OPERATING INSTRUCTIONS

MLS with RS485 Modbus RTU

Line guidance sensors
 Described product
MLS
MLSE-0200
MLSE-0300
MLSE-0400
MLSE-0500
MLSE-0600

Manufacturer
SICK AG
Erwin-Sick-Str. 1
79183 Waldkirch
Germany

Production location
SICK GHU, Hungary

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 modi‐
fication, abridgment 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.

NO

2006/42/EC
SAFETY

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 CONTENTS

Contents
1 About this document........................................................................ 5
1.1 Information on the operating instructions.............................................. 5
1.2 Scope......................................................................................................... 5
1.3 Explanation of symbols............................................................................ 5
1.4 Further information................................................................................... 6
1.5 Customer service...................................................................................... 6

2 Safety information............................................................................ 7
2.1 Intended use............................................................................................. 7
2.2 Improper use............................................................................................. 7
2.3 Limitation of liability................................................................................. 7
2.4 Requirements for skilled persons and operating personnel.................. 8
2.5 Hazard warnings and operational safety................................................. 8
2.6 Repairs...................................................................................................... 8

3 Product description........................................................................... 9
3.1 Product identification............................................................................... 9
3.2 Product characteristics............................................................................ 10

4 Transport and storage....................................................................... 13

4.1 Transport................................................................................................... 13
4.2 Transport inspection................................................................................. 13
4.3 Storage...................................................................................................... 13

5 Mounting............................................................................................. 14
5.1 Preparation for mounting......................................................................... 14
5.2 Mounting the sensor................................................................................ 15
5.3 Mounting of the magnetic tape............................................................... 16

6 Electrical installation........................................................................ 21
6.1 Safety......................................................................................................... 21
6.2 Pin assignment of the connections......................................................... 23
6.3 Connecting the supply voltage................................................................. 23
6.4 RS485 Modbus RTU connection............................................................. 24

7 Commissioning.................................................................................. 25
7.1 Overview of commissioning steps........................................................... 25
7.2 Commissioning the sensor for the first time.......................................... 25
7.3 Quick-start guide for the MLS with Modbus RTU.................................... 25

8 Operation............................................................................................ 26
8.1 Modbus RTU.............................................................................................. 26
8.2 Operating and status indicators.............................................................. 30
8.3 Teach-in mode........................................................................................... 31
8.4 Track guidance.......................................................................................... 32

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CONTENTS

8.5 Marker detection...................................................................................... 40

8.6 Inertial measuring unit............................................................................. 42
8.7 Temperature sensor.................................................................................. 45
8.8 Event detection......................................................................................... 45
8.9 Status........................................................................................................ 46

9 Maintenance...................................................................................... 48
9.1 Maintenance............................................................................................. 48
9.2 Repairs...................................................................................................... 48

10 Decommissioning............................................................................. 49
10.1 Decommissioning..................................................................................... 49

11 Troubleshooting................................................................................. 50

12 Technical data.................................................................................... 51

13 Annex.................................................................................................. 53
13.1 Conformities and certificates................................................................... 53
13.2 Modbus RTU Spezifikationen................................................................... 53
13.3 RTU Transmission Mode........................................................................... 53
13.4 Data Model................................................................................................ 53
13.5 Example Function 04 Read Input Registers............................................ 54
13.6 Example Function 16 (10Hex) Preset Multiple Registers...................... 54

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 ABOUT THIS DOCUMENT 1

1 About this document

1.1 Information on the operating instructions

These operating instructions provide important information on how to use sensors from
SICK AG.
Prerequisites for safe work are:
• Compliance with all safety notes and handling instructions supplied.
• Compliance with local work safety regulations and general safety regulations for
sensor applications.
The operating instructions are intended to be used by qualified personnel and electrical
specialists.

NOTE
Read these operating instructions carefully before starting any work on the sensor, in
order to familiarize yourself with the sensor and its functions.

The instructions constitute an integral part of the product and are to be stored in the
immediate vicinity of the sensor so they remain accessible to staff at all times. If the
sensor is passed on to a third party, these operating instructions should be handed
over with it.
These operating instructions do not provide information on operating the machine
in which the sensor is integrated. For information about this, refer to the operating
instructions of the particular machine.

1.2 Scope
These operating instructions are used for incorporating a sensor into a customer sys‐
tem. Step-by-step instructions are given for all the actions required.
These instructions apply to all available device variants of the sensor.

Available device variants are listed on the online product page.

► www.sick.com/mls

Commissioning is described using one particular device variant as an example.

Simplified device designation in the document

In the following, the sensor is referred to in simplified form as “MLS”.

1.3 Explanation of symbols

Warnings and important information in this document are labeled with symbols. The
warnings are introduced by signal words that indicate the extent of the danger. These
warnings must be observed at all times and care must be taken to avoid accidents,
personal injury, and material damage.

DANGER
… indicates a situation of imminent danger, which will lead to a fatality or serious
injuries if not prevented.

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1 ABOUT THIS DOCUMENT

WARNING
… indicates a potentially dangerous situation, which may lead to a fatality or serious
injuries if not prevented.

CAUTION
… indicates a potentially dangerous situation, which may lead to minor/slight injuries if
not prevented.

NOTICE
… indicates a potentially harmful situation, which may lead to material damage if not
prevented.

NOTE
… highlights useful tips and recommendations as well as information for efficient and
trouble-free operation.

1.4 Further information

NOTE
All the documentation available for the sensor can be found on the online product page
at:
► www.sick.com/mls
The following information is available for download from this page:
• Type-specific online data sheets for device variants, containing technical data and
dimensional drawings
• EU declaration of conformity for the product family
• Dimensional drawings and 3D CAD dimension models in various electronic for‐
mats
• These operating instructions, available in English and German, and in other lan‐
guages if necessary
• Other publications related to the sensors described here
• Publications dealing with accessories

1.5 Customer service

If you require any technical information, our customer service department will be happy
to help. To find your representative, see the final page of this document.

NOTE
Before calling, make a note of all type label data such as type code etc. to ensure faster
processing.

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 SAFETY INFORMATION 2

2 Safety information
2.1 Intended use
The MLS sensor is a non-contact sensor used to determine the position of a magnetic
line tape.
SICK AG assumes no liability for losses or damage arising from the use of the product,
either directly or indirectly. This applies in particular to use of the product that does not
conform to its intended purpose and is not described in this documentation.

NOTICE
Radio interference may occur when the sensor is used in residential areas.
► Only use the device in industrial environments (EN 61000-6-4).

2.2 Improper use

• The sensor does not constitute a safety-relevant device according to the EC Machi‐
nery Directive (2006/42/EC).
• The sensor must not be used in explosion-hazardous areas.
• Any other use that is not described as intended use is prohibited.
• Any use of accessories not specifically approved by SICK AG is at your own risk.
• The sensor is not suitable for outdoor applications.

NOTICE
Danger due to improper use!
Any improper use can result in dangerous situations.
Therefore, take note of the following information:
► The sensor should be used only in line with intended use specifications.
► All information in these operating instructions must be strictly complied with.

2.3 Limitation of liability

Applicable standards and regulations, the latest state of technological development,
and our many years of knowledge and experience have all been taken into account
when assembling the data and information contained in these operating instructions.
The manufacturer accepts no liability for damage caused by:

■ Failing to observe the operating instructions

■ Improper use
■ Use by untrained personnel
■ Unauthorized conversions
■ Technical modifications
■ Use of unauthorized spare parts, consumables, and accessories

With special variants, where optional extras have been ordered, or owing to the latest
technical changes, the actual scope of delivery may vary from the features and illustra‐
tions shown here.

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2 SAFETY INFORMATION

2.4 Requirements for skilled persons and operating personnel

WARNING
Risk of injury due to insufficient training.
Improper handling of the sensor may result in considerable personal injury and material
damage.
■ All work must only ever be carried out by the stipulated persons.

The operating instructions state the following qualification requirements for the various
areas of work:
■ Instructed personnel have been briefed by the operating entity about the tasks
assigned to them and about potential dangers arising from improper action.
■ Skilled personnel have the specialist training, skills, and experience, as well as
knowledge of the relevant regulations, to be able to perform tasks assigned to
them and to detect and avoid any potential dangers independently.
■ Electricians have the specialist training, skills, and experience, as well as knowl‐
edge 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. In
Germany, electricians must meet the specifications of the BGV A3 Work Safety
Regulations (e.g., Master Electrician). Other relevant regulations applicable in
other countries must be observed.

The following qualifications are required for various activities:

Activities Qualification
Mounting, maintenance ■ Basic practical technical training
■ Knowledge of the current safety regulations in the workplace
Electrical installation, ■ Practical electrical training
device replacement ■ Knowledge of current electrical safety regulations
■ Knowledge of the operation and control of the devices in their
particular application
Commissioning, configura‐ ■ Basic knowledge of the design and setup of the described
tion connections and interfaces
■ Basic knowledge of data transmission
■ Knowledge of the operation and control of the devices in their
particular application
Operation of the devices in ■ Knowledge of the operation and control of the devices in their
their particular application particular application
■ Knowledge of the software and hardware environment in the
application

2.5 Hazard warnings and operational safety

Please observe the safety notes and the warnings listed here and in other chapters
of these operating instructions to reduce the possibility of risks to health and avoid
dangerous situations.

2.6 Repairs
Repair work on the sensor may only be performed by qualified and authorized person‐
nel from SICK AG. Interruptions or modifications to the sensor on the part of the
customer will invalidate any warranty claims against SICK AG.

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 PRODUCT DESCRIPTION 3

3 Product description
3.1 Product identification

3.1.1 Type label

4 3 2
Figure 1: Type label
1 Type designation
2 Article number (P/N)
3 Serial number (S/N)
4 Production date (YYWW)

3.1.2 Device view

3
2
4

Figure 2: Device view

1 Aluminum housing with T-slot
2 Front end cap with capacitive teachpad
3 2 x LED indicators
4 Cable outlet
5 Rear end cap

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3 PRODUCT DESCRIPTION

(0.79)
20
3
2

ø 8.2 (0.32)
L1

ø 2.6 (0.10)
19.5 20
(0.79)
(0.77)

14 (0.55)
7.5 (0.3)
Total length
(L1) mm

MLSE-0200 217
MLSE-0300 325
MLSE-0400 397
MLSE-0500 505
MLSE-0600 613

Figure 3: Dimensional drawing

3.2 Product characteristics

3.2.1 Product features

The MLS is a non-contact sensor used to determine the position of a magnetic track
tape or the position of up to three track tapes simultaneously; these tapes are primarily
used in conjunction with AGCs (autonomous guided carts).
The sensor is also capable of detecting defined markers positioned adjacent to the
actual line.

3.2.2 Operating principle

Principle of operation
The MLS determines the position of the magnetic tape via a row of hall sensors. The
raw data from the hall sensors is fed into an algorithm to calculate the position of the
line tape.

Line position
The line position is indicated relative to the geometric center of the longitudinal axis of
the sensor. However, this only applies when the user has not set an offset for the zero
position.

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 PRODUCT DESCRIPTION 3

– +

Resolution
Resolution refers to the minimum position change of the magnetic tape relative to the
sensor that can be reflected in the sensor output.

Cycle time
The cycle time indicates the time interval within which the sensor can provide a new
output signal.

Repeatability
Repeatability refers to the change in output signal when the relative position of the
magnetic tape to the sensor does not change.

Orientation of the sensor

The orientation of the sensor determines the tilt of the sensor around the gravity axis
(expressed with roll and pitch angle) as well as the torsion of the sensor around this
axis (expressed by the yaw angle).

3.2.3 Suitable magnetic tape

The recommended magnetic tape width is 25 mm. Other dimensions should be tested
for suitability before use.
The sensor is compatible with
• Magnetic tape with a single pole pair (north or south), unipolar magnetization on
one side
• Various magnetic tape widths
• Various distances from the magnetic tape
Table 1: Magnetic tape

N S S N S N S N S
S N N S N S N S N

With magnetic tape that uses another form of magnetization (e.g., strip magnetization),
correct functioning cannot be guaranteed.
Suitable magnetic tapes are available as accessories for the MLS, see www.sick.com/
MLS.

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3 PRODUCT DESCRIPTION

NOTE
The suitability of foreign magnetic tapes should be checked before use.
1. Hold the MLS over the magnetic tape at the desired working distance.
✓ The track level (218) output should be ≥ 4 and therefore in the green range.
Please note that magnetic tapes of inferior quality may experience a sharp reduction
in field strength over their useful life and may therefore no longer be sufficient for
navigation.

Table 2: Track Levels

Track Level
Good (green) 7
Sensor detects the tape as specified
6
5
4
Critical (yellow) 3
Sensor detects the tape as specified, but near
2
the limits
1
Bad (red) 0
Sensor detects the tape, but not within the
specified range

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 TRANSPORT AND STORAGE 4

4 Transport and storage

4.1 Transport
For your own safety, please read and observe the following notes:

NOTE
Damage to the sensor due to improper transport.
■ The device must be packaged for transport with protection against shock and
damp.
■ Recommendation: Use the original packaging as it provides the best protection.
■ Transport should be performed by specialist staff only.
■ The utmost care and attention is required at all times during unloading and
transportation on company premises.
■ Note the symbols on the packaging.
■ Do not remove packaging until immediately before you start mounting.

4.2 Transport inspection

Immediately upon receipt at the receiving work station, check the delivery for complete‐
ness and for any damage that may have occurred in transit. In the case of transit
damage that is visible externally, proceed as follows:
■ Do not accept the delivery or only do so conditionally.
■ Note the scope of damage on the transport documents or on the transport compa‐
ny’s delivery note.
■ File a complaint.

NOTE
Complaints regarding defects should be filed as soon as these are detected. Damage
claims are only valid before the applicable complaint deadlines.

4.3 Storage
Store the device under the following conditions:
■ Recommendation: Use the original packaging.
■ Do not store outdoors.
■ Store in a dry area that is protected from dust.
■ So that any residual damp can evaporate, do not package in airtight containers.
■ Do not expose to any aggressive substances.
■ Protect from sunlight.
■ Avoid mechanical shocks.
■ For storage periods of longer than 3 months, check the general condition of all
components and packaging on a regular basis.

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5 MOUNTING

5 Mounting
5.1 Preparation for mounting

5.1.1 Mounting requirements

NOTICE
Radio interference may occur when the sensor is used in residential areas.
Only use the device in industrial environments (EN 61000-6-4).

■ Typical space requirements for sensor, see "Mechanics/electronics", page 51.

■ Comply with technical data such as the permitted ambient conditions for operation
of the sensor (e.g., temperature range, EM interference), see "technical data",
page 51.
■ Protect the sensor from direct sunlight.
■ Only affix the sensor using accessories supplied for this purpose -> there are no
screw connections on the sensor.

Mounting location
When selecting the mounting location, the following factors must be considered:
■ The mounting site must be as free from (electro-)magnetic interference fields
as possible and should therefore not be in the immediate vicinity of unshielded
electric motors.
■ The sensor should not be mounted in the direct vicinity of ferromagnetic materials.
If this cannot be avoided, the interference field compensation in section 8.4.5 can
help.
■ The sensor must be fitted on the AGC at a 90° angle to the direction of travel.
■ The sensor must be fitted with the greatest possible accuracy in a horizontal
position.
■ The sensor must be fitted with the label facing upward.
■ The center point of the sensor should be positioned at the AGC center point, at a
right angle to the direction of travel if possible.
■ The working distance between the sensor and SICK magnetic tape is 10 mm -
70 mm1). The use of other magnetic tapes is possible, but should be tested in
advance (see "Suitable magnetic tape", page 11).

90 °
10 - 70 mm
90 °

Figure 4: Mounting location

5.1.2 Scope of delivery

The following are included with delivery:
• 1 MLS sensor in the version ordered
• 1 quick-start guide

1) With magnetic averaging value “4”, see "Average filter for track output values", page 37

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 MOUNTING 5

Accessories:
Accessories (e.g., cables, fastening adapters) are only supplied if ordered separately.
The available accessories are listed at www.sick.com/mls.

5.2 Mounting the sensor

3
2
1

Figure 5: Horizontal mounting

1 MLS-xxx
2 Mounting bracket, part number number 2065973
3 Mounting panel

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5 MOUNTING

1
Figure 6: Vertical mounting

1 MLS-xxx
2 Mounting bracket, part number number 2065577
3 Mounting panel

5.3 Mounting of the magnetic tape

To navigate AGCs, the MLS is aligned to the Line Center Point of a magnetic tape, which
specifies the route of the AGC. The magnetic tape is stuck to the ground or embedded
in the ground. The criteria for selecting the suitable magnetic tape are described in
chapter 3.2.3. SICK offers respective self-adhesive magnetic tapes as accessories for
the MLS (see www.sick.com/MLS).

NOTE
The following information is based on internal test results. However, this does not mean
that all users do not have to test the suitability of the magnetic tape for their intended
purposes.

5.3.1 Preparation
The SICK magnetic tape is well-suited for laying in the inner area. The following points
must be ensured before mounting the magnetic tape:
• The surface must be fixed, flat and closed.
° Moisture and contamination such as dirt, grease, dust, etc. must be removed
to make sure the magnetic tape will really hold. Use clean cloths and solvents
(e.g. benzine, acetone, pure alcohol) or floor cleaners with degreasing effect.
Make sure the substrate can tolerate any solvents used.
• Any paint surfaces must adhere firmly, be free of solvents and silicone and be
completely dry.
• After cleaning with solvents, let the substrate air out for about 10 minutes.

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 MOUNTING 5

• The ambient and surface temperature should be at least +15 °C; if applicable,
provide for supply of warm air before, during and after processing. This activates
the adhesive very well.
• The route should be as free of ferromagnetic materials as possible.
A sample adhesion of the magnetic tape is recommended.

5.3.2 Laying
Before laying the magnetic tape, plan out the route on the ground in line with the layout.
Gaps and magnetic tape overlap should be avoided. Overlaps can be used specifically
for intersections (see Intersections).
• Remove about 10 cm of protective paper from the back of the magnetic tape.
• Place the exposed end of the strip in the correct position. Press firmly. Use your
hand to peel off the rest of the protective paper. Rub the strip well with the other
hand. With a suitable pressure roller or a wood roller, press down on the marking
tape.
• With wide strips, always roll from the center to the edge to roll out air pockets.
Curves
The magnetic tapes from SICK are suitable for laying curves with large radii. Smaller
radii can be laid with the curved magnetic tape available as an accessory. Alternatively,
the magnetic tape can be cut and stuck together in a flush position. A minimum curve
radius of 1.5 m must be ensured; also ensure that the “field of view” of the MLS on the
AGC does not leave the track, which causes detection to fail.

Figure 7: Laying curves

Diverters
To create diverters, one track per side can be detected in addition to the main track. If
the diverters are stuck together so that the forked track comes directly out of the main
track, data output as improved track detection at diverters (118) is recommended.

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5 MOUNTING

l l l

l l l

Diverters, in the case of the flush variant, should not be overlapping. In line with this,
the area marked in red should always be removed.
1

Figure 8: Flush variant

1 150 ... 200 mm

With the non-flush variant, for the best possible detection, the diverter should run
150 mm parallel to the main track before changing direction. The distance to the main
track should not be less than the track width.

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 MOUNTING 5

Figure 9: Non-flush variant

Intersections
For track intersections (the track tapes cross at a 90° angle), one track should be
completely glued over the other. No diverter should follow at a distance of 200 mm
before and after the intersection, taking into account the speed of travel.
Splitting a track tape and attaching a bump to the through track tape is not recom‐
mended. This leads to difficulties in track detection, since the sensor does not output
a valid position value in the intersection. Only in the ideal case does the sensor detect
such a situation and output the following process data:
#LCP = 7; LCP1 = LCP2 = LCP3

Zones

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5 MOUNTING

The MLS can detect and differentiate between both magnetic tape with north pole on
the top side (5337613) and south pole on the top side (5337614). To limit zones on
a route, it is therefore possible to change from one magnetic tape to the other in a
targeted manner.
Markers
The MLS is capable of detecting magnetic codes using so-called markers next to the
main track. For a detailed description, see chapter section 8.5.
For more information on parameterization, see section 8.4.5.

5.3.3 Protection
To protect the magnetic tape if there is a strong mechanical load, a protective tape or
protective epoxy layer can be attached to the magnetic tape.
In general, rotating or turning vehicles on the magnetic tape, as well as moving objects
like pallets against the tape, should be avoided. If this cannot be avoided, lowering the
magnetic tape into the ground is recommended.

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 ELECTRICAL INSTALLATION 6

6 Electrical installation
6.1 Safety

6.1.1 Notes on the electrical installation

CAUTION
Danger due to incorrect supply voltage!
An incorrect supply voltage may result in injuries from electric shocks and/or damage to
the device.
■ Only operate the sensor with safety extra-low voltage (SELV).

NOTICE
Sensor damage or unpredictable operation due to working with live parts.
Working with live parts may result in unpredictable operation.
■ Only carry out wiring work when the power is off.
■ Only connect and disconnect electrical connections when the power is off.

■ The electrical installation must only be performed by electrically qualified person‐

nel.
■ Standard safety requirements must be met when working in electrical systems.
■ Only switch on the supply voltage for the device when the connection tasks have
been completed and the wiring has been thoroughly checked.
■ When using extension cables with open ends, ensure that bare wire ends do not
come into contact with each other (risk of short-circuit when supply voltage is
switched on!). Wires must be appropriately insulated from each other.
■ Wire cross-sections in the supply cable from the customer’s power system must be
designed in accordance with the applicable standards. When this is being done in
Germany, observe the following standards: DIN VDE 0100 (Part 430) and DIN VDE
0298 (Part 4) and/or DIN VDE 0891 (Part 1).
■ Circuits connected to the device must be designed as SELV circuits (SELV = Safety
Extra Low Voltage).
■ Protect the device with a separate fuse at the start of the supply circuit.

A shielded cable is not required in order to adhere to the electromagnetic compatibility

guidelines specified by EN 61000-6-2/4. It is recommended, however, especially when
working with longer connecting cables.

The IP enclosure rating for the sensor is only achieved if the connected cable is
completely screwed in.

6.1.2 Wiring notes

NOTE
Preassembled cables can be found online at:

Please observe the following wiring notes:

■ During installation, pay attention to the different cable groups. The cables are
grouped into the following four groups according to their sensitivity to interference
or radiated emissions:

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6 ELECTRICAL INSTALLATION

° Group 1: Cables very sensitive to interference, such as analog measuring

cables
° Group 2: Cables sensitive to interference, such as sensor cables, communi‐
cation signals, bus signals
° Group 3: Cables which are a source of interference, such as control cables
for inductive loads, motor brakes
° Group 4: Cables which are powerful sources of interference, such as out‐
put cables from frequency inverters, welding system power supplies, power
cables
► Cables in groups 1, 2 and 3, 4 must be crossed at right angles, see figure 10.
► Cables in groups 1, 2 and 3, 4 must be routed in different cable channels
or metallic separators must be used, see figure 11 and see figure 12. This
applies particularly where cables of devices with a high level of radiated
emission, such as frequency converters, are laid parallel to sensor cables.
1

2
3

3 90
4
4
2
1
90

Figure 10: Cross cables at right angles

1 3

2 4

Figure 11: Ideal laying – Place cables in different cable channels

23

Figure 12: Alternative laying – Separate cables with metallic separators

NOTE
Prevent equipotential bonding currents via the cable shield with a suitable grounding
method, see "Safety", page 21.

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 ELECTRICAL INSTALLATION 6

6.2 Pin assignment of the connections

M8 connection
3 1

4 2

Figure 13: Pin assignment: M8-male, A-coded, 4-pin

PIN Wire color Pin assignment

1 Brown L+
2 White RS-485_D+ (not inverted)
3 Blue GND
4 Black RS-485_D- (inverted)

M12 connection
2 1

3 4

Figure 14: Pin assignment: M12-male, A-coded, 4-pin

PIN Wire color Pin assignment

1 Brown L+
2 White RS-485_D+ (not inverted)
3 Blue GND
4 Black RS-485_D- (inverted)

Cable outlet
Wire color Pin assignment
Brown L+
White RS-485_D+ (not inverted)
Blue GND
Black RS-485_D- (inverted)

6.3 Connecting the supply voltage

The sensor must be connected to a voltage supply with the following properties:
• Supply voltage DC 9 V ... 30 V (stabilized safety extra-low voltage [SELV] as per
current standard EN 60950-1)
• Electricity source with at least 5 W power

Protecting the supply cables

To ensure protection against short-circuits/overload in the customer’s supply cables,
the conductor cross sections used must be appropriately selected and protected.
The following standards must be observed in Germany:
• DIN VDE 0100 (part 430)
• DIN VDE 0298 (part 4) and/or DIN VDE 0891 (part 1)

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6 ELECTRICAL INSTALLATION

6.4 RS485 Modbus RTU connection

The sensor is available with a 120 Ohm terminator as an option.
The selection of the version with or without the internal terminator is made via the
product short text:
• MLSE-0200A2TP0 → T = Termination, internal 120 Ohm terminator
• MLSE-0200A2NP0 → N = No termination, no internal 120 Ohm terminator

NOTE
For the variant without an internal terminator, we strongly recommend connecting
an external 120 Ohm terminator at both ends of the Modbus network for maximum
protection against electromagnetic interference.

L+
M

RS485 GND
RS-485_D- Modbus
RTU
RS-485_D+ Master

Figure 15: MLS with terminator

L+
M Modbus RTU

RS485 GND
RS-485_D-
RS-485_D+

Figure 16: MLS without terminator

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 COMMISSIONING 7

7 Commissioning
7.1 Overview of commissioning steps
■ Connect the voltage supply.
■ Commission the sensor using the factory settings.
■ Configure the sensor.

7.2 Commissioning the sensor for the first time

Establish voltage supply: When the voltage supply is correct and no line is detected by
the sensor, the green LED flashes in the following pattern:
ON: 0.8 s, OFF: 0.2 s
If at least one line is detected with sufficient magnetic field strength, the yellow LED
lights up.
If exactly one line is detected, the approximate position is indicated via the green and
blue LED.

7.3 Quick-start guide for the MLS with Modbus RTU

7.3.1 Setting ID and bit rate

The following conditions must be met for communication with the Modbus master:
• A correct device id must be set on the MLS.
Correct is:
- A device id that is not yet assigned in the Modbus network
- A device id that the master expects
• The same baud rate must be set on the MLS as in the master. The following
parameters are factory set on the MLS:
° device id: 10 (allowed values 1 ... 247)
° Baud rate: 19,200 bps
• The following communication parameters can be allocated to the MLS:
° Slave address: 1 to 247 (0 is generally assigned to the master)
° Baud rate:
0: 1,200 bps
1: 2,400 bps
2: 4,800 bps
3: 9,600 bps
4: 19,200 bps
5: 38,400 bps
6: 57,600 bps
7: 115,200 bps
° Data bits: 8
° Stop bits: 1
° Parity: even

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8 OPERATION

8 Operation
8.1 Modbus RTU
“Input registers” register group (read-only)
The Input registers can be read using function code 0x04.

Device identification section

The Device Identification79 details (all of data type ASCII string) can be found from 0x00 onwards in the address
range of the Input register.
Table 3: Device identification
Register Register Parameter name Data type Description
no. width
0 4 Vendor name String Name of the manufacturer
4 4 Order number String Part number
8 6 Firmware version String Firmware version
14 6 Vendor URL String URL manufacturer
20 16 Product name String Product name
36 9 Model name String Product type
45 4 Serial number String Serial number
Format: YYWW-nnnn
YY: Year of manufacture
WW: Week of manufacture
nnnn: Sequential number
49 16 Application name String User-defined text, read only
65 6 Sick Modbus profile version String Sick Modbus profile version
71 4 Software revision number String Software revision number
75 4 Hardware revision number String Hardware revision number

Index section
The registers of the Index section contain the addresses (data type UINT16) of the subsequent sections. The
registers are therefore all 2 bytes in size and hold the same content. The values are stored in the following table:
Table 4: Index section
Register Register Parameter name Data type Description
no. width
128 1 Number of sections within table Uint16 Number of sections
129 1 Length of section 1 - Status (in register Uint16 Length of section 1 - Status
addresses)
130 1 Start address of section 1 Uint16 Start address of section 1
131 1 Register type of section 1 Uint16 Register type of section 1
132 1 Length of section 2 - Results (in register Uint16 Length of section 2 - Results
addresses)
133 1 Start address of section 2 Uint16 Start address of section 2
134 1 Register type of section 2 Uint16 Register type of section 2
135 1 Length of section 3 - Commands (in regis‐ Uint16 Length of section 3 - Commands
ter addresses)
136 1 Start address of section 3 Uint16 Start address of section 3
137 1 Register type of section 3 Uint16 Register type of section 3

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 OPERATION 8

Register Register Parameter name Data type Description

no. width
138 1 Length of section 4 - Configuration (in reg‐ Uint16 Length of section 4 - Configuration
ister addresses)
139 1 Start address of section 4 Uint16 Start address of section 4
140 1 Register type of section 4 Uint16 Register type of section 4

Result section
The result data start at address 0xC0:
Table 5: Result section
Register Register Parameter name Data type Description
no. width
192 1 LCP1 Int16 Line center point 1
193 1 LCP2 Int16 Line center point 2
194 1 LCP3 Int16 Line center point 3
195 1 #LCP Uint8 Number specifying the quantity of
detected tracks and marks
196 1 Status Uint8 Status
197 1 LCP1 width Uint8 Line width 1
198 1 LCP2 width Uint8 Line width 2
199 1 LCP3 width Uint8 Line width 3
200 1 Line level 1 Int8 Magnetic field strength of track 1
201 1 Line level 2 Int8 Magnetic field strength of track 2
202 1 Line level 3 Int8 Magnetic field strength of track 3
203 1 Roll Int16 Euler angle orientation - Roll angle ϕ
204 1 Pitch Int16 Euler angle orientation - Pitch angle θ
205 1 Yaw Int16 Euler angle orientation - Yaw angle ψ
206 1 Time stamp Uint16 Time stamp in ms for raw data values /
orientation
207 1 w(real part) Int16 Quaternion orientation - real part
208 1 x (imaginary part) Int16 Quaternion orientation - 1st imaginary part
209 1 y (imaginary part) Int16 Quaternion orientation - 2nd imaginary
part
210 1 z (imaginary part) Int16 Quaternion orientation - 3rd imaginary part
211 1 Time stamp Uint16 Time stamp in ms for raw data values /
orientation
212 1 Current temperature Int8 Current temperature
213 1 Max. temperature all time Int8 Maximum temperature during the entire
uptime of the sensor
214 1 Min. temperature all time Int8 Minimum temperature during entire
uptime of the sensor
215 1 LCP1 combi Uint16 Combination of LCP1 and LCP1 width
216 1 LCP2 combi Uint16 Combination of LCP2 and LCP2 width
217 1 LCP3 combi Uint16 Combination of LCP3 and LCP3 width
218 1 Track level Uint16 Evaluation of the magnetic field strength of
the track as a 3-bit value to associate the
field level with the track level

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8 OPERATION

Register Register Parameter name Data type Description

no. width
219 1 Field level Uint16 Maximum measured magnetic field
strength
220 1 Hall value 1 Int16 Raw value of the sensor element
... ... ... ... ...
387 1 Hall value 168 Int16 Raw value of the sensor element

The following registers can only be read together in a single query:

Function Address
Line guidance 192-202
Euler orientation 203-206
Quaternion orientation 207-211
Hall values 1-102 220-321
Hall values 103-168 322-387

NOTE
Registers 192-202, 203-206, 207-211, 220-321, 322-387 must always be read using the appropriate length.
These registers cannot be accessed individually. For example, the track guidance is read using length 11 at
Register 192.

Status section
Table 6: Status section
Register Register Parameter name Data type Description
no. width
10000 1 Event source Uint8 Event cause
10001 1 Inertial Uint8 Inertial system event number
10002 1 Magnetic field Uint8 Magnet field event number
10003 1 Temperature Uint8 Temperature event number

“Holding registers” register group (read-write)

The following registers are used to configure the sensor via Modbus and can be read using function code 0x03,
written to individually using function code 0x06, or written to continuously using function code 0x10.

Commands section
Table 7: Commands section
Register Register Parameter name Data type Description
no. width
96 16 Set application name String User-defined text of 32 characters
112 1 Lock teach Bool 0 => Teachpad activated
1 =>Teachpad locked
113 1 Set param to default Bool 1 => All parameters are reset to the fac‐
tory settings
114 1 User offset calibration Bool 1 => Offset calibration of the hall ele‐
ments is being performed; the sensor will
then be restarted
115 1 Zero position teach Bool 1 => The current position is defined as the
zero point
116 1 Reset yaw Uint8 1 => The yaw angle is set to 0
117 1 Reset event flag Uint8 1 => Reset the message

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 OPERATION 8

Register Register Parameter name Data type Description

no. width
118 1 Variant setup Uint8 0 => Standard
2 => Improved offset compensation
3 => Improved track detection at diverters
4 => Improved offset compensation and
diverter detection
119 1 IMU setup Uint8 0 => IMU and temperature sensor inactive
1 => IMU and temperature sensor active

The interference field suppression and the improved diverter detection can be parameterized with Register 118.
The interference field suppression can blank magnetic interference fields such as offset fields caused by magne‐
tized steel parts in a concrete floor.
Improved diverter detection allows for smooth navigation when diverters are laid flush.
The following table describes the setting options of Register 118:
Table 8: Register 118
Value Interference field suppression Improved diverter detection
0 - -
2 x -
3 - x
4 x x

For example, this means that Register 118 should be parameterized to the value 4 in an environment with
magnetic interference fields in the floor and flush diverters. If the diverters are not laid flush, a track width is
required and no interference fields occur, Register 118 can be parameterized to value 0.

Configuration section
Table 9: Configuration section
Register Register Parameter name Data type Description
no. width
4000 1 Min level Int16 Minimum magnetic field strength above
which a track is detected
4001 1 Offset line zero point Int16 Offset [mm] for sensor zero point
4002 1 Sensor flipped Bool 0 => Positive track value on cable side
1 => Negative track value on cable side
4003 1 Marker Bool 0 => No marker detection
1 => Detect marker and display in register
#LCP
4004 1 Marker style Uint8 0 => No marker detected
1 => SICK standard marker
2 => SICK advanced mode marker
4005 1 Failsafe mode Bool 0 => Failsafe mode deactivated
1 => Failsafe mode activated
4006 1 First level Uint8 Minimum detection level for track detec‐
tion in [%] of the main track
4007 1 Last level Uint8 Maximum detection level for track detec‐
tion in [%] of the main track
4008 1 Averaging magnetic Uint8 Average filter for track values
4009 1 Averaging inertial Uint8 Average filter for inertia values
4010 1 Tape polarity Uint8 0 => Both polarities possible
1 => Tape has a north polarity
2 => Tape has a south polarity

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8 OPERATION

Register Register Parameter name Data type Description

no. width
4011 4 Long term time stamp Uint64 Time stamp (Unix time)
4015 1 Upper temperature threshold Int8 Upper temperature value for which an
event is triggered
4016 1 Lower temperature threshold Int8 Lower temperature value for which an
event is triggered
4017 1 Max. temperature since last reset Int8 Maximum temperature since last reset /
uptime
4018 1 Min. temperature since last reset Int8 Minimum temperature since last reset /
uptime
4019 1 Device ID Uint8 Device address of the Modbus device
4020 1 Parity Uint8 0 = No parity
1 = Even parity
2 = Odd parity
4021 1 Stop bit Uint8 0 = One stop bit
1 = Two stop bits
4022 1 Baud rate Uint8 0 = 1,200 baud
1 = 2,400 baud
2 = 4,800 baud
3 = 9,600 baud
4 = 19,200 baud
5 = 38,400 baud
6 = 57,600 baud
7 = 115,200 baud

8.2 Operating and status indicators

Operating indicator
The sensor has a capacitive keypad for performing configuration and setting parame‐
ters.
Operation is carried out by pressing a series of keys with various time windows:
Press: Touch the keypad from 0.1 to 0.5 s, then release (> 0.1 s).
Hold: Touch the keypad for several seconds without releasing.
Lift finger: The finger does not touch the keypad for several seconds.

NOTE
Operating the keypad requires a little practice because the response times are limited
and the required settings are configured with time dependence.
Tip: Memorize the series for the required settings before you configure the sensor.

A full description of the various configuration options can be found in the chapter
"Teach mode", page 31.

Status indicators
The table below describes the individual function displays. The actual behavior of the
LEDs during operation represents a combination of these function displays.
There are two LED windows, each of which has two colors:
• LED window 1: yellow and red
• LED window 2: green and blue

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 OPERATION 8

LED window 1:
• Yellow LED on when a magnetic tape with sufficient magnetic field strength is
detected (at line level 3 or above)
• Yellow LED flashes when a magnetic field with insufficient field strength is
detected (at line level 2 or below)
• Yellow LED off if no magnetic tape is detected
• Red LED on if an error is detected
LED window 2:
• Indicates whether the line has been detected on the left or the right. The blue and
green LEDs are dimmed using a software PWM (base frequency 1 kHz, refresh
rate 50 Hz; see figure 17).
If the detected line is on the left-hand side, this is indicated via a dimly illuminated
green LED; if the detected line is on the right-hand side, this is indicated via a dimly
illuminated blue LED. In position = 0, both LEDs are permanently on.

– 0 +

Figure 17: Status indicators

For each color, the full scale ranges from 0 mm --> brightly lit |MB/2| --> very dimly lit.
If no magnetic field or multiple lines are detected, this indicator is off. In such cases,
the green LED flashes in a special cycle.
The inversion of the position signal (sensor flipped) does not affect the LED behavior.

8.3 Teach-in mode

8.3.1 General information on teach-in mode

In teach-in mode, the current mode is displayed by the LEDs lighting up in a specific
way.

8.3.2 Calling up teach-in mode

To activate teach-in mode, press and hold the keypad until the required teach-in mode
is reached.

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8 OPERATION

Double-click

2 Hz Inversion release
Measuring range End of teach

hold > 2 sec

Teach release
Zero point End of teach
2 Hz
hold > 5 sec

2 Hz Offset calibration release

execute End of teach

hold > 8 sec

Time out =
End of teach

Figure 18: Teach-in sequence

All incorrect teach-in attempts are acknowledged by the sensor with a red flashing LED.
If the user attempts to teach in an invalid configuration, the red LED will also flash (e.g.,
teach zero point with multiple lines).

8.4 Track guidance

8.4.1 Output of line center points

The MLS is capable of detecting up to three line center points (LCPs) and their width
(LCP_width), and providing the related data as output via the Modbus interface. The
position of each line center point is output to a resolution of 1 mm. The geometric
center of the sensor’s longitudinal axis is the zero point.
Should the installation space of the AGV not allow for center installation of the sensor,
the zero point of the sensor can be offset using offset line zero point (4,001).

– 0 +

By default, the negative measuring range is towards the cable outlet, and the positive
measuring range is on the opposite side.
The alignment of the sensor (positive/negative measuring range) can also be changed
using sensor flipped (4,002).
If only one line center point is found, it is output as LCP2. If a further line center point is
found, it is output as LCP1 or LCP3, depending on its direction. If three LCPs are found,
then each LCP is output.

x m m m

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 OPERATION 8

To make it easier for the control system to evaluate this process byte, the combination
of tracks detected is output in an additional data item #LCP (195). The LCPs are
binary-weighted:
Table 10: Line center points
LCP1 detected LCP2 detected LCP3 detected Output value Comments
No No No 0 Special case: No line
detected
No Yes No 2 Only one line detected
Yes Yes No 3 Single diverter detected
No Yes Yes 6 Single diverter detected
Yes Yes Yes 7 Double diverter detected

The principle of LCP1 < LCP2 < LCP3 always applies to the LCPs.
Table 11: Position of line center point
Value Data type Description
LCP1 INT16 Position of line center point 1 [mm]
LCP2 INT16 Position of line center point 2 [mm]
LCP3 INT16 Position of line center point 3 [mm]

Table 12: #LCP

Bit 0 Bit 1 Bit 2 Bit 3 Bit 4 Bit 5 Bit 6 Bit 7
#LCP #LCP #LCP #LCP Markers Markers Markers Markers Markers
Bit 0 Bit 1 Bit 2 Bit 0 Bit 1 Bit 2 Bit 3 Bit 4

Value Data type Description

#LCP UINT3 The following assignment applies (see "Output
of line center points", page 32):
0 => No track found
2 => One track found
3 => Two tracks found: Left diverter
6 => Two tracks found: Left diverter
7 => Three tracks found or 90 °C intersection2
2 see "Laying", page 17

8.4.2 Inversion of the relative position

This function enables the user to invert the convention that the negative range is at the
cable outlet. This flips the position by 180° to facilitate sensor installation.
The selected setting affects the output of the inertial measuring unit (IMU), see "Inertial
measuring unit", page 42.
Die inversion can be performed via Modbus (4,002) or the teach-in on the device.
The inversion of the position signal does not affect the LED behavior.

8.4.3 Accuracy of line detection

In order to guarantee the specified repeatability of +/- 1 mm even at large working
distances, a configured average filter (section 8.4.4.3) is installed in the MLS. In
general, the following applies: The greater the working distance, the higher the filter
value should be. At the same time, a higher filter value also results in a higher delay
time in the signal output. Die t90-time of the step response for various filters settings is
listed in the following table:

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8 OPERATION

Table 13: Filter settings

Filter value t90-time
0 0
1 35 ms
2 57 ms
3 80 ms
4 100 ms

The correlation between track distance, magnetic field strength and filter setting are
listed in the following table. The magnetic field strength is output in three parameters:
• Field Level (219): Maximum measured absolute field strength (UINT16, measuring
range 25 mT, resolution 0.00076 mT)
• Line Level (200-202): Field strength for each detected track (Int16, measuring
range 6.25 mT, resolution 0.049 mT)
• Track Level (218): Evaluation of the magnetic field strength as 3-bit value. For the
assignment of Field Level to Track Levelsee table 14
Table 14: Assignment table
FieldLevel LineLevel Track Level Magnetic field Distance to Recommended
strength [mT] track tape1 filtering
4500 71 7 3.43 10 mm 0
2250 35 7 1.72 20 mm 0
2000 31 7 1.53 22 mm 0
1750 28 6 1.34 25 mm 0
1500 24 5 1.14 28 mm 0
1250 20 4 0.95 31 mm 0
1000 16 3 0.76 37 mm 1
750 12 2 0.57 44 mm 1
500 8 1 0.38 55 mm 1
450 7 0 0.34 60 mm 2
350 5 0 0.27 70 mm 4
1 Measured with SICK track tape item 5337613

At an increased working distance (< Track Level 3), an offset calibration should be run.
Permanent interfering factors by the AGV can be suppressed in this way.

NOTE
Do not run the offset calibration in the presence of the magnetic tape.

8.4.4 Track optimization

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 OPERATION 8

8.4.4.1 Offset calibration

In production, the MLS is calibrated RAW Data

(11.81)
300 3
freely in the air (not mounted) at the (10.24)
260

factory. 220
(8.66)

In this case, the raw data is near the 180

(7.09)

zero line (sensor orientation: label on

140
(5.51)

100
the upper side). (3.94)

60
(2.36)

Field Level [digits]

20
2
(0.79)
0
-20 1
(-0.79)

-60
(-2.36)

-100
(-3.94)

-140
(-5.51)

-180
(-7.09)

-220
(-8.66)

-260
(-10.24)

-300
(-11.81) 4
-159 -120 -80 -40 0 40 80 120 161
(-6.26) (-4.72) (-3.15) (-1.57) (1.57) (3.15) (4.72) (6.34)
Position [mm]
[inch]

Figure 19: MLS not mounted

If the MLS is mounted in the applica‐ RAW Data

(11.81)
300 3
tion (in the AGC/AGV), installation can (10.24)
260

influence the sensor: 220

(8.66)

180
(7.09)

140
(5.51)

100
(3.94)

60
(2.36)
Field Level [digits]

20
(0.79)
0 1
-20
(-0.79)

-60
(-2.36)

-100 2
(-3.94)

-140
(-5.51)

-180
(-7.09)

-220
(-8.66)

-260
(-10.24)

-300
(-11.81) 4
-159 -120 -80 -40 0 40 80 120 161
(-6.26) (-4.72) (-3.15) (-1.57) (1.57) (3.15) (4.72) (6.34)
Position [mm]
[inch]

Figure 20: MLS mounted

These influences can be permanently RAW Data

(11.81)
300 3
compensated for with an offset calibra‐ (10.24)
260

tion in address 114. To do so, write 220

(8.66)

value 1 in user offset calibration (114). 180

(7.09)

The raw data then looks as follows: 140

(5.51)

100
(3.94)

60
(2.36)
Field Level [digits]

20
(0.79) 2
0
-20 1
(-0.79)

-60
(-2.36)

-100
(-3.94)

-140
(-5.51)

-180
(-7.09)

-220
(-8.66)

-260
(-10.24)

-300
(-11.81) 4
-159 -120 -80 -40 0 40 80 120 161
(-6.26) (-4.72) (-3.15) (-1.57) (1.57) (3.15) (4.72) (6.34)
Position [mm]
[inch]

Figure 21: Raw data after offset calibration

1 Detection Level positive

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8 OPERATION

2 Raw data
3 Min Level positive
4 Min Level negative
5 Detection Level negative

8.4.4.2 Detection Level

If the MLS is placed over the magnetic RAW Data
4000
(157.48)

track, it detects positive and negative 3600

(141.73)

signal peaks. 3200

(125.98)

The set Detection Level applies both 2800

(110.24)

for the detection of positive and nega‐

2400
(94.49)

2000
tive signal peaks. (78.74)

1600 1
(62.99)

• Positive peaks are detected above 1200 2

Field Level [digits]

(47.24)

the level of the blue solid line (1). 800

(31.50)

• Negative peaks are detected below

400
(15.75)
3
0
the level of the blue dashed line (5). -400
4
(-15.75)

If the magnetic field has a main max‐ -800

(-31.50)

imum (largest absolute value is posi‐

-1200
(-47.24)

tive), it should be ensured that the neg‐

-1600
(-62.99) 5
-2000

ative Detection Level (5) is far enough (-78.74)

-159
(-6.26)
-120
(-4.72)
-80
(-3.15)
-40
(-1.57)
0 40
(1.57)
80
(3.15)
120
(4.72)
161
(6.34)

UNDER the negative overshoots. In Position [mm]

[inch]

contrast, with a main minimum, the Figure 22: Magnetic field with main maxi‐
positive Detection Level (1) must be mum
high enough OVER the positive over‐
shoots. This prevents unwanted error RAW Data

detection of tracks or markers.

1200
(47.24) 1
800
(31.50)
2
400
(15.75)
3
0
4
-400
Field Level [digits]

(-15.75)

-800
(-31.50)
5
-1200
(-47.24)

-1600
(-62.99)

-2000
(-78.74)

-2400
(-94.49)

-2800
(-110.24)

-3200
(-125.98)

-3600
(-141.73)
-159 -120 -80 -40 0 40 80 120 161
(-6.26) (-4.72) (-3.15) (-1.57) (1.57) (3.15) (4.72) (6.34)
Position [mm]
[inch]

Figure 23: Magnetic field with main mini‐

mum

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 OPERATION 8

The Detection Level of the MLS can be RAW Data

4200
(165.35)

adjusted using the First Level (4,006) 4000

(157.48)

and Last Level (4,007) parameters. The 3600

(141.73)

currently implemented algorithm of the 3200

(125.98)

MLS works with only one level, which is

2800
(110.24)

why: First_Level = Last_Level. The value

2400
(94.49)

2000

is given in percent of the peak level. (78.74)

2

Field Level [digits]

1600

The actual Detection Level is calcu‐

(62.99)
1
1200
(47.24)

lated as follows: 800

(31.50)

Detection Level = (Field Level – Min 400

(15.75)
3
Level)*First Level + Min Level 0
4
-400
In addition, the MinLevel (4,000), which (-15.75)

-800

defines the threshold for detection of a

(-31.50)

-1200
(-47.24) 5
track, can be moved. The parameters -1600
(-62.99)

can be best optimized when two tracks -159

(-6.26)
-120
(-4.72)
-80
(-3.15)
-40
(-1.57)
0 40
(1.57)
80
(3.15)
120
(4.72)
161
(6.34)
Position [mm]

are very close to one another (e.g. with [inch]

a diverter). The negative overshoots Figure 24: Min Level

can lead to problems (figure 24) which
can be prevented by a higher (abso‐ RAW Data
4200

lute) MinLevel (figure 25).

(165.35)

4000
(157.48)

3600
(141.73)

3200
(125.98)

2800
(110.24)

2400
(94.49)

2000
(78.74)
1

Field Level [digits]

1600
(62.99)

1200
2
(47.24)
3
800
(31.50)

400
(15.75)

-400
(-15.75)

-800
(-31.50) 4
-1200
(-47.24)

-1600
(-62.99) 5
-2000
(-78.74)
-159 -120 -80 -40 0 40 80 120 161
(-6.26) (-4.72) (-3.15) (-1.57) (1.57) (3.15) (4.72) (6.34)
Position [mm]
[inch]

Figure 25: Moved Min Level

1 Detection Level positive
2 Raw data
3 Min Level positive
4 Min Level negative
5 Detection Level negative

8.4.4.3 Average filter for track output values

Another optimization of the track detection is possible thanks to the averaging magnetic
function. This function encompasses the filtering of the LCP (Line Center Point), Line
Width and Line Level track parameters. The filter value is calculated as follows:
Value_filtered(n) = (value_filtered(n-1)*<averaging magnetic>+value(n))/(<averaging
magnetic>+1)
Value_filtered(n): Currently filtered value
Value_filtered(n-1): Old filtered value
Value(n): Current (unfiltered) measured value
The averaging_magnetic filter value = 0 deactivates this function.
The filter value is configured using averaging magnetic (4,008):

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8 OPERATION

In general, the following applies: The greater the working distance, the higher the filter
value should be. At the same time, a higher filter value also results in a higher delay
time in the signal output (see table 13, page 34).

8.4.4.4 Track polarity setting

The track polarity of the track tape used can be fixed to increase the reliability of
the sensor in challenging applications. The following setting options exist (tape polarity
(4,010)):
Value Meaning
0 The track polarity is automatically detected, both track polarities are valid.
Both south tracks (with north markers) and north tracks (with south mark‐
ers) are detected (standard setting).
1 Only tracks with north polarity are detected. Markers must have south polar‐
ity.
2 Only tracks with south polarity are detected. Markers must have north polar‐
ity.

8.4.5 General notes on track guidance

The following descriptions are for track guidance purposes only. For newly installed
magnetic tape, the notes in section 5.3 must also be taken into account.

Diverters
Diverters can be driven over both flush and non-flush. Here, the different effects on
reliability, driving behavior and the recommended sensor setting should be taken into
account.
Table 15: Diverters
Type of diverter Non-flush Flush

l l
Reliability Reliable More susceptible to misinterpre‐
tation
Driving behavior Rough track change: Track is Soft transition
detected abruptly
Recommended sensor set‐ Improved diverter detection Improved diverter detection at
ting from (Register 118)
(Register 118)

More information on improved diverter detection:

Including the measured line width makes it possible to detect diverters early on and
prevent jumps in line center point output.

NOTE
When switching the sensor on, it should not be located in the area of a diverter and
should be at a 90° angle to the track if possible. Switching on can occur without a
track.

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 OPERATION 8

Figure 26: Behavior with standard setting Figure 27: Behavior with improved track
detection on diverters

The improved track detection on diverters can be set using variant setup (118).
The following table offers an overview of the setting options:
Table 16: Setting options for variant setup
Value Behavior
0 Improved track detection deactivated
3 Improved track output at diverters

Intersections
Ideally, intersections are identified as follows: #LCP = 7; LCP1 = LCP2 = LCP3. Since
this case rarely occurs due to very small tolerances and also cannot be guaranteed,
navigation should be done via markers and not via LCP=7.

Curves
When navigating on curves, paying attention to the following parameters is advised:
• Max. AGV speed
• MLS event timer
• MLS measuring range
• Turning circle = min. curve radius of the AGV
The spatial resolution at maximum traversing speed can be calculated from the maxi‐
mum speed of the AGV and the set event timer of the MLS:
Spatial resolution [mm] = MaxSpeedAGV [m/s] * EventTimer [ms]
The spatial resolution can be used to calculate the positional deflection of the first
sample in the curve at a defined curve radius. This first sample must in any case be
within the measuring range of the MLS. If this first sample is no longer in the measuring
range, the curve is overrun and the track is lost.
In addition, the minimum curve radius must be larger than the turning circle of the AGV.
In summary, the following statements describe the behavior when navigating on curves:
• The higher the traversing speed, the larger the curve radius
• The smaller the event timer, the smaller the curve radius
• The larger the measuring range, the smaller the curve radius

Speed
The spatial resolution of the position output in the traverse direction can be calculated.
This should be considered e.g. for curves, diverters as well as markers. If a diverter
has too large an angle or if a marker is too short, these will be “overlooked” due to the
insufficient spatial resolution, since the detection situation lies between two successive
measured values.

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8 OPERATION

Angle (for diverters)

• The greater the speed, the smaller the angle should be for diverters, whereby the
diverter must always remain within the MLS measuring range, depending on the
spatial resolution.
• The smaller the speed, the greater the angle can be for diverters, since the
magnetic field separates earlier and detection is therefore better.
If improved diverter detection is activated, the behavior can also be optimized via the
filter strength (Register 4008):
• The greater the speed, the smaller the selected value should be.
• The larger the angle, the smaller the selected value should be.

Interference field suppression

• The interference field suppression can suppress and thus eliminate large-scale
interference fields.
• The slope of the magnetic track to be detected must be large enough to distin‐
guish it from the large-scale interference fields with low slope in the magnetic
field.
• The slope (difference from one magnetic sensor in the MLS to the next) can be
set via Register 4007. The slope should be set so that the track is still reliably
detected.
• When setting the slope, the following applies: The higher this value, the better
the interference field suppression, but only magnetic tracks with high magnetic
field strength are detected. The lower this value, the lower the interference field
suppression, but tracks with low magnetic field strength are also detected.

Procedure in case of errors during track guidance:

If track guidance problems occur and the sensor does not provide the desired values,
then the following steps can be followed to analyze and correct the problem in more
detail:
1. Reading out the raw data
The raw data can be read out via the configurator available on the website. These
are often helpful for situation-specific problems. Interference fields, misinterpreted
values and faulty spots can be identified in this way.
2. Adjusting the field level and detection level
The desired sensitivity of the sensor can be set by adjusting the field level and
detection level. To do this, view the previously read raw data and the desired output
values of the sensor. Make the required settings.
Example: The sensor should detect two tracks with magnetic fields of different
strengths simultaneously. Here, better detection can be achieved by lowering the
detection level.
3. Switching on interference field compensation
If interference fields cause the sensor to supply incorrect information, interference
field compensation can be activated via Register 118.

8.5 Marker detection

The MLS is capable of detecting magnetic codes using so-called markers (4,003). Mark‐
ers are small strips of magnetic tape placed adjacent to the actual track.
Various types of marker can be detected:
SICK marker detection
SICK marker detection uses one or two markers adjacent to the line, but only 1 marker
may be placed on each side.

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 OPERATION 8

The system supports both polarities: Track tape with the north pole facing up, marker
with the south pole facing up; track tape with the south pole facing up, marker with the
north pole facing up. The sensor automatically detects the polarity of the (main) track
tape.
The value of the code is determined by the distance between the marker and the track.
The markers are placed on a 30 mm raster.
If the main track is 50 mm and wider, directly adjacent markers cannot be used.
The distance of 30 mm to the track center can then no longer be realized without
overlapping.
A marker length of 100 mm is recommended.

NOTE
For optimum functioning of automated polarity detection, we recommend that the
sensor is not switched on over a marker.

a1

S N S
a2

The following principle applies:

If a1 > a2: Marker detected in positive travel direction
If a1 < a2: Marker detected in negative travel direction

NOTICE
The inversion of the position signal (sensor flipped) affects marker detection! The posi‐
tion signals after inversion are used to detect the markers!

Several possible settings are available using marker style (4,004):

Standard mode (7 different codes possible): The values of the markers are added:
Marker 1 Marker 2
A1 [mm] Template 1
A2 [mm] -Template1 Total Code
30 M4 - - 30 1
60 M3 - - 60 2
60 M3 30 M5 90 3
90 M2 - - 90 3
90 M2 30 M5 120 4
120 M1 - - 120 4
90 M2 60 M6 150 5
120 M1 30 M5 150 5
120 M1 60 M6 180 6

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8 OPERATION

Marker 1 Marker 2
A1 [mm] Template 1
A2 [mm] -Template1 Total Code
120 M1 90 M7 210 7
1 Marker template (SICK accessories, part number 4097520)

Extended mode (10 different codes possible):

Marker 1 Marker 2
A1 [mm] template 1
A2 [mm] template1 Code
30 M4 - - 1
60 M3 - - 2
60 M3 30 M5 3
90 M2 - - 4
90 M2 30 M5 5
90 M2 60 M6 6
120 M1 - - 7
120 M1 30 M5 8
120 M1 60 M6 9
120 M1 90 M7 10
1 Marker template (SICK accessories, part number 4097520)

FailSafe mode (applies to SICK marker detection only):

FailSafe mode (4005) is intended to prevent codes from being read incorrectly if the
AGC is not aligned completely parallel to the track and the markers. In such situations,
one of the markers may be detected sooner than the marker on the other side. This
results in the marker code being misinterpreted. In FailSafe mode, the sensor outputs
the detected code after it has completely passed over a frame. If FailSafe mode is
deactivated, the sensor constantly outputs the currently detected marker code. This
can cause a code to change or be output incorrectly at a certain time.
Value Data type Description
Markers INT5 Bit 0 is the introductory character bit
Bit 1...4 represent code 1...15

8.6 Inertial measuring unit

The line guidance sensor contains an integrated inertial measuring unit (IMU) which
enables determination of the current orientation of the sensor. The orientation is output
as sensor torsion compared to a reference system which is defined in "Coordinate sys‐
tem", page 43. The torsion can be represented either by Euler angles or a quaternion.
The IMU is located at the following position (x | y | z): 89.1 | 2.5 | -9.4 [mm]. The zero
point shown in figure 28 is located in the center of the edge of the status LEDs.

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 OPERATION 8

Figure 28: XYZ reference for the IMU position

NOTE
The IMU is activated by default and can be deactivated using imu setup (119).
Value Meaning
0 IMU and temperature sensor inactive
1 IMU and temperature sensor active

NOTE
The determined rotation of the sensor around the gravity axis (yaw angle) is not stable
in the long term due to the principle.
Tip: Only use the yaw angle for relative measurements over limited periods of time. It
can be reset to zero before a measurement, see "Resetting the yaw angle", page 45.

NOTE
During its initialization, which runs in 640 ms after start-up of the sensor, the inertial
measuring unit does not output valid data (all output values are zero at this time).

8.6.1 Coordinate system

During orientation measurement, the sensor torsion is determined compared to a refer‐
ence system. The coordinate system used depends on the value of the sensor flipped
(4002) parameter. For the sensor flipped = 0 setting, the coordinate system is illustrated
as in the following figure:

Figure 29: Standard axis definition

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8 OPERATION

For the sensor flipped = 1 setting, on the other hand, the following coordinate system is
used:

Figure 30: Flipped axis definition

Reference system:
In the reference system, the z-axis is antiparallel to the gravity vector.
z-axis
↑
↓
Gravity
The zero point for torsion of the reference coordinate system around the z-axis results
from the orientation of the sensor at the power-up delay time (or at the time at which
the respective alignment was reset to zero, see "Resetting the yaw angle", page 45).

8.6.2 Time stamp

A associated time stamp (206, 211) is provided for the measured values. This specifies
the measuring time in milliseconds. From the output UINT16 value, the sample time
can be calculated as
TIME = 1/1,000 s · TIMESTAMP_UINT16
The time stamp runs to zero every 65,536 s.

8.6.3 Output of orientation in Euler angle representation

The current orientation in Euler angle representation (203-206) can be accessed in ,
whereby the addresses 203 - 205 contain the Roll, Pitch and Yaw components. Address
206 returns the time stamp.
The angles specify the rotation of the sensor compared to the reference position
according to DIN 9300 / DIN ISO 8855 in Z/Y'/X'’ sequence (intrinsic) or X/Y/Z (extrin‐
sic).
The Euler angles are output in radians. The output INT16 value can be converted to the
angle in radians as follows:
ANGLE = 1/10,000 rad · VALUE_INT16

8.6.4 Output of orientation in quaternion display

The current orientation in quaternion representation (207-211) can be accessed,
whereby the addresses 207-210 contain the real part and the three imaginary parts
of the quaternion, and address 211 contains the associated time stamp. The output
quaternion is standardized to value 1 and the real part of the quaternion is always
positive.
Due to the standardization, the real part of the quaternion (not contained in the
addresses) can be calculated as the imaginary parts with

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 OPERATION 8

x, y and z and the real part with w.

The components of the quaternions do not have units. The value of the components is
output as the INT16 value, the actual value can be calculated as
COMPONENT = 1/10000 · VALUE_INT16

8.6.5 Resetting the yaw angle

The output yaw angle is not stable in the long term due to the principle of its measure‐
ment. That is why it can be reset to zero by writing the value 1 into reset yaw (116).

8.6.6 Low pass filter for orientation

The output values for the orientation can be filtered with an adjustable IIR low pass of
the first order, whereby the filter affects the Euler angle and the quaternion representa‐
tions in the same manner.
The filter is configured via filter parameter K in Averaging Inertial (4,009), which can
be set to whole values between 0 and 100. The resulting -3 dB limit frequency for the
output signals can be calculated as

Higher values for K therefore result in stronger low pass filtering of the signal. For a
value of 0 for K, the low pass filter is deactivated (default setting).

8.7 Temperature sensor

The temperature currently measured in the sensor can be accessed in current tempera‐
ture (212) . The temperature values have data type Int16 and represent the tempera‐
ture in °C.
The minimum or maximum temperature measured over the entire operating time of the
sensor is available in max. temperature all time (213) and min. temperature all time (213) .
The minimum and maximum temperature during the operating time can also be read
from max. temperature since last reset (4,017) and min. temperature since last reset (4,018),
however the values can be reset in this case. Resetting is done by writing the value
-127 into (4,017) and the value 127 into (4,018). The temperature can be monitored
via the adjustable temperature threshold in upper temperature threshold (4,015) and lower
temperature threshold (4,016), see "Event detection", page 45.

NOTE
The temperature sensor is activated/deactivated by activating/deactivating the IMU in
imu setup (119).

8.8 Event detection

The line guidance sensor can detect two types of events:
• Magnet field: This event is triggered when the critical magnetic field strength
is not reached. When the critical magnetic field strength is not reached, it can
no longer be guaranteed that the unfiltered track position meets the data sheet
specifications.
• Temperature: This event is triggered when the current temperature exceeds the
temperature set in upper temperature threshold (4,015) or falls below the tempera‐
ture threshold set in lower temperature threshold (4,016).

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8 OPERATION

When the event occurs, the “Event” flag is set in the status byte in in status (196). The
cause of the event can be accessed in event source (10,000). The assignment is shown
in table table 17.
Table 17: Event source
Value in Event source Cause of event
0 No event
2 Magnetic field
4 Temperature
6 Magnetic field and temperature

Further details of the cause of the event can be accessed in magnetic field (10,002) for
a magnetic field event, and temperature (10,003) for a temperature event. The possible
error codes are shown in table table 18 and table 19.
Table 18: Magnetic field error code
Magnetic field error code Cause of event
0 No event
1 Magnetic field falls below critical magnetic field strength

Table 19: Temperature error code

Temperature error code Cause of event
0 No event
1 Current temperature is below the lower threshold (4016)
2 Current temperature exceeds the upper threshold (4015)

The event flag can be reset by writing to reset event flag (117).

8.9 Status
Table 20: Status
Bit 0 Bit 1 Bit 2 Bit 3 Bit 4 Bit 5 Bit 6 Bit 7
Status Line Track Track Track Sensor Polarity Reading Event
good Level Level Level flipped code flag
Bit 0 Bit 1 Bit 2

Value Data type Description

Line good BOOL 0 => No track or track too weak
1 => Sufficiently strong track detected

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 OPERATION 8

Value Data type Description

Track Level UINT3 Display of magnetic field strength in accord‐
ance with the following table:
Table 21: Track Level
FieldLevel Line Level
4500 7
2250 7
2000 7
1750 6
1500 5
1250 4
1000 3
750 2
500 1
450 0
350 0

NOTE
Detailed table see table 14, page 34.

Sensor flipped BOOL Indicates whether or not the measuring range

has been inverted
0 => Negative positions on cable outlet side
1 => Positive positions on cable outlet side
Polarity BOOL Indicates whether the upper surface of the
magnetic tape is magnetized to the north or
south pole
0 => North pole
1 => South pole
Reading code BOOL 0 => No code present to read
1 => Sensor is reading code

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9 MAINTENANCE

9 Maintenance
9.1 Maintenance
The sensor is maintenance-free.
To ensure it continues operating without problems, however, the screw connection
between the sensor and the slot, and for the electrical connection, should be checked
regularly. The interval at which they are checked should be adapted in line with the
conditions of the application, but should be no more than 6 months.

9.2 Repairs
Repairs on the sensor may only be carried out by the manufacturer. Any interruption or
modification of the sensor will invalidate the manufacturer warranty.

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 DECOMMISSIONING 10

10 Decommissioning
10.1 Decommissioning
Removing the sensor
1. Switch off the supply voltage to the sensor.
2. Detach all connecting cables from the sensor.
3. If the sensor is being replaced, mark its position and alignment on the bracket or
surroundings.
4. Remove the sensor from the slot.

Disposing of the sensor

Any sensor which can no longer be used must be disposed of in an environmentally
friendly manner in accordance with the applicable country-specific waste disposal regu‐
lations. The sensor is electronic waste and must under no circumstances be disposed
of with general waste.

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11 TROUBLESHOOTING

11 Troubleshooting
Possible faults and corrective actions are described in the table below for troubleshoot‐
ing. In the case of faults that cannot be rectified using the description below, please
contact the manufacturer. See the back page for relevant contact details.
Table 22: Troubleshooting
LED indicator/fault pattern Cause Measure
No LED illuminated/sensor Problem with sensor voltage Check and restore voltage sup‐
not communicating via bus supply ply
interface
Green LED flashing/sensor Problem with sensor voltage Reduce threshold for detec‐
does not output track data supply tion of track tape (MinLevel
even though track tape is (4,000))
positioned at the correct dis‐
tance

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 TECHNICAL DATA 12

12 Technical data
Performance
Table 23: Performance
Parameter Conditions Icon Unit min. Typ. max.
Measuring range MR300 mm 300
Repeatability1 mm 1
Resolution mm 1
Working distance 2
mm 10 704
Output refresh Hz 100
rate3
LED display Yellow / red, blue / green
Reverse polarity protection Yes
Short-circuit protection Yes
1 Depending on magnetic tape used and working distance
2 Depending on magnetic tape used
3 Depending on sensor length:
200: 100 Hz
300: 100 Hz
400: 80 Hz
500: 70 Hz
600: 60 Hz
4 With magnetic averaging value “4”, see "Track optimization", page 34

Interfaces
Table 24: Interfaces
Parameter Specification
Interface RS485 Modbus RTU
Device profile No device profile is supported
Address setting 0 ... 247, default: 10
Data transmission rate 1.2 kBaud ... 115.2 kBaud, default:
19.2 kBaud
Configuration data Minimum permissible magnetic field strength,
offset zero point, inversion of measuring range,
marker detection, activation of teach-in button
Diagnostic data Current magnetic field strength
Status information No LED allocated to Modbus
Bus termination Internal 120 Ohm terminator (optional)

Mechanics/Electronics
Table 25: Mechanics/Electronics
Parameter Specification
Electrical connection PUR cable 0.3 m; M8 4-pin or
PUR cable 0.3 m; M12, 4-pin or
PUR cable 2 m; cable connection (open strand
end)
Supply voltage 9 … 30 V DC, reverse polarity protected
Residual ripple </= 10%
Power consumption </= 600 mW
Housing Aluminum, PA

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12 TECHNICAL DATA

Parameter Specification
Housing color Black, end caps: Black
EMC EN 61000-6-2
EN 61000-6-4
Protection class 3
Enclosure rating IP 65, IP 67, IP 68 (in accordance with EN
60529)
Mounting Mounted using accessories in sensor T-slot

Total length Measuring range

MLSE-0200 217 200
MLSE-0300 325 300
MLSE-0400 397 400
MLSE-0500 505 500
MLSE-0600 613 600

Ambient data
Table 26: Ambient data
Parameter Specification
Permissible impact load 30 g / 11 ms
Permissible impact load 10 ... 55 Hz / 1 mm
Permissible ambient temperature -20 °C ... 70 °C

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 ANNEX 13

13 Annex
13.1 Conformities and certificates
You can obtain declarations of conformity, certificates and the current documentation
for the product at www.sick.com. To do so, enter the product part number in the search
field (part number: see the entry in the “P/N” or “Ident. no.” field on the type label).

13.2 Modbus RTU Spezifikationen

For detailed information about Modbus see:
https://modbus.org/
We recommend for test purposes or quick parameterization:
https://sourceforge.net/projects/qmodmaster/

13.3 RTU Transmission Mode

13.4 Data Model

The data model of Modbus is based on a series of tables that have distinguishing
characteristics. The primary tables are:
Table 27: Primary table
Primary table Object type Type of Comments
Discrete Input Single bit Read-Only This type of data can be provided by an I/0
system.
Coils Single bit Read-Write This type of data can be alterable by an appli‐
cation program.
Input Registers1 16-bit word Read-Only This type of data can be provided by an I/0
system.
Holding Regis‐ 16-bit word Read-Write This type of data can be alterable by an appli‐
ters1 cation program.
1 MLS supports Input and Holding Registers

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13 ANNEX

13.5 Example Function 04 Read Input Registers

Query
The query message specifies the starting register and quantity of registers to be read.
This is an example of a request to read registers 212 – 214 from MLS device:
Table 28: Query
Field Name Example (Hex)
Devide Address 0A
Function 04
Starting Address Hi 00
Starting Address Lo D4
No. of Points Hi 00
No. of Points Lo 03
Error Check Hi (CRC) F1
Error Check Lo (CRC) 48

Response
The register data in the response message are packed as two bytes per register, with
the binary contents being aligned to the right within each byte. For each register, the
first byte contains the high order bits and the second contains the low order bits. The
response is returned when the data is completely assembled. This is an example of a
response to the previous query:
Table 29: Response
Field Name Example (Hex)
Devide Address 0A
Function 04
Byte Count 06
Data Hi (Register 212) 00
Data Lo (Register 212) 19
Data Hi (Register 213) 00
Data Lo (Register 213) 19
Data Hi (Register 214) 00
Data Lo (Register 214) 19
Error Check Hi (CRC) 1E
Error Check Lo (CRC) 6C

13.6 Example Function 16 (10Hex) Preset Multiple Registers

Query
The query message specifies the register references to be preset. This is an example of
a request to preset two registers starting at 4000, in slave device 10 (0x10):
Table 30: Query
Field Name Example (Hex)
Devide Address 0A
Function 10
Starting Address Hi 0F
Starting Address Lo A0

54 O P E R A T I N G I N S T R U C T I O N S | MLS with RS485 Modbus RTU 8026177.1K5M/2023/07/03 | SICK

Subject to change without notice
 ANNEX 13

Field Name Example (Hex)

No. of Registers Hi 00
No. of Registers Lo 02
Byte Count 04
Data Hi 01
Data Lo F4
Data Hi 00
Data Lo 05
Error Check Hi (CRC) 1D
Error Check Lo (CRC) 0E

Response
The normal response returns the device address, function code, starting address, and
quantity of registers preset. This is an example of a response to the query shown above.
Table 31: Response
Field Name Example (Hex)
Devide Address 0A
Function 10
Starting Address Hi 0F
Starting Address Lo A0
No. of Registers Hi 00
No. of Registers Lo 02
Error Check Hi (CRC) 43
Error Check Lo (CRC) 85

8026177.1K5M/2023/07/03 | SICK O P E R A T I N G I N S T R U C T I O N S | MLS with RS485 Modbus RTU 55

Subject to change without notice
8026177.1K5M/2023/07/03/en

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