in conveying direction



11.2 ALIS Camera - Camera Based Bar Code Reading System

11.2.1 ALIS Camera - Camera System with 8 Matrix Cameras and 2 Laser Scanner

Fig. 64: Side view

Fig. 65: Tow view B






11.2.2 ALIS Camera - Camera System with 10 Matrix Cameras

Fig. 67: Side View

Fig. 68: Top view B






11.3 ALIS RFID - Radio Frequency Identification System

Fig. 70: Side view

Fig. 71: Top view



Fig. 72: Side view in conveying direction



11.4 ALIS - Hybrid

11.4.1 RFID and Laser Scanner Reading System

Fig. 73: Side view

Fig. 74: Top view



Fig. 75: View in conveying direction



11.4.2 RFID Camera and Laser Scanner Reading System

Fig. 76: Side view

Fig. 77: Top view



Fig. 78: View in conveying direction


DISPOSAL 12

12 Disposal

The following assemblies may contain substances that must be disposed of separately:

Electronics: capacitors, accumulators, batteries

Displays: Liquid in the LC-Displays

NoteNote the relevant currently valid local and legal environment regulations and directives for the disposal of industrial and electronic waste.

Disposal of batteries, electrical and electronic equipmentAccording to international directives and regulations, batteries, accumulators and electri-cal or electronic devices must not be disposed of as household waste.

The owner is obliged to dispose of the equipment at the end of its service life at the appropriate public collection points.

This symbol on the product, packaging or in this document indicates that a product is subject to these regulations.

SICK AG | Waldkirch | Germany | www.sick.com

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Further locations at www.sick.com

AustraliaPhone +61 (3) 9457 0600 1800 33 48 02 – tollfreeE-Mail [email protected]

AustriaPhone +43 (0) 2236 62288-0E-Mail [email protected]

Belgium/LuxembourgPhone +32 (0) 2 466 55 66E-Mail [email protected]

BrazilPhone +55 11 3215-4900E-Mail [email protected]

CanadaPhone +1 905.771.1444E-Mail [email protected]

Czech RepublicPhone +420 2 57 91 18 50E-Mail [email protected]

ChilePhone +56 (2) 2274 7430E-Mail [email protected]

ChinaPhone +86 20 2882 3600E-Mail [email protected]

DenmarkPhone +45 45 82 64 00E-Mail [email protected]

FinlandPhone +358-9-25 15 800E-Mail [email protected]

FrancePhone +33 1 64 62 35 00E-Mail [email protected]

GermanyPhone +49 (0) 2 11 53 01E-Mail [email protected]

Hong KongPhone +852 2153 6300E-Mail [email protected]

HungaryPhone +36 1 371 2680E-Mail [email protected]

IndiaPhone +91-22-6119 8900E-Mail [email protected]

IsraelPhone +972-4-6881000E-Mail [email protected]

ItalyPhone +39 02 27 43 41E-Mail [email protected]

JapanPhone +81 3 5309 2112E-Mail [email protected]

MalaysiaPhone +603-8080 7425E-Mail [email protected]

MexicoPhone +52 (472) 748 9451E-Mail [email protected]

NetherlandsPhone +31 (0) 30 229 25 44E-Mail [email protected]

New Zealand Phone +64 9 415 0459 0800 222 278 – tollfreeE-Mail [email protected]

Norway Phone +47 67 81 50 00E-Mail [email protected]

PolandPhone +48 22 539 41 00E-Mail [email protected]

RomaniaPhone +40 356-17 11 20 E-Mail [email protected]

RussiaPhone +7 495 283 09 90E-Mail [email protected]

SingaporePhone +65 6744 3732E-Mail [email protected]

SlovakiaPhone +421 482 901 201E-Mail [email protected]

SloveniaPhone +386 591 78849E-Mail [email protected]

South AfricaPhone +27 (0)11 472 3733E-Mail [email protected]

South KoreaPhone +82 2 786 6321E-Mail [email protected]

SpainPhone +34 93 480 31 00E-Mail [email protected]

SwedenPhone +46 10 110 10 00E-Mail [email protected]

SwitzerlandPhone +41 41 619 29 39E-Mail [email protected]

TaiwanPhone +886-2-2375-6288E-Mail [email protected]

ThailandPhone +66 2 645 0009E-Mail [email protected]

TurkeyPhone +90 (216) 528 50 00E-Mail [email protected]

United Arab EmiratesPhone +971 (0) 4 88 65 878E-Mail [email protected]

United KingdomPhone +44 (0)17278 31121E-Mail [email protected]

USAPhone +1 800.325.7425 E-Mail [email protected]

VietnamPhone +65 6744 3732E-Mail [email protected]

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MMMI MMMSYSTEM DESCRIPTION - SICK Germany

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