Leuze BCL504i TECHNICAL DESCRIPTION

BCL504i

Barcode reader

GB 02-09/08 50108327

TECHNICAL DESCRIPTION

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• 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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reproductions in any form require the written consent of the manufacturer. Changes reflecting technical improvements may be made.

BCL 504

Navigate

upward/laterally

Navigate

downward/laterally ESCAPE

Leave

ENTER

confirm

Device buttons:

Delete character

Enter digit

Save input

The main menus

ESC

Input of values

12|

<-|0123456789 save Standard ----- Unit 126 | |

BCL504i 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 PROFIBUS

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 78.

Parameter - main menu

Configuration of the barcode reader. See "Parameter menu" on page 83.

Language selection - main menu

Selection of the display language. See "Language selection menu" on page 90.

Service - main menu

Scanner diagnosis and status messages. See "Service menu" on page 90.

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 91.

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

3 Fast commissioning / operating principle..................................................... 16

3.1 Mounting the BCL 504i.................................................................................................... 16

3.2 Device arrangement and selection of the mounting location...................................... 16

3.3 Electrical connectionBCL 504

3.4 Starting the device........................................................................................................... 17

3.4.1 Setting the device address on the display ................................................................................... 18

3.5 BCL 504i on the PROFIBUS ............................................................................................19

3.6 Barcode reading............................................................................................................... 20

....................................................................................... 17

4 Device description ........................................................................................... 21

4.1 About the barcode readers of the BCL 500i series....................................................... 21

4.2 Characteristics of the barcode readers of the BCL 500

4.3 Device construction......................................................................................................... 24

4.4 Reading techniques......................................................................................................... 25

4.4.1 Line scanner (single line)............................................................................................................. 25

4.4.2 Line scanner with oscillating mirror.............................................................................................. 26

4.4.3 Omnidirectional reading............................................................................................................... 27

4.5 Fieldbus systems.............................................................................................................28

4.5.1 PROFIBUS DP ............................................................................................................................28

4.6 Heater................................................................................................................................ 28

4.7 External parameter memory ........................................................................................... 29

4.8 autoReflAct....................................................................................................................... 30

4.9 Reference codes ..............................................................................................................30

4.10 autoConfig ........................................................................................................................31

Leuze electronic BCL 504

series................................... 21

Table of contents

5 Specifications .................................................................................................. 32

5.1 General specifications of the barcode readers............................................................. 32

5.1.1 Line scanner.................................................................................................................................32

5.1.2 Oscillating-mirror scanner ............................................................................................................34

5.1.3 Line scanner with deflection mirror...............................................................................................34

5.2 Heating models of the barcode readers ........................................................................ 35

5.2.1 Line scanner with heating ............................................................................................................36

5.2.2 Oscillating-mirror scanner with heating ........................................................................................36

5.2.3 Line scanner with deflection mirror and heating...........................................................................37

5.3 Dimensioned drawings.................................................................................................... 38

5.3.1 Line scanner with / without heating ..............................................................................................38

5.3.2 Deflection mirror scanner with / without heating...........................................................................39

5.3.3 Oscillating-mirror scanner with / without heating..........................................................................40

5.4 Type overview BCL 504i.................................................................................................. 41

5.5 Reading field curves / optical data................................................................................. 42

5.6 Reading field curves........................................................................................................ 43

5.6.1 High Density (N) Optics: BCL 504iSN 100/102...........................................................................44

5.6.2 High Density (N) Optics: BCL 504

5.6.3 Medium Density (M) Optics: BCL 504

5.6.4 Medium Density (M) Optics: BCL 504

5.6.5 Low Density (F) Optics: BCL 504

5.6.6 Low Density (F) Optics: BCL 504

5.6.7 Ultra Low Density (L) Optics: BCL 504

5.6.8 Ultra Low Density (L) Optics: BCL 504

5.7 Reading field curves for heating devices ...................................................................... 52

5.7.1 High Density (N) Optics: BCL 504iSN 102 H ..............................................................................52

5.7.2 High Density (N) Optics: BCL 504

5.7.3 High Density (N) Optics: BCL 504

5.7.4 Medium Density (M) Optics: BCL 504

5.7.5 Medium Density (M) Optics: BCL 504

5.7.6 Medium Density (M) Optics: BCL 504

5.7.7 Low Density (F) Optics: BCL 504

5.7.8 Low Density (F) Optics: BCL 504

5.7.9 Low Density (F) Optics: BCL 504

5.7.10 Ultra Low Density (L) Optics: BCL 504

5.7.11 Ultra Low Density (L) Optics: BCL 504

ON 100 .................................................................................45

SM 100/102.....................................................................46

OM 100 ...........................................................................47

SF 100/102 ............................................................................48

OF 100...................................................................................49

SL 102 ...........................................................................50

OL 100...........................................................................51

SN 100 H ..............................................................................53

ON 100 H..............................................................................54

SM 102 H........................................................................55

SM 100 H........................................................................56

OM 100 H........................................................................57

SF 102 H................................................................................58

SF 100 H................................................................................59

OF 100 H ...............................................................................60

SL 102 H........................................................................61

OL 100 H .......................................................................62

6 Installation and mounting ............................................................................... 63

6.1 Storage, transportation ...................................................................................................63

6.2 Mounting the BCL 504

6.2.1 Fastening with M4 x 6 screws ......................................................................................................64

6.2.2 BT 56 mounting device ................................................................................................................65

2BCL504

.................................................................................................... 64

Leuze electronic

Table of contents

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 504

6.4 Attaching laser warning sign.......................................................................................... 69

6.5 Cleaning............................................................................................................................ 69

7 Electrical connection....................................................................................... 70

7.1 Safety notices for the electrical connection.................................................................. 70

7.2 Electrical connection of the BCL 504

7.2.1 PWR – Voltage supply and switching input/outputs 3 and 4 .......................................................72

7.2.2 SERVICE – USB interface (type A) ............................................................................................. 74

7.2.3 SW IN/OUT – Switching input/switching output........................................................................... 75

7.2.4 HOST / BUS IN for BCL 504

7.2.5 BUS OUT for the BCL 504

7.2.6 PROFIBUS termination................................................................................................................ 77

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

.......................................................................................................... 77

............................................................................ 71

7.3 Line lengths and shielding.............................................................................................. 77

8 Display and control panel ............................................................................... 78

8.1 Structure of the control panel......................................................................................... 78

8.2 Status display and operation.......................................................................................... 78

8.2.1 Indicators in the display ............................................................................................................... 78

8.2.2 LED status indicators................................................................................................................... 79

8.2.3 Control buttons ............................................................................................................................81

8.3 Menu description .............................................................................................................82

8.3.1 The main menus .......................................................................................................................... 82

8.3.2 Parameter menu .......................................................................................................................... 83

8.3.3 Language selection menu............................................................................................................ 90

8.3.4 Service menu............................................................................................................................... 90

8.3.5 Actions menu ............................................................................................................................... 91

8.4 Operation .......................................................................................................................... 93

and barcode........................................... 69

9 Leuze webConfig tool...................................................................................... 95

9.1 Connecting the SERVICE USB interface........................................................................ 95

9.2 Installing the required software...................................................................................... 95

9.2.1 System requirements................................................................................................................... 95

9.2.2 Installing the USB driver ..............................................................................................................96

Leuze electronic BCL 504

Table of contents

9.3 Starting the webConfig tool ............................................................................................ 97

9.4 Short description of the webConfig tool ....................................................................... 98

9.4.1 Module overview in the Configuration menu ................................................................................98

10 Commissioning and configuration .............................................................. 100

10.1 General information on the PROFIBUS implementation of the BCL 504i................. 100

10.1.1 Communication profile ...............................................................................................................100

10.1.2 Bus-access protocol...................................................................................................................100

10.1.3 Device types...............................................................................................................................101

10.1.4 Expanded DP functions..............................................................................................................101

10.1.5 Automatic baud rate detection ...................................................................................................102

10.2 Measures to be performed prior to the initial commissioning .................................. 103

10.3 Address setting .............................................................................................................. 104

10.3.1 Setting the device address on the display..................................................................................104

10.4 Commissioning via the PROFIBUS ..............................................................................106

10.4.1 General information....................................................................................................................106

10.4.2 Preparing the control system for consistent data transmission..................................................106

10.4.3 General information on the GSD file ..........................................................................................107

10.4.4 Permanently defined parameters / device parameters...............................................................108

10.5 Overview of the project modules ................................................................................. 112

10.6 Decoder modules ........................................................................................................... 115

10.6.1 Modules 1-4 – Code table extensions 1 to 4..............................................................................115

10.6.2 Module 5 – Code type features (symbology)..............................................................................117

10.6.3 Module 7 – Code fragment technology ......................................................................................118

10.7 Control modules ............................................................................................................ 119

10.7.1 Module 10 – Activations .............................................................................................................119

10.7.2 Module 11 – Reading gate control .............................................................................................121

10.7.3 Module 12 – Multi-label ..............................................................................................................123

10.7.4 Module 13 – Fragmented read result .........................................................................................124

10.7.5 Module 14 – Interlinked read result............................................................................................125

4BCL504

Leuze electronic

Table of contents

10.8 Result Format ................................................................................................................. 126

10.8.1 Module 20 – Decoder state........................................................................................................ 126

10.8.2 Modules 21-27 – Decoding result .............................................................................................. 128

10.8.3 Module 30 – Data formatting .....................................................................................................130

10.8.4 Module 31 – Reading gate number ...........................................................................................131

10.8.5 Module 32 – Reading gate time................................................................................................. 131

10.8.6 Module 33 – Code position ........................................................................................................ 132

10.8.7 Module 34 – Reading reliability (equal scans) ........................................................................... 132

10.8.8 Module 35 – Barcode length...................................................................................................... 133

10.8.9 Module 36 – Scans with information.......................................................................................... 133

10.8.10 Module 37 – Decoding quality ...................................................................................................134

10.8.11 Module 38 – Code direction....................................................................................................... 134

10.8.12 Module 39 – Number of digits.................................................................................................... 135

10.8.13 Module 40 – Code type.............................................................................................................. 135

10.8.14 Module 41 – Code position in the swivel range ......................................................................... 136

10.9 Data Processing ............................................................................................................. 137

10.9.1 Module 50 – Characteristics filter ..............................................................................................137

10.9.2 Module 51 – Data filtering.......................................................................................................... 139

10.10 Identifier.......................................................................................................................... 140

10.10.1 Module 52 – Segmentation according to the EAN process ....................................................... 140

10.10.2 Module 53 – Segmentation via fixed positions ..........................................................................141

10.10.3 Module 54 – Segmentation according to identifier and separator .............................................144

10.10.4 Module 55 – String handling parameters................................................................................... 146

10.11 Device Functions ...........................................................................................................147

10.11.1 Module 60 – Device status ........................................................................................................147

10.11.2 Module 61 – Laser control ......................................................................................................... 148

10.11.3 Module 62 – Display .................................................................................................................. 149

10.11.4 Module 63 – Alignment.............................................................................................................. 150

10.11.5 Module 64 – Oscillating mirror................................................................................................... 151

10.11.6 Module 65 – Deflection mirrors.................................................................................................. 152

10.12 Switching inputs/ outputs SWIO 1..4............................................................................ 153

10.12.1 Parameters for operating as an output ...................................................................................... 153

10.12.2 Parameters for operating as an input ........................................................................................155

10.12.3 Switch-on and switch-off functions for operation as an output ..................................................157

10.12.4 Input functions for operation as an input.................................................................................... 157

10.12.5 Module 70 – Switching input/output SWIO1 .............................................................................. 158

10.12.6 Module 71 – Switching input/output SWIO2 .............................................................................. 160

10.12.7 Module 72 – Switching input/output SWIO3 .............................................................................. 162

10.12.8 Module 73 – Switching input/output SWIO4 .............................................................................. 164

10.12.9 Module 74 – SWIO status and control....................................................................................... 166

10.13 Data output ..................................................................................................................... 169

10.13.1 Module 80 – Sorting................................................................................................................... 169

Leuze electronic BCL 504

Table of contents

10.14 Reference code comparison......................................................................................... 170

10.14.1 Module 81 – Reference code comparator 1...............................................................................170

10.14.2 Module 82 – Reference code comparator 2...............................................................................172

10.14.3 Module 83 – Reference code comparison pattern 1 ..................................................................174

10.14.4 Module 84 – Reference code comparison pattern 2 ..................................................................175

10.15 Special Functions .......................................................................................................... 176

10.15.1 Module 90 – Status and control .................................................................................................176

10.15.2 Module 91 – AutoReflAct (automatic reflector activation) ..........................................................177

10.15.3 Module 92 – AutoControl ...........................................................................................................178

10.16 Example configuration: Indirect activation via the PLC............................................. 179

10.16.1 Task ...........................................................................................................................................179

10.16.2 Procedure...................................................................................................................................179

10.17 Sample configuration: Direct activation via the switching input ..............................181

10.17.1 Task ...........................................................................................................................................181

10.17.2 Procedure...................................................................................................................................181

11 Diagnostics and troubleshooting................................................................. 183

11.1 General causes of errors............................................................................................... 183

11.2 Interface errors............................................................................................................... 183

12 Type overview and accessories ................................................................... 185

12.1 Type key.......................................................................................................................... 185

12.2 Type overview BCL 504

12.3 Accessory terminating resistor ....................................................................................187

12.4 Accessory connectors .................................................................................................. 187

12.5 Accessory USB cable .................................................................................................... 187

12.6 Accessory external parameter memory....................................................................... 187

12.7 Accessory mounting device ......................................................................................... 187

12.8 Accessory ready-made cables for voltage supply ..................................................... 188

12.8.1 Contact assignment of PWR connection cable ..........................................................................188

12.8.2 Specifications of the cables for voltage supply...........................................................................188

12.8.3 Order codes of the cables for voltage supply.............................................................................188

12.9 Accessory ready-made cables for bus connection ....................................................189

12.9.1 General information....................................................................................................................189

12.9.2 Contact assignment of KB PB… connection cable for PROFIBUS/multiNet plus......................189

12.9.3 Technical data of interface connection cable .............................................................................190

12.9.4 Order codes for interface connection cables..............................................................................190

................................................................................................ 186

6BCL504

Leuze electronic

Table of contents

13 Maintenance ................................................................................................... 191

13.1 General maintenance information ................................................................................ 191

13.2 Repairs, servicing ..........................................................................................................191

13.3 Disassembling, packing, disposing .............................................................................191

14 Appendix ........................................................................................................ 192

14.1 Declaration of conformity ............................................................................................. 192

14.2 ASCII character set ........................................................................................................193

14.3 Barcode samples ........................................................................................................... 197

14.3.1 Module 0.3................................................................................................................................. 197

14.3.2 Module 0.5................................................................................................................................. 198

Leuze electronic BCL 504

Figures and tables

Figure 2.1: Attachment of the stick-on labels with warning notices at the BCL 504i ................................. 15

Figure 3.1: Connections of the BCL 504i .................................................................................................. 17

Figure 4.1: Line scanner, line scanner with deflection mirror and oscillating-mirror scanner.................... 21

Figure 4.2: Possible barcode orientation................................................................................................... 23

Figure 4.3: Device construction................................................................................................................. 24

Figure 4.4: Deflection principle for the line scanner .................................................................................. 25

Figure 4.5: Deflection principle for the line scanner with oscillating mirror add-on ................................... 26

Figure 4.6: Principle arrangement for omnidirectional reading ................................................................. 27

Figure 4.7: PROFIBUS DP........................................................................................................................ 28

Figure 4.8: External parameter memory ................................................................................................... 29

Figure 4.9: Reflector arrangement for autoReflAct ................................................................................... 30

Table 5.1: Specifications of the BCL 504i line scanners without heating ................................................ 32

Table 5.2: Specifications of the BCL 504i oscillating-mirror scanners without heating............................ 34

Table 5.3: Specifications of the BCL 504i deflection-mirror scanners without heating............................ 34

Table 5.4: Specifications of the BCL 504i line scanners with heating ..................................................... 36

Table 5.5: Specifications of the BCL 504i oscillating-mirror scanners with heating................................. 36

Table 5.6: Specifications of the BCL 504i deflection-mirror scanners with heating................................. 37

Figure 5.1: Dimensioned drawing BCL 504i line scanner S…102 ............................................................ 38

Figure 5.2: Dimensioned drawing BCL 504i deflection-mirror scanner S…100........................................ 39

Figure 5.3: Dimensioned drawing BCL 504i oscillating-mirror scanner O…100 ....................................... 40

Table 5.7: Type overview BCL 504i......................................................................................................... 41

Figure 5.4: The most important characteristics of a barcode .................................................................... 42

Figure 5.5: Zero position of the reading distance ...................................................................................... 43

Table 5.8: 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)................. 48

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

8BCL504

Leuze electronic

Figures and tables

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

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 504i .................................................................................................. 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 504i ................................................................................................... 66

Figure 6.5: Total reflection – line scanner ................................................................................................. 67

Figure 6.6: Total reflection – BCL 504i 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 504i .................................................................................................. 71

Table 7.1: Pin assignment PWR ..............................................................................................................72

Figure 7.1: Switching input connection diagram SWIO_3 and SWIO_4 ................................................... 73

Figure 7.2: Switching output connection diagram SWIO_3 / SWIO_4 ...................................................... 73

Table 7.2: Pin assignments of SERVICE – USB interface....................................................................... 74

Table 7.3: Pin assignment SW IN/OUT.............................................................................................

Figure 7.3: Switching input connection diagram SWIO_1 and SWIO_2 ................................................... 75

Figure 7.4: Switching output connection diagram SWIO_1 / SWIO_2 ...................................................... 76

Table 7.4: Pin assignment HOST / BUS IN BCL 504i.............................................................................. 76

Table 7.5: Pin assignment BUS OUT....................................................................................................... 77

Table 7.6: Line lengths and shielding....................................................................................................... 77

Figure 8.1: Structure of the control panel ..................................................................................................78

Table 8.1: Parameter handling submenu ................................................................................................. 83

Table 8.2: Decoder table submenu.......................................................................................................... 84

Table 8.3: Digital SWIO submenu............................................................................................................ 87

Table 8.4: PROFIBUS submenu .............................................................................................................. 90

Figure 9.1: Connecting the SERVICE USB interface ................................................................................95

Figure 9.2: The start page of the webConfig tool ...................................................................................... 97

Figure 9.3: Module overview in the webConfig tool................................................................................... 98

Table 10.1: PROFIBUS bus-access processes .......................................................................................100

Table 10.2: PROFIBUS DP master and slave types................................................................................ 101

Table 10.3: Services for DPVM1 class 1 and slaves ............................................................................... 101

Table 10.4: Services for DPVM1 class 2 and slaves ............................................................................... 102

Figure 10.1: Connections of the BCL 504i ................................................................................................ 103

Table 10.5: "Common" Parameters.......................................................................................................... 108

....... 75

Leuze electronic BCL 504

Figures and tables

Table 10.6: Module overview................................................................................................................... 113

Table 10.7: Parameters for modules 1-4 ................................................................................................. 115

Table 10.8: Parameters for module 5 ...................................................................................................... 117

Table 10.9: Parameters for module 7 ...................................................................................................... 118

Table 10.10: Parameters for module 10 .................................................................................................... 119

Table 10.11: Output data for module 10 .................................................................................................... 119

Table 10.12: Parameters for module 11 .................................................................................................... 121

Table 10.13: Parameters for module 12 .................................................................................................... 123

Table 10.14: Input data for module 12....................................................................................................... 123

Table 10.15: Parameters for module 13 .................................................................................................... 124

Table 10.16: Input data for module 13....................................................................................................... 124

Table 10.17: Parameters for module 13 .................................................................................................... 125

Table 10.18: Input data for module 20....................................................................................................... 126

Table 10.19: Input data for modules 21 … 27............................................................................................ 128

Table 10.20: Parameters for module 30 .................................................................................................... 130

Table 10.21: Input data for module 31....................................................................................................... 131

Table 10.22: Input data for module 32....................................................................................................... 131

Table 10.23: Input data for module 33....................................................................................................... 132

Table 10.24: Input data for module 34...........................................................................................

Table 10.25: Input data for module 35....................................................................................................... 133

Table 10.26: Input data for module 36....................................................................................................... 133

Table 10.27: Input data for module 37....................................................................................................... 134

Table 10.28: Input data for module 38....................................................................................................... 134

Table 10.29: Input data for module 39....................................................................................................... 135

Table 10.30: Input data for module 40....................................................................................................... 135

Table 10.31: Input data for module 41....................................................................................................... 136

Table 10.32: Parameters for module 50 .................................................................................................... 137

Table 10.33: Parameters for module 51 .................................................................................................... 139

Table 10.34: Parameters for module 52 .................................................................................................... 140

Table 10.35: Parameters for module 53 .................................................................................................... 141

Table 10.36: Parameters for module 54 .................................................................................................... 144

Table 10.37: Parameters for module 55 .................................................................................................... 146

Table 10.38: Input data for module 60....................................................................................................... 147

Table 10.39: Output data for module 60 .................................................................................................... 147

Table 10.40: Parameters for module 61 .................................................................................................... 148

Table 10.41: Parameters for module 62 .................................................................................................... 149

Table 10.42: Input data for module 63....................................................................................................... 150

Table 10.43: Output data for module 63 ..........................................................................................

Table 10.44: Parameters for module 64 .................................................................................................... 151

Table 10.45: Parameters for module 65 .................................................................................................... 152

Figure 10.2: Example 1: Start-up delay > 0 and switch-on time = 0 ......................................................... 153

Figure 10.3: Example 2: Start-up delay > 0 and switch-on time > 0 ......................................................... 153

Figure 10.4: Example 3: Start-up delay >0 Switch-off signal prior to lapsing of the start-up delay........... 154

............ 132

.......... 150

10 BCL 504

Leuze electronic

Figures and tables

Figure 10.5: Start-up delay in input mode ................................................................................................. 155

Figure 10.6: Switch-on time in input mode................................................................................................ 156

Figure 10.7: Switch-off delay in input mode .............................................................................................. 156

Table 10.46: Switch-on/switch-off functions............................................................................................... 157

Table 10.47: Input functions....................................................................................................................... 157

Table 10.48: Parameters for module 70 – Input/Output 1.......................................................................... 158

Table 10.49: Parameters for module 71 – Input/Output 2.......................................................................... 160

Table 10.50: Parameters for module 72 – Input/Output 3.......................................................................... 162

Table 10.51: Parameters for module 73 – Input/Output 4.......................................................................... 164

Table 10.52: Input data for module 74 Input/output status and control...................................................... 166

Table 10.53: Output data for module 74 Input/output status and control ................................................... 167

Table 10.54: Parameters for module 80..................................................................................................... 169

Table 10.55: Parameters for module 81 – Reference code comparison.................................................... 170

Table 10.56: Parameters for module 82 – Reference code comparison.................................................... 172

Table 10.57: Parameter module 83 – Reference code comparison pattern .............................................. 174

Table 10.58: Parameter module 84 – Reference code comparison pattern .............................................. 175

Table 10.59: Input data for module 90 – Status and control ......................................................................176

Table 10.60: Parameters for module 91 – AutoreflAct ............................................................................... 177

Table 10.61: Parameters for module 92 – AutoControl.............................................................................. 178

Table 10.62: Input data for module 92 – AutoControl ................................................................................178

Table 10.63: Device parameters for example configuration 2.................................................................... 18

Table 11.1: General causes of errors....................................................................................................... 183

Table 11.2: Interface error........................................................................................................................ 183

Table 12.1: Type overview BCL 504i ....................................................................................................... 186

Table 12.2: Terminating resistor for the BCL 504i ................................................................................... 187

Table 12.3: Connectors for the BCL 504i................................................................................................. 187

Table 12.4: Cables for the BCL 504i........................................................................................................ 187

Table 12.5: External parameter memory for the BCL 504i ...................................................................... 187

Table 12.6: Mounting devices for the BCL 504i ....................................................................................... 187

Table 12.7: PWR cables for the BCL 504i ............................................................................................... 188

Figure 12.8: Cable structure of PROFIBUS/multiNet plus connection cable............................................. 189

Table 12.9: Bus connection cables for the BCL 504i ............................................................................... 190

Figure 14.1: Barcode sample labels (module 0.3)..................................................................................... 197

Figure 14.2: Barcode sample labels (module 0.5)..................................................................................... 198

Leuze electronic BCL 504

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.

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 192.

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.

12 BCL 504

series is "UL LISTED" according to American and Canadian safety standards,

LISTED

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 explosive atmospheres

• operation for medical purposes

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

Leuze electronic BCL 504

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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 504i at persons!

When mounting and aligning the BCL 504i, avoid reflections of the laser beam off reflective surfaces!

The BCL 504i 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 504i 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!

14 BCL 504

Leuze electronic

Safety notices

BCL 504

Line scanner

BCL 504

with oscillating/deflection mirror

A Included stick-on labels B Aperture label C Name plate

The housing of the BCL 504i 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 BCL 504

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 504i, attach them instead in the immediate vicinity of the BCL 504i in such a way that it is not necessary to look into the laser beam when reading the notices!

Leuze electronic BCL 504

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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 BCL 504i. Detailed explanations for all listed points can be found throughout this technical description.

3.1 Mounting the BCL 504

There are two different types of mounting arrangements for the BCL 504i:

• 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.

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 504

• 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 504 on which interface is used.

• The correct time for data output. The BCL 504 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 504i 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 504i 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.

in relation to the barcode module width.

and the host system depending

should be positioned in such a way

16 BCL 504

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)

3.3 Electrical connectionBCL 504

The BCL 504i is equipped with four M12 plugs/sockets which are A- and B-coded.

SERVICE

GND D+ D-

BUS OUT

A (N)

B (P)

GND485

2134

N.C.

VOUT

HOST / BUS IN

A (N)

B (P)

Figure 3.1: Connections of the BCL 504

The voltage supply (10 … 30VDC) is connected at the PWR M 12 connector. Available at both the PWR M12 connector as well as at the SW IN/OUT M12 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. The PROFIBUS is connected via BUS IN, or, in the case of a continuing network, via

BUS OUT. If BUS OUT is not used, the PROFIBUS must be terminated at this point with an M12 terminating resistor (see chapter 12.3 "Accessory terminating resistor"). In the case of a stub cable, BUS OUT can remain open.

3.4 Starting the device

Connect the supply voltage +10 … 30VDC (typ. +24 V DC); the BCL 504i starts up and the barcode reading window appears on the display:

SW IN/OUT

SWIO_1

SWIO_2

N.C.

GND

PWR

SWIO_3

GND VIN

SWIO_4

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As a first step, you need to set the device address of the BCL 504i.

Leuze electronic BCL 504

By default, parameter enabling is deactivated and you cannot 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 93.

Fast commissioning / operating principle

3.4.1 Setting the device address on the display

The display of the BCL 504i possesses an important function for setting the PROFIBUS address. The PROFIBUS address is set here, i.e. the respective station number of the network device.

Notice!

The address setting can only be performed via the display if parameter enabling is active. Information on this topic can be found in chapter "Parameter enabling" on page 93.

The set address must be > ≥0 and < 126. Each network device is thereby automatically informed that it is a slave on the PROFIBUS with its specific address and that it is initialised and queried by the PLC.

The PROFIBUS permits an address range from 0 to 126. Address 126 must not be used for data communication. It may only be used temporarily for commissioning. The default address is 126.

The address must be assigned individually for each barcode reader of type BCL 504 can be performed by making entries on the display or with the webConfig tool.

Notice!

The BCL 504i does not permit address assignment via the PROFIBUS!

To set the address via the display, proceed as follows: In the main menu, use the buttons to select the Parameter menu and use the enter

button to activate the Parameter menu. The following screen appears:

; this

Parameter 1

Parameter handling Decoder table Digital SWIO PROFIBUS

In the Parameter menu, use the buttons to select the PROFIBUS menu item.

Press the enter button to enter the PROFIBUS menu.

PROFIBUS

o PROFIBUS address

Press the enter button again to enter the menu for setting the PROFIBUS address.

PROFIBUS address

12|

<-|0123456789 save Standard ----- Unit 126 | |

Use the and buttons to set the desired PROFIBUS address. An accidental, incorrect entry can be corrected by selecting Then use the buttons to select save and save the set PROFIBUS address by pressing .

18 BCL 504

<-| and then pressing .

Leuze electronic

After saving the PROFIBUS address, the BCL 504i performs a restart and then returns to

operation with the barcode reading menu.

In the upper right part of this display, you can check the address which you set.

Notice!

Permissible values for the PROFIBUS address are 0 … 125. Make certain that a different PROFIBUS address is assigned to each PROFIBUS participant.

All other parameters required for the reading task, such as setting the code type and number of digits, etc., are set using the engineering tool of the PLC with the aid of the various available modules (see chapter 10.4).

3.5 BCL 504i on the PROFIBUS

Install the GSD file associated with the BCL 504i in the PROFIBUSmanager of your control.

Activate the desired modules (at least module 10 and one of the modules 21 … 27).

Store the slave address for the BCL 504i in the PROFIBUSmanager. Ensure that the address is the same as the address configured in the device.

You can find further information beginning on page 106.

Fast commissioning / operating principle

Leuze electronic BCL 504

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Fast commissioning / operating principle

3.6 Barcode reading

With the aid of the "Action menu", you can instruct the BCL 504i 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").

20 BCL 504

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.

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 504

series offer optimum connection to the primary host system.

-> Plug-and-Play fieldbus coupling and easy net-

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.

22 BCL 504

series make available the

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

With the BCL 504 The BCL 504

the reading field. This opens a time window ("reading gate") in the BCL 504 process during which the barcode reader has time to detect and decode a barcode.

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 504 nosis 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 504 isation 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 504 PLC.

System, warning and error messages provide assistance in set-up/troubleshooting during commissioning and read operation.

, configuration is generally performed with the aid of the GSD file.

needs a suitable activation to start a read process as soon as an object is in

for the read

collects additional useful pieces of data for diag-

as well as for visual-

or external devices, such as a

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Leuze electronic BCL 504

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

24 BCL 504

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

Leuze electronic BCL 504

TNT 35/7-24V

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 504 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.

can also scan

Figure 4.5: Deflection principle for the line scanner with oscillating mirror add-on

26 BCL 504

Leuze electronic

4.4.3 Omnidirectional reading

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

Leuze electronic BCL 504

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+ 172 hidden pages

Leuze BCL504i TECHNICAL DESCRIPTION

Specifications and Main Features

Frequently Asked Questions

User Manual

1 General information

1.1 Explanation of symbols

1.2 Declaration of conformity

2 Safety notices

2.1 General safety notices

Documentation

Safety regulations

Repair

2.2 Safety standards

2.3 Approved purpose

Areas of application

2.4 Working safely

Safety regulations

Qualified personnel

3 Fast commissioning / operating principle

3.2 Device arrangement and selection of the mounting location

3.4 Starting the device

3.4.1 Setting the device address on the display

3.5 BCL 504i on the PROFIBUS

3.6 Barcode reading

4 Device description

4.1 About the barcode readers of the BCL 500i series

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

General information

4.3 Device construction

4.4 Reading techniques

4.4.1 Line scanner (single line)

Areas of application of the line scanner

4.4.2 Line scanner with oscillating mirror

Areas of application of the line scanner with oscillating mirror

4.4.3 Omnidirectional reading