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BCL 501i
Data Sheet
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TECHNICAL DESCRIPTION
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Table of contents
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Leuze BCL500i, BCL501i TECHNICAL DESCRIPTION

BCL500i and BCL501i
Barcode Readers
GB 02-10/08 50108325
TECHNICAL DESCRIPTION
Nortécnica S. R. L. Tel. Int. + 54 1147 57-3129 Fax Int. + 54 1147 57-1088
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Countapulse Controls (PTY.) Ltd.
04/2008
Tel. Int. + 27 116 1575-56 Fax Int. + 27 116 1575-13
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Schmachtl GmbH
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Leuze electronic GmbH + Co. KG P.O. Box 1111, D- 73277 Owen / Teck Tel. +49(0) 70 21/ 573-0, Fax +49(0 )7021 / 573-199
• www.leuze.com
Sales Region East
Phone 035027/629-106 Fax 035027/629-107
Postal code areas 01000-19999 39000-39999 98000-99999
Sales Region North
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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AU + NZ (Australia + New Zealand)
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CL (Chile)
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PT (Portugal)
PL (Poland)
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MK (Macedonia)
© All rights reserved, especially the right of reproduction, distribution and translation. Copying or
reproductions in any form require the written consent of the manufacturer. Changes reflecting technical improvements may be made.
BCL 500
31
Navigate
upward/laterally
Navigate
downward/laterally ESCAPE
Leave
ENTER
confirm
Device buttons:
Delete character
Enter digit
Save input
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The main menus
ESC
Input of values
12|
<-|0123456789 save Standard----- Unit 126 | |
BCL500i SF 102
Leuze electronic GmbH & Co. KG SW: V 1.3.1 HW:1 SN: 0704-081894 001
IO1 IO2 IO3 IO4 ATT ERR
12345678
Parameter
Parameter handling Decoder table Digital SWIO Com
Language selection o Deutsch o English o Español o Français o Italiano
Ser vi ce
Diagnostics Status messages
Device information - main menu
Information about
• Device type
• Software version
• Hardware version
• Serial number
Barcode reading window - main menu
Visualisation of the read barcode informa­tion. See "Indicators in the display" on page 87.
Parameter - main menu
Configuration of the barcode reader. See "Parameter menu" on page 92.
Language selection - main menu
Selection of the display language. See "Language selection menu" on page 100.
Service - main menu
Scanner diagnosis and status messages. See "Service menu" on page 101.
PWR LED BUS LED
Off Device OFF Off No supply voltage
Flashes green Device ok, initialisation phase Flashes green Initialisation
Green, continuous light Device OK Green, continuous light Operation OK
Orange, continuous light Service mode Flashes orange Timeout
Flashes red Device ok, warning set Flashes red Communication error
Red, continuous light Device error Red, continuous light Network error
Actions
o Start decoding o Start alignment o Start auto-setup o Start teach-in
Actions main menu
Various functions for scanner configuration and manual operation. See "Actions menu" on page 101.
Table of contents
1 General information......................................................................................... 10
1.1 Explanation of symbols................................................................................................... 10
1.2 Declaration of conformity ............................................................................................... 10
2 Safety notices .................................................................................................. 11
2.1 General safety notices..................................................................................................... 11
2.2 Safety standards .............................................................................................................. 11
2.3 Approved purpose ........................................................................................................... 11
2.4 Working safely ................................................................................................................. 12
3 Fast commissioning / operating principle..................................................... 14
3.1 Mounting the BCL 500i\ BCL 501i.................................................................................. 14
3.2 Device arrangement and selection of the mounting location...................................... 14
3.3 Electrical connection BCL 500
3.4 Starting the device........................................................................................................... 16
3.5 Barcode reading............................................................................................................... 18
4 Device description........................................................................................... 19
4.1 About the barcode readers of the BCL 500i series....................................................... 19
4.2 Characteristics of the barcode readers of the BCL 500
4.3 Device construction......................................................................................................... 22
4.4 Reading techniques......................................................................................................... 23
4.4.1 Line scanner (single line)............................................................................................................. 23
4.4.2 Line scanner with oscillating mirror.............................................................................................. 24
4.4.3 Omnidirectional reading............................................................................................................... 25
4.5 Stand-alone connection ..................................................................................................25
4.6 Networking - Leuze multiNet plus ..................................................................................26
4.7 Leuze multiScan............................................................................................................... 26
4.8 Heater................................................................................................................................ 28
4.9 External parameter memory ........................................................................................... 28
4.10 autoReflAct....................................................................................................................... 29
4.11 Reference codes ..............................................................................................................29
4.12 autoConfig ........................................................................................................................ 30
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and BCL 501i............................................................... 15
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series................................... 19
Leuze electronic BCL 500i\BCL501
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Table of contents
5 Specifications .................................................................................................. 31
5.1 General specifications of the barcode readers............................................................. 31
5.1.1 Line scanner.................................................................................................................................31
5.1.2 Oscillating-mirror scanner ............................................................................................................33
5.1.3 Line scanner with deflection mirror...............................................................................................33
5.2 Heating models of the barcode readers ........................................................................ 34
5.2.1 Line scanner with heating ............................................................................................................35
5.2.2 Oscillating-mirror scanner with heating ........................................................................................35
5.2.3 Line scanner with deflection mirror and heating...........................................................................36
5.3 Dimensioned drawings.................................................................................................... 37
5.3.1 Line scanner with / without heating ..............................................................................................37
5.3.2 Deflection mirror scanner with / without heating...........................................................................38
5.3.3 Oscillating-mirror scanner with / without heating..........................................................................39
5.4 Type overview ..................................................................................................................40
5.4.1 BCL 500i......................................................................................................................................40
5.4.2 BCL 501
5.5 Reading field curves / optical data................................................................................. 42
5.6 Reading field curves........................................................................................................ 43
5.6.1 High Density (N) Optics: BCL 500i\ BCL 501iSN 100/102.........................................................44
5.6.2 High Density (N) Optics: BCL 500
5.6.3 Medium Density (M) Optics: BCL 500
5.6.4 Medium Density (M) Optics: BCL 500
5.6.5 Low Density (F) Optics: BCL 500
5.6.6 Low Density (F) Optics: BCL 500
5.6.7 Ultra Low Density (L) Optics: BCL 500
5.6.8 Ultra Low Density (L) Optics: BCL 500
5.7 Reading field curves for heating devices ...................................................................... 52
5.7.1 High Density (N) Optics: BCL 500i\ BCL 501iSN 102 H ............................................................52
5.7.2 High Density (N) Optics: BCL 500
5.7.3 High Density (N) Optics: BCL 500
5.7.4 Medium Density (M) Optics: BCL 500
5.7.5 Medium Density (M) Optics: BCL 500
5.7.6 Medium Density (M) Optics: BCL 500
5.7.7 Low Density (F) Optics: BCL 500
5.7.8 Low Density (F) Optics: BCL 500
5.7.9 Low Density (F) Optics: BCL 500
5.7.10 Ultra Low Density (L) Optics: BCL 500
5.7.11 Ultra Low Density (L) Optics: BCL 500
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......................................................................................................................................41
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\ BCL 501iON 100 ...............................................................45
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\ BCL 501iSM 100/102...................................................46
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\ BCL 501iOM 100 .........................................................47
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\ BCL 501iSF 100/102 ..........................................................48
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\ BCL 501iOF 100.................................................................49
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\ BCL 501iSL 102 .........................................................50
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\ BCL 501iOL 100.........................................................51
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\ BCL 501iSN 100 H ............................................................53
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\ BCL 501iON 100 H............................................................54
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\ BCL 501iSM 102 H......................................................55
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\ BCL 501iSM 100 H......................................................56
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\ BCL 501iOM 100 H......................................................57
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\ BCL 501iSF 102 H..............................................................58
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\ BCL 501iSF 100 H..............................................................59
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\ BCL 501iOF 100 H .............................................................60
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\ BCL 501iSL 102 H......................................................61
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\ BCL 501iOL 100 H .....................................................62
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\ BCL 501
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Leuze electronic
Table of contents
6 Installation and mounting ............................................................................... 63
6.1 Storage, transportation ...................................................................................................63
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6.2 Mounting the BCL 500
6.2.1 Fastening with M4 x 6 screws...................................................................................................... 64
6.2.2 BT 56 mounting device ................................................................................................................ 65
6.3 Device arrangement......................................................................................................... 66
6.3.1 Selecting a mounting location...................................................................................................... 66
6.3.2 Avoiding total reflection – Line scanner ....................................................................................... 67
6.3.3 Avoiding total reflection – oscillating/deflection-mirror scanner ................................................... 67
6.3.4 Mounting location......................................................................................................................... 68
6.3.5 Devices with integrated heating................................................................................................... 68
6.3.6 Maximum permissible read angles between BCL 500
6.4 Attaching laser warning sign.......................................................................................... 69
6.5 Cleaning............................................................................................................................ 69
7 Electrical connection....................................................................................... 70
7.1 Safety notices for the electrical connection.................................................................. 71
7.2 Electrical connection of the BCL 500
7.2.1 PWR – Voltage supply and switching input/outputs 3 and 4 .......................................................73
7.2.2 SERVICE – USB interface (type A) ............................................................................................. 75
7.2.3 SW IN/OUT – Switching input/switching output........................................................................... 76
7.2.4 HOST / BUS IN for BCL 500
7.2.5 BUS OUT for the BCL 500
7.3 Electrical connection of the BCL 501i............................................................................ 80
7.3.1 PWR – Voltage supply and switching input/outputs 3 and 4 .......................................................80
7.3.2 SERVICE – USB interface (type A) ............................................................................................. 80
7.3.3 SW IN/OUT – Switching input/switching output........................................................................... 80
7.3.4 HOST / BUS IN for BCL 501
7.3.5 BUS OUT for the BCL 501
7.4 Leuze multiNet plus ......................................................................................................... 82
7.4.1 Wiring the multiNet plus............................................................................................................... 83
7.4.2 The BCL 500
7.4.3 The BCL 500
7.4.4 The BCL 501
7.5 Line lengths and shielding.............................................................................................. 86
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as network master ................................................................................................84
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as network slave................................................................................................... 85
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as network slave................................................................................................... 86
\ BCL 501i.................................................................................. 64
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\ BCL 501i and barcode......................... 69
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............................................................................ 72
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....................................................................................................... 77
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.......................................................................................................... 79
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....................................................................................................... 81
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Leuze electronic BCL 500i\BCL501
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Table of contents
8 Display and control panel ............................................................................... 87
8.1 Structure of the control panel......................................................................................... 87
8.2 Status display and operation.......................................................................................... 87
8.2.1 Indicators in the display................................................................................................................87
8.2.2 LED status indicators ...................................................................................................................88
8.2.3 Control buttons.............................................................................................................................90
8.3 Menu description .............................................................................................................91
8.3.1 The main menus ..........................................................................................................................91
8.3.2 Parameter menu ..........................................................................................................................92
8.3.3 Language selection menu ..........................................................................................................100
8.3.4 Service menu .............................................................................................................................101
8.3.5 Actions menu .............................................................................................................................101
8.4 Operation ........................................................................................................................ 103
9 Leuze webConfig tool.................................................................................... 104
9.1 Connecting the SERVICE USB interface ..................................................................... 104
9.2 Installing the required software.................................................................................... 104
9.2.1 System requirements .................................................................................................................104
9.2.2 Installing the USB driver.............................................................................................................105
9.3 Starting the webConfig tool .......................................................................................... 106
9.4 Short description of the webConfig tool ..................................................................... 107
9.4.1 Module overview in the Configuration menu ..............................................................................107
10 Commissioning and configuration .............................................................. 109
10.1 BCL 500i.......................................................................................................................... 110
10.1.1 Measures to be performed prior to the initial commissioning.....................................................110
10.1.2 Starting the device .....................................................................................................................110
10.1.3 Operation as a stand-alone device ............................................................................................110
10.1.4 Selecting the operating mode ....................................................................................................111
10.1.5 Operation as a multiNet plus master..........................................................................................112
10.2 multiNet plus slave BCL 501i........................................................................................ 114
10.2.1 Measures to be performed prior to the initial commissioning.....................................................114
10.2.2 Starting the device .....................................................................................................................115
10.2.3 Setting the device address.........................................................................................................115
10.3 Additional settings for the BCL 500i and the BCL 501i.............................................. 117
10.3.1 Decoding and processing the read data ....................................................................................117
10.3.2 Control of the decoding ..............................................................................................................118
10.3.3 Control of the switching outputs .................................................................................................119
10.4 Transmitting configuration data................................................................................... 120
10.4.1 Via the webConfig tool ...............................................................................................................120
10.4.2 With the external parameter memory.........................................................................................120
4BCL500
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Table of contents
11 Online commands.......................................................................................... 123
11.1 Overview of commands and parameters..................................................................... 123
11.1.1 General 'online' commands .......................................................................................................124
11.1.2 ’Online’ commands for system control....................................................................................... 131
11.1.3 ’Online’ commands for the parameter set operations................................................................ 132
12 Diagnostics and troubleshooting................................................................. 139
12.1 General causes of errors............................................................................................... 139
12.2 Interface errors............................................................................................................... 139
13 Type overview and accessories ................................................................... 141
13.1 Type key.......................................................................................................................... 141
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13.2 Type overview BCL 500
13.2.1 BCL 500i.................................................................................................................................... 141
13.2.2 BCL 501
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.................................................................................................................................... 143
13.3 Accessory terminating resistor .................................................................................... 144
13.4 Accessory connectors .................................................................................................. 144
13.5 Accessory USB cable .................................................................................................... 144
13.6 Accessory external parameter memory....................................................................... 144
13.7 Accessory mounting device .........................................................................................144
13.8 Accessory ready-made cables for voltage supply...................................................... 145
13.8.1 Contact assignment of PWR connection cable.......................................................................... 145
13.8.2 Specifications of the cables for voltage supply.......................................................................... 145
13.8.3 Order codes of the cables for voltage supply ............................................................................145
13.9 Accessory ready-made cables for bus connection .................................................... 146
13.9.1 General information ................................................................................................................... 146
13.9.2 Contact assignment of KB PB… connection cable for PROFIBUS/multiNet plus .....................146
13.9.3 Technical data of interface connection cable.............................................................................147
13.9.4 Order codes for interface connection cables ............................................................................. 147
................................................................................................ 141
14 Maintenance ................................................................................................... 148
14.1 General maintenance information................................................................................ 148
14.2 Repairs, servicing .......................................................................................................... 148
14.3 Disassembling, packing, disposing ............................................................................. 148
Leuze electronic BCL 500i\BCL501
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Table of contents
15 Appendix ........................................................................................................ 149
15.1 Declaration of conformity ............................................................................................. 149
15.2 ASCII character set ........................................................................................................ 150
15.3 Barcode samples ...........................................................................................................154
15.3.1 Module 0.3 .................................................................................................................................154
15.3.2 Module 0.5 .................................................................................................................................155
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Figures and tables
Figure 2.1: Attachment of the stick-on labels with warning notices at the BCL 500i \BCL501i ................................ 13
Figure 3.1: Connections of the BCL 500i ................................................................................................................... 15
Figure 3.2: Connections of the BCL 501i ................................................................................................................... 15
Figure 4.1: Line scanner, line scanner with deflection mirror and oscillating-mirror scanner .....................................19
Figure 4.2: Possible barcode orientation .................................................................................................................... 21
Figure 4.3: Device construction .................................................................................................................................. 22
Figure 4.4: Deflection principle for the line scanner ................................................................................................... 23
Figure 4.5: Deflection principle for the line scanner with oscillating mirror add-on .................................................... 24
Figure 4.6: Principle arrangement for omnidirectional reading................................................................................... 25
Figure 4.7: Stand-alone connection ........................................................................................................................... 25
Figure 4.8: Networking possibilities using the multiNet plus ...................................................................................... 26
Figure 4.9: Scanner arrangement with the multiScan function................................................................................... 27
Figure 4.10: External parameter memory..................................................................................................................... 28
Figure 4.11: Reflector arrangement for autoReflAct..................................................................................................... 29
Table 5.1: Specifications of the BCL 501i and BCL 500i line scanners without heating........................................... 31
Table 5.2: Specifications of the BCL 501i and BCL 500i oscillating-mirror scanners without heating ...................... 33
Table 5.3: Specifications of the BCL 501i and BCL 500i deflection-mirror scanners without heating ...................... 33
Table 5.4: Specifications of the BCL 501i
Table 5.5: Specifications of the BCL 501i and BCL 500i oscillating-mirror scanners with heating ........................... 35
Table 5.6: Specifications of the BCL 501i and BCL 500i deflection-mirror scanners with heating ........................... 36
Figure 5.1: Dimensioned drawing BCL 500i \ BCL 501i line scanner S…102 ...........................................................37
Figure 5.2: Dimensioned drawing BCL 500i \ BCL 501i deflection-mirror scanner S…100....................................... 38
Figure 5.3: Dimensioned drawing BCL 500i \ BCL 501i oscillating-mirror scanner O…100 ...................................... 39
Table 5.7: Type overview BCL 500i .......................................................................................................................... 40
Table 5.8: Type overview BCL 501i .......................................................................................................................... 41
Figure 5.4: The most important characteristics of a barcode ..................................................................................... 42
Figure 5.5: Zero position of the reading distance .......................................................................................................43
Table 5.9: Reading conditions................................................................................................................................... 43
Figure 5.6: "High Density" reading field curve for line scanner (with/without deflection mirror) ................................. 44
Figure 5.7: "High Density" reading field curve for oscillating-mirror scanners............................................................ 45
Figure 5.8: Lateral "High Density" reading field curve for oscillating-mirror scanners ................................................ 45
Figure 5.9: "Medium Density" reading field curve for line scanner (with/without deflection mirror) ............................46
Figure 5.10: "Medium Density" reading field curve for oscillating-mirror scanners ......................................................47
Figure 5.11: Lateral "Medium Density" reading field curve for oscillating-mirror scanners .......................................... 47
Figure 5.12: "Low Density" reading field curve for line scanner (with/without deflection mirror) .................................
Figure 5.13: "Low Density" reading field curve for oscillating-mirror scanners ............................................................ 49
Figure 5.14: Lateral "Low Density" reading field curve for oscillating-mirror scanners................................................. 49
Figure 5.15: "Ultra Low Density" reading field curve for line scanner without deflection mirror ...................................50
Figure 5.16: "Ultra Low Density" reading field curve for oscillating-mirror scanners .................................................... 51
Figure 5.17: Lateral "Ultra Low Density" reading field curve for oscillating-mirror scanners ........................................ 51
Figure 5.18: "High Density" reading field curve for line scanner with heating (without deflection mirror)..................... 52
Figure 5.19: "High Density" reading field curve for line scanner with heating (with deflection mirror).......................... 53
Figure 5.20: "High Density" reading field curve for oscillating-mirror scanners with heating........................................ 54
Figure 5.21: Lateral "High Density" reading field curve for oscillating-mirror scanners with heating............................ 54
Figure 5.22: "Medium Density" reading field curve for line scanner with heating (without deflection mirror) ...............55
Figure 5.23: "Medium Density" reading field curve for line scanner with heating (with deflection mirror) ....................56
Figure 5.24: "Medium Density" reading field curve for oscillating-mirror scanners with heating ..................................57
Figure 5.25: Lateral "Medium Density" reading field curve for oscillating-mirror scanners with heating ......................57
and BCL 500i line scanners with heating................................................ 35
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Leuze electronic BCL 500i\BCL501
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Figures and tables
Figure 5.26: "Low Density" reading field curve for line scanner with heating (without deflection mirror) ..................... 58
Figure 5.27: "Low Density" reading field curve for line scanner with heating (with deflection mirror) ..........................59
Figure 5.28: "Low Density" reading field curve for oscillating-mirror scanners with heating ........................................ 60
Figure 5.29: Lateral "Low Density" reading field curve for oscillating-mirror scanners with heating ............................ 60
Figure 5.30: "Ultra Low Density" reading field curve for line scanner with heating (without deflection mirror)............. 61
Figure 5.31: "Ultra Low Density" reading field curve for oscillating-mirror scanners with heating................................ 62
Figure 5.32: Lateral "Ultra Low Density" reading field curve for oscillating-mirror scanners with heating.................... 62
Figure 6.1: Device name plate BCL 500i \BCL501i ................................................................................................. 63
Figure 6.2: Fastening options using M 4x6 threaded holes........................................................................................ 64
Figure 6.3: BT 56 mounting device ............................................................................................................................ 65
Figure 6.4: Mounting example BCL 500i \BCL501i .................................................................................................. 66
Figure 6.5: Total reflection – line scanner .................................................................................................................. 67
Figure 6.6: Total reflection – BCL 500i \BCL501i with oscillating/deflection mirror.................................................. 68
Figure 6.7: Reading angle for the line scanner .......................................................................................................... 69
Figure 7.1: Location of the electrical connections ...................................................................................................... 70
Figure 7.2: Connections of the BCL 500i ................................................................................................................... 72
Table 7.1: Pin assignment PWR ............................................................................................................................... 73
Figure 7.1: Switching input connection diagram SWIO_3 and SWIO_4 .................................................................... 74
Figure 7.2: Switching output connection diagram SWIO_3 / SWIO_4 .................................................................
Table 7.2: Pin assignments of SERVICE – USB interface........................................................................................ 75
Table 7.3: Pin assignment SW IN/OUT..................................................................................................................... 76
Figure 7.3: Switching input connection diagram SWIO_1 and SWIO_2 .................................................................... 76
Figure 7.4: Switching output connection diagram SWIO_1 / SWIO_2 ....................................................................... 77
Table 7.4: Pin assignment HOST / BUS IN BCL 500i............................................................................................... 77
Figure 7.5: Pin assignments - HOST / BUS IN as RS 232 ......................................................................................... 78
Figure 7.6: Pin assignments - HOST / BUS IN as RS 422 ......................................................................................... 78
Table 7.5: Pin assignment BUS OUT ....................................................................................................................... 79
Figure 7.7: Connections of the BCL 501i ................................................................................................................... 80
Table 7.6: Pin assignment HOST / BUS IN BCL 501i............................................................................................... 81
Figure 7.8: Leuze multiNet plus system topology....................................................................................................... 82
Figure 7.9: System topology of Leuze multiNet plus with BCL 500i as slave ............................................................ 85
Table 7.7: Line lengths and shielding ....................................................................................................................... 86
Figure 8.1: Structure of the control panel ...................................................................................................................87
Table 8.1: Parameter handling submenu ..................................................................................................................92
Table 8.2: Decoder table submenu ...........................................................................................................................93
Table 8.3: Digital SWIO submenu............................................................................................................................. 96
Table 8.4: Com submenu.......................................................................................................................................... 99
Figure 9.1: Connecting the SERVICE USB interface ...............................................................................................104
Figure 9.2: The start page of the webConfig tool ..................................................................................................... 106
Figure 9.3: Module overview in the webConfig tool.................................................................................................. 107
Figure 10.1: Connections of the BCL 500i ................................................................................................................. 110
Figure 10.2: Connections of the BCL 501i ................................................................................................................. 114
Figure 10.3: Storing configuration data in the webConfig tool ................................................................................... 120
Figure 10.4: Installing the external parameter memory.............................................................................................. 121
Figure 10.5: BCL 500i \BCL501i with installed parameter memory .........................................................................121
Table 12.1: General causes of errors ....................................................................................................................... 139
Table 12.2: Interface error ........................................................................................................................................ 139
Table 13.1: Type overview BCL 500i........................................................................................................................ 141
...... 74
8BCL500
i
\ BCL 501
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Leuze electronic
Figures and tables
Table 13.2: Type overview BCL 501i ........................................................................................................................ 143
Table 13.3: Terminating resistor for the BCL 500i \ BCL 501i .................................................................................. 144
Table 13.4: Connectors for the BCL 500i \BCL501i................................................................................................ 144
Table 13.5: Cables for the BCL 500i \BCL501i ....................................................................................................... 144
Table 13.6: External parameter memory for the BCL 500i \ BCL 501i ..................................................................... 144
Table 13.7: Mounting devices for the BCL 500i \ BCL 501i ...................................................................................... 144
Table 13.8: PWR cables for the BCL 500i \BCL501i .............................................................................................. 145
Figure 13.9: Cable structure of PROFIBUS/multiNet plus connection cable.............................................................. 146
Table 13.10: Bus connection cables for the BCL 500i \ BCL 501i .............................................................................. 147
Figure 15.1: Barcode sample labels (module 0.3)...................................................................................................... 154
Figure 15.2: Barcode sample labels (module 0.5)...................................................................................................... 155
Leuze electronic BCL 500i\BCL501
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General information

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 barcode readers of the BCL 500i series have been developed and manufactured in accordance with the applicable European standards and directives.
i
The BCL 500 and fulfils the requirements of Underwriter Laboratories Inc. (UL).
Notice!
You can find the Declaration of Conformity of the devices in the appendix of the manual on page 149.
The manufacturer of the product, Leuze electronic GmbH & Co KG in D-73277 Owen/Teck, possesses a certified quality assurance system in accordance with ISO 9001.
10 BCL 500i\ BCL 501
series is "UL LISTED" according to American and Canadian safety standards,
U
L
C
US
LISTED
i
Leuze electronic

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 authorised representative.

2.2 Safety standards

The barcode readers of the BCL 500iseries were developed, manufactured and tested in accordance with the applicable safety standards. They correspond to the state of the art.

2.3 Approved purpose

Safety notices
Attention!
The protection of personnel and the device cannot be guaranteed if the device is operated in a manner not complying with its intended use.
Barcode readers of the BCL 500i series are conceived as stationary, high-speed scanners with integrated decoders for all current barcodes used for automatic object detection.
In particular, unauthorised uses include:
• rooms with explosiv operation for medical purposes
•
e atmospheres

Areas of application

The barcode readers of the BCL 500i 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 transportation applications
• Automobile sector
• Omnidirectional reading
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Safety notices

2.4 Working safely

Attention!
Access to or changes on the device, except where expressly described in this operating manual, are not authorised.

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 500i \ BCL 501i at persons!
When mounting and aligning the BCL 500i \ BCL 501i, avoid reflections of the laser beam off reflective surfaces!
The BCL 500i \ BCL 501i barcode readers comply with safety standards EN 60825-1 for a class 2 product. 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 500i \ BCL 501i 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 class 2 lasers.
Adjustments: Do not attempt any adjustments to or alterations of this product.
Do not remove the protective housing of the barcode reader. There are no user-serv­iceable parts inside.
The scanner window is the only aperture through which light 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 barcode reader has safeguards to prevent this occurrence. If, however, a stationary beam is emitted, the failing barcode reader should be disconnected from its power source im­mediately.
CAUTION: Use of controls or adjustments or performance of procedures other than specified herein may result in hazardous light exposure.
The use of optical instruments or devices in combination with the device increases the danger of eye damage!
12 BCL 500i\ BCL 501
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Leuze electronic
Safety notices
A
B
BCL 500
i
\ BCL 501
i
Line scanner
BCL 500
i
\ BCL 501
i
with oscillating/deflection mirror
C
A Included stick-on labels B Aperture label C Name plate
The housing of the BCL 500i \ BCL 501i is provided with warning notices B and C 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
Notice!
It is important that you attach the stick-on labels supplied to the device (A in figure 2.1)! If the signs would be covered due to the installation situation of the BCL 500i \ BCL 501i, at­tach them instead in the immediate vicinity of the BCL 500i \ BCL 501i in such a way that it is not necessary to look into the laser beam when reading the notices!
Leuze electronic BCL 500i\BCL501
BCL 500
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\ BCL 501
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Fast commissioning / operating principle

3 Fast commissioning / operating principle

Below you will find a short description for the initial commissioning of the
i
BCL 500 technical description.
\BCL501i. Detailed explanations for all listed points can be found throughout this
3.1 Mounting the BCL 500i\ BCL 501
The BCL 500i\ BCL 501i barcode readers can be mounted in two different ways:
• Using two M4x6 screws on the rear of the device or using four M4x6 screws on the bottom of the device.
• Using a BT 56 mounting device on the two fastening grooves.
i

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 barcodes on the objects to be scanned.
• The reading field of the BCL 500
• The resulting minimum and maximum reading distance from the respective reading field (see chapter 5.5 "Reading field curves / optical data").
• The permissible line lengths between the BCL 500 depending on which interface is used.
• The correct time for data output. The BCL 500 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 visible and accessible.
• For configuring and commissioning with the webConfig tool, the USB interface should be easily accessible.
For specific information, please refer to chapter 4.4.
Notice!
The beam exits the BCL 500i \BCL501i as follows for the respective devices:
- line scanner parallel to the housing base
- oscillating mirror and deflection mirror perpendicular to the housing base The black areas in figure 6.1 are the housing base. The best read results are obtained when:
• The BCL 500i\ BCL 501i is mounted in such a way that the scanning beam is inci­dent on the barcode at an angle of inclination greater than ±10° … 15° to vertical.
•
The reading distance lies in the middle area of the reading field.
• The barcode labels are of good print quality and have good contrast ratios.
•
You do not use high-gloss labels.
• There is no direct sunlight.
i
\ BCL 501i in relation to the barcode module width.
i
\BCL501i and the host system
i
\ BCL 501i should be positioned in
14 BCL 500i\ BCL 501
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Leuze electronic
Fast commissioning / operating principle
USB socket
Type A
M12 socket
(A-coded)
M12 socket
(B-coded)
M12 plug (B-coded)
M12 plug (A-coded)
SW IN/OUT
VOUT
1
2
3
4
SWIO_1
SWIO_2
GND
FE
5
SERVICE
2134
GND D+ D-
U
B
PWR
SWIO_4
SWIO_3
3
2
1
4
5
GND VIN
FE
BUS OUT RS 485
VCC485
1
2
3
4
RS485B
RS485A
GND485
FE
5
HOST / BUS IN
GND485
3
2
1
4
FE
RS485B
RS485A
NC
5
USB socket
Type A
M12 socket
(A-coded)
M12 socket
(B-coded)
M12 plug (B-coded)
M12 plug (A-coded)
3.3 Electrical connection BCL 500i and BCL 501
The BCL 500i\ BCL 501i is equipped with four M12 plugs/sockets which are A- and B­coded, and an A-coded USB socket.
SERVICE
GND D+ D-
U
B
2134
BUS OUT RS 485
RS485B
VCC485
1
RS485A
2
GND485
3
5
4
FE
HOST / BUS IN
GND_H
3
RXD/RX-
TXD/TX-
RTS/TX+
Figure 3.1: Connections of the BCL 500
SW IN/OUT
SWIO_1
2
VOUT
1
5
4
SWIO_2
GND
3
FE
PWR
SWIO_3
2
CTS/RX+
1
5
4
2
GND VIN
3
5
4
FE
SWIO_4
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i
1
Figure 3.2: Connections of the BCL 501
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Fast commissioning / operating principle

Voltage supply and switching inputs/outputs

The voltage supply (10 … 30VDC) is connected at the PWR M12 connector. Available at both the PWR M12 connector as well as at the SW IN/OUT M 12 socket are four
freely programmable switching inputs/outputs for custom adaptation to the respective application. Detailed information on this topic can be found in chapter 7.2.1 and chapter
7.2.3 (for the BCL 500
i
) and in chapter 7.3.1 and chapter 7.3.3 (for the BCL 501i).

Stand-alone operation

During stand-alone operation of the BCL 500i, the host interface of the primary system is connected to HOST/BUS IN. Please make certain that the correct interface is used on the primary system. The standard setting of the BCL 500

Network operation in the Leuze multiNet plus

In Leuze multiNet plus network operation, the primary system (PC/PLC) is connected to the
i
host interface of the BCL 500 occurs via BUS OUT.
If BUS OUT is not used for the connection to the next participant, the Leuze multiNet plus network must be terminated with an M12 terminating resistor at the last participant (see chapter 13.3 "Accessory terminating resistor").
, the bus connection to the next participant, e.g. a BCL 501i,

3.4 Starting the device

ª
Connect the supply voltage +10 … 30V DC (typ. +24 V DC); the BCL 500i \ BCL 501i starts up and the barcode reading window appears on the display:
i
for the host interface is RS 232.
As a first step, you need to set the operating mode of the BCL 500i. The BCL 500i can be operated as a stand-alone device, multiNet plus master, or multiNet plus slave.
You can make the necessary settings via the display or via the webConfig tool. Provided here is only a brief description of the settings via the webConfig tool; detailed information can be found in chapter 10.
Select the desired operating mode
ª
• Via webConfig:
Configuration -> Communication -> Overview
By default, parameter enabling is deactivated and you can-
31
not change any settings. If you wish to carry out the config­uration via the display, you must activate parameter enabling. Further information can be found in chapter "Parameter enabling" on page 103

Operation as a multiNet plus master

ª
Set the max. slave number parameter to the desired value:
• Via webConfig:
Configuration -> Communication -> BUS OUT -> Protocol
16 BCL 500i\ BCL 501
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Leuze electronic
Fast commissioning / operating principle
ª
Select the desired interface standard (RS 232 / RS 422) and set the associated commu­nication parameters:
• Via webConfig:
Configuration -> Communication -> HOST/BUS IN -> Data transmission
Select the desired communication protocol and set associated parameters:
ª
• Via webConfig: first
Configuration -> Communication -> HOST/BUS IN -> Protocol

Operation as a multiNet plus slave

Notice!
The BCL 501i always automatically starts as a slave participant in the multiNet plus. The default address is 1.
The Leuze multiNet plus permits an address range from 0 to 31. Address 31 must not be used for data communication. It may only be used temporarily for commissioning.
ª
Set the Slave address parameter to a value > 0 and <31. Start with address 01 for the first slave and assign further addresses in contiguous ascending order.
• Via webConfig:
Configuration -> Communication -> BUS OUT -> Protocol

Further settings

After the basic configuration of the operating mode and the communication parameters, you need to carry out further settings:
• Decoding and processing the read data
ª
Define at least one code type with the desired settings.
• Via webConfig:
Configuration -> Decoder
• Control of the decoding
Configure the connected switching inputs according to your requirements. To do
ª
this, first set the I/O mode to Input and then configure the switching behaviour:
• Via webConfig:
Configuration -> Device -> Switching inputs/outputs
• Control of the switching outputs
ª
Configure the connected switching outputs according to your requirements. To do this, first set the I/O mode to Output and then configure the switching behaviour:
• Via webConfig:
Configuration -> Device -> Switching inputs/outputs
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Fast commissioning / operating principle

3.5 Barcode reading

With the aid of the "Action menu", you can instruct the BCL 500i\ BCL 501i to read a barcode.
Actions
o Start decoding o Start alignment o Start auto-setup o Start teach-in
To test, you can use the following barcode in the 2/5 Interleaved format. The barcode module here is 0.5:
In the main menu, use the buttons to select the Actions menu item. Activate the Actions menu with . Then select Start decoding with and press again to start the barcode reading operation.
Modul 0,5
6677889900
The read information appears in the display and is simultaneously passed on to the primary system (PLC or PC).
Please check the incoming data of the barcode information there. Alternatively, you can connect a photoelectric sensor or a 24 V DC switching signal to the
SW IN/OUT socket for read activation. To do this, however, you must appropriately configure the switching input (see chapter 7.2.3 "SW IN/OUT – Switching input/switching output").
18 BCL 500i\ BCL 501
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Leuze electronic

4 Device description

Line scanner
Oscillating-mirror scanner /
Line scanner with deflection mirror

4.1 About the barcode readers of the BCL 500i series

Barcode readers of the BCL 500i series are high-speed scanners with integrated decoder for all commonly used barcodes, e.g. 2/5 Interleaved, Code 39, Code 128, EAN 8/13 etc., as well as codes from the RSS family.
i
Barcode readers of the BCL 500 scanners, line scanners with deflection mirrors, oscillating mirrors and also optionally as heated models.
series are available in various optics models as well as line
Device description
Figure 4.1: Line scanner, line scanner with deflection mirror and oscillating-mirror scanner
The extensive options for device configuration via display or software enable adaptation to a multitude of reading tasks. Due to the large reading distance combined with the great depth of field and a very compact construction, the device is ideally suited for package and pallet transportation systems. In general, the barcode readers of the BCL 500 designed for the conveyor 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 and Ethernet) of the barcode readers of the BCL 500

4.2 Characteristics of the barcode readers of the BCL 500i series

Performance features:
• Integrated fieldbus connectivity = working
• Numerous interface variants facilitate connection to the primary systems
• RS 232, RS 422 as well as with integrated multiNet plus master
Leuze electronic BCL 500i\BCL501
i
series offer optimum connection to the primary host system.
i
-> Plug-and-Play fieldbus coupling and easy net-
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i
series are
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Device description
• RS 485 and multiNet plus slave alternatively, various fieldbus systems, such as
•PROFIBUS DP
•PROFINET
• Ethernet
• Integrated code fragment technology (CRT) enables the identification of soiled or damaged barcodes
• Maximum depth of field and reading distances from 200mm to 1600mm
• Large optical opening angle and, thus, large reading field width
• High scanning rate from 800 - 1200 scans/s for fast reading tasks
• Intuitive, backlit, multi-language display with user-friendly menu navigation
• Integrated USB 1.1 service interface
• Adjustment of all device parameters with a web browser
• Connection options for an external parameter memory
• Easy alignment- and diagnosis functions
• M12 connections with Ultra-Lock™ technology
• Four freely programmable switching inputs/outputs for the activation or signalling of states
• Automatic monitoring of the read quality with autoControl
• Automatic recognition and setting of the barcode type using autoConfig
• Reference code comparison
• Optional heating models to -35°C
• Heavy-duty housing of protection class IP 65
Notice!
Information on technical data and characteristics can be found in chapter 5.

General information

The integrated fieldbus connectivity = i contained in the barcode readers of the BCL 500 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 additional software.
For decoding barcodes, the barcode readers of the BCL 500 proven CRT decoder with code fragment technology:
The proven code fragment technology (CRT) enables barcode readers of the BCL 500 series to read barcodes with a small bar height, as well as barcodes with a damaged or soiled print image.
20 BCL 500i\ BCL 501
i
i
series make available the
i
i
Leuze electronic
Device description
With the aid of the CRT decoder, barcodes 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 barcode orientation
The BCL 500 tool via the USB service interface; alternatively, the barcode readers can be adjusted using configuration commands via the host/service interface.
The BCL 500 object is in the reading field. This opens a time window ("reading gate") in the BCL 500 detect and decode a barcode.
In the basic setting, triggering takes place through an external reading cycle signal. Alterna­tive activation options include online commands via the host interface and the autoReflAct function.
Through the read operation, the BCL 500 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.
A multi-language display with buttons is used to operate the BCL 500 for visualisation purposes. Two LEDs provide additional optical information on the current operating state of the device.
The four freely configurable switching inputs/outputs "SWIO 1 … SWIO 4" can be assigned various functions and control e.g. activation of the BCL 500 such as a PLC.
System, warning and error messages provide assistance in set-up/troubleshooting during commissioning and read operation.
i
\ BCL 501i can be operated and configured using the integrated webConfig
i
\ BCL 501i needs a suitable activation to start a read process as soon as an
i
\ BCL 501i for the read process during which the barcode reader has time to
i
\ BCL 501i collects additional useful pieces of
i
\BCL501i as well as
i
\BCL501i or external devices,
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Device description
USB interface
M12 connection
technology
Reading window
Dovetail mounting and 4 mounting threads
Dovetail mounting and 2 mounting threads
Display, LEDs
and buttons

4.3 Device construction

Figure 4.3: Device construction
22 BCL 500i\ BCL 501
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Leuze electronic

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 barcode is automatically transported through the scan line.
The integrated code fragment technology permits twisting of the barcode (tilt angle) within certain limits. These are dependent on the transport speed, the scanning rate of the scanner and the barcode properties.
Areas of application of the line scanner
The line scanner is used:
• when the bars of the barcode are printed in the conveying direction ('ladder arrange­ment').
• with barcodes having very short bar lengths.
• when the ladder code is turned out of the vertical position (tilt angle).
• when the scanning distance is large.
Device description
Figure 4.4: Deflection principle for the line scanner
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Device description

4.4.2 Line scanner with oscillating mirror

The oscillating mirror deflects the scan line additionally to both sides across the scan direc­tion at a randomly adjustable oscillation frequency. In this way, the BCL 500 also scan larger areas or spaces for barcodes. The reading field height (and the scan line length useful for evaluation) depends on the reading distance due to the optical beam width of the oscillating mirror.
Areas of application of the line scanner with oscillating mirror
For line scanners with oscillating mirror, oscillation frequency, start/stop position etc. are adjustable. It is used:
• when the position of the label is not fixed, e.g. on pallets – various labels can, thus, be detected at various positions.
• when the bars of the barcode are printed perpendicular to the conveying direction ('picket fence arrangement').
• when reading stationary objects.
• when the barcode is turned out of the horizontal position.
• when the scanning distance is large.
• when a large reading field (reading window) has to be covered.
i
\ BCL 501i can
Figure 4.5: Deflection principle for the line scanner with oscillating mirror add-on
24 BCL 500i\ BCL 501
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Leuze electronic

4.4.3 Omnidirectional reading

Supply voltage
PC / PLC host interface
Switching inputs/outputs
In order to read arbitrarily oriented barcodes on an object, at least 2 barcode readers are necessary. If the barcode is not printed over-square, i.e. bar length > code length, barcode readers with integrated code fragment technology are necessary.
Device description
Figure 4.6: Principle arrangement for omnidirectional reading

4.5 Stand-alone connection

The barcode readers of the BCL 500i series can be operated as individual "stand alone"
i
devices. The BCL 500 tion of the supply voltage, the interface and the switching inputs and outputs.
Figure 4.7: Stand-alone connection
Leuze electronic BCL 500i\BCL501
features multiple M12 connectors / sockets for the electrical connec-
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25
Device description
BCL 500i master
BCL 501i slave 1 BCL 501i slave 2 BCL 501i slave n
to PC/PLC
Terminating resistor on the last slave

4.6 Networking - Leuze multiNet plus

In the Leuze multiNet plus network, up to 32 barcode readers can be networked together. The respective network devices transmit the read data when requested to by the BCL 500 (or MA 31) network master. For this purpose, each BCL 500i / BCL 501i is assigned its own station address which is set with the aid of the display on the respective BCL 500
i
BCL 501 The master then transmits the data of all network devices via its host interface to a primary
PLC control system or a computer, i.e. it "collects" the scanner data in the network and trans­mits it to an interface on the host computer. This reduces interface costs (CPs) and time spent programming the software.
.
i
i
/
Figure 4.8: Networking possibilities using the multiNet plus

Two-wire RS 485

The Leuze multiNet plus is optimised for fast transmission of scanner data to a primary host computer. The multiNet plus consists physically of a two-wire RS 485 interface through which the Leuze multiNet plus software protocol is controlled. This makes wiring the network easy and inexpensive as slaves are connected to one another in parallel.
In principle, networking occurs via a parallel connection of the individual RS 485 interfaces of the respective barcode scanners. Shielded, twisted pair conductors should be used for the Leuze multiNet plus. This allows a total network length of up to 1200m.

4.7 Leuze multiScan

The multiScan operating mode is based on Leuze multiNet plus and links individual barcode readings from multiple barcode scanners into a single decoding result. This is used, for example, on a packet conveyor system on which the label can be affixed on either the right or left side, thereby requiring two read stations. To prevent the host from having to
26 BCL 500i\ BCL 501
i
Leuze electronic
Device description
always process two readings for a single packet, i.e. a decoding result and a No Read, a multiScan arrangement is used which transmits only one reading from the two read stations to the host; this single reading is transmitted by the multiScan master.
Notice!
Thus, from the perspective of the host, the scanner network appears to be just a single bar­code reader!
For this purpose one multiScan master and one or more multiScan slaves are connected together via the RS 485 interface.
Figure 4.9: Scanner arrangement with the multiScan function
Notice!
The multiScan function on the RS 485 interface is possible for minimum of 2 and a maxi­mum of 32 devices!
The protocol set on the RS 485 interface is the multiNet protocol. As a result, during multi-
Scan operation on the RS 485 interface, the multiNet master also functions as the multiScan master and the multiNet slaves function as multiScan slaves (thus, all multiNet
slave are included in multiScan operation).
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