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BCL 304i
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TECHNICAL DESCRIPTION
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Leuze BCL304i TECHNICAL DESCRIPTION

BCL304i
Bar code reader
en 01-10/2011 50117112
TECHNICAL DESCRIPTION
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Sales Region East
Phone 035027/629-106 Fax 035027/629-107
Postal code areas 01000-19999 39000-39999 98000-99999
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Phone 07021/573-306 Fax 07021/9850950
Postal code areas 20000-38999 40000-65999 97000-97999
Sales Region South
Phone 07021/573-307 Fax 07021/9850911
Postal code areas 66000-96999
Sales and Service
Worldwide
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© All rights reserved, especially the right of reproduction, distribution and translation. Copying or
reproductions in any form require the written consent of the manufacturer. Product names used without guarantee of free usability. Changes reflecting technical improvements may be made.
Table of contents
1 General information......................................................................................... 12
1.1 Explanation of symbols................................................................................................... 12
1.2 Declaration of conformity ............................................................................................... 12
2 Safety notices .................................................................................................. 13
2.1 General safety notices..................................................................................................... 13
2.2 Safety standards .............................................................................................................. 13
2.3 Approved purpose ........................................................................................................... 13
2.4 Working safely ................................................................................................................. 14
3Fast commissioning / operating principle..................................................... 16
3.1 Mounting the BCL 304i .................................................................................................... 16
3.2 Device arrangement and selection of the mounting location ...................................... 16
3.3 Electrical connectionBCL 304i ....................................................................................... 17
3.4 Starting the device........................................................................................................... 19
3.5 Bar code reading.............................................................................................................. 21
4 Device description........................................................................................... 22
4.1 About the bar code readers of the BCL 300i series...................................................... 22
4.2 Characteristics of the bar code readers of the BCL 300i series.................................. 23
4.3 Device construction......................................................................................................... 25
4.4 Reading techniques ......................................................................................................... 28
4.4.1 Line scanner (single line)............................................................................................................. 28
4.4.2 Line scanner with oscillating mirror.............................................................................................. 29
4.4.3 Raster scanner (Raster Line).......................................................................................................30
4.5 Fieldbus systems ............................................................................................................. 31
4.5.1 PROFIBUS DP ............................................................................................................................31
4.6 Heater................................................................................................................................ 31
4.7 autoReflAct....................................................................................................................... 32
4.8 Reference codes .............................................................................................................. 32
4.9 autoConfig........................................................................................................................ 33
Leuze electronic BCL 304i 1
Table of contents
5 Specifications .................................................................................................. 34
5.1 General specifications of the bar code readers............................................................ 34
5.1.1 Line scanner / raster scanner.......................................................................................................34
5.1.2 Oscillating-mirror scanner ............................................................................................................36
5.1.3 Line scanner / raster scanner with deflection mirror.....................................................................36
5.2 Heating models of the bar code readers ....................................................................... 37
5.2.1 Line scanner / raster scanner with heater ....................................................................................38
5.2.2 Oscillating-mirror scanner with heating ........................................................................................38
5.2.3 Line scanner / raster scanner with deflection mirror and heating.................................................39
5.3 Dimensioned drawings.................................................................................................... 40
5.3.1 Dimensioned drawing of complete overview of the BCL 304i with MS3xx / MK 3xx...................40
5.3.2 Dimensioned drawing of line scanner with / without heating........................................................41
5.3.3 Dimensioned drawing of deflection mirror scanner with / without heating....................................42
5.3.4 Dimensioned drawing of oscillating-mirror scanner with / without heating...................................43
5.3.5 Dimensioned drawing of MS3xx hood with integrated connectors / MK 3xx terminal hood ........44
5.4 Reading field curves / optical data................................................................................. 45
5.4.1 Bar code characteristics ...............................................................................................................45
5.4.2 Raster scanner.............................................................................................................................46
5.5 Reading field curves........................................................................................................ 47
5.5.1 High Density (N) - optics: BCL 304i S/R1 N 102 (H)....................................................................48
5.5.2 High Density (N) - optics: BCL 304i S/R1 N 100 (H)....................................................................48
5.5.3 High Density (N) - optics: BCL 304i ON 100 (H)..........................................................................49
5.5.4 Medium Density (M) - optics: BCL 304i S/R1 M 102 (H)..............................................................50
5.5.5 Medium Density (M) - optics: BCL 304i S/R1 M 100 (H)..............................................................50
5.5.6 Medium Density (M) - optics: BCL 304i OM 100 (H)....................................................................51
5.5.7 Low Density (F) - optics: BCL 304i S/R1 F 102 (H) .....................................................................52
5.5.8 Low Density (F) - optics: BCL 304i S/R1 F 100 (H) .....................................................................52
5.5.9 Low Density (F) - optics: BCL 304i OF 100 (H)............................................................................53
5.5.10 Ultra Low Density (L) - optics: BCL 304i S/R1 L 102 (H) .............................................................54
5.5.11 Ultra Low Density (L) - optics: BCL 304i S/R1 L 100 (H) .............................................................54
5.5.12 Ultra Low Density (L) - optics: BCL 304i OL 100 (H) ...................................................................55
2BCL304i Leuze electronic
Table of contents
6Installation and mounting ............................................................................... 56
6.1 Storage, transportation ................................................................................................... 56
6.2 Mounting the BCL 304i .................................................................................................... 57
6.2.1 Fastening with M4 x 5 screws......................................................................................................57
6.2.2 BT 56 mounting device................................................................................................................58
6.2.3 BT 59 mounting device................................................................................................................ 60
6.3 Device arrangement......................................................................................................... 61
6.3.1 Selecting a mounting location......................................................................................................61
6.3.2 Avoiding total reflection – Line scanner.......................................................................................62
6.3.3 Avoiding total reflection – deflection mirror scanner.................................................................... 62
6.3.4 Avoiding total reflection – oscillating-mirror scanner ................................................................... 63
6.3.5 Mounting location.........................................................................................................................63
6.3.6 Devices with integrated heating...................................................................................................64
6.3.7 Possible reading angles between BCL 304i and bar code..........................................................64
6.4 Cleaning............................................................................................................................ 65
7 Electrical connection....................................................................................... 66
7.1 Safety notices for the electrical connection.................................................................. 67
7.2 Electrical connectionBCL 304i ....................................................................................... 68
7.2.1 MS304 hood with 3 integrated M12 connectors ......................................................................... 68
7.2.2 MK 304 terminal hood with spring-loaded terminals ....................................................................69
7.3 Detailed description of the connections ........................................................................ 71
7.3.1 PWR / SW IN/OUT - Voltage supply and switching input/outputs 1 and 2 .................................. 71
7.3.2 SERVICE – USB interface (Mini-B type) .....................................................................................74
7.3.3 HOST/BUS IN for BCL 304i.......................................................................................................75
7.3.4 BUS OUT for the BCL 304i..........................................................................................................76
7.3.5 PROFIBUS termination................................................................................................................77
7.4 Cable lengths and shielding ........................................................................................... 77
8Display elements and display......................................................................... 78
8.1 LED indicators BCL 304i ................................................................................................. 78
8.2 Display BCL 304i.............................................................................................................. 80
Leuze electronic BCL 304i 3
Table of contents
9Leuze webConfig tool...................................................................................... 82
9.1 Connecting the SERVICE USB interface ....................................................................... 82
9.2 Installing the required software...................................................................................... 83
9.2.1 System requirements ...................................................................................................................83
9.2.2 Installing the USB driver...............................................................................................................83
9.3 Starting the webConfig tool ............................................................................................ 84
9.4 Short description of the webConfig tool ....................................................................... 85
9.4.1 Module overview in the Configuration menu ................................................................................85
4BCL304i Leuze electronic
Table of contents
10 Commissioning and configuration................................................................. 87
10.1 General information on the PROFIBUS implementation of the BCL 304i ................... 87
10.1.1 Communication profile................................................................................................................. 87
10.1.2 Bus-access protocol ....................................................................................................................87
10.1.3 Device types ................................................................................................................................ 88
10.1.4 Expanded DP functions ...............................................................................................................88
10.1.5 Automatic baud rate detection.....................................................................................................89
10.2 Measures to be performed prior to the initial commissioning .................................... 90
10.3 Setting of the PROFIBUS address.................................................................................. 91
10.4 Commissioning via the PROFIBUS ................................................................................ 92
10.4.1 General information.....................................................................................................................92
10.4.2 Preparing the control system for consistent data transmission ................................................... 92
10.4.3 General information on the GSD file............................................................................................93
10.4.4 Permanently defined parameters / device parameters ................................................................ 94
10.5 Overview of the project modules ................................................................................... 98
10.6 Decoder modules ........................................................................................................... 101
10.6.1 Modules 1-4 – Code table extensions 1 to 4 .............................................................................101
10.6.2 Module 5 – Code type features (symbology).............................................................................103
10.6.3 Module 7 – Code fragment technology......................................................................................104
10.7 Control modules ............................................................................................................ 105
10.7.1 Module 10 – Activations.............................................................................................................105
10.7.2 Module 11 – Reading gate control............................................................................................. 107
10.7.3 Module 12 – Multi-label..............................................................................................................109
10.7.4 Module 13 – Fragmented read result.........................................................................................110
10.7.5 Module 14 – Interlinked read result ...........................................................................................111
10.8 Result Format................................................................................................................. 112
10.8.1 Module 20 – Decoder state........................................................................................................112
10.8.2 Modules 21-27 – Decoding result ..............................................................................................114
10.8.3 Module 30 – Data formatting .....................................................................................................116
10.8.4 Module 31 – Reading gate number ........................................................................................... 117
10.8.5 Module 32 – Reading gate time................................................................................................. 117
10.8.6 Module 33 – Code position........................................................................................................118
10.8.7 Module 34 – Reading reliability (equal scans)........................................................................... 118
10.8.8 Module 35 – Bar code length..................................................................................................... 119
10.8.9 Module 36 – Scans with information..........................................................................................119
10.8.10 Module 37 – Decoding quality ................................................................................................... 120
10.8.11 Module 38 – Code direction.......................................................................................................120
10.8.12 Module 39 – Number of digits .................................................................................................... 121
10.8.13 Module 40 – Code type..............................................................................................................121
10.8.14 Module 41 – Code position in the swivel range .........................................................................122
10.9 Data Processing ............................................................................................................. 123
10.9.1 Module 50 – Characteristics filter .............................................................................................. 123
10.9.2 Module 51 – Data filtering.......................................................................................................... 125
Leuze electronic BCL 304i 5
Table of contents
10.10 Identifier.......................................................................................................................... 126
10.10.1 Module 52 – Segmentation according to the EAN process ........................................................126
10.10.2 Module 53 – Segmentation via fixed positions...........................................................................127
10.10.3 Module 54 – Segmentation according to identifier and separator..............................................130
10.10.4 Module 55 – String handling parameters ...................................................................................132
10.11 Device Functions ........................................................................................................... 133
10.11.1 Module 60 – Device status .........................................................................................................133
10.11.2 Module 61 – Laser control..........................................................................................................134
10.11.3 Module 63 – Alignment ..............................................................................................................135
10.11.4 Module 64 – Oscillating mirror....................................................................................................136
10.12 SWIO 1 and SWIO 2 switching inputs / outputs.......................................................... 137
10.12.1 Parameters for operating as an output.......................................................................................137
10.12.2 Parameters for operating as an input .........................................................................................139
10.12.3Switch-on and switch-off functions for operation as an output...................................................140
10.12.4 Input functions for operation as an input ....................................................................................141
10.12.5 Module 70 – Switching input/output SWIO1...............................................................................141
10.12.6 Module 71 – Switching input/output SWIO2...............................................................................143
10.12.7 Module 74 – SWIO status and control .......................................................................................145
10.13 Data output ..................................................................................................................... 147
10.13.1 Module 80 – ...............................................................................................................................147
10.14 Reference code comparison......................................................................................... 148
10.14.1 Module 81 – Reference code comparator 1...............................................................................148
10.14.2 Module 82 – Reference code comparator 2...............................................................................150
10.14.3 Module 83 – Reference code comparison pattern 1 ..................................................................152
10.14.4 Module 84 – Reference code comparison pattern 2 ..................................................................153
10.15 Special Functions .......................................................................................................... 154
10.15.1 Module 90 – Status and control .................................................................................................154
10.15.2 Module 91 – AutoReflAct (automatic reflector activation) ..........................................................155
10.15.3 Module 92 – AutoControl ...........................................................................................................156
10.16 Example configuration: Indirect activation via the PLC............................................. 157
10.16.1 Task ...........................................................................................................................................157
10.16.2 Procedure...................................................................................................................................157
10.17 Sample configuration: Direct activation via the switching input .............................. 159
10.17.1 Task ...........................................................................................................................................159
10.17.2 Procedure...................................................................................................................................159
11 Diagnostics and troubleshooting................................................................. 161
11.1 General causes of errors............................................................................................... 161
11.2 Interface errors............................................................................................................... 161
6BCL304i Leuze electronic
Table of contents
12 Type overview and accessories................................................................... 163
12.1 Part number code .......................................................................................................... 163
12.2 Type overview BCL 304i................................................................................................ 163
12.3 Connection hood accessories ...................................................................................... 164
12.4 Accessory terminating resistor .................................................................................... 165
12.5 Accessory connectors .................................................................................................. 165
12.6 Accessory USB cable .................................................................................................... 165
12.7 Accessory mounting device ......................................................................................... 165
12.8 Reflector accessories for autoReflAct ......................................................................... 165
12.9 Accessory ready-made cables for voltage supply...................................................... 166
12.9.1 Contact assignment of PWR connection cable..........................................................................166
12.9.2 Specifications of the cables for voltage supply.......................................................................... 166
12.9.3 Order codes of the cables for voltage supply ............................................................................166
12.10 Accessory ready-made cables for bus connection ....................................................166
12.10.1 General information ................................................................................................................... 166
12.10.2 Contact assignments of PROFIBUS connection cable KB PB…...............................................167
12.10.3 Technical data of interface connection cables ...........................................................................167
12.10.4 Order code interface connection cable ......................................................................................168
13 Maintenance ................................................................................................... 169
13.1 General maintenance information ................................................................................ 169
13.2 Repairs, servicing .......................................................................................................... 169
13.3 Disassembling, packing, disposing ............................................................................. 169
14 Appendix ........................................................................................................ 170
14.1 Declaration of Conformity ............................................................................................. 170
14.2 ASCII character set ........................................................................................................ 172
14.3 Bar code samples .......................................................................................................... 176
14.3.1 Module 0.3 .................................................................................................................................176
14.3.2 Module 0.5................................................................................................................................. 177
Leuze electronic BCL 304i 7
Figures and tables
Figure 2.1: Attachment of the stick-on labels with warning notices at the BCL 304i.................................................. 15
Figure 3.1: BCL 304i - MS 304 hood with integrated M12 connectors....................................................................... 17
Figure 3.2: BCL 304i - MK 304 terminal hood with spring-loaded terminals.............................................................. 18
Figure 3.3: Cable fabrication for MK 304 terminal hood............................................................................................. 18
Figure 4.1: Line scanner, line scanner with deflection mirror and oscillating-mirror scanner.....................................22
Figure 4.2: Possible bar code orientation................................................................................................................... 24
Figure 4.3: BCL 304i device construction - line scanner............................................................................................ 25
Figure 4.4: BCL 304i device construction -line scanner with deflection mirror........................................................... 25
Figure 4.5: BCL 304i device construction - oscillating-mirror scanner....................................................................... 26
Figure 4.6: Device construction MS 304 hood with integrated connectors ................................................................ 27
Figure 4.7: Device construction MK 304 hood with integrated connectors ................................................................ 27
Figure 4.8: Deflection principle for the line scanner...........................................................................
Figure 4.9: Deflection principle for the line scanner with oscillating mirror add-on .................................................... 29
Figure 4.10: Deflection principle for the raster scanner................................................................................................ 30
Figure 4.11: PROFIBUS DP......................................................................................................................................... 31
Figure 4.12: Reflector arrangement for autoReflAct..................................................................................................... 32
Table 5.1: Specifications of the BCL 304i line/raster scanners without heating ....................................................... 34
Table 5.2: Specifications of the BCL 304i oscillating-mirror scanners without heating............................................. 36
Table 5.3: Specifications of the BCL 304i deflection-mirror scanners without heating............................................. 36
Table 5.4: Specifications of the BCL 304i line/raster scanners with heating ............................................................ 38
Table 5.5: Specifications of the BCL 304i oscillating-mirror scanners with heating.................................................. 38
Table 5.6: Specifications of the BCL 304i deflection mirror scanners with heating .................................................. 39
Figure 5.1: Dimensioned drawing of complete overview of the BCL 304i with MS 3xx / MK 3xx .............................. 40
Figure 5.2: Dimensioned drawing BCL 304i line scanner S…102 ............................................................................. 41
Figure 5.3: Dimensioned drawing BCL 304i deflection mirror scanner S…100......................................................... 42
Figure 5.4: Dimensioned drawing BCL 304i oscillating mirror scanner O…100........................................................ 43
Figure 5.5: Dimensioned drawing of MS 3xx hood with integrated connectors / MK 3xx terminal hood.................... 44
Figure 5.6: The most important characteristics of a bar code .................................................................................... 45
Table 5.7: Raster line cover as a function of the distance ........................................................................................ 46
Figure 5.7: Zero position of the reading distance....................................................................................................... 47
Table 5.8: Reading conditions ...................................................................................................
Figure 5.8: "High Density" reading field curve for line scanner without deflection mirror........................................... 48
Figure 5.9: "High Density" reading field curve for line scanner with deflection mirror................................................ 48
Figure 5.10: "High Density" reading field curve for oscillating-mirror scanners............................................................ 49
Figure 5.11: Lateral "High Density" reading field curve for oscillating-mirror scanners................................................ 49
Figure 5.12: "Medium Density" reading field curve for line scanner without deflection mirror...................................... 50
Figure 5.13: "Medium Density" reading field curve for line scanner with deflection mirror........................................... 50
Figure 5.14: "Medium Density" reading field curve for oscillating-mirror scanners...................................................... 51
Figure 5.15: Lateral "Medium Density" reading field curve for oscillating-mirror scanners ..........................................51
Figure 5.16: "Low Density" reading field curve for line scanner without deflection mirror............................................ 52
Figure 5.17: "Low Density" reading field curve for line scanner with deflection mirror................................................. 52
Figure 5.18: "Low Density" reading field curve for oscillating-mirror scanners ............................................................ 53
Figure 5.19: Lateral "Low Density" reading field curve for oscillating-mirror scanners ................................................ 53
Figure 5.20: "Ultra Low Density" reading field curve for line scanner without deflection mirror................................... 54
Figure 5.21: "Ultra Low Density" reading field curve for line scanner with deflection mirror ........................................ 54
Figure 5.22: "Ultra Low Density" reading field curve for oscillating-mirror scanners.................................................... 55
Figure 5.23: Lateral "Ultra Low Density" reading field curve for oscillating-mirror scanners........................................ 55
Figure 6.1: Device name plate BCL 304i ................................................................................................................... 56
........................ 28
............................... 47
8 BCL 304i Leuze electronic
Figures and tables
Figure 6.2: Fastening options using M4x5 threaded holes ........................................................................................ 57
Figure 6.3: BT 56 mounting device ............................................................................................................................ 58
Figure 6.4: Mounting example of BCL 304i with BT 56.............................................................................................. 59
Figure 6.5: BT 59 mounting device ............................................................................................................................ 60
Figure 6.6: Total reflection – line scanner .................................................................................................................. 62
Figure 6.7: Total reflection – line scanner .................................................................................................................. 62
Figure 6.8: Total reflection – BCL 304i with oscillating mirror .................................................................................... 63
Figure 6.9: Reading angle for the line scanner .......................................................................................................... 64
Figure 7.1: Location of the electrical connections ...................................................................................................... 66
Figure 7.2: BCL 304i - MS 304 hood with integrated M12 connectors....................................................................... 68
Figure 7.3: BCL 304i - MK 304 terminal hood with spring-loaded terminals.............................................................. 69
Figure 7.4: Cable fabrication for MK 304 terminal hood............................................................................................. 70
Table 7.1: Pin assignment PWR / SW IN/OUT ......................................................................................................... 71
Figure 7.1: Switching input connection diagram SWIO_1 and SWIO_2 .................................................................... 72
Figure 7.2: Switching output connection diagram SWIO_1 / SWIO_2 ....................................................................... 73
Table 7.2: Pin assignment SERVICE – Mini-B type USB interface........................................................................... 74
Table 7.3: Pin assignment HOST / BUS IN BCL 304i............................................................................................... 75
Table 7.4: Pin assignment BUS OUTBCL 304i......................................................................................................... 76
Table 7.5: Cable lengths and shielding..................................................................................................................... 77
Figure 8.1: BCL 304i - LED indicators..............................................................................................................
Figure 8.2: BCL 304i - Display ................................................................................................................................... 80
Figure 9.1: Connecting the SERVICE USB interface ................................................................................................. 82
Figure 9.2: The start page of the webConfig tool ....................................................................................................... 84
Figure 9.3: Module overview in the webConfig tool.................................................................................................... 85
Table 10.1: PROFIBUS bus-access processes .......................................................................................................... 87
Table 10.2: PROFIBUS DP master and slave types................................................................................................... 88
Table 10.3: Services for DPVM1 class 1 and slaves .................................................................................................. 88
Table 10.4: Services for DPVM1 class 2 and slaves .................................................................................................. 89
Figure 10.1: BCL 304i - MS 304 hood with integrated M12 connectors....................................................................... 90
Figure 10.2: BCL 304i - MK 304 terminal hood with spring-loaded terminals .............................................................. 90
Figure 10.3: BCL 304i - setting of the PROFIBUS address ......................................................................................... 91
Table 10.5: "Common" Parameters ............................................................................................................................ 94
Table 10.6: Module overview ...................................................................................................................................... 99
Table 10.7: Parameters for modules 1-4................................................................................................................... 101
Table 10.8: Parameters for module 5........................................................................................................................ 103
Table 10.9: Parameters for module 7........................................................................................................................ 104
Table 10.10: Parameters for module 10...................................................................................................................... 105
Table 10.11: Output data for module 10 ..................................................................................................................... 105
Table 10.12: Parameters for module 11...................................................................................................................... 107
Table 10.13: Parameters for module 12...................................................................................................................... 109
Table 10.14: Input data for module 12 ...........................................................................................
Table 10.15: Parameters for module 13...................................................................................................................... 110
Table 10.16: Input data for module 13 ........................................................................................................................ 110
Table 10.17: Parameters for module 13...................................................................................................................... 111
Table 10.18: Input data for module 20 ........................................................................................................................ 112
Table 10.19: Input data for modules 21 … 27............................................................................................................. 114
Table 10.20: Parameters for module 30...................................................................................................................... 116
Table 10.21: Input data for module 31 ........................................................................................................................ 117
............................. 109
.......... 78
Leuze electronic BCL 304i 9
Figures and tables
Table 10.22: Input data for module 32 ........................................................................................................................ 117
Table 10.23: Input data for module 33 ........................................................................................................................ 118
Table 10.24: Input data for module 34 ........................................................................................................................ 118
Table 10.25: Input data for module 35 ........................................................................................................................ 119
Table 10.26: Input data for module 36 ........................................................................................................................ 119
Table 10.27: Input data for module 37 ........................................................................................................................ 120
Table 10.28: Input data for module 38 ........................................................................................................................ 120
Table 10.29: Input data for module 39 ........................................................................................................................ 121
Table 10.30: Input data for module 40 ........................................................................................................................ 121
Table 10.31: Input data for module 41 ........................................................................................................................ 122
Table 10.32: Parameters for module 50 ..................................................................................................................... 123
Table 10.33: Parameters for module 51 ..................................................................................................................... 125
Table 10.34: Parameters for module 52 ..................................................................................................................... 126
Table 10.35: Parameters for module 53 ..................................................................................................................... 127
Table 10.36: Parameters for module 54 ..................................................................................................................... 130
Table 10.37: Parameters for module 55 ..................................................................................................................... 132
Table 10.38: Input data for module 60 ........................................................................................................................ 133
Table 10.39: Output data for module 60 ..................................................................................................................... 133
Table 10.40: Parameters for module 61 ..................................................................................................................... 134
Table 10.41: Input data for module 63 ........................................................................................................................ 135
Table 10.42: Output data for module 63 ..................................................................................................................... 135
Table 10.43: Parameters for module 64 ..................................................................................................................... 136
Figure 10.4: Example 1: Start-up delay > 0 and switch-on time = 0........................................................................... 137
Figure 10.5: Example 2: Start-up delay > 0 and switch-on time > 0........................................................................... 137
Figure 10.6: Example 3: start-up delay > 0 switch-off signal prior to lapsing of the start-up delay ........................... 138
Figure 10.7: Start-up delay in input mode .................................................................................................................. 139
Figure 10.8: Switch-on time in input mode................................................................................................................. 139
Figure 10.9: Switch-off delay in input mode ............................................................................................................... 140
Table 10.44: Switch-on/switch-off functions................................................................................................................ 140
Table 10.45: Input functions........................................................................................................................................ 141
Table 10.46: Parameters for module 70 – Input/Output 1........................................................................................... 141
Table 10.47: Parameters for module 71 – Input/Output 2........................................................................................... 143
Table 10.48: Input data for module 74 Input/output status and control....................................................................... 145
Table 10.49: Output data for module 74 Input/output status and control .................................................................... 146
Table 10.50: Parameters for module 80 ..................................................................................................................... 147
Table 10.51: Parameters for module 81 – Reference code comparison..................................................................... 148
Table 10.52: Parameters for module 82 – Reference code comparison..................................................................... 150
Table 10.53: Parameter module 83 – Reference code comparison pattern ............................................................... 152
Table 10.54: Parameter module 84 – Reference code comparison pattern ............................................................... 153
Table 10.55: Input data for module 90 – Status and control ....................................................................................... 154
Table 10.56: Parameters for module 91 – AutoreflAct ................................................................................................ 155
Table 10.57: Parameters for module 92 – AutoControl............................................................................................... 156
Table 10.58: Input data for module 92 – AutoControl ................................................................................................. 156
Table 10.59: Device parameters for example configuration 2..................................................................................... 159
Table 11.1: General causes of errors ....................................................................................................................... 161
Table 11.2: Interface error ........................................................................................................................................ 161
Table 12.2: Type overview BCL 304i........................................................................................................................ 163
Table 12.3: Connection hoods for the BCL 304i ....................................................................................................... 164
10 BCL 304i Leuze electronic
Figures and tables
Table 12.4: Terminating resistor for the BCL 304i .................................................................................................... 165
Table 12.5: Connectors for the BCL 304i.................................................................................................................. 165
Table 12.6: Service cable for the BCL 304i .............................................................................................................. 165
Table 12.7: Mounting devices for the BCL 304i ........................................................................................................ 165
Table 12.8: Reflector for autoReflAct operation ........................................................................................................ 165
Table 12.9: PWR cables for the BCL 304i ................................................................................................................ 166
Figure 12.10: Cable configuration PROFIBUS/multiNet plus connection cables......................................................... 167
Table 12.11: Interface connection cable for the BCL 304i .......................................................................................... 168
Figure 14.1: Declaration of conformity BCL 304i ....................................................................................................... 170
Figure 14.2: Connection hood / connector unit declaration of conformity .................................................................. 171
Figure 14.3: Bar code sample labels (module 0.3)..................................................................................................... 176
Figure 14.4: Bar code sample labels (module 0.5)..................................................................................................... 177
Leuze electronic BCL 304i 11
1 General information
1.1 Explanation of symbols
The symbols used in this technical description are explained below.
Attention!
This symbol precedes text messages which must strictly be observed. Failure to comply with this information results in injuries to personnel or damage to the equipment.
Attention Laser!
This symbol warns of possible danger caused by hazardous laser radiation.
Notice!
This symbol indicates text passages containing important information.
1.2 Declaration of conformity
The bar code readers of the BCL 300i series have been developed and manufactured in accordance with the applicable European standards and directives.
General information
Notice!
You can find the Declaration of Conformity of the devices in the appendix of the manual on page 145.
The manufacturer of the product, Leuze electronic GmbH & Co KG in D-73277 Owen, possesses a certified quality assurance system in accordance with ISO 9001.
Leuze electronic BCL 304i 9
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Safety notices
2 Safety notices
2.1 General safety notices
Documentation
All entries in this technical description must be heeded, in particular the present chapter "Safety notices". Keep this technical description in a safe place. It should be available at all times.
Safety regulations
Observe the locally applicable regulations and the rules of the employer's liability insurance association.
Repair
Repairs must only be carried out by the manufacturer or an authorized representative.
2.2 Safety standards
The bar code readers of the BCL 300i series were developed, manufactured and tested in accordance with the applicable safety standards. They correspond to the state of the art.
2.3 Approved purpose
Attention!
The protection of personnel and the device cannot be guaranteed if the device is operated in a manner not corresponding to its intended use.
Bar code readers of the BCL 300i series are conceived as stationary, high-speed scanners with integrated decoders for all current bar codes used for automatic object detection.
In particular, unauthorized uses include:
• in rooms with explosive atmospheres
•operation for medical purposes
Areas of application
The bar code readers of the BCL 300i series are especially designed for the following areas of application:
• Storage technology and materials handling, in particular for object identification on fast-moving transport systems
•Pallet transport systems
•Automobile sector
• Omnidirectional reading
10 BCL 304i Leuze electronic
2.4 Working safely
Attention!
Access and changes to the device, except where expressly described in this operating manual, are not authorized.
Safety regulations
Observe the locally applicable legal regulations and the rules of the employer's liability insurance association.
Qualified personnel
Mounting, commissioning and maintenance of the device must only be carried out by qualified personnel. Electrical work must be carried out by a certified electrician.
Attention, laser radiation!
If you look into the beam path over a longer time period, the retina of your eye may be damaged!
Never look directly into the beam path!
Do not point the laser beam of the BCL 304i at persons!
When mounting and aligning the BCL 304i, avoid reflections of the laser beam off reflective surfaces!
The BCL 304i bar code readers correspond to the EN 60825-1 safety standard for a class 2 laser systems. They also comply with the U.S. 21 CFR 1040.10 regulations for a class II laser product except for deviations pursuant to Laser Notice No. 50, dated July 26, 2001.
Radiant Energy: The BCL 304i uses a low power visible laser diode. The emitted wavelength is 655nm. The average laser power is less than 1mW in accordance with the definition of laser class 2.
Adjustments: Do not attempt any adjustments to or alterations of this product.
Do not remove the protective housing of the bar code reader. There are no user­serviceable parts inside.
The glass optics cover is the only aperture through which laser radiation may be observed on this product. A failure of the scanner motor, while the laser diode continues to emit a laser beam, may cause emission levels to exceed those for safe operation. The bar code reader has protective devices to prevent this occurrence. If, however, a stationary beam is emitted, the failing bar code reader should be discon­nected from the voltage supply immediately.
CAUTION: Use of controls or adjustments or performance of procedures other than specified herein may result in hazardous light exposure.
Safety notices
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Leuze electronic BCL 304i 11
Safety notices
A
BCL 304i
Line scanner and
M12 MS 3xx connection hood
BCL 304i
with oscillating mirror and
M12 MS 3xx connection hood
B
A Warning: laser aperture B Name plate
BCL 304i
with deflection mirror and
M12 MS 3xx connection hood
The use of optical instruments or devices in combination with the device increases the danger of eye damage!
The housing of the BCL 304i is provided with warning notices A and B above and next to the reading window as shown in the following figure:
Figure 2.1: Attachment of the stick-on labels with warning notices at the BCL 304
12 BCL 304i Leuze electronic
i
Fast commissioning / operating principle
3Fast commissioning / operating principle
Below you will find a short description for the initial commissioning of the BCL 304i. Detailed explanations for all listed points can be found throughout this technical description.
3.1 Mounting the BCL 304i
The BCL 304i bar code readers can be mounted in two different ways:
•Via four M4x6 screws on the bottom of the device.
•Via a BT 56 mounting device in the fastening groove on the bottom of the housing.
3.2 Device arrangement and selection of the 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 BCL 304i in relation to the bar code module width.
• The resulting minimum and maximum reading distance from the respective reading field.
• The permissible cable lengths between the BCL 304i and the host s on which interface is used.
• The correct time for data output. The BCL 304i 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 and control panel should be very visib
• For configuring and commissioning with the webConfig tool, the USB interface should be easily accessible.
For specific information, please refer to chapter 6 and chapter 7.
le and accessible.
ystem depending
Notice!
The beam exits the BCL 304i as follows for the respective devices:
- line scanner parallel to the housing base
- deflection mirror 105 degrees to the housing base
- oscillating mirror perpendicular to the housing base. The black areas in figure 6.2 are the housing base. The best read results are obtained when:
• The BCL 304i is mounted in such a way that the scanning beam is incident on the bar code at an angle of inclination greater than ±10° … 15° to vertical.
• The reading distance lies in the middle area of the reading field.
• The bar code labels are of good print quality and have good contrast ratios.
• You do not use high-gloss labels.
• There is no direct sunlight.
16 BCL 304i Leuze electronic
Fast commissioning / operating principle
PWR / SW IN/OUT
SWIO_2
SWIO_1
3
2
1
4
5
GNDIN VIN
FE
SERVICE
21354
GNDD+D-VB ID
BUS OUT
VP
1
2
3
4
N
P
GNDP
FE
5
HOST / BUS IN
3
2
1
4
5
n.c.GNDP
FE
N
P
Mini-B USB socket
(behind protective cap)
M12 plug (A-coded)
M12 plug (B-coded)
M12 socket
(B-coded)
Hood with integrated connectors
MS304
3.3 Electrical connectionBCL 304i
For the electrical connection of the BCL 304i, 2 connection variants are available. The voltage supply (18 … 30VDC) is connected acc. to the connection type selected. 2 freely programmable switching inputs/outputs for individual adaptation to the respec-
tive application are also available here. Detailed information on this topic can be found in chapter 7.4.1 and chapter 7.4.3.
MS 304 hood with 2 integrated M12 connectors
Figure 3.1: BCL 304i - MS304 hood with integrated M12 connectors
Notice!
The shielding connection is done via the M12 connector housing.
Notice!
PROFIBUS address 126 is set by default in the MS 304. The integrated parameter memory for the simple replacement of the BCL 304i is located in the MS 304.
Notice!
The PROFIBUS is looped through the MS 304, i.e. the bus is not interrupted when the BCL 304i is removed from the MS 304.
Leuze electronic BCL 304i 17
The bus is terminated at BUS OUT via an external mounted terminating resistor (see chap­ter 13.4 "Accessory terminating resistor").
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Fast commissioning / operating principle
Terminal hood
MK 304
SERVICE
21354
GNDD+D-VB ID
Mini-B USB socket
(behind protective cap)
Terminal block
PWR / SW IN/OUT
Terminal block
HOST / BUS IN
Terminal block
BUS OUT
Slide switch T:
bus
termination
Bus address switch: slide switch
x100 = hundreds digit, rotary switch x10 = tens digit, rotary switch x1 = ones digit
Terminal designation
MK 304
ON
OFF
MK 304 terminal hood with spring-loaded terminals
Figure 3.2: BCL 304i - MK 304 terminal hood with spring-loaded terminals
Notice!
PROFIBUS address 126 is set by default in the MK 304. The integrated parameter memory for simple exchange of the BCL 304i is located in the MK 304.
Notice!
The PROFIBUS is looped through the MK 304, i.e. the bus is not interrupted when the BCL 304i is removed from the MK 304. The PROFIBUS is terminated via slide switch T in the MK 304. If the termination is activated (slide switch T in the ON position), the down­stream bus is disconnected.
Cable fabrication and shielding connection
Remove approx. 78mm of the connection cable sheathing. 15 mm of sheath of the shielded line must be freely accessible.
≈ 55 mm ≈ 8 mm ≈ 15 mm
Figure 3.3:Cable fabrication for MK 304 terminal hood
The shield is automatic
ally contacted when the cable is lead into the metal screw fitting and fastened when the cord grip is closed. Then lead the individual wires into the terminals according to the diagram. Wire end sleeves are not necessary.
18 BCL 304i Leuze electronic
3.4 Starting the device
ª Set the PROFIBUS address of the BCL304i in your PROFIBUS network via the address
switch (one slide and two rotary switches) provided for this purpose in the MS 304 or MK 304.
ª Install the GSD file associated with the BCL 304i in the PROFIBUS Manager of your
control.
ª Activate the desired modules (at least module 10 and one of the modules 21 … 27).
ª Store the slave address for the BCL 304i in the PROFIBUSmanager. Ensure that the
address is the same as the address configured in the device.
ª Connect the +18 … 30VDC supply voltage (typ. +24VDC).
The BCL 304i starts up, the PWR and BUS LEDs display the operating state. If there is a display, the bar code reading window appears in it.
PWR LED
flashes green Device ok, initialization phase
green continuous light Device ok
green, briefly off - on Good read, successful reading
Fast commissioning / operating principle
green, briefly off - briefly red - on No read, reading not successful
orange continuous light Service mode
flashes red Warning set
red continuous light Device error / parameter enable
Leuze electronic BCL 304i 19
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Fast commissioning / operating principle
BUS LED
flashes green Initialization
green continuous light Bus operation ok
flashes red Communication error
red continuous light Bus error
If a display is available, the following information appears successively during startup:
• Startup
• Device designation e.g. BCL 304i SM 102 D
• Reading Result
If Reading Result is displayed, the device is ready.
Operation of BCL 304i
After voltage (18 … 30 V DC) has been connected to the switching input, a read process is activated. In the standard setting, the 2/5 interleaved code type is enabled. The decoding
result module (21-27) must be configured and the BCL 304i must be connected to the PROFIBUS.
If a code is led through the reading field, the code content is decoded and passed to the PLC via the PROFIBUS.
20 BCL 304i Leuze electronic
3.5 Bar code reading
Modul 0,5
6677889900
To test, you can use the following bar code in the 2/5 Interleaved format. The bar code module here is 0.5:
Provided your BCL 304i model has a display, the read information appears on this display. The PWR LED goes off briefly and then turns green again. S imultaneously, the read infor­mation is forwarded to the superior system (PLC/PC) via the PROFIBUS.
Please check the incoming da Alternatively, you can use a switching input for read activation (switching signal of a photo-
electric sensor or 24VDC switching signal).
Fast commissioning / operating principle
ta of the bar code information there.
Leuze electronic BCL 304i 21
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4 Device description
Line scanner
Line scanner with deflection mirror
Oscillating-mirror scanner
4.1 About the bar code readers of the BCL 300i series
Bar code readers of the BCL 300i series are high-speed scanners with integrated decoder for all commonly used bar codes, e.g. 2/5 Interleaved, Code 39, Code 128, EAN 8/13 etc., as well as codes from the GS1DataBar family.
Bar code readers of the BCL 300i series are available in various optics models as well as line scanner heated models.
s, line scanners with deflection mirrors, oscillating mirrors and also optionally as
Device description
Figure 4.1: Line scanner, line scanner with deflection mirror and oscillating-mirror scanner
The extensive options for device configuration enable adaptation to a multitude of reading tasks. Due to the large reading distance combined with the great depth of field, a large opening a and storage technology market.
The interfaces (RS 232, RS 485 and RS 422) integrated in the various device models and the fieldbus systems (PROFIBUS DP, PROFINET-IO and Ethernet) offer optimum connec- tion to the superior host system.
Leuze electronic BCL 304i 25
ngle and a very compact construction, the device is ideally suited for the conveyor
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Device description
4.2 Characteristics of the bar code readers of the BCL 300i series
Performance characteristics:
•Integrated fieldbus connectivity = i -> Plug-and-Play fieldbus coupling and easy networking
•Numerous interface variants facilitate connection to the superior systems
•RS 232, RS 422
•RS 485 and multiNet plus slave alternatively, various fieldbus systems, such as
•PROFIBUS
•PROFINET-IO
•EtherNet
•Integrated code fragment technology (CRT) enables the identification of soiled or damaged bar codes
•Maximum depth of field and reading distances from 30mm to 700 mm
•Large optical opening angle and, thus, large reading field width
• High scanning rate of 1000 scans/s for fast reading tasks
•On request with display to easily detect and activate functions
•Integrated USB service interface, Mini-B type
•Easy alignment- and diagnostics functions
• Up to four possible connection technologies
• 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 comp
•Optional heating models to -35°C
•Heavy-duty housing of protection class IP 65
DP
and status messages.
arison
Notice!
Information on technical data and characteristics can be found in Kapitel 5.
General information
The integrated fieldbus connectivity = i contained in the bar code readers of the BCL 300i series facilitates the use of identification systems which function without connector unit or
gateways. The integrated fieldbus interface considerably simplifies handling. The Plug-and­Play concept enables easy networking and very simple commissioning: Directly connect the respective fieldbus and all configuration is performed with no
For decoding bar codes, the bar code readers of the BCL 300i series make available the proven CRT decoder with code fragment technology:
The proven code fragment technology (CRT) enables bar code readers of the BCL 300i
series to read bar codes with a small bar height, as well as bar codes with a damaged or soiled print image.
26 BCL 304i Leuze electronic
additional software.
Device description
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 twist angle).
Figure 4.2: Possible bar code orientation
With the BCL 304i, configuration is generally performed with the aid of the GSD file. The BCL 304i needs a suitable activation to start
the reading field. This opens a time window ("reading gate") in the BCL 304i for the read process during which the bar code reader has time to detect and decode a bar code.
Alternative activation options include online commands via the host interface and the In the basic setting, triggering takes place through an external reading cycle signal or via the PROFIBUS. An alternative option for activation is the autoReflAct function.
Through the read operation, the BCL 304i collects additional useful pieces of data for diag­nosis 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.
An optional display in English with button visualization purposes. Two LEDs provide additional optical information on the current oper­ating state of the device.
The two freely configurable switching inputs/outputs SWIO1 and SWIO2 can be assigned various functions and control e.g. activation of the BCL 304i or external devices, such PLC.
System, warning and error messages provide assistance in setup/troubleshooting during commissioning and read operation.
a read process as soon as an object is in
s is used to operate the BCL 304i as well as for
as a
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Leuze electronic BCL 304i 27
Device description
Connection side for: MK 3xx terminal hood MS3xx hood with integrated connectors
Reading window
Dovetail mounting and 4 mounting threads
Display, LEDs and buttons
Line scanner
Connection side for: MK 3xx terminal hood MS3xx hood with integrated connectors
Reading window
Dovetail mounting and 4 mounting threads
Display, LEDs and buttons
Line scanner with deflection mirror
4.3 Device construction
BCL 304i bar code readers
Figure 4.3:BCL304i device construction - line scanner
Figure 4.4: BCL 304i device construction -line scanner with deflection mirror
28 BCL 304i Leuze electronic
Device description
Connection side for: MK 3xx terminal hood MS3xx hood with integrated connectors
Reading window
Dovetail mounting and 6 mounting threads
Display, LEDs and buttons
Oscillating-mirror scanner
Figure 4.5: BCL 304i device construction - oscillating-mirror scanner
Leuze electronic BCL 304i 29
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Device description
Connection side with
system plug for
connection to
BCL 304i
M12 connector, 3 x M12
Mini-B type USB service interface
Address setting
for PROFIBUS
Connection side with system plug for connection to BCL 304i
Cable lead-throughs
Mini-B type USB service interface
Terminal compartment with address setting and termination for PROFIBUS
MS 304 hood with integrated connectors
Figure 4.6: Device construction MS304 hood with integrated connectors
MK 304 terminal hood
30BCL304i Leuze electronic
Figure 4.7: Device construction MK 304 hood with integrated connectors
4.4 Reading techniques
4.4.1 Line scanner (single line)
A line (scan line) scans the label. Due to the opt. 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 fragment 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
The line scanner is used:
• when the bars of the bar code are printed in 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).
• when the reading distance is large.
Device description
Figure 4.8: Deflection principle for the line scanner
Leuze electronic BCL 304i 31
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