Datalogic AL5010 Product Line Manual

AL5010

Product Line Manual

AccuLazr™ AL5010 Product Line Manual

PN 1000068393 2.1 | CMS 11-0023 | 2013.01.31 | RAY

Document Revision Control

This document is under revision control in accordance with Datalogic’s Quality
System. Any addenda or other documents associated with this manual are under
separate revision controls. A revision number is changed by 0.1 whenever
technical information is changed or added to a document.

Copyright Information

Copyright © 2011-2012 DATALOGIC. All rights reserved.

No part of this document is to be reproduced or utilized in any form or by any
means, electronic or mechanical, including photocopying, recording, or by an
information storage and retrieval system without prior written consent of
Datalogic Systems, Inc. All drawings and specifications contained in this manual
are the property of Datalogic Systems, Inc. and shall not be reproduced, copied
or used in whole or in part as the basis for the sale or manufacture of products
without the written permission.

Datalogic and DRX® are registered trademarks and the AS logotype, 1-800­BAR-CODE™ is a trademark of Datalogic.

All other company or product names are mentioned for purposes of identification
only, and may be trademarks of their respective owners.

Disclaimer Information

The information contained in this manual is subject to change without notice.
Supplemental information or documentation may be required for certain
applications or usage.

The examples and diagrams in this manual are included solely for illustrative
purposes. Because of the many variables and requirements associated with any
particular installation, Datalogic cannot assume responsibility or liability for
actual use based on the examples and diagrams.

No patent liability is assumed by Datalogic with respect to use of information,
circuits, equipment, or software described in this manual.

In no event will DATALOGIC. be responsible or liable for indirect or
consequential damages resulting from the use or application of this equipment.

Datalogic 511 School House Rd. Telford, PA 18969 1-800-BAR-CODE™

AccuLazr™ AL5010 Product Line Manuals Contents iii

Contents

Preface

Intended Audience
Thank
Overview
Other
Conventions
Customer

You

...................................................................................................... vii

of Contents

Sources of Information

Service

.........................................................................................

....................................................................................

........................................................................ viii

.................................................................................................. viii

......................................................................................... viii

vii

viii

1 Introduction

AL5010 Product Line Overview .......................................................................9

The AL5010 Scan Head ................................................................................10

The AL5010 Mounting Base ..........................................................................10

The AL5010 Interface Module

AccuLazr™ User Interface.............................................................................12

Typical AL5010 Mid-Range Bar Code Reading Applications ........................13

Options and Accessories ...............................................................................14

.......................................................................11

2 Safety

Symbols .........................................................................................................15

General Precautions ......................................................................................16

Unpacking, Mounting and Installation Recommendations

Compliance Requirements ............................................................................17

Electrical Safety .............................................................................................17

Electrical Grounding Requirements
Elec

trostatic Discharge ..................................................................................18

Basic

Rules for ESD

Laser Safety...................................................................................................19

Safety Labels and Locations..........................................................................20

Control..........................................................................18

...............................................................18

............................16

3 Mechanical Installation

Prerequisites ..................................................................................................21

Tools Required...............................................................................................21

Additional Information ....................................................................................21

Unpacki

Installation Sequence.....................................................................................22

Orientation Considerations ............................................................................

Read Range...................................................................................................23

Bar Code Orientation to

General Mounting Guidelines ........................................................................

Reader

Dimensions and Clearances..........................................................................

Attaching the Mounting Base.........................................................................26

Attaching
Installing an AL5010

Mounting the Trigger Photoeye .....................................................................29

Mounting

Mounting the Interface Module ......................................................................31

Mounting the I/O

ng Instruct

Positioning.........................................................................................25

the Universal Mounting Bracket (UMB) .........................................

the Tachometer

ions ..................................................................................21

23

Scanning Area .......................................................24

25

26

27

Scan Head ...................................................................28

..............................................................................30

Modules..............................................................................34

00b-AL5010_Table of Contents_R10.doc Accu-Sort Systems, Inc.

iv Contents AccuLazr™ AL5010 Product Line Manuals

4 Electrical Installation

Prerequisites ..................................................................................................37

Tools Required.............................................................................................. 37

Additional Information ....................................................................................37

Installation Sequence(s) ................................................................................38

Installing

Multiple Readers.............................................................................38

General Electrical Installation Guidelines and Precautions...........................39

Cable and Conduit Connections ....................................................................40

Wiring

the AL5010 Interface Modules............................................................

41

Power Requirements .....................................................................................45

Power

Supply Connections............................................................................45

Trigger Connections.......................................................................................46

Tachometer Connections...............................................................................

Serial Communications Connections
Ethernet Communications

Connections ........................................................50

(COM1 and COM2) ............................48

47

I/O Module Connections ................................................................................51

DeviceNet ......................................................................................................53

Profibus
Connecting
Wiring to the AL5010 without an Interface Module

..........................................................................................................53

the AL5010 .................................................................................

53

........................................54

Check Installation...........................................................................................55

5 Setup

Getting Started...............................................................................................57

AccuLazr User Interface Basics.....................................................................60

Getting Help ...................................................................................................

60

Modify Settings ..............................................................................................61

Configuration ...........................................................................................62

Codes................................................................................................63

Bar

Modulo Checks........................................................................................65

Stripping/Padding ....................................................................................66

Codes

Match
Serial Communic

...........................................................................................67

ations

...........................................................................68

Network ...................................................................................................71

Trigger .....................................................................................................74

Relay .......................................................................................................75

king

Trac

...................................................................................................76

FAST Monitor™.......................................................................................77

Advanced

Save / Retrieve

.................................................................................................79

..............................................................................................80

Diagnostics ....................................................................................................81

Monitor.....................................................................................................82

Log

Viewer

...............................................................................................

83

Update Firmware.....................................................................................90

6 Operations

First-time Startup ...........................................................................................91

Default Parameters ........................................................................................91

First-time Setup..............................................................................................92

k Operations using Test

Chec
Operations Checklist

......................................................................................93

Control Panel Indicators ................................................................................94

Backup / Restore Procedures........................................................................

Checking Operations with

Mode ..............................................................92

99

User Interface ....................................................100

Accu-Sort Systems, Inc. 00b-AL5010_Table of Contents_R10.doc

AccuLazr™ AL5010 Product Line Manuals Contents v

Standalone Operation ..................................................................................102

Tracking Operation ......................................................................................103

Dual X-Scanning Operation .........................................................................104

Multiple-Reader Network Operatio
Scanning Array / Tunnel

Operation .............................................................106

n ............................................................105

7 Maintenance

Laser Shutoff Procedure..............................................................................107

Maintenance Tasks......................................................................................108

Cleaning Exit Window ..................................................................................109

Cleaning Trigger Photoeye ..........................................................................110

Cleaning Tachometer...................................................................................110

Tighten Mounting Hardware ........................................................................

Checking Interface Module Connections.....................................................111

Verify Reader Operation ..............................................................................

Verify Photoeye Operation...........................................................................112

Verify Tachometer Operation.......................................................................112

111

112

8 Troubleshooting

Test Mode ....................................................................................................113

Status Indicators ..........................................................................................113

Control Panel Indicators ..............................................................................114

Diagnostics ..................................................................................................

Log Viewer ...................................................................................................120

Update Firmware .........................................................................................126

Troubleshooting Tables ..............................................................................131

117

9 Service

Replacement Procedures ............................................................................129

AL5010 Field Replaceable Units (FRUs) Spare Parts ...............................130

Interface Module FRU Spare Parts .............................................................131

Appendices

A Specifications

Al5010 Technical Specifications

Interface Module Technical

Basic
Enhanced
Power Supply

Output Modules............................................................................................135

Input Modules ..............................................................................................135

Certifications ................................................................................................

Interface Module Technical

..................................................................

Specificati

...............................................................................................

ons

........................................

Specifications

................................134

133
133

134

136

B Read Charts

AL5010 Read Charts ...................................................................................137

C User Interface

AccuLazr User Interface ..............................................................................149

Modify Settings ............................................................................................150

Configuration .........................................................................................151

00b-AL5010_Table of Contents_R10.doc Accu-Sort Systems, Inc.

vi Contents AccuLazr™ AL5010 Product Line Manuals

Bar Codes..............................................................................................153

Modulo Checks......................................................................................155

Stripping/Padding ..................................................................................156

Match Code Patterns.............................................................................157

Serial Communications .........................................................................161

Network .................................................................................................166

Trigger ...................................................................................................170

Relay .....................................................................................................172

Tracking.................................................................................................174

FAST Moni

tor™.....................................................................................176

Advanced...............................................................................................177

Save / Retrieve ............................................................................................

179

Diagnostics ..................................................................................................181

Monitor...................................................................................................182

Log

Viewer

.............................................................................................184

Update Firmware...................................................................................185

D Networking Guide

.................................................................................................................... 187

E FAST Monitor Configuration

.....................................................................................................................207

F Installation Drawings

.....................................................................................................................209

G Test Label for Adjustable Raster Setup

.....................................................................................................................231

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viii Preface AccuLazr™ AL5010 Product Line Manuals

Conventions

WARNINGS or CAUTIONS: This symbol identifies a hazard or

procedure that, if incorrectly performed, could cause personal injury or
result in equipment damage. It is also used to bring the user’s attention to
details that are considered IMPORTANT.

HIGH VOLTAGE CAUTION: This symbol alerts the user they are about
to perform an action involving, either a dangerous level of voltage, or to
warn against an action that could result in damage to devices or electrical
shock.

LASER CAUTION: This symbol alerts the user they are about to perform
an action involving possible exposure to laser light radiation.

ESD CAUTION: This symbol identifies a procedure that requires you take
measures to prevent Electrostatic Discharge (ESD) e.g., use an ESD wrist
strap. Circuit boards are most at risk. Please follow ESD procedures.

NOTES: This symbol draws attention to details or procedures that may be
useful in improving, maintaining, or enhancing the performance of the
hardware or software being discussed.

NOTE REGARDING DIMENSIONAL REFERENCES: This manual
provides all dimensional references in inches and in most cases Metric
referenced in brackets, for example 10 inches [254 mm].

Customer Service

Training

Accu-Sort Systems offers a complete set of training courses to help you and
your staff get the most out of your investment. We can help you develop a
training plan that provides thorough training for both your project team and
your end users. We will work with you to organize courses appropriate to
your job or area of responsibility. Training professionals can show you how
to plan your training throughout the implementation process so that the right
amount of information is delivered to key people when they need it the most.
You can attend courses at our training center, or you can arrange for our
trainers to teach at your facility. In addition, we can tailor standard courses or
develop custom courses to meet your needs.

Support

From on–site support to central support, our team of experienced
professionals provides the help and information you need to keep your
equipment working for you. This team includes your Account Manager and
Accu-Sort’s large staff of support specialists with expertise in your business
area and managing your hardware and software environment.

NOTE: If you have any problems or questions that require Accu-Sort's
assistance, direct your calls to Customer Service at 1-800-BAR-CODE

[phone].

™

or

Accu-Sort Systems, Inc. 00c-AL5010_Preface_R20.doc

AccuLazr™ AL5010 Product Line Manual Introduction 1

1 Introduction

This chapter presents an introductory description of the AccuLazr™ AL5010
laser barcode scanner product line including:

 AL5010 Product Line Overview
 AccuLazr User Interface

AL5010 Product Line Overview

The AL5010 line of laser barcode readers is designed with industrial and
manufacturing applications in mind, providing high-speed scanning and high
reliability in a rugged industrial enclosure. The entire AL5010 product line
offers a large depth of field that provides accurate barcode reading from as
little as 4 inches up to 48 inches.

The AccuLazr AL5010 Mid-Range Laser Barcode Readers include:

 AL5010 Scan Head
 AL5010 Mounting Base
 AccuLazr Interface Module (optional)
 Power Supply Module (optional)

AL5010 Barcode Reader

AccuLazr Basic Interface Module

01-AL5010_Introduction_R20.doc Accu-Sort Systems, Inc.

2 Introduction AccuLazr™ AL5010 Product Line Manuals

AL5010 Scan Head

The AL5010 Scan Head incorporates the optics and laser module(s) for
scanning barcodes as well as the decoding engine and parameter storage
module. The control panel provides several LED status indicators and three
function buttons.

There are five models of the AL5010 Scan Head (each available with
optional adjustable raster):

 One-laser models for standard and high-density
 Two-laser models for standard, near-focus high-density and high-density

An optional Adjustable Raster (adjustable up to 20-degrees above or below
0-degrees, variable DOF) is available in the existing scan head housing. No

bolt-on additions are required.

AL5010 Mounting Base

The AL5010 Mounting Base provides for the mounting of the AL5010 as well
as the wiring interface between the scan head and AccuLazr Interface
Module. It includes a parameter storage module that enables parameters to
be uploaded/downloaded with the ‘hot-swappable’ scan head.

Accu-Sort Systems, Inc. 01-AL5010_Introduction_R20.doc

AccuLazr™ AL5010 Product Line Manual Introduction 3

AccuLazr Interface Module

The AccuLazr Interface Module is fully compatible with the AL5010 line of
barcode readers and is available in both a Basic and Enhanced version.

The AccuLazr Basic Interface Module provides the following connections:

 Scanner (15-pin and RJ45)
 Ethernet / EtherNet/IP (1)
 Serial ports (2)
 Trigger Input
 Power

The Enhanced Interface Module provides the following additional
connections:

 Tach Input
 Up to four Opto22 I/O modules
 Fieldbus communications (either DeviceNet or Profibus)

01-AL5010_Introduction_R20.doc Accu-Sort Systems, Inc.

4 Introduction AccuLazr™ AL5010 Product Line Manuals

AccuLazr™ User Interface

The AccuLazr User Interface lets you configure an AL5010 through a series
of intuitive, user-friendly menus, tools and dialog boxes accessed via a web
browser. Context sensitive help is available to assist with use of the software.

With the user interface, you can:
 Integrate AL5010 to your system and application without custom

software.

 Modify output messages to accommodate your system needs.
 Add or modify the barcode symbologies read by AL5010.
 Define up to four (4) relay input/outputs.
 Monitor AL5010 performance using diagnostic tools.
 Fine-tune optional adjustable raster.

You can easily configure your AL5010 reader by using a desktop or laptop
computer, an Ethernet network connection and the browser-based interface.

Accu-Sort Systems, Inc. 01-AL5010_Introduction_R20.doc

AccuLazr™ AL5010 Product Line Manual Introduction 5

Typical AL5010 Mid-Range Barcode Reading Applications

Use the AL5010 in the following applications:

 single-reader applications (side or top)
 pick module scanning
 multi-sided scanning
 retail distribution centers
 industrial manufacturing

With optional Adjustable Raster:

 pallet scanning
 hard-to-read barcodes
 plastic shrink-wrapped barcodes
 unknown label positioning

01-AL5010_Introduction_R20.doc Accu-Sort Systems, Inc.

6 Introduction AccuLazr™ AL5010 Product Line Manuals

Options and Accessories

Contact your sales representative for assistance in determining which
options and accessories will be applicable to your application.

If you know which items are needed, contact Accu-Sort’s Customer Service
Department (ask for the Spare Parts Coordinator) between 8 AM and
4:30PM (EST) Monday through Friday at 1-800-BAR-CODE (Fax: 215-723-

1515).

Accu-Sort Systems, Inc. 01-AL5010_Introduction_R20.doc

AccuLazr™ AL5010 Product Line Manuals Safety 7

2 Safety

Please follow the safety precautions and warnings found in this manual when
installing, setting up, operating, maintaining, troubleshooting or replacing any
Accu-Sort products, parts, or related equipment. Following these precautions
will prevent personal injury or damage to the unit. Failure to follow these
precautions may also void your warranty.

This section provides important information regarding safety and your
AL5010, especially involving issues regarding:

 General Precautions during Mounting and Installation

 Compliance Requirements

 Electrical Safety

 Electrical Grounding Requirements

 Electrostatic Discharge Precautions and Control

 Laser Safety

Contact Accu-Sort at 1-800-BAR-CODE™ if you need more information.

Symbols

Throughout this manual, special safety alerts are indicated by the following
symbols:

WARNINGS or CAUTIONS: This symbol identifies a hazard or
procedure that, if incorrectly performed, could cause personal injury or
result in equipment damage.

HIGH VOLTAGE CAUTION: This symbol alerts the user they are about
to perform an action involving, either a dangerous level of voltage, or to
warn against an action that could result in damage to devices or electrical
shock.

LASER CAUTION: This symbol alerts the user they are about to perform
an action involving possible exposure to laser light radiation.

ESD CAUTION: This symbol identifies a procedure that requires you take
measures to prevent Electrostatic Discharge (ESD) e.g., use an ESD wrist
strap. Circuit boards are most at risk. Please follow ESD procedures.

Alerts help you to:

02-AL5010_Safety_R20.doc Accu-Sort Systems, Inc.

 Identify a hazard and its consequences

 Avoid a hazard by taking adequate safety precautions

 Get the most out of your bar code solution

8 Safety AccuLazr™ AL5010 Product Line Manuals

General Precautions

Installation and Service by Qualified Service Technician Only

WARNING: All procedures involving exposure to the inside of the
AL5010 Interface Module must be performed by a trained
technician because of possible exposure to emitted laser radiation,
high voltage, and could reduce the effectiveness of the device’s IP
rating. There are no user-serviceable parts inside. Do not attempt
to open the unit or perform any installation/service procedures
unless you are a trained technician! DO NOT REMOVE the
faceplate from the scan head enclosure. Opening the AL5010 will
void the factory warranty.

Refer all servicing and advanced troubleshooting to a qualified service
technician. Technical training is available from Accu-Sort Systems.

Furthermore, even trained technicians should always reference the specific
product documentation for more detailed service procedures that may not be
described in the AL5010 Product Manual.

Unpacking, Mounting and Installation Recommendations

CAUTION: Firmly fasten mounting structures in place before installing the

equipment to any mounting structure. Avoid using freestanding mounting
structures. If your application requires a freestanding mounting structure,
avoid making the structure top-heavy.

 Follow all procedures regarding electrical safety, laser safety, and

electrostatic discharge safety (ESD) as outlined in this manual.

 Save all packing material in case you have to transport your readers.

 Use steel or aluminum as a mounting structure. An Accu-Sort mounting

structure is recommended for optimum system performance.

 Check mounting hardware periodically for tightness and stability.

 Do not use sheet rock, plaster board, wood, or other unstable mounting

surfaces.

 Do not use mounting surfaces that are subject to high vibrations.

 Do not create any obstructions of airflow around the modules. Keep the

area around the modules clean to provide for cooling. (Refer to specific
product manuals for minimum clearances.)

 Avoid dropping the readers during unpacking and installation.

 Do not touch the window glass of the scan head.

Accu-Sort Systems, Inc. 02-AL5010_Safety_R20.doc

AccuLazr™ AL5010 Product Line Manuals Safety 9

Compliance Requirements

FCC NOTICE: The AL5010 has been tested and found to comply with the

limits for a Class A digital device, pursuant to Title 47, Part 15 of the FCC
Rules. These limits are designed to provide a reasonable protection against

harmful interference when the equipment is operated in a commercial
environment. This equipment generates, uses, and can radiate radio frequency
energy and, if not installed and used in accordance with the instruction
manuals, may cause harmful interference to radio communications. Operation
of this equipment in a residential area is likely to cause harmful interference in
which case the user will be required to correct the interference at his own
expense.

WARNING: These are Class A products. In a domestic environment, these
products can cause radio interference, in which case the user may be required
to take adequate measures. (Ref. CISPR 22 = EN 55 022:1995.)

IMPORTANT: Follow the guidelines below to maintain Electromagnetic
Compatibility (EMC) Compliance:

 Interconnecting cables must be twisted pair cables.

Electrical Safety

 All shielded I/O cables shall have the shield terminated to the chassis.

 NOTE: DRAIN WIRE SHIELDING IS NOT ADEQUATE.

 Do not remove the shielding covers.

 Refer to the details on making custom cables as provided in the specific

technical manual for the component.

AL5010 must be installed in accordance with Canadian Electrical Code, Part I,
CSA C22.1; CSA C22.2 No. 0; and the National Electrical Code, NFPA 70.
For complete requirements, National Electrical Code, ANSI/NFPA 70,
Canadian Electrical Code, Part I, C22.1, or other national standard must be
consulted.

 For PERMANENTLY CONNECTED EQUIPMENT/RACK MOUNTED,

incorporate a readily accessible disconnect device in the fixed wiring.

 For PLUGGABLE EQUIPMENT/RACK MOUNTED, install the socket-

outlet near the equipment so it is easily accessible.

 Make sure that all personnel who work with the equipment know where

the disconnect switches or circuit breakers are located.

 Before performing any type of maintenance, turn off power to the unit and

disconnect the power cord.

02-AL5010_Safety_R20.doc Accu-Sort Systems, Inc.

 Be certain your hands and the floor of your work area are dry before

touching electrical equipment or connecting cords.

 Routinely check all power cords, plugs, wiring, and cable connections for

any signs of exposed wire or deteriorating insulation. If you notice any
damage, make arrangements with service personnel to repair or replace
the damaged item immediately.

10 Safety AccuLazr™ AL5010 Product Line Manuals

Electrical Grounding Requirements

Before applying power to any device, ALL components MUST be electrically
grounded. Follow these precautions:

 Ensure all AC power outlets have a properly grounded receptacle.

 ALL components MUST be properly cabled and grounded with three-

conductor AC power cords.

 Use the correct power cord for your country.

 Reference specific grounding instructions for each component.

 Do not use a two-prong adapter.

 Do not cut/remove the round grounding prong from any plug.

 Do not use an extension cord to defeat any ground.

Electrostatic Discharge

ESD CAUTION: Measures must be taken to prevent Electrostatic

Discharge (ESD) at all times when handling any product, equipment, unit or
part (e.g. use a grounded ESD wrist strap). It should be noted that circuit
boards are at greatest risk to damage from ESD. Please follow standard
ESD precautions!

Electrostatic discharge (ESD), the transfer of static electricity from one object
to another, is an often-unnoticeable hazard to electronic components.
Boards and other devices with integrated circuits are particularly sensitive to
ESD damage. Product failures may not occur until days or weeks after the
component was damaged.

Static damage to units can take the form of upset failures or catastrophic
failures (direct and latent).

An upset failure occurs when an electrostatic discharge is not significant
enough to cause total failure, but may result in intermittent gate leakage,
causing loss of software or incorrect storage of information.

Direct catastrophic failures occur when a unit is damaged to the point where
it is permanently damaged.

Basic Rules for ESD Control

Below are some keys to effectively control unnecessary ESD damage when
working with ESD-sensitive devices:

 Define an ESD protective area and work on the ESD-sensitive devices in

this area only.

 Define static sensitivity of devices to be handled in ESD protective area.

 Establish suitable static control program that limits static generation to

less than the damage threshold of the most sensitive device and
provides a safe, defined path for static charge dissipation.

Accu-Sort Systems, Inc. 02-AL5010_Safety_R20.doc

 Prevent contamination of the protective area by unnecessary non-static

controlled materials.

 Audit the ESD protective area regularly to ensure that static control is

maintained. Document the findings for future reference.

AccuLazr™ AL5010 Product Line Manuals Safety 11

 Refer to the specific ESD precautions for each component.

Laser Safety

The AL5010 uses visible laser diodes and emits a “moving” red beam. Do
not stare into the AL5010’s exit window at the laser light source. Avoid
unintentional exposure to laser light whenever possible. The laser light level
does not constitute a health hazard, however staring at the laser light for
prolonged periods could result in eye damage.

The following appears next to the AL5010 laser exit window:

WARNING! LASER LIGHT EMITTED FROM THIS APERTURE

Warning on AL5010 Laser Exit Window to Avoid Exposure

WARNING: Use of controls, adjustments, or procedures other than those
specified in this document may result in hazardous laser light exposure.

The AL5010 Line Scanning Bar Code Reader is rated as a Class 1 Laser
Product by the International Electrotechnical Commission. Compliances are
as follows: Class 1 Laser Product (IEC-60825-1) 2007.

Before performing any maintenance or service procedures, perform
the laser shutoff procedure provided in Chapter 7.

02-AL5010_Safety_R20.doc Accu-Sort Systems, Inc.

12 Safety AccuLazr™ AL5010 Product Line Manuals

Safety Labels and Locations

Refer to the following figures for specific label locations and warnings. When
operating, repairing, or replacing an AL5010, note all label content on the
unit. These labels provide special precautions for operation, usage
specifications, product identification, and service information.

WARNING: LASER LIGHT EMITTED FROM THIS APERTURE.

Label Placement AL5010 Scan Head

Accu-Sort Systems, Inc. 02-AL5010_Safety_R20.doc

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14 Mechanical Installation AccuLazr™ AL5010 Product Line Manuals

Unpacking Instructions

IMPORTANT: The AL5010 packaging is designed to protect the unit(s)

during shipment. Do not throw it away. Save all packing material in case
you need to transport your unit(s).

Accu-Sort Systems, Inc. 03-AL5010_Mechanical_Installation_R20.doc

AccuLazr™ AL5010 Product Line Manuals Mechanical Installation 15

Installation Sequence

NOTE: Everything should be MECHANICALLY INSTALLED before

performing any ELECTRICAL INSTALLATION. Reference Chapter 4 for
electrical installation details.

Installing a Single Unit

To install a single unit, follow this sequence of steps:

 Complete mechanical installation.

 Review the details of your application’s requirements.

 Determine and mark the reader mounting location.

 Erect mounting frame or other supporting structures.

 Attach the Universal Mounting Bracket (UMB) to the frame.

(UMB and mounting frame options are available from Accu-Sort.)

 Install the mounting base to the UMB (or frame, if UMB not used).

 Mount the AccuLazr Basic or Enhanced Interface Module to

structure.

 Mount the Accu-Sort power supply to structure.

 Mount Trigger Photoeye (optional).

 Mount tachometer (Enhanced Interface Module only).

 Complete electrical installation.

 Install the scan head to the mounting base and wire interface

module. (See Chapter 4.)

NOTE: To reduce the possibility of damage to the scan head, install it after
the mounting base is mounted, wired, and all wiring checked for accuracy.

 Setup your reader.

 See Chapter 5.

 Check operations.

 See Chapter 6.

03-AL5010_Mechanical_Installation_R20.doc Accu-Sort Systems, Inc.

Installing multiple units

To mechanically install multiple units, follow the same sequence of steps, per
reader, as defined in Installing a Single Unit. Your application will define how
the mounting requirements vary for each reader.

Multiple-reader networks may require a different approach to physical
location of the power source, trigger photoeye, and tachometer since they
are most likely being shared by the group of readers.

16 Mechanical Installation AccuLazr™ AL5010 Product Line Manuals

Orientation Considerations

Consider the important factors that affect how the reader is oriented in
respect to the barcoded packages (products) and their method of
conveyance.

Mounting the reader for optimum performance depends on these factors:

 Read Range defining the distance (and variations) between the reader

and packages, including the near/far distances, and overall depth of field

 Barcode Orientation on products (ladder or picket fence) as well as the

angle in which codes will appear (skew, pitch and tilt)

 Reader Positioning for type of scanning required to accommodate

picket fence or ladder barcode orientation (yaw, pitch and roll angles)

Read Range

The AL5010 must be positioned in the scanning area to accommodate
reading products over a read range specific to your application. Use the
following diagram to determine the near/optimum/far read distances. These
dimensions result in the overall depth of field your application requires.

Accu-Sort Systems, Inc. 03-AL5010_Mechanical_Installation_R20.doc

AccuLazr™ AL5010 Product Line Manuals Mechanical Installation 17

Barcode Orientation to Scanning Area

Picket Fence or Ladder Orientation Barcode placement usually

determines the AL5010’s positioning. The AL5010 can be mounted to read
codes in either a ladder or picket fence orientation.

Picket Fence and Ladder Orientation Illustrated

Barcode Skew, Pitch and Tilt These angles affect barcode readability.

Barcodes pitched or skewed up to 45 degrees are still readable. Although
some skew may occur, it should not exceed 45 degrees.

← DIRECTION OF TRAVEL →

03-AL5010_Mechanical_Installation_R20.doc Accu-Sort Systems, Inc.

18 Mechanical Installation AccuLazr™ AL5010 Product Line Manuals

General Mounting Guidelines

As you plan and install the AL5010 barcode solution for your application, be
sure to keep the following mounting guidelines in mind:

 Determine the proper orientation and position of the reader.

 Leave adequate clearances for maintenance and wiring.

 AL5010 Reader: ~ 1-inch [25 mm]

Required for scan head removal from mounting base.

 Interface Modules: ~ 8-12 inches [203-305 mm]

 Plan mechanical installation based on the application’s electrical require-

ments. See General Electrical Installation Guidelines in Chapter 4.

It is important that you follow all safety precautions when installing, setting
up, operating, maintaining, troubleshooting or replacing any Accu-Sort

products, parts or related equipment. See Chapter 2, Safety.

Reader Positioning: Fixed Laser

IMPORTANT: The AL5010 is able to decode barcodes at a variety of

angles; however significant angular distortion may degrade reading
performance. When positioning the reader, remember that the scan beam
exits the scan window parallel to the mounting base.

 When mounting the AL5010, take into consideration your

application’s barcode orientation.

 Mount the reader so that the scan beams will intersect barcodes.

10°



0°



IMPORTANT: To avoid the laser reflecting back onto itself
and lowering performance, install at a 10-degree skew.

Accu-Sort Systems, Inc. 03-AL5010_Mechanical_Installation_R20.doc

10°



AL5010’s Range of Motion with Universal
Mounting Bracket (UMB)

AccuLazr™ AL5010 Product Line Manuals Mechanical Installation 19

Reader Positioning: Adjustable Raster

The Adjustable Raster version (sometimes referred to as “vibrating vein”) of
the AL5010 uses an additional mirror that oscillates to throw the laser over a
configurable area. This extra functionality has all been engineered into the
original AL5010 housing. As the mirror oscillates, the scan line sweeps
across the target surface in application where greater coverage is needed.
Specifically, the AL5010 Adjustable Raster can be configured to sweep up to
20-degrees above or below zero. When an AL5010 with the adjustable raster

feature is installed, the user interface will include a Raster setup screen (see

chapter 5 Setup).

The adjustable raster is ideal for pallet scanning or other applications when
the position of the barcode is variable, but scan rate (scans/second) is
decreased because of the oscillation of the mirror. The sweep of the raster
and scanner skew angle is adjusted to get the best coverage over the
probable scan area.

03-AL5010_Mechanical_Installation_R20.doc Accu-Sort Systems, Inc.

20 Mechanical Installation AccuLazr™ AL5010 Product Line Manuals

Raster Setup

The Adjustable Raster version of the AccuLazr™ AL5010 Laser barcode
scanner requires some extra care during installation. The procedures below
will help achieve the coverage needed for your application while ensuring the
maximum read rate.

AL5010 Adjustable Raster Installation

Mount the Scanner

1. Mount the scanner according to specifications.

2. Tilt the scanner back at a 15-degree angle.

Accu-Sort Systems, Inc. 03-AL5010_Mechanical_Installation_R20.doc

0.

Set Up the Raster Sweep

1. Start the user interface (See chapter 5, Setup).

2. In Modify Settings > Barcode, select Code 128. The test barcode

label is a 12 character, code 128.

3. Print out or photo copy the barcode test label sheet found at the end
of this appendix.

4. Place the barcode test labels on a test box.

AccuLazr™ AL5010 Product Line Manuals Mechanical Installation 21

5. Position box at nearest read distance to the scanner.

6. Identify the highest and lowest code placement on the side of a box
in your system. Mark the highest and lowest code positions on the
test box.

03-AL5010_Mechanical_Installation_R20.doc Accu-Sort Systems, Inc.

22 Mechanical Installation AccuLazr™ AL5010 Product Line Manuals

7. In the user interface, navigate to Modify Settings > Raster.

8. Type -20 in the Upper Sweep and Lower Sweep text fields.

NOTE: This will stop the raster from

sweeping and lock it in position at the -20
degrees.

9. Adjust the height of the scanner, so that at -20-degrees, the scan
line is aligned with the lowest barcode mark on the test box.

10. With the laser line intersecting the barcode, put the scanner into test

mode using the user interface. To do this, navigate to Diagnostics >
Monitor.

Accu-Sort Systems, Inc. 03-AL5010_Mechanical_Installation_R20.doc

11. On the Monitor screen, click Start Test Mode.

12. Check the read quality on the monitor. The quality should be 100%.