Intermec MaxiScan 3010, MaxiScan 3100, MaxiScan 3300, MaxiScan 3000 Series User Manual
Fixed industrial scanner data book June1999
The MaxiScan 3000 Series
Fixed Industrial Scanner
Data Book
David Downey
Copyright 1999
Intermec STC, Toulouse France
All rights reserved
Intermec recognises that all trade marks are the property of their respective owners
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Fixed industrial scanner data book June1999
1.0. Introduction
The MaxiScan 3000 series scanners are industrial fixed scanners. The scanners are compact and
ruggedised to operate in the following environments:
In
• Manufacturing Shopfloor
• Rece ivin g and des patc h
• Warehousing
• Laboratory
• Integrated
This data book is d esigned to explain the ma ny feat ures and ben efits of the scanner and to provide
informat ion to cus tomer s on fix e d position sc anning, opt ions a nd specifica tions. Additional information can
be provided by Intermec Technical Product Support.
On Performing
• Conveyor
• Fixed applications
• Pr o ces sin g ma ch i n es
• Lift-truck mount
• Identification
• Tracking
• Qua lity control
• Pr oc ess co ntrol
• Sortation
Figure 1. The M000 range of industrial scanners
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2.0 MaxiScan 3000 Series Key Features
Features of the MaxiScan range:
• Range of Scanners for industrial applications
• EasySet software makes them simple to install
• Compact and rugged metal cases (IP65/Nema12)
• High performance optics and decode
• Common connectivity: 15 Pin D type connector with RS 232, 422, 485 and Current
Loop interfaces
• Wide input power range: +7 to 25V unregulated
• Accessories include:
• MCS connection box and power supply
• M3010 RS 485 network concentrator
• Package sensor
• Adjustable stand
Scanner Range:
• MaxiScan 3100SR - linear
• MaxiScan 3100ST - linear
• MaxiScan 3100ML - linear, fixed raster
• MaxiScan 3300ST - linear, raster, multi line
• MaxiScan 3300HR - linear, raster, multi line
•
Maxiscan 3010 network concentrator
The M3100 provides the following key features:
• Cost effective industrial scanning
• Choice of reading distance from 0-10cm (4”) or to 35cm (14”)
• Auto wake up modes (Sensing of codes M3100SR, sensing of item
M3100ST/ML)
• Input and Output synchro signals (voltage or software)
• All main 1D Symbologies and PDF 417
• High ambient light immunity in laser models
The M3300 provides the following key features:
• Very flexible industrial scanning
•
•
•
Providing Line, Raster and Multi-direction patterns using Active Line Control (ALC).
Reading distance to 65cm (25”)
Advanced functions easily configured through EasySet
Simplifies industrial fixed scanning
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3.0 Application Areas
3.1. Conveyor reading
A primary application for the M3xxx is reading products on passing conveyors. The M3100ST and M3300
are designed to be fixed to conveyors and to read codes in ladder or picket orientations (see section 5.3 for
an explanation of these terms). The M3100SR is best suited to ladder orientations. For this application, the
M3000 series is ‘ruggedised’ and sealed so that it can work near heavy machinery and withstand high
levels of dust and moisture. A trigger input allows a signal from a sensor (photo-sensor) on the conveyor to
turn the scanner on so that it is ready to read. When used in this way, the life of the scanner is greatly
extended. The scanners can also send a trigger out on good read or no read that can be used to operate
gat es on th e convey or and assis t product rejection or sorting.
In this application th e s c anners may perform identif ic ation, tr acking or qua lity co ntrol funct ions a nd such
applications ex ist in all forms of au tomated manuf acturing, in logis tics and in ot her pr ocess ing operatio ns
(laboratory clinical chemistry, etc.).
3.2. Fixed reading
The M3300 can be used as a fixed reader in industrial environments. A typical application is identifying
goods from their shipping labels as they are accepted in a goods receiving area. Here the scanner would be
fixed to a surface or wall allowing packages to be presented or passed in front for reading.
3.3. Truck-mount
The M3300 scanner can be mounted to the front of a fork-lift truck in such a way that it automatically scans
packages picked by the truck. A raster pattern is normally selected to cover the label area and code data is
transmitted to an on-board wireless terminal for sending to the controlling host system. Power would be
supplied by the truck’s VMT (12 or 24V).
3.4. Integrated
In some special applications the M3100 or M3300 are integrated into other machines to provide process
control data. The scanners’compact size, screening and sealing make this application possible. Examples
include photo-processing, medical analysis and packaging machines.
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4.0 MaxiScan 3000 Series key features
4.1. Active Line Control (ALC) – M3300 only
The MaxiScan 3300 is a multi-functional moving-beam bar code laser scanner providing line, raster and
multi-directional scan patterns. The unique scan pattern range stems from Active Line Control (ALC)
technology. ALC gives the user complete control of the scan pattern generation via the configuration
software.
The M3300 can be described as multi-functional because it is equally suited to line, raster and multidire c tional scanning a nd is capable of working in a ll main industria l f ixed applications : ident ification,
tracking, process co ntrol and sortation on all common 1D symbologies. Most other in dustrial sc anners can
only produce one set pattern (i.e. simple line) and many scanner types are needed to cover a full range of
applications.
The MaxiScan 3300 is easy to install and operate and is supplied with Intermec’s EasySet System (ESS), a
PC Windows based set-up software to support the multi-functional features. ESS simplifies installation
and c onfigura tion for both n e w and a dvance d user s.
The M3300 generates a moving spot by reflecting a laser beam onto two mirrors that are rotated by stepper
motors. By rotati n g these very smal l mirrors i n different directions an d speeds, li nes and curves can be
produced.
• Horizontal Scan lines
The basic pa ttern is a horiz ontal sc an line of
varying lengths for reading picket codes.
• Angled scan lines
Lin es at different angles can be produced and
at around 45° can be used to scan picket and
ladder codes by reconstructing the code (from
a fixed length, using check digits etc.).
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• Vertical scan lines
Vertical lines can be generated without
needing to tilt the scanner. These are used for
scanning ladder codes.
• Raster patterns
The horizontal or vertical lines can be swept
through angles of up to 30° to produce raster
patterns. The speed of the raster and length of
lines can b e varied. Ras ter patterns a re ver y
useful for scanning picket codes that may vary
slightly in position as they pass the scanner.
Also raster patterns can read multi-cod e labels
and the scan ner can sort the data before it is
transmitted.
• Multi-direction patterns
The M3300 can produce more complete
patterns to read omni-directional codes.
Diff erent densities of pattern ca n be produced
depending on the codes to be read. However
it has to be re member e d that t h e more lin es
the slower the scan rate on each line.
• Cir c ular patterns
Different size circles can be produced to read
coded ladder codes passing the scanner at
different angles or to read codes randomly
pla ced around a c i rcular object’s
circumference (such as a tyre wall).
These patterns can be configured using the EasySet setup software supplied. A very useful feature is that a
host system/PLC can send the configuration instructions to the scanner to change its pattern ( to read codes
on different packages on the same conveyor line). It is also possible to set-up a continuously rotating
multi-pattern set with the pattern changing at set time intervals.
Through EasySet, custom patterns can be created to suit particular applications and codes. These patterns
can be tested and tuned on-line to the scanner to ensure the highest reading efficiency.
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Applications often change. ALC allows the scan pattern to be changed to follow the new requirements
without hardware updates. This can result in much lower running costs when compared to conventional
scanners.
ALC simplifies scanner model selection since many applications can be solved by just one scanner model.
This simplifies model selection by the system integrator and the end-user alike. It also reduces the stock
levels from what would be necessary if different scanners had to be supplied for different applications
Key points on ALC :
Pr ovides line, a ngled line, raster and multi-direction p atterns
•
Adapts to ladder, picket and omni-directional codes
•
Easy to set-up and customise via EasySet
•
Options include rotating up to 5 patterns continuously or changing patterns under host control
•
4.2. Optics
The M3100ST and M3300 are equipped with a CPC, a patented light collecting device that improves depth
of field a nd allows the reading of poor quality and very lo w contras t c odes. These scanners theref ore have a
sup erior reading ra nge and d e pth of f ield (see chart s in the Appendix) such that the readin g dist ance of the
standard scanner can be compared to other extended range scanners. The CPC allows the scanner to read
labe l contrast s down to 2 5% (the C PC is protected by I N TERMEC patents).
4.3. Decoding
All decoding is performed by the on-board processor and performed in real-time for single codes. The
M3000 series can recognise and read all common symbologies including: Code 39, 128, EAN 128,
UPC/EAN etc. The M3300 can reconstruct fixed length 39 and 128 codes from partial scans or damaged
labels to ensure high read rates even in the toughest of environments. Also multi-code labels, including
EAN 128, and the stacked code Codablock can be scanned and sorted. A raster pattern would normally be
used to scan these codes.
The M3100 can also read PDF 417.
4.4. Environment
The M3000 series is housed in a tough aluminium case and this is sealed with gaskets to meet the IP65 and
Nema 12 standards. The aluminium is epoxy coated to prevent surface corrosion. This makes the scanner
suitable for most industrial environments including areas where there are dust particles, water droplets and
corrosive ch emicals.
The M3300 scanner can operate in a wide temperature range from 0°C to 50°C (32 to 122°F) using an
optional thermo-cooling device to regulate the temperature of the laser diode. The thermo-cooler is a solid
state device that acts as a heat-pump. The laser diode is attached to a metal heat-sink and then to the
thermo-cooler. This in turn is in contact with the outer aluminium case. Heat is thus pumped from the
diode to the case for dissipation. Red laser diodes, as used by most laser scanners, are normally lifespecified at 25°C. When working above 40°C their life is shortened considerably. The thermo-cooler is
designed to keep the diode temperature below this limit even when the ambient temperature is up to 50°C.
Because the internal scanner temperature is above ambient it is recommended that the thermo-cooler be
selected as an option if the scanner’s working ambient temperature is likely to be over 27°C. An
alternative way of controlling the diode’s temperature is to turn the scanner off after each successful scan
and to use an external photo-sensor trigger to wake the scanner up for the next read. Synchronising the
scanner in this way will maximise the working life of the unit (see also section 7.7).
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4.5 EasySet System configuration software
The configuration, testing and tuning of fixed scanners is simplified by Intermec’s EasySet, a Windows
based PC configuration software. EasySet is a unique tool that allows you to work off- or on-line.
In the off-line mode a page is constructed with the configuration codes that specify the desired
configuration. This page is printed and used to perform a quick set-up of one or multiple scanners by
reading the codes. The embedded concatenation feature (patent pending) allows even complicated
configurations to be printed as one bar code. This page can be used to make very fast scanner set-ups in the
field and also to provide a way of co nfir ming th e set-u p or quickly changing it for a new operati on. The
page could be used by an unskilled operator if required.
When using on-line, different configurations can be downloaded instantly via an RS 232 link, tested, and
feedback on eff iciency used to aid the selection of the best pa rameters.
EasySet a revolutionary new way to configure bar code scanners.
See secti on 6 for a full desc ription of EasySet.
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5.0 Fundamentals of Fixed Position Scanning
5.1 The bar code
The M3000 series is principally designed to read linear symbologies (bar codes). A linear bar code is a
number of bars and spaces containing data arranged in parallel rows. These codes are usually read in 1D
using a scanning line. The scanners can read some stacked codes such as PDF 417 (M3100) and
Codablock (M3300). Stacked codes are essentially a number of linear codes stacked on each other with
some common organisation. Stacked codes are a type of 2D code but they can be read by 1D readers if the
scanning line is swept over the code in such a way that each individual line is read.
123 Codablock
Fig 3. A linear bar code (Code 39) Fig 4. A stacked bar code (Codablock)
For fixed applications it is important to understand the symbology(s) used by the application and also its
print specification. It is often useful to get a sample of the code and make some reading tests before
attempting to install a scanner.
To understand the bar code it is necessary to know the following details:
• The Symbology
1. Whic h symbology, is it availabl e a s standard?
1. If more than one, how many (can influence decoding time if more than two are selected)?
2. Is it a fixed length or is there a check digit that can be used to speed decoding and maximise
security?
• Physic al dimensi ons
1. Length and height. What size is the code? This is important in calculating the number of times it
will be scanned as it passes the scanner in conveyor applications. The height of the bars is
important as, depending on the scanning method, it can provide ‘redundancy’ - damaged areas in
one slice (plane) can be read in another slice above or below the damaged area.
2. W hat is the X Dime nsion? The X dime nsio n is the width of the na rrowest elem e nt and is
expressed in mm or mils (1 mil=0.254mm). This di me nsion c an be compare d against rea ding zone
gra phs to s e e what t he depth of field will be for a given code.
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3. Q uiet Zone. This clear area is required by the specification of most c o des. For reliable reading
this zone should be equal to 10 * the X Dimension.
The Quiet Zone
(more than 10X)
• Pr int quality
1. How is the code printed? Thermal transf er or direct thermal give the best qualit y although
some newer i nk-jet p rinters can give compar able quality. D o the codes range in quality or
contrast? samples of the worst quality expected will help to ensure that the scanner is set-up
to read all codes.
2. What is the print media, a pack or label? What is the stock? Is it matt, glossy or reflective.
Will it degrade wit h t ime?
The X
dimension
The bar height
Fig 5. The parts of a code (EAN 13 code)
In general it is useful to use a bar code verifier to check the code sample and compare against the scanner
specifications.
5.2 Bar code scanning
The M3xxx scanners illuminate the bar code with a laser beam produced by a visible red laser diode or, in
the case of the M3100SR, an led array. The beam is used to generate a line or pattern to cover the bar code.
Reflecte d light is filtered and captured by a phot o-diode or CCD. The r es u lting s ignal is opti mised,
ana l ysed and finally d e coded to dis cover the ac tual data .
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5.3 Orientation
Linear bar codes do not have significant error correction and therefore the scanning line must completely
cover the bar code to achieve a successful scan. The size of the code, its Aspect Ratio (ratio of height to
length) and orientation to the scanner are critical if the scanner is to be correctly configured for an
application.
Maximum
angle
Good scan
Fig 6. Maximum code/scan
line tilt angles
Maximum
angle
Two or ientations of co des are used: Picket and Ladder:
• Picket Codes
Picket codes are more commonly used as they give the reader more time to see the code (as the code passes
along the scan line) and make a number of successful scans. However if a mono line pattern is selected,
only a thin slice of the bar code will be used. This wastes the vertical redundancy in the height of the code
and if t her e i s a printing error i n the s lic e see n by t he sc ann er the code will not be read. Therefore for
picket codes it is preferential to use a slightly tilted line or a raster pattern. Some scanners (M3100ML) use
a set number of parallel lines to cover the code. This is often called a raster but is really a multi-line
pattern. The lines are often usually very close (equal to a raster angle of 5-10°). The M3300 is a true
raster scanner. A sweeping line covers the codes and can be adjusted depending on the bar-height and any
var iation in the p lacement of the labe l. The wh ole height of the bars is scanned to ensure maxi mum rea d
rates.
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It is important to know how good the label placement is relative to the scanner. Each scanner has a spec for
reading a label and the following terms are used to describe the position of the label relative to the scan:
Tilt
can severely reduce the number of scans per label by effectively reducing the bar height from the
Fig 8 Picket codes - problems and terms
scanners view. Tilt should be avoided as far as possible. If this is not possible then it may be worth trying a
multi-direction pattern or alternating pattern to ensure that every code intersects a scan line and is read.
Skew
again reduces the bar height when viewed from the scanners position. Varying the pattern will not help
improve skew .
Pitch
occurs when the label is at an angle to the scanner such that one end is further from the scanner than the
ot her. The effect is th e same as reducing th e X Dim ension to t he scanner. The d enser the label, the more
important it is to eliminate pitch.
Ladder Codes
•
Ladder codes can perform well with line scanners and patterns as when the code passes the scan line the whole
Fig. 9. A ladder code and scan line
height of the code is used. However, the time that the code is being read by the line is very short compared to
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a picket code and thus the number of scans per code can be very small. This has security problems (see
section 7.4 on nu mber of scans per code).
The position of the label relative to the scanner causes similar effects to picket codes. The Pitch and Skew
definitions have to be understood since they apply to the label but appear to be different according to the
package:
5.3 Conveyor / code speed
The label orientation, scan line length, scan rate, bar height and conveyor speed should all be adjusted so
Fig 10. Ladder co des - problems and terms
that the scanner is able to make at least five complete scans (preferably more than 7) as the code passes by.
This will guarantee good read rates.
For picket codes the number of scans ca n be c al culated as follows:
Number of sc ans = ((Ws-Wc ) x Sr/Cs) - 2
Where Ws = Width of scan lin e
Note: ensure that t he units of measurement used are common.
Wc = Width of code
Sr = Scan rate
Cs = Conveyor spe e d
Example :
For a conveyor moving at 5m/s, a code width of 4cm, a scan line of 20cm and a scan rate of
450 scans/sec the number of scans will be
((20-4) x 450/500)-2 = 12 scans
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For angled picket codes, the number of scans should be calculated by reducing the width of scan figure
(Ws) in proportion to the tilt angle.
For ladder cod es the formula is
Number of scans = (Hc/Cs x Sr) - 2
Where Hc = Height of code
Cs = Conveyor spe e d
Sr = Scan rate
Example :
For a conveyor moving at 5m/s, a code height of 7cm and a scan rate of 450 the number of
scans will be :
This demonst rates how wit h s imilar parameters , the numb e r of scans for a ladder code w ill be s ma ller t han
(7/500 x 450) - 2 = 4.3 scans
for a picket code. In the above situation the code height would have to be increased or the conveyor speed
slowed for the given scan rate.
It can be useful to calculate the minimum height required for a given scan rate and conveyor speed:
Height of code = Cs x (Ns + 2 )/Sr
Where Cs = Conveyor speed
Ns = Number of scans
Sr = Scan rate
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6.0 INTERME C’s EasySet Syste m
The M3000 series is supplied with a Windows compatible configuration software package on CD-ROM.
This software makes the configuration easy to do and gives two options for communicating to the scanner:
Off-line mode – by printing a custom configuration card
•
On-line mode – by RS 232 link with the scanner
•
EasySet is in fact common to different Intermec products and when entering the software, the correct
product must be selected. EasySet provides the following features:
6.1 Displays default set-up
The set-up commands are show in a ‘command selector’ window. Set-up commands selected by default
are marked with an asterix.
Send commands to
read er via comms
Pr oduct
port
Selector
Command
search box
Selected
commands a nd
set-up codes
Command
Selector
Set-up viewer.
Can be printed
as a custom setup sheet. See
off-line mode
Fig 11. The EasySet System software
6.2 Off-line use
The software can be used off-line to make custom set-up pages including the selected commands as bar
codes. This allows a co nf i guration (or several possible configura tions) to be made off-site and used on -s ite
to quickly set-up scanners. The set-up page should be kept on-site as a reference. It also makes it possible
for u ntra ined staff to change the conf iguration quickl y if required.
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By printing this page the
codes can be used as a
custom set-up page for
configuring one or many
scanners. The page also
becomes a reference for
future use.
Fig 12. The page viewer showing set-up
codes
A unique concatenation feature makes it possible for the set-up codes to be merged as one code that
contains all the information to configure the scanner. This feature is especially useful if the sheet is to be
used to set-up many scanners or is to be used by untrained staff.
A unique
concatenation feature
allows the set-up
codes to be merged
and printe d as one
code. This makes
setting up multiple
scanners very fast.
Fig 13. The page viewer with a concatenated
code.
6.3 On-line Mode
In this mode the software communicates directly with a scanner to send set-up information. An advantage
of this is that each set-up change can be immediately tested to ensure it works and also to see if it helps
reading efficiency.
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