SICK Master Data Analyzer Operating Instructions Manual

MASTER DATA ANALYZER
Track and trace systems
OPERATING INSTRUCTIONS
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OPERATING INSTRUCTIONS | Master Data Analyzer
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Product described
Product name: Master Data Analyzer
Document identification
Title: Operating instructions for Master Data Analyzer
Status: 2017-08-10
Manufacturer
SICK AG Erwin-Sick-Str. 1 · 79183 Waldkirch · Germany
Trademarks
IBM is a trademark of the International Business Machine Corporation.
only used here for identification purposes.
Original documents
The German issue 8020064-ZSP4 of this document is an original SICK AG
In case of doubt, contact SICK AG or your local dealer.
Legal notes
Subject to change without notice
© SICK AG. All rights reserved
Part number: 8020065-ZSP4
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
document. SICK AG does not assume liability for the correctness of a non-authorized translation.
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Contents
CONTENTS
1 About these operating instructions ..............................................................................7
1.1 Purpose of this document .................................................................................... 7
1.2 Information depth ................................................................................................ 7
1.3 Abbreviations used ............................................................................................... 7
1.4 Symbols used ....................................................................................................... 8
2 Safety ..............................................................................................................................9
2.1 Qualified safety personnel ................................................................................... 9
2.2 Applications of the system ................................................................................... 9
2.3 Intended use ...................................................................................................... 10
2.4 General safety notes and protective measures .............................................. 11
2.4.1 Safety notes and symbols ................................................................. 11
2.4.2 General safety notes .......................................................................... 12
2.4.3 Additional operating instructions ...................................................... 12
2.4.4 Dangers connected with handling of the device .............................. 13
2.4.4.1 Danger due to electrical current ...................................... 13
2.4.4.2 Risks during transport and installation ............................ 14
2.4.4.3 Risks during operation ...................................................... 15
2.4.5 Protective devices .............................................................................. 17
2.4.6 Work station ....................................................................................... 18
2.4.7 Protective equipment ......................................................................... 18
2.4.8 The operating entity’s responsibilities .............................................. 18
2.5 Protecting the environment .............................................................................. 19
2.5.1 Power consumption ........................................................................... 19
2.5.2 Disposal after final decommissioning ............................................... 19
3 System description ..................................................................................................... 20
3.1 Scope of delivery ............................................................................................... 20
3.2 System components ......................................................................................... 21
3.3 The system’s operating principle...................................................................... 26
3.4 Project planning ................................................................................................ 31
3.5 Status indicators ............................................................................................... 32
3.5.1 Status indicators – Light grids .......................................................... 32
3.5.2 Status indicators – Hand-held scanner (only in operating
mode with bar code scanning) .......................................................... 33
3.5.3 Status indicators – IP camera ........................................................... 34
3.5.4 Status indicators – Display ................................................................ 34
3.5.5 Status indicators – Electronic scales ................................................ 35
3.5.6 Status indicators – WLAN module .................................................... 35
3.6 Interfaces ........................................................................................................... 36
4 Transport, assembly, and mounting .......................................................................... 37
4.1 Accepting the delivery ....................................................................................... 37
4.1.1 Packaging ........................................................................................... 37
4.1.2 Checking delivery for visible transport damage ............................... 37
4.2 Transporting the MDA to its location of use .................................................... 38
4.3 Unpacking and setting up the device ............................................................... 39
4.3.1 Unpacking the MDA ........................................................................... 39
4.3.2 Checking delivery for hidden transport damage .............................. 40
4.3.3 Setting up the MDA ............................................................................ 41
4.4 Removing the transport locks ........................................................................... 43
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4.5 Mounting ............................................................................................................44
4.5.1 Ready to go .........................................................................................44
4.5.2 Mounting the WLAN module ..............................................................44
5 Electrical installation .................................................................................................. 45
5.1 Connections on the MDA ...................................................................................46
5.1.1 Components connected as standard ................................................46
5.1.2 Connections on the controller housing ..............................................46
5.2 Connecting the MDA to the supply voltage ......................................................47
5.3 Connecting the MDA to the target network ......................................................48
5.4 Connecting the sliding table with rechargeable battery ..................................48
5.5 Connecting the WLAN adapter ..........................................................................49
6 Commissioning ............................................................................................................ 50
6.1 Starting the MDA ................................................................................................50
6.1.1 Starting up the MDA ...........................................................................50
6.1.2 Checking operational readiness ........................................................50
6.2 Preparing the configuration PC .........................................................................52
6.2.1 Establishing a connection with the configuration PC .......................52
6.2.2 Service and data interface .................................................................52
6.2.3 Installing SOPAS .................................................................................53
6.2.4 Launching SOPAS ...............................................................................54
6.3 Adding the MDA to the SOPAS project ..............................................................55
6.3.1 Starting the device search .................................................................55
6.3.2 Transferring the controller to a SOPAS project .................................57
6.3.3 Loading device drivers into the SOPAS project .................................57
6.3.4 Setting the controller to online...........................................................59
6.4 Configuring the MDA in SOPAS .........................................................................60
6.4.1 Incorporating the MDA controller into the customer’s network .......61
6.4.1.1 Issuing the Data interface IP address ..............................61
6.4.1.2 Testing the server connection ...........................................62
6.4.2 Storing connection data for the customer server .............................63
6.5 Saving data permanently ...................................................................................64
6.6 Performing a test run .........................................................................................65
6.7 Setting up the IP camera ...................................................................................66
6.8 Configuring the WLAN module ..........................................................................67
7 Operation ...................................................................................................................... 68
7.1 Safety information .............................................................................................68
7.2 Steps for preparing for your first measurement ...............................................70
7.2.1 Adjusting the display and operating position ....................................70
7.2.2 Starting up the MDA ...........................................................................71
7.2.3 Structure of the measurement window .............................................72
7.2.4 Moving the measurement gantry to a start position ........................74
7.2.5 Positioning a measuring object ..........................................................75
7.3 Performing measurements ................................................................................76
7.3.1 Starting the measurement process ...................................................76
7.3.1.1 Scanning the bar code (only for the operating mode
with bar code scanning) ....................................................76
7.3.1.2 Weighing the object (only for the operating mode
without bar code scanning) ...............................................78
7.3.2 Measuring the volume ........................................................................79
CONTENTS
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7.3.3 Checking the measurement results .................................................. 80
7.3.3.1 Reading measurement data ............................................. 80
7.3.3.2 Checking measurements with the 2D display ................. 81
7.3.3.3 Displaying the measuring object in a live view ................ 81
7.4 Transmitting measurement results .................................................................. 82
7.4.1.1 Direct data output if the device is connected
to a server .......................................................................... 82
7.4.1.2 Saving measurement data internally (only for
operating mode with bar code scanning) ........................ 82
7.4.1.3 Displaying the transmission status (only for
operating mode without bar code scanning) .................. 84
7.4.1.4 Restoring a server connection manually ......................... 85
7.5 Performing new measurements ....................................................................... 86
7.6 Repeating incorrect measurements ................................................................. 88
7.6.1 Object was positioned incorrectly ..................................................... 88
7.6.2 Volume measurement without bar code (only for operating
mode with bar code scanning) .......................................................... 89
7.6.3 Volume measurement without a stable weight (only for
operating mode without bar code scanning) .................................... 90
7.7 Performing mobile measurements ................................................................... 91
7.8 Using the sliding table with rechargeable battery ........................................... 91
7.9 Configuration ..................................................................................................... 92
7.9.1 Logging into the configuration area .................................................. 92
7.9.2 General settings ................................................................................. 93
7.9.2.1 Selecting a language ......................................................... 93
7.9.2.2 Correcting the zero point .................................................. 93
7.9.2.3 Performing teach-in ........................................................... 93
7.9.3 Display settings .................................................................................. 95
8 Maintenance and repairs ........................................................................................... 96
8.1 Maintenance and repairs.................................................................................. 97
8.1.1 Visual inspection for mechanical and electrical damage ................ 98
8.1.2 Cleaning the light grids ...................................................................... 99
8.1.3 Cleaning the display ......................................................................... 100
8.1.4 Cleaning the glass panel ................................................................. 101
8.1.5 Cleaning the internal housing area ................................................. 101
8.1.6 Cleaning the IP camera’s dust shield housing ............................... 103
8.2 Replacing components ................................................................................... 104
8.2.1 Replacing the hand-held scanner (only in operating mode
with bar code scanning) ................................................................... 105
8.2.2 Replacing the display ....................................................................... 105
8.2.3 Replacing the glass panel ............................................................... 106
8.2.4 Replacing the IP camera .................................................................. 108
8.2.5 Replacing the WLAN module ........................................................... 109
9 Fault diagnosis .......................................................................................................... 110
9.1 Response to faults .......................................................................................... 110
9.2 Fault indicators ................................................................................................ 110
9.2.1 Status indicator on the display ........................................................ 110
9.2.1.1 Dealing with status messages ........................................ 110
9.2.1.2 Overview of status messages ......................................... 111
9.2.2 Status indicators for components ................................................... 114
9.3 SICK support .................................................................................................... 115
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10 Technical specifications .......................................................................................... 116
10.1 Data sheets ..................................................................................................... 116
10.1.1 System data sheet ........................................................................... 116
10.1.2 Data sheet for the IDM26x hand-held scanner (wired) ................. 116
10.1.3 IP camera Axis M3005-V ................................................................. 117
10.1.4 WLAN Ethernet port adapter FL WLAN EPA.................................... 117
10.2 Dimensional drawings .................................................................................... 118
10.3 Spare parts list ................................................................................................ 118
10.4 Data interface ................................................................................................. 119
11 Appendix .................................................................................................................... 120
11.1 List of tables .................................................................................................... 120
11.2 List of figures ................................................................................................... 121
11.3 Keywords index ............................................................................................... 123
ABOUT THESE OPERATING INSTRUCTIONS 1
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Tasks
Target group
Mounting, electrical installation,
components
Qualified personnel, such as service technicians or Commissioning
Qualified personnel, such as service technicians or industrial electricians
Operation
Qualified personnel

1 About these operating instructions

Please read through this chapter carefully before you use the documentation and work with the Master Data Analyzer (also abbreviated to MDA in these operating instructions).

1.1 Purpose of this document

These operating instructions are intended for people who install, connect, commission, operate, and maintain the Master Data Analyzer.
maintenance, and replacement of
Tab. 1: Target group

1.2 Information depth

Note
These operating instructions contain information on the Master Data Analyzer relating to the following topics:
Safety
System description
Transport, assembly, and mounting
• Electrical installation
• Commissioning
• Operation
• Maintenance and repairs
• Fault diagnosis and troubleshooting
• Technical data and dimensional drawings
industrial electricians

1.3 Abbreviations used

FTP
LED
MDA
MLG
MSC
File Transfer Protocol
Light emitting diode
Master Data Analyzer
Modular light grid
Modular system controller (MSC800)
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1.4 Symbols used

Recommendation
Note
1. / 2. ...
  , 
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 that must be carried out in the described order are referred to as step-by-step instructions and are indicated by numbered lists. Carefully read and follow the instructions for action.
Instructions for taking action are indicated by an arrow. Carefully read and follow the instructions for action.
LED symbols describe the status of a diagnostics LED. Examples:
The LED is illuminated continuously.  The LED is flashing.  The LED is off.
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2 Safety

Tasks
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
Commissioning, operation,
Basic knowledge of data transmission
Basic knowledge of the Windows operating system used
This chapter concerns your own safety and the safety of the system operator.
Please read this chapter carefully before you begin working with the Master Data
Analyzer.

2.1 Qualified safety personnel

The Master Data Analyzer must only be set up, commissioned, operated, and maintained by adequately qualified personnel.
The following qualifications are necessary for the various tasks:
and configuration
SAFETY 2
  Basic knowledge of the design and setup (addressing)
of Ethernet connections when connecting the system to the Ethernet
Basic knowledge of how to use an HTML browser
(e.g., Internet Explorer) to access the online help
Basic knowledge of 1D/2D code technology
Tab. 2: Qualified safety personnel

2.2 Applications of the system

The Master Data Analyzer is a stationary DWS system (Dimensioning-Weighing-Scanning). It enables master data for products to be logged in a standardized manner for goods entry or shipping. The products are measured, weighed, identified, and visualized in a single operation. Data are processed in real time, regardless of their shape, surface, and material properties.
Operating modes
The Master Data Analyzer is set up at the factory to support two operating modes:
Operating mode with bar code scanning: The object is identified using its bar code
and is then measured. In this case, the Master Data Analyzer supplies the complete set of master data with bar code, weight, and dimensions.
Operating mode without bar code scanning. This variant assumes that the bar code
for the object is already available, meaning that only the weights and dimensions have to be logged. The measurement results are assigned to an existing bar code in the customer’s system.
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WARNING
Note
Brief description
The object is placed on a rugged glass plate. The object does not need to be aligned.
In the operating mode with bar code scanning, the object is identified using a wired bar
code scanner. Electronic scales measure the weight of the object.
In the operating mode without bar code scanning, the measuring process starts with
the system detecting a stable weight value. There is no hand-held scanner.
To measure the dimensions, a gantry with two pairs of light grids is moved manually over the object using two linear guides. Measurements can be taken in both directions. The object’s dimensions and volume are measured.
The data are sent to the warehouse management system in a stationary solution via Ethernet. An external PC or screen is not required. In the mobile variant of the Master Data Analyzer, the data are sent via a WLAN access point.
All system components are pre-assembled in a rugged industrial design and are ready for operation immediately after commissioning.
The majority of the images and screenshots in these operating instructions visualize the Master Data Analyzer in the operating mode with bar code scanning.

2.3 Intended use

The Master Data Analyzer may only be used as described in 2.2 Applications of the
system. It may only be used by qualified personnel in the environment in which it was
mounted and initially commissioned by qualified safety personnel in accordance with these operating instructions.
The equipment may only be operated in an industrial environment. Operation of the system is not allowed outdoors or in an explosion-protected environment.
If used in any other way or if alterations are made to the system or the devices are opened – including in the context of mounting and installation – this will void any warranty claims directed to SICK AG.
Examples of non-intended use:
Measurement of products not defined in the contract or in these operating instructions.
Non-observance of the permitted parameters for measuring objects.
Failure to observe the operating instructions.
Use of parts other than original spare parts.
Danger due to improper use
Non-intended use of the device can lead to danger to the life and limb of persons and damage to the plant.
The device must only be used for the intended use.
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2.4 General safety notes and protective measures

HAZARD
WARNING
CAUTION
NOTE

2.4.1 Safety notes and symbols

The following safety and hazard symbols are used for your own safety, for the safety of third parties, and for the safety of the system. You must therefore observe these symbols at all times.
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).
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 suspended loads).
SAFETY 2
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).
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.
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WARNING

2.4.2 General safety notes

General, recognized safety-related rules and regulations were taken into account in the design and manufacture of the Master Data Analyzer. However, risks for the user resulting from the MDA cannot be completely ruled out. The safety notes below must therefore be observed.
Safety notes
Observe the following to ensure the safe use of the system as intended.
The notes in these operating instructions (e.g., regarding use, mounting, installation, or integration into the machine controller) must be observed.
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.

2.4.3 Additional operating instructions

Other operating instructions of the individual components are enclosed along with these operating instructions.
When working on or with these components, please observe the notes in the operating instructions of the relevant manufacturer.
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2.4.4 Dangers connected with handling of the device

HAZARD
The Master Data Analyzer has been designed and built in a way that allows for safe operation. Protective devices reduce potential risks to the maximum possible extent. Furthermore, the system has been subjected to an internal safety check.
However, certain residual risks apply in the event of misconduct or misuse.
Awareness of potential sources of danger in the Master Data Analyzer will help you to work in a safer manner and thus prevent accidents.
That is why all persons involved with the transport and storage, mounting, commissioning and decommissioning, operation, maintenance, and repair must carefully read and observe the following safety notes.
In order to avoid danger, also follow the special warning information in the individual chapters as well as the current national accident prevention regulations and any company work, operation, and safety regulations.
2.4.4.1 Danger due to electrical current
SAFETY 2
Risk of injury due to electrical current
The Master Data Analyzer is connected to the power supply (AC 100 to 264 V/50 to 60 Hz).
Only a qualified electrician or trained person working under the guidance and supervision of a qualified electrician is permitted to work on electrical systems or equipment, and they must comply with the electrical regulations.
Improper handling of live devices may lead to severe personal injury or death by electric shock.
Measures
Electrical installation and maintenance work must only be performed by electrically
qualified personnel.
Standard safety requirements must be met when carrying out any work on electrical
systems or equipment.
Do not touch any live parts.
In the event of danger, immediately disconnect the device from the grid.
Electrical connections may only be made or disconnected when there is no power in the
system.
Only switch on the supply voltage when the connection tasks have been completed and
the wiring has been thoroughly checked.
Only carry out maintenance and repair work when the power is off.
Always use original fuses with the specified current rating.
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WARNING
WARNING
WARNING
WARNING
2.4.4.2 Risks during transport and installation
Risk of injury from suspended load
The Master Data Analyzer is delivered in a transport crate on a pallet. Use a suitable lifting device to unload and transport the device.
During transport, tipping or falling loads pose a risk of severe injury or damage to property.
Measures
Only use lifting equipment which is suitable for the weight and dimensions of the
freight.
Make sure that the center of gravity is in the center between the forks of the lifting
device and the forks are completely entrenched under the transport pallet.
Do not stop underneath the suspended load.
Wear safety shoes in addition to your personal protective equipment.
Risk of injury due to components falling over
The side panels and lid of the transport crate are heavy and difficult to handle.
Falling objects pose a risk of crushing during dismantling.
Measures
Always use 2 people to mount the side panels and lid.
Wear protective shoes in addition to your personal protective equipment.
Risk of injury when lifting heavy objects
There is a risk of injury when lifting heavy objects.
Depending on the system variant, the MDA weighs around 65 kg to 80 kg.
Measures
Use 4 people to lift the MDA.
In order to do this, use the four handles on the two long sides of the MDA.
Lift and carry the MDA according to ergonomic principles.
Wear protective shoes in addition to your personal protective equipment.
Impermissible handling of the device
There is a risk of damage to the device when lifting the MDA using the measurement gantry.
Measures
Do not lift the MDA using the measurement gantry under any circumstances!
SAFETY 2
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WARNING
WARNING
WARNING
WARNING
Risk of crushing when settings down the MDA
The adjustable feet are designed so that the safety distance between the bottom of the device and the tabletop can be observed.
There is a risk of crushing when installing the MDA on the tabletop.
Measures
Do not put your hands under the base of the housing when installing the MDA.
Risk of crushing due to the device tipping over
There is a risk of the MDA tipping over during installation. An unsuitable surface may also lead to the device tipping over.
The device tipping over can lead to the severe crushing or even loss of limbs.
There is also the risk of inflicting damage to the device.
Measures
Place the MDA on a sufficiently stable and steady table.
Secure the table against rolling away.
Make sure that all four adjustable feet are completely on the tabletop.
2.4.4.3 Risks during operation
Risk of injury and/or damage caused by faulty operation.
Risk of injury and/or property damage from absence of qualification and/or incorrect and non-intended use.
Measures
Follow the instructions on proper operation.
Only use the device in perfect working order and for its intended purpose, keeping
safety and potential dangers in mind, and in compliance with the operating instructions.
Never exceed the permitted technical limit values.
Do not do work on the device
• If you do not have the required qualification
If you have not received full instructions from the operating entity
If you have not completely read or understood these operating instructions.
Risk of injury when lifting heavy objects.
There is a risk of injury when placing down and removing the objects to be measured. Objects weighing up to 30 kg can be measured.
Measures
Consider ergonomic aspects when placing down and removing the objects.
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WARNING
WARNING
WARNING
WARNING
Risk of injury when moving the measurement gantry
There is a risk of crushing when moving the measurement gantry.
Hands may be crushed between the measurement frame and the side recesses in the housing.
The device has been designed with sufficient safety distances to prevent fingers from being crushed.
Measures
Always use the handles to move the measurement gantry.
Do not grip onto the side recesses in the housing.
Risk of tripping due to cables. Risk of damage to cables
Exposed cables on the floor in areas used by people can pose a risk.
Measures
Lay the connecting cables for the hand-held scanner and the voltage supply so that
there is no risk of people tripping over them and the cables are protected against damage.
Risk of injury when transporting the MDA to the place of use
The measurement gantry may accidentally be damaged when the MDA is transported on a sliding table. Hands may be crushed between the measurement frame and the side recesses in the housing.
Measures
Use cable ties to secure the handles of the measurement gantry so that it does not
move accidentally during transport.
Danger due to malfunction!
Cease operation if the cause of the malfunction has not been clearly identified.
Measures
Immediately stop system operation if you cannot clearly identify the fault and if you
cannot safely remedy the problem.
SAFETY 2
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WARNING
NOTE
Risk of injury caused by accidental movement of the measurement gantry
Whenever work is performed on the housing interior, there is a risk of crushing if the measurement gantry moves accidentally.
There is also a risk of damage to the wire draw encoder.
Measures
Use cable ties to secure the handles of the measurement gantry so that it does not
move accidentally during maintenance and repair work.
Claims under the warranty rendered void
If the device is opened, any warranty claims against SICK AG will be void.
Measure
Do not open the device housing.

2.4.5 Protective devices

The Master Data Analyzer has been built in a way that allows for safe operation. Protective devices reduce potential risks to people and the device to the maximum possible extent.
Fig. 1: Protective devices
Four handles (1) make it easier to unpack and lift the MDA in line with ergonomic principles.
Handles (2) allow the measurement gantry to be moved safely over the object to be measured.
Cover plates (3) protect cables and electronic components.
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2.4.6 Work station

The work station for measuring objects is located on the side of the display and the hand­held scanner. The handles for moving the measurement gantry are also located on this side.
Fig. 2: Work station
We recommend placing the Master Data Analyzer on a sufficiently stable and steady table so that the measuring objects can be loaded and unloaded in line with ergonomic principles. The table must be secured against rolling away.
A sliding table is available as an accessory.

2.4.7 Protective equipment

The operating entity must wear personal protective equipment (PPE) in accordance with the locally applicable safety regulations.
Personal protective equipment for transport and installation
Wear safety shoes in addition to your basic safety equipment during transport and
installation.

2.4.8 The operating entity’s responsibilities

The operating entity must execute the electrical installation in compliance with the respective provisions of the local electricity supply company as well as applicable standards.
The following directive applies to the Master Data Analyzer:
EMC Directive: 2014/30/EU
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2.5 Protecting the environment

The Master Data Analyzer is designed to minimize its impact on the environment. Apart from the housing, the system contains no materials using silicon.
Always act in an environmentally responsible manner at work. For this reason, please note the following information regarding disposal.

2.5.1 Power consumption

All components in the Master Data Analyzer are supplied centrally with voltage via a power cable.
The MDA’s typical power consumption in running operation is around 36 watts.

2.5.2 Disposal after final decommissioning

SICK does not currently take back devices that are unusable or irreparable.
Always dispose of unusable or irreparable devices in an environmentally safe manner in accordance with the relevant national waste disposal regulations.
Always dispose of unusable or irreparable devices in an environmentally safe manner
in accordance with the relevant national waste disposal regulations.
Dispose of all electronic assemblies as hazardous waste. The electronic assemblies are
easy to dismantle.
Dispose of the controller’s battery separately as per the ROHS directives (Europe).
SAFETY 2

3 SYSTEM DESCRIPTION

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Part no.
Description
1079161
Master Data Analyzer MDA650 with a monitoring length of 650 mm
1079162
Master Data Analyzer MDA800 with a monitoring length of 800 mm
1079163
Master Data Analyzer MDA650 Image with a monitoring length of 650 mm and a fixed IP camera
1079164
Master Data Analyzer MDA800 Image with a monitoring length of 800 mm and a fixed IP camera
Part no.
Description
2087193
WLAN module with mounting kit for mobile applications
2087216
Sliding table
2087217
Sliding table with built-in rechargeable battery
6062161
Power supply unit
3 System description
This chapter provides information on the special properties of the DWS system. It describes the design and operating principle of the system solution.

3.1 Scope of delivery

The Master Data Analyzer is available in two different monitoring lengths, each of which is available with and without an IP camera.
System variants
Tab. 3: System variants
Optional accessories
Note
Tab. 4: Optional accessories
On request, the Master Data Analyzer is available with scales that can be verified. Verification takes place at the factory.
Operating the scales in LFT mode (Legal for Trade mode) is useful if the logged data are used for invoicing purposes or if certified accuracy must be ensured.
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3.2 System components

The Master Data Analyzer consists of:
1. One hand-held scanner for scanning bar code information (only in the operating mode with bar code scanning).
2. One set of rugged electronic scales with a glass panel for supporting the measuring object.
3. One moving measurement gantry with two pairs of light grids for recording the object’s dimensions and a wire draw encoder for calculating the length.
4. One controller for recording the measurement data and emitting the measurement results to the customer’s system.
5. One display for visualizing the measurement results.
6. One IP camera (only for MDA650 Image/MDA800 Image).
7. One stable mechanism for holding the components
8. One WLAN module available as an accessory for mobile applications of the MDA.
SYSTEM DESCRIPTION 3
Fig. 3: System components
1 – Hand-held scanner
In the operating mode with bar code scanning, the number used to identify the object is detected using a wired hand-held scanner. The IDM26x hand-held scanner recognizes 1D and 2D bar codes and all common stacked codes.
Fig. 4: Hand-held scanner
The hand-held scanner is connected to the MDA’s controller by a cable. This cable is used to both supply the hand-held scanner with voltage and transmit data.
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2 – Electronic scales
The electro-mechanical scales consist of a glass panel as the weighing surface (1), four weighing cells at the corners (2), one electronic evaluating system, and a separate display (3).
Fig. 5: Electronic scales
Four positioning points are used for measurement. These points transfer the force to the weighing cells installed on the corners. The glass panel made of safety glass makes sure the force is distributed evenly on all four corners.
The scales’ display only visualizes the recorded object weight.
3 – Measurement gantry with MLG-2 light grids and wire draw encoder
The measurement gantry consists of a horizontal and vertical pair of light grids, which are arranged at right angles. Both pairs of light grids determine the object’s contour based on the principles of shadows.
Each pair of light grids consists of a sender unit with emitting diodes and a receiver unit with receiving diodes.
Fig. 6: MLG-2 light grids
SYSTEM DESCRIPTION 3
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The horizontal light grid’s is mounted on the frame underneath the glass plate with the receiver above it. This minimizes any interference caused by ambient light or dirt. The beam from the lower light grid passes through the glass plate to the upper light grid. The vertical light grid’s sender is secured to the frame with two handles.
Wire draw encoder
Fig. 7: Measurement gantry with light grids
A wire draw encoder mounted in the housing interior supplies the positional data of the light grids above the object which is required for measuring lengths. The encoder transfers the linear movement obtained from the path of the measurement gantry into a rotational movement. The drum rotation, which is proportional to the length, is output to the controller via corresponding incremental signals regarding the exact positioning of the light grids.
Fig. 8: Wire draw encoder
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4 – Controller MSC800
The controller housing contains the MSC800 system controller and the power supply unit for the central voltage supply.
Fig. 9: Controller MSC800
The MSC800 is the system’s central control unit. It controls the coordination of the individual components and processes all incoming signals. The measurement results are transmitted via the Ethernet interface to the higher-level customer system.
5 – Display
The display is the system’s central visualization unit. It displays the measured values from the various components during operation and allows for the convenient handling of error messages.
Fig. 10: Display
6 – IP camera (MDA650 Image/MDA800 Image only)
An IP camera mounted on the measurement gantry generates a photo-realistic image of the object during the measurement process. The photo is transmitted to the higher-level customer system together with the measurement data.
The IP camera is supplied with power via PoE (power over Ethernet).
Fig. 11: IP camera (MDA650 Image/MDA800 Image only)
SYSTEM DESCRIPTION 3
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7– Housing
All of the Master Power Analyzer’s components are integrated into a stable mechanical system.
The recesses on the long sides of the housing are required for the measurement gantry to travel along the linear guides. The recesses are sealed on both sides with brushes.
Fig. 12: Housing
8 – WLAN module
The WLAN Ethernet Port Adapter, which is available as an accessory for the controller housing, enables the Ethernet interface to be connected wirelessly to a WLAN access point. This enables measurement results to be transmitted to the customer system when using the MDA in a mobile setup, regardless of the measurement location.
Fig. 13: WLAN module
The WLAN Ethernet Port Adapter has a circular, polarized 5 dB directional antenna that also enables it to be used in surroundings with a high number of reflections from metals.
Sliding table
On request, the Master Data Analyzer is available with a sliding table, with or without a rechargeable battery.
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3.3 The system’s operating principle

The Master Data Analyzer is designed for stationary and mobile use, depending on the system variant.
In the stationary variant, the Master Data Analyzer is placed at a fixed location and connected (e.g., at the receiving work station). With the mobile variant, data can be recorded at any chosen location (e.g., right on the high-bay racking). A WLAN adapter must be connected in this case.
The measurement process depends on the operating mode in question.
Fig. 14: Measurement process for each operating mode
In the operating mode with bar code scanning, the measuring process starts once the object has been placed on the measurement field and the bar code has been scanned. The volume and weight are then measured in one procedure.
In the operating mode without bar code scanning, the measuring process starts with the weight measurement. The volume cannot be measured until a stable weight value is present.
SYSTEM DESCRIPTION 3
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Placing an object in the measurement field
The measurement object is placed in the clear-glass area of the glass plate. This area marks the measurement field, i.e., the area in which the object can be captured by the light grids. If the object, or any part of it, is outside of the measurement field (in the opal glass area) an error message will be issued.
Fig. 15: Marked measurement field on the glass panel
Bar code reading (only for operating mode with bar code scanning)
The wired hand-held scanner identifies the object and transmits the shipping number to the controller. The scanner creates a scan line on the object to read the bar code using a red light. The bar code that is read is then shown on the display.
Fig. 16: Operating principle – bar code reading
Note
The bar code can also be entered manually using the display.
Weight measurement (only for operating mode with bar code scanning)
In the operating mode without bar code scanning, the measuring process starts with the system detecting a stable weight value. Bar codes cannot be scanned or processed.
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Measuring the volume
The volume measurement is carried out if a valid bar code or stable weight value is available.
To do so, the light grids mounted on the measurement gantry are manually moved over the measurement object using the two linear guides. Measurements can be taken in both directions, stopped whilst doing so, and then recommenced.
If the monitoring field is interrupted by an object, the shadowing and the resulting number of interrupted light beams on the receiver lines can be used to detect the profile of the object.
The change in the number of beams on the receiver lines as a result of the shadowing is transmitted via the light grids’ interfaces to the MSC800 as a digital signal.
Two-dimensional cross sections are created by moving the light grids across the object. The controller then combines the individual 2D cross sections of the object.
Fig. 17: Operating principle – volume measurement
By taking into consideration the speed with which the measurement gantry is moved across the object and the respective position of the light grids above the object, a spatial image is produced which is used to calculate the smallest possible cuboid which could surround the object as well as its volume.
SYSTEM DESCRIPTION 3
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Weighing process
In the operating mode with bar code scanning, the weighing process takes place in parallel to the volume measurement; in the operating mode without bar code scanning, the weight is calculated once the object has been positioned, i.e., before the volume measurement.
The weighing cells determine the weight of the object by using the four recording points at the corners of the glass panel whilst the object is situated on the glass panel.
The electronic scales use weighing cells with strain gauges to bear the weight to be measured. Strain gauges are metallic conductors which convert mechanical actions of force into an electronic signal. Strain gauge weighing cells use the physical principle that an electrical conductor changes its electrical resistance as a result of mechanical changes.
Fig. 18: Operating principle – Weighing process
If a load is placed on the glass panel, this causes the strain gauges to deform. As a result of this deformation causing the resistance in the strain gauges to change, the weight of the load can be determined by using the electronic scales. The greater the deformation, the greater the resistance due to the strain and, as a result, the heavier the weight of the measured object.
In order to achieve maximum measurement accuracy, the electronic signal resulting from the change in resistance is converted to a digital signal by an integrated A/D converter (analog-digital transducer).
The weight recorded is then shown on the display. It is added to the bar code already displayed.
If the weight value of an object is outside of the pre-configured absolute limit values, this is output as an error in the measurement report.
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Visualization of measurement results
All of the measurement data recorded by the MDA is constantly shown on the display. The measurement is additionally displayed in the form of a 2D visualization.
If the MDA650 Image / MDA 800 Image system variant is in use, the symbol for the live display appears on the right, next to the measurement field.
Fig. 19: Operating principle – Visualization of measurement results
Output of measured values
All information converges in the MSC800 central control unit. The MSC800 processes the encoder signals and assigns the measurement results from the individual systems to the respective object.
Depending on the system variant, the output of measured values are sent to the higher­level customer system via Ethernet (LAN) or via a WLAN access point.
When using the MDA650 Image/MDA800 Image), a photo-realistic image of the measuring object can be emitted with the measurement results.
Note
In the operating mode with bar code scanning, the measurement results are stored temporarily during the output of measured values if the device is not connected to the customer server. This allows multiple measurements to be carried out in sequence, even without a connection. Data are transmitted automatically as soon as the connection is available again.
In the operating mode without bar code scanning, the data must be transferred directly after the measurement otherwise the data cannot be allocated to the bar code in the customer system. The temporary storage of measurement results is not supported.
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