Leuze BCL 248i Operating Instructions
Original operating instructions
BCL 248i
Bar code reader
We reserve the right to make technical changes
EN • 2020-08-26 • 50144275
© 2020
Leuze electronic GmbH + Co. KG
Leuze electronic GmbH + Co. KG BCL 248i 2
Table of contents
1 About this document ............................................................................................7
2 Safety .....................................................................................................................9
2.1 Intended use ...........................................................................................................................9
2.2 Foreseeable misuse ............................................................................................................... 9
2.3 Competent persons .............................................................................................................. 10
2.4 Disclaimer .............................................................................................................................10
2.5 Laser safety notices.............................................................................................................. 10
3 Fast commissioning ........................................................................................... 11
3.1 Mounting ...............................................................................................................................11
3.2 Selecting a mounting location............................................................................................... 11
3.3 Electrical connection............................................................................................................. 11
3.4 Preparatory settings.............................................................................................................. 12
3.4.1 Commissioning the BCL 248i on the PROFINET-IO.........................................................12
3.4.2 Prepare the control............................................................................................................12
3.4.3 Installing GSD file..............................................................................................................13
3.4.4 Configuration .....................................................................................................................13
3.4.5 Transmit the configuration to the IO controller .................................................................. 13
3.4.6 Setting the device name – device naming......................................................................... 14
3.4.7 Check device name...........................................................................................................15
3.5 Further settings..................................................................................................................... 15
3.6 Starting the device ................................................................................................................16
3.7 Bar code reading .................................................................................................................. 17
Table of contents
4 Device description ..............................................................................................18
4.1 Device overview.................................................................................................................... 18
4.2 Performance characteristics .................................................................................................18
4.3 Device construction .............................................................................................................. 20
4.4 Display elements .................................................................................................................. 20
4.5 Reading techniques ..............................................................................................................22
4.5.1 Line scanner (single line) ..................................................................................................22
4.5.2 Raster scanner (raster line)...............................................................................................23
4.6 Fieldbus systems ..................................................................................................................24
4.6.1 PROFINET-IO ...................................................................................................................24
4.6.2 PROFINET-IO – star topology........................................................................................... 26
4.7 autoReflAct ...........................................................................................................................26
4.8 Reference codes................................................................................................................... 27
4.9 autoConfig ............................................................................................................................27
5 Mounting..............................................................................................................28
5.1 Transport and storage .......................................................................................................... 28
5.2 Mounting ...............................................................................................................................28
5.2.1 Mounting with M4 fastening screws ..................................................................................28
5.2.2 Mounting with BT56 or BT56-1 mounting device ............................................................29
5.2.3 Mounting with BT300-1 mounting device ......................................................................... 29
5.2.4 Mounting with the BT300W mounting bracket................................................................. 29
5.3 Selecting a mounting location............................................................................................... 29
5.4 Cleaning................................................................................................................................ 31
6 Electrical connection..........................................................................................32
6.1 PWR/SWIO (supply voltage, switching input and switching output) ..................................... 33
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Table of contents
6.2 HOST (PROFINET, cable assignments)............................................................................... 35
6.3 PROFINET-IO topologies .....................................................................................................36
6.4 Cable lengths and shielding.................................................................................................. 36
7 Starting up the device – Leuze webConfig tool ............................................... 37
7.1 System requirements............................................................................................................ 37
7.2 Start webConfig tool ............................................................................................................. 37
7.3 Short description of the webConfigtool ................................................................................38
7.3.1 CONFIGURATION menu ..................................................................................................38
8 Starting up the device - Configuration..............................................................40
8.1 PROFINET-IO....................................................................................................................... 40
8.2 Starting the device ................................................................................................................40
8.3 Configuration steps for a Siemens SimaticS7 control.......................................................... 41
8.3.1 Step 1 – Prepare the control .............................................................................................41
8.3.2 Step 2 – Installing GSD file ...............................................................................................41
8.3.3 Step 3 – Hardware configuration of the S7 PLC: Configuration ........................................42
8.3.4 Step 4 – Transmit the configuration to the IO controller....................................................42
8.3.5 Step 5 – Set device name – device naming ......................................................................43
8.3.6 Step 6 – Check device name ............................................................................................44
8.3.7 Manually setting the IP address ........................................................................................ 44
8.3.8 MAC address..................................................................................................................... 45
8.3.9 Ethernet host communication............................................................................................46
8.3.10 TCP/IP...............................................................................................................................46
8.3.11 UDP...................................................................................................................................47
8.4 Commissioning via the PROFINET-IO.................................................................................. 47
8.4.1 General information...........................................................................................................47
8.4.2 Permanently defined parameters/device parameters........................................................ 48
8.5 Overview of the project modules .......................................................................................... 52
8.6 Decoder modules.................................................................................................................. 56
8.6.1 Modules 1-4 – Code table extensions 1 to 4 .....................................................................56
8.6.2 Module 5 – Code type features (symbology)..................................................................... 57
8.6.3 Module 7 – Code reconstruction technology .....................................................................59
8.7 Control modules.................................................................................................................... 60
8.7.1 Module 10 – Activations ....................................................................................................60
8.7.2 Module 11 – Reading gate control ....................................................................................61
8.7.3 Module 12 – Multi-label .....................................................................................................63
8.7.4 Module 13 – Fragmented read result ................................................................................ 64
8.7.5 Module 14 – Interlinked read result ...................................................................................64
8.8 Result format......................................................................................................................... 65
8.8.1 Module 20 – Decoder state ...............................................................................................65
8.8.2 Modules 21-29 – Decoding result...................................................................................... 67
8.8.3 Module 30 – Data formatting .............................................................................................69
8.8.4 Module 31 – Reading gate number ...................................................................................70
8.8.5 Module 32 – Reading gate time ........................................................................................70
8.8.6 Module 33 – Code position................................................................................................ 71
8.8.7 Module 34 – Reading reliability (equal scans)................................................................... 71
8.8.8 Module 35 – Bar code length ............................................................................................72
8.8.9 Module 36 – Scans with information .................................................................................72
8.8.10 Module 37 – Decoding quality ...........................................................................................73
8.8.11 Module 38 – Code direction ..............................................................................................73
8.8.12 Module 39 – Number of digits ...........................................................................................74
8.8.13 Module 40 – Code type (symbology)................................................................................. 74
8.9 Data Processing ................................................................................................................... 75
8.9.1 Module 50 – Characteristics filter ......................................................................................75
8.9.2 Module 51 – Data filtering .................................................................................................76
8.10 Identifier ................................................................................................................................77
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Table of contents
8.10.1 Module 52 – Segmentation acc. to the EAN process........................................................77
8.10.2 Module 53 – Segmentation via fixed positions ..................................................................79
8.10.3 Module 54 – Segmentation according to identifier and separator .....................................81
8.10.4 Module 55 – String handling parameters ..........................................................................83
8.11 Device functions ................................................................................................................... 83
8.11.1 Module60–Device status ................................................................................................83
8.11.2 Module 61 – Laser control.................................................................................................85
8.11.3 Module 63 – Alignment...................................................................................................... 85
8.12 Switching inputs/outputs SWIO1/2 ...................................................................................... 86
8.12.1 Parameters for operating as an output..............................................................................86
8.12.2 Parameters for operating as an input ................................................................................88
8.12.3 Switch-on and switch-off functions for operation as an output ..........................................89
8.12.4 Input functions for operation as an input ........................................................................... 89
8.12.5 Module 70 – Switching input SWI1.................................................................................... 90
8.12.6 Module 71 – Switching output SWO2................................................................................ 91
8.12.7 Module 74 – SWIO status and control............................................................................... 92
8.13 Data output ...........................................................................................................................93
8.13.1 Module 80 – Sorting ..........................................................................................................93
8.14 Reference code comparison................................................................................................. 95
8.14.1 Module 81 – Reference code comparator1 ......................................................................95
8.14.2 Module 82 – Reference code comparator2 ......................................................................97
8.14.3 Module 83 – Reference code comparison pattern1 .........................................................99
8.14.4 Module 84 – Reference code comparison pattern2 .......................................................100
8.15 Special functions................................................................................................................. 102
8.15.1 Module90–Status and control....................................................................................... 102
8.15.2 Module 91 – AutoReflAct (automatic reflector activation) ...............................................102
8.15.3 Module 92 – AutoControl................................................................................................. 103
8.15.4 Module 100 – multiScan master......................................................................................104
8.15.5 Module 101 – multiScan slave addresses1....................................................................106
8.15.6 Module 102 – multiScan slave addresses2....................................................................107
8.16 Example configuration: Indirect activation via the PLC....................................................... 107
8.16.1 Task................................................................................................................................. 107
8.16.2 Procedure........................................................................................................................108
8.17 Example configuration: Direct activation via the switching input ........................................ 109
8.17.1 Task................................................................................................................................. 109
8.17.2 Procedure........................................................................................................................109
9 Online commands.............................................................................................111
9.1 Overview of commands and parameters ............................................................................ 111
9.2 General online commands.................................................................................................. 111
9.3 Online commands for system control ................................................................................. 117
9.4 Online commands for configuration of switching inputs/outputs......................................... 118
9.5 Online commands for the parameter set operations........................................................... 119
10 Care, maintenance and disposal .....................................................................124
11 Diagnostics and troubleshooting ....................................................................125
11.1 Error signaling via LED .......................................................................................................125
11.2 Interface error .....................................................................................................................126
12 Service and support .........................................................................................127
13 Technical data ...................................................................................................128
13.1 General specifications ........................................................................................................ 128
13.2 Reading fields .....................................................................................................................130
13.2.1 Bar code characteristics ..................................................................................................130
13.2.2 Raster scanner ................................................................................................................130
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Table of contents
13.2.3 Reading field curves........................................................................................................131
13.3 Dimensioned drawings ....................................................................................................... 133
14 Order guide and accessories...........................................................................134
14.1 Part number code ...............................................................................................................134
14.2 Type overview..................................................................................................................... 134
14.3 Accessories – connection technology................................................................................. 134
14.4 Accessories – mounting systems ....................................................................................... 135
14.5 Accessories – Reflectors and reflective tapes .................................................................... 135
15 EC Declaration of Conformity ..........................................................................136
16 Appendix............................................................................................................137
16.1 ASCII character set............................................................................................................. 137
16.2 Bar code sample................................................................................................................. 141
Leuze electronic GmbH + Co. KG BCL 248i 6
About this document
1 About this document
Used symbols and signal words
Tab.1.1: Warning symbols and signal words
NOTE Signal word for property damage
CAUTION Signal word for minor injuries
WARNING Signal word for serious injury
Symbol indicating dangers to persons
Symbol indicating possible property damage
Indicates dangers that may result in property damage if the measures for danger avoidance are not followed.
Indicates dangers that may result in minor injury if the measures for danger
avoidance are not followed.
Indicates dangers that may result in severe or fatal injury if the measures for
danger avoidance are not followed.
DANGER Signal word for life-threatening danger
Tab.1.2: Other symbols
Indicates dangers with which serious or fatal injury is imminent if the measures
for danger avoidance are not followed.
Symbol for tips
Text passages with this symbol provide you with further information.
Symbol for action steps
Text passages with this symbol instruct you to perform actions.
Symbol for action results
Text passages with this symbol describe the result of the preceding action.
Leuze electronic GmbH + Co. KG BCL 248i 7
About this document
Terms and abbreviations
Tab.1.3: Terms and abbreviations
AutoConfig Function for easily configuring a code type or number of digits
AutoReflAct Function for activation without additional sensors (Automatic Reflector Activa-
BCL Bar code reader
CRT Code reconstruction technology
EMC Electromagnetic compatibility
EN European standard
FE Functional earth
GSDML Generic Station Description Markup Language
IO controller Control that initiates the IO data communication
IO device Decentral PROFINET fieldbus device
IP address Network address, which is based on the Internet Protocol (IP)
MAC address Media Access Control Address; hardware address of a device in the network
tion)
PELV Protective Extra-Low Voltage; protective extra-low voltage with reliable discon-
nection
PLC Programmable Logic Controller
SWI1 Digital switching input (Switching Input)
SWO2 Digital switching output (Switching Output)
TCP/IP Transmission Control Protocol/Internet Protocol; Internet protocol family
UL Underwriters Laboratories
Leuze electronic GmbH + Co. KG BCL 248i 8
Safety
2 Safety
The barcode readers of the BCL200iseries were developed, manufactured and tested in accordance with
the applicable safety standards. They correspond to the state of the art.
2.1 Intended use
Barcode readers of the BCL200i series are conceived as stationary, high-speed scanners with integrated
decoders for all current barcodes used for automatic object detection.
Areas of application
The bar code readers of the BCL200i series are especially designed for the following areas of application:
• Storage and conveying technologies, in particular for object identification on fast-moving conveyor belts
• Pallet transport systems
• Automobile sector
Observe intended use!
The protection of personnel and the device cannot be guaranteed if the device is operated in a
manner not complying with its intended use.
Ä Only operate the device in accordance with its intended use.
Ä LeuzeelectronicGmbH+Co.KG is not liable for damages caused by improper use.
Ä Read these operating instructions before commissioning the device. Knowledge of the oper-
CAUTION
ating instructions is an element of proper use.
NOTICE
Comply with conditions and regulations!
Ä Observe the locally applicable legal regulations and the rules of the employer's liability insur-
ance association.
2.2 Foreseeable misuse
Any use other than that defined under "Intended use" or which goes beyond that use is considered improper use.
In particular, use of the device is not permitted in the following cases:
• in rooms with explosive atmospheres
• in circuits which are relevant to safety
• for medical purposes
NOTICE
Do not modify or otherwise interfere with the device!
Ä Do not carry out modifications or otherwise interfere with the device. The device must not be
tampered with and must not be changed in any way.
Ä The device must not be opened. There are no user-serviceable parts inside.
Ä Repairs must only be performed by Leuze electronic GmbH + Co. KG.
Leuze electronic GmbH + Co. KG BCL 248i 9
Safety
2.3 Competent persons
Connection, mounting, commissioning and adjustment of the device must only be carried out by competent
persons.
Prerequisites for competent persons:
• They have a suitable technical education.
• They are familiar with the rules and regulations for occupational safety and safety at work.
• They are familiar with the operating instructions for the device.
• They have been instructed by the responsible person on the mounting and operation of the device.
Certified electricians
Electrical work must be carried out by a certified electrician.
Due to their technical training, knowledge and experience as well as their familiarity with relevant standards
and regulations, certified electricians are able to perform work on electrical systems and independently detect possible dangers.
In Germany, certified electricians must fulfill the requirements of accident-prevention regulations DGUV
(German Social Accident Insurance) provision 3 (e.g. electrician foreman). In other countries, there are respective regulations that must be observed.
2.4 Disclaimer
LeuzeelectronicGmbH+Co.KG is not liable in the following cases:
• The device is not being used properly.
• Reasonably foreseeable misuse is not taken into account.
• Mounting and electrical connection are not properly performed.
• Changes (e.g., constructional) are made to the device.
2.5 Laser safety notices
ATTENTION
LASER RADIATION – CLASS 1 LASER PRODUCT
The device satisfies the requirements of IEC/EN 60825-1:2014 safety regulations for a product
of laser class1 and complies with 21 CFR 1040.10 except for conformance with IEC 60825-1
Ed. 3., as described in Laser Notice No. 56, dated May 8, 2019.
Ä Observe the applicable statutory and local laser protection regulations.
Ä The device must not be tampered with and must not be changed in any way.
There are no user-serviceable parts inside the device.
Repairs must only be performed by Leuze electronic GmbH + Co. KG.
CAUTION
Laser radiation
Opening the device can lead to dangerous exposure to radiation.
Leuze electronic GmbH + Co. KG BCL 248i 10
Fast commissioning
3 Fast commissioning
Below you will find a short description for the initial commissioning of the BCL248i. Detailed explanations
for all listed points can be found throughout these operating instructions.
3.1 Mounting
The bar code reader can be mounted in the following ways:
• Mounting with four M4x5 screws on the rear side of the housing.
• Mounting with mounting devices on the fastening groove on one side of the housing.
3.2 Selecting a mounting location
In order to select the right mounting location, several factors must be considered:
• Size, orientation, and position tolerance of the bar codes on the objects to be scanned.
• The reading field of the bar code reader in relation to the bar code module width.
• The resulting minimum and maximum reading distance from the respective reading field with the respective module width (see chapter 13.2 "Reading fields").
• alignment of the bar code reader for avoiding reflections.
• Distance between bar code reader and host system with respect to the interface.
• The correct time for data output. The bar code reader should be positioned in such a way that, taking
into consideration the time required for data processing and the conveyor belt speed, there is sufficient
time to e.g. initiate sorting operations on the basis of the read data.
• The display elements such as LEDs should be highly visible.
• For configuring and commissioning with the webConfig tool, the HOST interface should be easily accessible.
For further information, see see chapter 5 "Mounting" and see chapter 6 "Electrical connection".
The best read results are obtained if the following prerequisites are fulfilled:
• The reading distance lies in the middle area of the reading field.
• There is no direct sunlight and protect against ambient light effects.
• The bar code labels are of good print quality and have good contrast ratios.
• You are not using high-glossy labels.
• The bar code is moved past with an angle of inclination of ±10°…15° to vertical.
NOTICE
Avoid direct reflection of the laser beam!
The beam on the bar code reader is emitted at 105° to the housing base. An angle of incidence
of 15° of the laser to the label has already been integrated in the deflecting mirror so that the bar
code reader can be installed parallel to the bar code (rear housing wall).
3.3 Electrical connection
The bar code reader is equipped with two connection cables, each with an M12 connector.
• PWR/SWIO: M12 connection for supply voltage and switching input/output, 5-pin, A-coded, cable
length 0.9m (unshielded)
• HOST: M12 connection for Ethernet/PROFINET, 4-pin, D-coded, cable length 0.7m (shielded)
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Fast commissioning
1
2
2
3
1
4
5
1
32
4
1 PWR/SWIO
2 HOST
1 PWR/SWIO, M12 connector, 5-pin, A-coded
2 HOST, M12 socket, 4-pin, D-coded
Fig.3.1: Electrical connections
NOTICE
The shielding is connected using the M12 connector of the Ethernet cable.
Details on the connectors see chapter 6 "Electrical connection".
3.4 Preparatory settings
Ä Connect the +18…30 VDC supply voltage (typically +24VDC).
ð The bar code reader starts up.
First, you need to assign its individual device name to the BCL248i. The PLC must communicate this device name to the participant during the "device naming". Further information may be found below and in
see chapter 8.3.5 "Step 5 – Set device name – device naming".
3.4.1
3.4.2
Commissioning the BCL 248i on the PROFINET-IO
Ä Complete the necessary steps for commissioning a Siemens-S7 control as described below.
Further information regarding the individual commissioning steps is provided in see chapter 8.3 "Configuration steps for a Siemens SimaticS7 control".
Prepare the control
Ä In the first step, assign an IP address to the IO controller (S7 PLC) and prepare the control for a consis-
tent data transmission.
NOTICE
Ä With the S7 control, make sure that at least Simatic Manager Version5.4 + Service Pack5
(V5.4+SP5) is used.
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Fast commissioning
3.4.3
3.4.4
Installing GSD file
For the subsequent configuration of the IOdevices, e.g., BCL248i, the corresponding GSD file must be
loaded first. In this file, all data necessary for operating the BCL248i is described in modules. These are input and output data and device parameters for the functioning of the BCL248i and the definition of the control and status bits.
Ä Install the GSD file associated with the BCL248i in the PROFINET-IO Manager of your control.
Configuration
Ä Configure the PROFINET-IO system with the HW Config of the SIMATIC Manager by inserting the
BCL248i into your project.
ð Here, an IP address is assigned to a unique "device name".
Fig.3.2: Assignment of the device names to IP addresses
3.4.5
Transmit the configuration to the IO controller
Ä Transmit the PROFINET-IO configuration to the IO controller (S7 PLC).
After correct transmission to the IO controller (S7 PLC), the PLC automatically carries out the following activities:
• Check of device names
• Assignment of the IP addresses that were configured in the HW Config to the IOdevices
• Establishment of a connection between the IOController and configured IOdevices
• Cyclical data exchange
NOTICE
Participants that have not been "named" cannot be contacted yet at this point in time.
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Fast commissioning
3.4.6
Setting the device name – device naming
PROFINET-IO defines the "naming of the device" as the creation of a name-based relationship for a
PROFINET-IO device.
Assigning the device name to the configured IO devices
Ä Select the respective BCL248i bar code reader for the "device naming" based on its MAC address.
ð This participant is assigned the unique "device name." This must match the device name in the HW
config and must not be longer than 255 characters.
Fig.3.3: Assigning the device names to the configured IOdevices
NOTICE
Multiple BCL248i can be distinguished by the MAC addresses displayed. The MAC address
may be found on the name plate of the respective bar code reader.
Assignment of MAC address – IP address – individual device name
Ä Assign an IP address (suggested by the PLC), a subnet mask and, if required, a router address, and
assign this data to the named participant ("device name").
ð From now on, and when programming, only the unique "device name" is used.
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Fast commissioning
Fig.3.4: MAC address – IP address – individual device name
3.4.7
Check device name
Ä After completing the configuration phase, recheck the "device names" that have been assigned. Ensure
that these are unique and that all participants are located in the same subnet.
3.5 Further settings
Carry out further settings, such as the control of the decoding and processing of the read data and the configuration of the connected switching inputs and outputs.
Decoding and processing the read data
Ä Define at least one code type with the desired settings.
In the webConfig tool:
Configuration > Decoder
Control of the decoding
Configure the connected switching inputs according to your requirements.
Ä First set the I/O mode to input.
Ä Then configure the switching behavior.
In the webConfig tool:
Configuration > Device > Switching inputs/outputs
Control of the switching outputs
Configure the connected switching outputs according to your requirements.
Ä First set the I/O mode to output.
Ä Then configure the switching behavior.
In the webConfig tool:
Configuration > Device > Switching inputs/outputs
Carry out further settings via the PROFINET-IOController, such as the control of the decoding and processing of the read data and the configuration of the connected switching inputs and outputs, using the parameters provided by the GSD file.
Ä Activate the desired modules (at least module10 and one of the modules 21…29).
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Fast commissioning
192.168.060.101
3.6 Starting the device
Ä Connect the +18…30 VDC supply voltage (typically +24VDC).
ð The BCL248i starts up, the PWR, NET and LINK LEDs indicate the operating state.
Tab.3.1: Display of operating state
LED Color State Description
PWR Green Flashing Device ok, initialization
Continuous light Power On, device OK
Briefly off - on Good read, reading successful
Green - red Green off – briefly
red – green on
Yellow Continuous light Service mode
Red Flashing Warning
Continuous light Error, device error
NET Green Flashing Initialization
Continuous light Network mode ok
Orange Flashing Topology error
Red Flashing Communication error
Continuous light Network error
LINK Green Continuous light Ethernet connected (LINK)
Yellow Flashing Data communication (ACT)
During the initialization phase (power on), the laser is switched on for approx. 2seconds. A configuration
code can be read in during this time.
NOTICE
Setting the IP address to the Leuze default address
By reading in the configuration code during the initialization phase, the IP address and the subnet mask are set to the Leuze default.
IP address: 192.168.60.101
Subnet mask: 255.255.255.0
No Read, reading not successful
Operating the bar code reader
After connecting a supply voltage of +18…30VDC to the switching input, a read process is activated. In
the standard setting, all common code types for decoding are released. Only the 2/5Interleaved code type
is limited to 10 digits of code content.
If a code is moved through the reading field, the code content is decoded and forwarded to the superior
system (PLC/PC) via PROFINET-IO.
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Fast commissioning
Modul 0,5
6677889900
3.7 Bar code reading
Ä Test the device with the following bar code in format 2/5 Interleaved. The bar code module here is 0.5.
The PWR LED goes off briefly and then turns green again. Simultaneously, the read information is forwarded to the superior system (PLC/PC) via the PROFINET-IO.
Ä Check the incoming data of the bar code information.
Alternatively, you can use a switching input for read activation (switching signal of a photoelectric sensor or
24 V DC switching signal).
Leuze electronic GmbH + Co. KG BCL 248i 17
Device description
4 Device description
4.1 Device overview
Barcode readers of the BCL200i series are high-speed scanners with integrated decoder for all commonly
used barcodes, e.g. 2/5Interleaved, Code39, Code128, EAN8/13 etc., as well as codes from the
GS1DataBar family.
Bar code readers of the BCL200i series are available in various models as line/raster scanners with deflecting mirror.
The interfaces integrated in the various device models offer an optimum connection to the superior host
system:
• Ethernet TCP/IP UDP
• Ethernet/IP
• PROFINETIO
4.2 Performance characteristics
• Integrated fieldbus connectivity, Plug-and-Play fieldbus coupling and easy networking
• Numerous interface variants facilitate connection to the superior systems
• PROFINETIO
• Ethernet
• Integrated code reconstruction technology (CRT) enables the identification of soiled or damaged bar
codes
• Maximum depth of field and reading distances from 40mm to 255mm
• Large optical opening angle and, thus, large reading field width
• High scanning rate with 1000scans/s for fast reading tasks
• Adjustment of all device parameters with a web browser
• Easy alignment and diagnostics functions
• Two freely programmable switching inputs/outputs for the activation or signaling of states
• Automatic monitoring of the read quality with autoControl
• Automatic recognition and setting of the bar code type using autoConfig
• Reference code comparison
• Heavy-duty housing of degree of protection IP65
NOTICE
Information on technical data and characteristics: see chapter 13 "Technical data"
Integrated fieldbus connectivity
The integrated fieldbus connectivity contained in the bar code readers of the BCL200i series facilitates the
use of identification systems which function without connection unit or gateways. The integrated fieldbus interface considerably simplifies handling. The Plug-and-Play concept enables easy networking and very
simple commissioning: Directly connect the respective fieldbus and all configuration is performed with no
additional software.
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Device description
CRT decoder
For decoding bar codes, the bar code readers of the BCL200i series make available the proven CRT decoder with code reconstruction technology.
The proven code reconstruction technology (CRT) enables bar code readers of the BCL200i series to read
bar codes with a small bar height, as well as bar codes with a damaged or soiled print image.
With the aid of the CRT decoder, bar codes can also be read without problem in other demanding situations, such as with a large tilt angle (azimuth angle or even angle of rotation).
Fig.4.1: Possible bar code orientation
Configuration
With the BCL248i, configuration is generally performed with the aid of the GSD file.
The bar code reader needs a suitable activation to start a read process as soon as an object is in the reading field. This opens a time window ("reading gate") in the bar code reader for the read process during
which the bar code reader has time to detect and decode a bar code.
In the basic setting, triggering takes place through an external reading cycle signal or via PROFINETIO.
An alternative option for activation is the autoReflAct function.
Through the read operation, the bar code reader collects additional useful pieces of data for diagnostics
which can also be transmitted to the host. The quality of the read operation can be inspected using the
alignment mode which is integrated in the webConfig tool.
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Device description
1
2
3
4
5
4.3 Device construction
1 Reading window
2 Indicator LEDs
3 M4 mounting threads on the rear of the device
4 Connection cable
5 Dovetail mounting
Fig.4.2: Device construction BCL248i – Line scanner with deflecting mirror
4.4 Display elements
Located on the front side of the housing are three multicolor indicator LEDs: PWR, NET, LINK.
Fig.4.3: LED indicators
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Device description
PWR LED
Tab.4.1: PWR indicators
Color State Description
--- OFF Device off
Green Flashing Device ok
No supply voltage
• Initialization phase
• Bar code reading not possible
• Supply voltage applied
• Self test running
Continuous light Device ok
• Bar code reading possible
• Self test successfully finished
• Device monitoring active
Briefly off - on Good Read
• Bar code reading successful
Green briefly off –
briefly red – green on
No read
• Bar code reading not successful
Orange Continuous light Service mode
• Bar code reading possible
• No data on the host interface
Red Flashing Device ok, warning set
• Bar code reading possible
• Temporary operating fault
Continuous light Device error/parameter enable
• Bar code reading not possible
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Device description
NET LED
Tab.4.2: NET indicators
Color State Description
--- OFF No supply voltage
Green Flashing Initialization of the device
Orange Flashing Topology error
Red Flashing Communication error
• No communication possible
• PROFINET-IO communication not initialized or inactive
Establishing communication
Continuous light Operation ok
• Network mode ok
• Connection and communication to IOController (PLC) established ("data exchange")
• Deviating target/actual topology detected
• Parameterization or configuration failed ("parameter failure")
• IO error
• No data exchange
Continuous light Network error
LINK LED
Tab.4.3: LINK indicators
Color State Description
Green Continuous light Ethernet connected (LINK)
Yellow Flashing Data communication (ACT)
4.5 Reading techniques
4.5.1
Line scanner (single line)
The scan line scans the label. Due to the optical opening angle, the reading field width is dependent on the
read distance. Through the movement of the object, the entire bar code is automatically transported
through the scan line.
The integrated code reconstruction technology permits twisting of the bar code (tilt angle) within certain limits. These are dependent on the transport speed, the scanning rate of the scanner and the bar code properties.
Areas of application of the line scanner
• With the bars of the bar code arranged lengthwise with respect to the conveying direction ("ladder arrangement")
• With bar codes having very short bar lengths
• When the ladder code is turned out of the vertical position (tilt angle)
• No connection established
• No communication possible
Leuze electronic GmbH + Co. KG BCL 248i 22
Device description
4.5.2
Fig.4.4: Deflection principle for the line scanner
Raster scanner (raster line)
Multiple scan lines scan the label. Due to the optical opening angle, the reading field width is dependent on
the read distance. Provided the code is located in the reading field, it can be read during standstill. If the
code moves through the reading field, it is scanned by multiple scan lines.
The integrated code reconstruction technology permits twisting of the bar code (tilt angle) within certain limits. These are dependent on the transport speed, the scanning rate of the scanner and the bar code properties. In most cases, everywhere a line scanner is used, a raster scanner can be used.
Areas of application of the raster scanner
• With the bars of the bar code arranged perpendicular with respect to the conveying direction ("picket
fence arrangement")
• With bar codes with low height displacement
• With very glossy bar codes
NOTICE
There may not be two or more bar codes in the raster detection range simultaneously.
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Device description
Fig.4.5: Deflection principle for the raster scanner
4.6 Fieldbus systems
Various product variants of the BCL200i series are available for connecting to different fieldbus systems
such as PROFINET, Ethernet, and EtherNet/IP.
4.6.1
PROFINET-IO
Performance characteristics of the PROFINET-IO interface
• GSDML file for the device description
• Certified as a PROFINET-IO device according to V2.34
• PROFINET-IO with real-time (RT) communication
• Standard Fast Ethernet (100 Mbit/s) connections (M12 technology)
• Auto-crossover and auto-negotiation
• Cyclical data exchange
• 4-pin, M12 connectors with D-coding are used for the electrical connection
• Identification & maintenance function (I&M) IM0-IM4
• The IP address – or name assignment – is set using, e.g., TIA portal or comparable tools
• Cycle time: maximum 2ms (MinDeviceInterval=64)
• Function range acc. to Conformance ClassB
• Network load classI
The functionality of the device is defined via parameter sets which are clustered in modules. These modules are contained in a GSDML file.
On delivery, each BCL248i comes with a unique MAC-ID. This information is used to assign a unique,
plant-specific device name ("NameOfStation") to the device via the "Discovery and Configuration Protocol" (DCP).
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Device description
When configuring a PROFINET-IO system, the assignment of the device names to the configured IOdevices creates a name-based relationship for the participating IOdevices ("device naming"). Further information see chapter 8.3.5 "Step 5 – Set device name – device naming".
Identification & Maintenance functions
The BCL248i supports the base record I&M0:
Tab.4.4: Base record I&M0
Index Contents Data type Description Value
0 Header 10bytes Manufacturer specific
10 MANUFACTURER_ID UNSIGNED16 Leuze manufacturer ID (Leuze
338
PNO manufacturer ID)
12 ORDER_ID ASCII string 20
Leuze order no.
bytes
32 SERIAL_NUMBER ASCII string 16
bytes
48 HARDWARE_REVISION UNSIGNED16 Hardware revision number, e.g.,
50 SOFTWARE_REVISION 1x CHAR,
3x UNSIGNED8
54 REVISION_COUNTER UNSIGNED16 Is incremented when updating
Unique device serial number Device-de-
pendent
Device-de-
0…65535
Software version number, e.g.,
V130 corresponds to V1.3.0
pendent
Device-dependent
0
individual modules. This function
is not supported.
56 PROFILE_ID UNSIGNED16 PROFIBUS application profile
number
58 PROFILE_SPE-
CIFIC_TYPE
UNSIGNED16 Information about subchannels
and submodules, not relevant
0x0000 (Non
Profile)
0x0003 (I/O
Module)
60 IM_VERSION 2x UNSIGNED8 Implemented I&M version V1.1 0x01, 0x01
62 IM_SUPPORTED Bit[16] Optional I&M records available 0
The BCL248i supports further protocols and services for communication:
• TCP/IP (Client / Server)
• UDP
• DCP
• ARP
• PING
Further information on commissioning: see chapter 7 "Starting up the device – Leuze webConfig tool"
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Device description
1
2
3
4
4.6.2
PROFINET-IO – star topology
The BCL248i can be operated as a single device (stand-alone) with an individual device name in a star
topology. The PLC must communicate this device name to the participant during the "device naming".
1 Ethernet switch
2 Bar code reader of the BCL200i series
3 Other network participants
4 Host interface - PC/control
Fig.4.6: PROFINET-IO in a star topology
4.7 autoReflAct
autoReflAct stands for automatic Reflector Activation and permits an activation without additional sensors.
This is achieved by directing the scanner with reduced scanning beam towards a reflector mounted behind
the conveyor path.
NOTICE
Suitable reflectors are available, see chapter 14.5 "Accessories – Reflectors and reflective
tapes".
As long as the scanner is targeted at the reflector, the reading gate remains closed. If, however, the reflector is blocked by an object such as a container with a bar code label, the scanner activates the read procedure, and the label on the container is read. When the path from the scanner to the reflector has cleared,
the read procedure has completed and the scanning beam is reduced and again directed onto the reflector.
The reading gate is closed.
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Device description
Fig.4.7: Reflector arrangement for autoReflAct
The autoReflAct function uses the scanning beam to simulate a photoelectric sensor and thus permits an
activation without additional sensors.
4.8 Reference codes
The bar code reader offers the possibility of storing one or two reference codes.
It is possible to store the reference codes via the webConfigtool, via online commands or via PROFINETIO.
The bar code reader can compare read bar codes with one and/or both reference codes and execute userconfigurable functions depending on the comparison result.
4.9 autoConfig
With the autoConfig function, the bar code reader offers an extremely simple and convenient configuration
option to users who only want to read one code type (symbology) with one number of digits at a time.
After starting the autoConfig function via the switching input or from a superior control, it is sufficient to position a bar code label with the desired code type and number of digits in the reading field of the bar code
reader.
Afterward, bar codes with the same code type and number of digits are recognized and decoded.
NOTICE
The settings made via the webConfig configuration tool only temporarily push the parameters
set in the PROFINET-IO into the background. The settings are overwritten during integration
into the PROFINET-IO or after deactivation of service mode of the PROFINET master with
those settings made via the GSD file.
Device settings for operating the BCL248i on the PROFINET-IO are managed and configured
exclusively by the PROFINET-IO controller (PLC).
Ä Make permanent changes in the PROFINET-IO controller.
For further information, see chapter 8 "Starting up the device - Configuration".
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Mounting
5 Mounting
5.1 Transport and storage
NOTICE
Ä Package the device for transport and storage in such a way that is protected against shock
and humidity. Optimum protection is achieved when using the original packaging.
Ä Ensure compliance with the approved environmental conditions listed in the specifications.
Unpacking
Ä Check the packaging content for any damage. If damage is found, notify the post office or shipping
agent as well as the supplier.
Ä Check the delivery contents using your order and the delivery papers:
• Delivered quantity
• Device type and model as indicated on the nameplate
• Package insert
The name plate on the bottom of the device provides information as to what BCL type your device is, see
chapter 13 "Technical data".
Ä Save the original packaging for later storage or shipping.
Ä If you have questions, please contact your supplier or Leuze customer service, see chapter 12 "Service
and support".
Ä Observe the applicable local regulations when disposing of the packaging materials.
5.2 Mounting
The bar code reader can be mounted in the following ways:
• Mounting with four M4x5 screws on the rear side of the housing.
• Mounting with mounting devices on the fastening groove on one side of the housing.
5.2.1
Mounting with M4 fastening screws
Ä Mount the device on the system with M4 fastening screws (not included in delivery contents).
ð Max. tightening torque of the fastening screws: 2.5Nm
ð Location and thread depth of the mounting thread: see chapter 13.3 "Dimensioned drawings"
NOTICE
Ä When mounting, ensure that the scanning beam is not reflected directly back to the scanner
by the label which is being read. For further information, see the notes in see chapter 5.3
"Selecting a mounting location".
Ä Please refer to see chapter 13.2 "Reading fields" for the permissible minimum and maximum
distances between the bar code reader and the labels to be read.
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Mounting
5.2.2
5.2.3
5.2.4
Mounting with BT56 or BT56-1 mounting device
Mounting with the mounting device is intended for rod mounting.
Order guide: see chapter 14.4 "Accessories – mounting systems"
Ä Mount the mounting device on the rod with the clamp profile (system-side).
Ä Mount the device on the mounting device using the fastening grooves.
ð Max. tightening torque of the fastening screws: 1.4Nm
Mounting with BT300-1 mounting device
Mounting with the mounting device is intended for rod mounting (10–16mm).
Order guide: see chapter 14.4 "Accessories – mounting systems"
Ä Mount the mounting device on the rod with the clamp profile (system-side).
Ä Mount the device on the mounting device (included with delivery) using the fastening screws.
ð Max. tightening torque of the fastening screws: 2.5Nm
Mounting with the BT300W mounting bracket
Mounting with the BT300W mounting bracket is intended for wall mounting.
Order guide: see chapter 14.4 "Accessories – mounting systems"
Ä Mount the mounting bracket on the system side with M4 fastening screws (not included in delivery con-
tents).
Ä Mount the device to the mounting bracket (included in delivery) with M4 fastening screws.
ð Max. tightening torque of the fastening screws: 2.5Nm
5.3 Selecting a mounting location
NOTICE
The size of the bar code module influences the maximum reading distance and the width of the
reading field.
Ä When selecting a mounting location and/or the bar code label, take into account the different
reading characteristics of the bar code reader with various bar code modules.
NOTICE
Observe when choosing the mounting location!
Ä Maintain the permissible environmental conditions (humidity, temperature).
Ä Avoid possible soiling of the reading window due to liquids, abrasion by boxes, or packaging
material residues.
Ä Ensure that there is the lowest possible chance of damage to the bar code reader by me-
chanical collision or jammed parts.
Ä Avoid possible ambient light influence (no direct sunlight).
In order to select the right mounting location, several factors must be considered:
• Size, orientation, and position tolerance of the bar codes on the objects to be scanned.
• The reading field of the bar code reader in relation to the bar code module width.
• The resulting minimum and maximum reading distance from the respective reading field with the respective module width (see chapter 13.2 "Reading fields").
• alignment of the bar code reader for avoiding reflections.
• Distance between bar code reader and host system with respect to the interface.
• The correct time for data output. The bar code reader should be positioned in such a way that, taking
into consideration the time required for data processing and the conveyor belt speed, there is sufficient
time to e.g. initiate sorting operations on the basis of the read data.
• The display elements such as LEDs should be highly visible.
• For configuring and commissioning with the webConfig tool, the HOST interface should be easily accessible.
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Mounting
15°
1
2
3
The best read results are obtained if the following prerequisites are fulfilled:
• The reading distance lies in the middle area of the reading field.
• There is no direct sunlight and protect against ambient light effects.
• The bar code labels are of good print quality and have good contrast ratios.
• You are not using high-glossy labels.
• The bar code is moved past with an angle of inclination of ±10°…15° to vertical.
NOTICE
Avoid direct reflection of the laser beam!
The beam on the bar code reader is emitted at 105° to the housing base. An angle of incidence
of 15° of the laser to the label has already been integrated in the deflecting mirror so that the bar
code reader can be installed parallel to the bar code (rear housing wall).
Ä Mount the bar code reader with deflecting mirror parallel to the bar code.
1 Zero position
2 Bar code
3 Distance acc. to reading field curves
Fig.5.1: Total reflection – line scanner
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