Leuze BCL 604i Operating Instructions
BCL 604i
Bar Code Reader
EN 2015/04 - 50129186
We reserve the right to
make technical changes
Original operating instructions
1 About this document. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Used symbols and signal words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 Foreseeable misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 Competent persons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4 Exemption of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.5 Laser safety notices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.5.1 Laser safety notices– laser class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 Device description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.1 Device overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2 Performance characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3 Device construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.4 Connection technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.5 Display elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.5.1 Structure of the control panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.5.2 Status display and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.5.3 LED indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.6 Operational controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.7 External parameter memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.1 autoReflAct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.2 autoConfig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5 Reading techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.1 Line scanner (single line). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.2 Line scanner with oscillating mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.3 Omnidirectional reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6 Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.1 Device arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.1.1 Selecting a mounting location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.1.2 Avoiding total reflection – Line scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.1.3 Avoiding total reflection – oscillating-mirror scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.1.4 Possible read angles between device and bar code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.2 Installing the external parameter memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.2 PWR – Voltage supply and switching inputs/outputs 3 and 4 . . . . . . . . . . . . . . . . . . . . . . 29
7.3 SERVICE – USB interface (type A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.4 SW IN/OUT – Switching input/switching output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.5 HOST / BUS IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.6 BUS OUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.7 PROFIBUS termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7.8 Cable lengths and shielding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8 Menu description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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8.1 The main menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8.2 Parameter menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8.3 Language selection menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8.4 Service menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8.5 Actions menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8.6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
9 Commissioning – Leuze electronic webConfig tool . . . . . . . . . . . . . . . . . . . . . . 45
9.1 Connecting the service USB interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9.2.1 System requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9.2.2 Installing the USB driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9.3 Starting the webConfig tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9.4 Short description of the webConfig tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
9.5 Module overview in the Configuration menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
10 Starting up the device - Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
10.1 General information on the PROFIBUS implementation . . . . . . . . . . . . . . . . . . . . . . . . . . 48
10.1.1Communication profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
10.1.2Bus-access protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
10.1.3Device types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
10.1.4Expanded DP functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
10.1.5Automatic baud rate detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
10.2 Measures to be performed prior to the initial commissioning . . . . . . . . . . . . . . . . . . . . . . 49
10.3 Setting the address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
10.3.1Setting the device address on the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
10.4 Commissioning via the PROFIBUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
10.4.1General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
10.4.2Preparing the control system for consistent data transmission . . . . . . . . . . . . . . . . . . . . . 51
10.4.3General information on the GSD file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
10.4.4Permanently defined parameters/device parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
10.5 Overview of the project modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
10.6 Decoder modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
10.6.1Modules 1-4 – Code table extensions 1 to 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
10.6.2Module 5 – Code type features (symbology) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
10.6.3Module 7 – Code reconstruction technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
10.7 Control modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
10.7.1Module 10 – Activations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
10.7.2Module 11 – Reading gate control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
10.7.3Module 12 – Multi-label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
10.7.4Module 13 – Fragmented read result. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
10.7.5Module 14 – Interlinked read result . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
10.8 Result Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
10.8.1Module 20 – Decoder state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
10.8.2Modules 21-27 – Decoding result . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
10.8.3Module 30 – Data formatting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
10.8.4Module 31 – Reading gate number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
10.8.5Module 32 – Reading gate time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
10.8.6Module 33 – Code position . . . . . . . . . . . . . . . .
10.8.7Module 34 – Reading reliability (equal scans) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
10.8.8Module 35 – Bar code length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
10.8.9Module 36 – Scans with information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
10.8.10Module 37 – Decoding quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
10.8.11Module 38 – Code direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
10.8.12Module 39 – Number of digits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
10.8.13Module 40 – Code type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
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10.8.14Module 41 – Code position in the swivel range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
10.9 Data Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
10.9.1Module 50 – Characteristics filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
10.9.2Module 51 – Data filtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
10.10 Identifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
10.10.1Module 52 – Segmentation according to the EAN process . . . . . . . . . . . . . . . . . . . . . . . 73
10.10.2Module 53 – Segmentation via fixed positions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
10.10.3Module 54 – Segmentation according to identifier and separator . . . . . . . . . . . . . . . . . . 76
10.10.4Module 55 – String handling parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
10.11 Device Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
10.11.1Module 60 – Device status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
10.11.2Module 61 – Laser control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
10.11.3Module 62 – Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
10.11.4Module 63 – Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
10.11.5Module 64 – Oscillating mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
10.11.6Module 65 – Deflection mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
10.12 Switching inputs/ outputs SWIO 1 … 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
10.12.1Parameters for operating as an output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
10.12.2Parameters for operating as an input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
10.12.3Switch-on and switch-off functions for operation as an output. . . . . . . . . . . . . . . . . . . . . 85
10.12.4Input functions for operation as an input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
10.12.5Module 70 – Switching input/output SWIO1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
10.12.6Module 71 – Switching input/output SWIO2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
10.12.7Module 72 – Switching input/output SWIO3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
10.12.8Module 73 – Switching input/output SWIO4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
10.12.9Module 74 – SWIO status and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
10.13 Data output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
10.13.1Module 80 – Sorting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
10.14 Reference code comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
10.14.1Module 81 – Reference code comparator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
10.14.2Module 82 – Reference code comparator 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
10.14.3Module 83 – Reference code comparison pattern 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
10.14.4Module 84 – Reference code comparison pattern 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
10.15 Special Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10.15.1Module 90
10.15.2Module 91 – AutoReflAct (automatic reflector activation) . . . . . . . . . . . . . . . . . . . . . . . . 98
10.15.3Module 92 – AutoControl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
10.16 Example configuration: Indirect activation via the PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
10.16.1Task . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
10.16.2Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
10.17 Sample configuration: Direct activation via the switching input . . . . . . . . . . . . . . . . . . . . 100
10.17.1Task . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
10.17.2Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
– Status and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
. . . 97
11 Care, maintenance and disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
11.1 Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
11.2 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
11.3 Disposing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
12 Diagnostics and troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
12.1 General causes of errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
12.2 Interface errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
13 Service and support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
13.1 What to do should servicing be required? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Leuze electronic BCL 604i 5
14 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
14.1 General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
14.1.1 Line scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
14.1.2Oscillating-mirror scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
14.2 Dimensioned drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
14.3 Dimensioned drawings: Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
14.4 Reading field curves / optical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
14.5 Reading field curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
14.5.1Medium Density (M) - optics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
14.5.2Low Density (F) - optics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
15 Ordering information and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
15.1 Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
15.2 Type overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
15.3 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
16 EC Declaration of Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
17 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
17.1 ASCII character set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
17.2 Bar code samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
17.2.1Module 0.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
17.2.2Module 0.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Leuze electronic BCL 604i 6
1 About this document
1.1 Used symbols and signal words
Table 1.1: Warning symbols and signal words
Symbol indicating dangers to persons
NOTICE Signal word for property damage
Indicates dangers that may result in property damage if the measures for danger avoidance are not followed.
Table 1.2: Other symbols
Symbol for tips
Text passages with this symbol provide you with further information.
About this document
Table 1.3: Terms and abbreviations
BCL Bar code reader
CRT Code reconstruction technology
Symbols for action steps
Text passages with this symbol instruct you to perform actions.
Leuze electronic BCL 604i 7
2 Safety
This sensor was developed, manufactured and tested in line with the applicable safety standards. It corresponds to the state of the art.
2.1 Intended use
The device is designed as a stationary high-speed scanner with integrated decoder for all common bar
codes for automatic object detection.
Areas of application
The device is specially designed for the following areas of application:
• Object identification on fast-moving conveyor lines
• Omnidirectional reading
CAUTION
Comply with conditions and regulations!
Observe the locally applicable legal regulations and the rules of the employer's liability insurance asso-
ciation.
Safety
2.2 Foreseeable misuse
Any use other than that defined under “Intended use” or which goes beyond that use is considered
improper use.
In particular, use of the device is not permitted in the following cases:
• Rooms with explosive atmospheres
• Circuits relevant to safety
• For medicinal purposes
CAUTION
Do not modify or otherwise interfere with the device.
Do not carry out modifications or otherwise interfere with the device.
The device must not be tampered with and must not be changed in any way.
The device must not be opened. There are no user-serviceable parts inside.
Repairs must only be performed by Leuze electronic GmbH + Co. KG.
2.3 Competent persons
Connection, mounting, commissioning and adjustment of the device must only be carried out by competent
persons.
Prerequisites for competent persons:
• They have a suitable technical education.
• They are familiar with the rules and regulations for occupational safety and safety at work.
• They are familiar with the technical description of the device.
• They have been instructed by the responsible person on the mounting and operation of the device.
Certified electricians
Electrical work must be carried out by a certified electrician.
Due to their technical training, knowledge and experience as well as their familiarity with relevant stan-
dards and regulations, certified electricians are able to perform work on electrical systems and independently detect possible dangers.
In Germany, certified electricians must fulfill the requirements of accident-prevention regulations BGV A3
(e.g. electrician foreman). In other countries, there are respective regulations that must be observed.
Leuze electronic BCL 604i 8
2.4 Exemption of liability
Leuze electronic GmbH + Co. KG is not liable in the following cases:
• The device is not being used properly.
• Reasonably foreseeable misuse is not taken into account.
• Mounting and electrical connection are not properly performed.
• Changes (e.g., constructional) are made to the device.
2.5 Laser safety notices
2.5.1 Laser safety notices– laser class 2
ATTENTION, LASER RADIATION – LASERCLASS2
Never look directly into the beam!
The device fulfills the IEC 60825-1:2007 (EN 60825-1:2007) requirements for a product in laser class 2
as well as the U.S. 21 CFR 1040.10 regulations with deviations corresponding to “Laser Notice No. 50”
from June 24th, 2007.
Never look directly into the laser beam or in the direction of reflecting laser beams.
If you look into the beam path over a longer time period, there is a risk of injury to the retina.
Do not point the laser beam of the device at persons!
Interrupt the laser beam using a non-transparent, non-reflective object if the laser beam is accidentally
directed towards a person.
When mounting and aligning the device, avoid reflections of the laser beam off reflective surfaces!
CAUTION! The use of operating or adjusting devices other than those specified here or carrying out
of differing procedures may lead to dangerous exposure to radiation.
Adhere to the applicable legal and local regulations regarding protection from laser beams.
The device must not be tampered with and must not be changed in any way.
There are no user-serviceable parts inside the device.
Repairs must only be performed by Leuze electronic GmbH + Co. KG.
Safety
CAUTION
Affix laser information and warning signs!
Laser information and warning signs attached to the device(see figure 2.1). Also included with the device
are self-adhesive laser warning and laser information signs (stick-on labels) in multiple languages (see
figure 2.3).
Affix the laser information sheet to the device in the language appropriate for the place of use.
When using the device in the US, use the stick-on label with the “Complies with 21 CFR 1040.10”
notice.
Affix the laser information and warning signs near the device if no signs are attached to the device (e.g.
because the device is too small) or if the attached laser information and warning signs are concealed
due to the installation position.
Affix the laser information and warning signs so that they are legible without exposing the reader to the
laser radiation of the device or other optical radiation.
Leuze electronic BCL 604i 9
1 Laser aperture
LASER RADIATION
DO NOT STARE INTO BEAM
CLASS 2 LASER PRODUCT
EN 60825-1:2007
Maximum Output (peak):
Pulse duration:
Wavelength:
2 mW
<150 µs
405 nm
AVOID EXPOSURE – LASER RADIATION
IS EMITTED FROM THIS APERTURE
2 3
1
LASER RADIATION
DO NOT STARE INTO BEAM
CLASS 2 LASER PRODUCT
EN 60825-1:2007
Maximum Output (peak):
Pulse duration:
Wavelength:
2 mW
<150 μs
405 nm
AVOID EXPOSURE – LASER RADIATION
IS EMITTED FROM THIS APERTURE
2 3
1
2 Laser warning sign
3 Laser information sign with laser parameters
Figure 2.1: Laser aperture, laser warning and information signs - line scanner
Safety
1 Laser aperture
2 Laser warning sign
3 Laser information sign with laser parameters
Figure 2.2: Laser aperture, laser warning and information signs - oscillating-mirror scanner
Leuze electronic BCL 604i 10
Safety
AVOID EXPOSURE – LASER RADIATION
IS EMITTED FROM THIS APERTURE
EXPOSITION DANGEREUSE – UN RAYONNEMENT
LASER EST ÉMIS PAR CETTE OUVERTURE
LASERSTRAHLUNG
NICHT IN DEN STRAHL BLICKEN
LASER KLASSE 2
DIN EN 60825-1:2008-05
Max. Leistung (peak):
Impulsdauer:
Wellenlänge:
RADIAZIONE LASER
NON FISSARE IL FASCIO
APARRECCHIO LASER DI CLASSE 2
EN 60825-1:2007
Potenza max. (peak):
Durata dell'impulso:
Lunghezza d'onda:
LASER RADIATION
DO NOT STARE INTO BEAM
CLASS 2 LASER PRODUCT
EN 60825-1:2007
Maximum Output (peak):
Pulse duration:
Wavelength:
RAYONNEMENT LASER
NE PAS REGARDER DANS LE FAISCEAU
APPAREIL À LASER DE CLASSE 2
EN 60825-1:2007
Puissance max. (crête):
Durée d`impulsion:
Longueur d`onde:
RADIACIÓN LÁSER
NO MIRAR FIJAMENTE AL HAZ
PRODUCTO LÁSER DE CLASE 2
EN 60825-1:2007
Potencia máx. (peak):
Duración del impulso:
Longitud de onda:
RADIAÇÃO LASER
NÃO OLHAR FIXAMENTE O FEIXE
EQUIPAMENTO LASER CLASSE 2
EN 60825-1:2007
Potência máx. (peak):
Período de pulso:
Comprimento de onda:
LASER RADIATION
DO NOT STARE INTO BEAM
CLASS 2 LASER PRODUCT
IEC 60825-1:2007
Complies with 21 CFR 1040.10
Maximum Output (peak):
Pulse duration:
Wavelength:
䉏⏘戟⺓
▎䦃展⏘㧮
伊䉏⏘ℶ❐
GB7247.1-2012
㦏⮶戢⒉᧤⽿⋋᧥
厘⑁㖐兼㢅梃
㽱栎
2 mW
<150 µs
405 nm
2 mW
<150 µs
405 nm
2 mW
<150 µs
405 nm
2 mW
<150
µ
s
405 nm
2 mW
<150 µs
405 nm
2 mW
<150 µs
405 nm
2 mW
<150 µs
405 nm
2 mW
<150 µs
405 nm
50127630
Figure 2.3: Laser warning and information signs – supplied stick-on labels
Leuze electronic BCL 604i 11
3 Device description
2
1
3.1 Device overview
Bar code readers of the BCL 600i series are high-speed scanners with integrated decoder for all
commonly used bar codes, e.g. 2/5 Interleaved, Code 39, Code 128, EAN 8/13 etc., as well as codes from
the GS1 DataBar family.
Bar code readers of the BCL 600i series are available in various optics models and as line scanners and
oscillating mirrors.
Device description
1 Line scanner
2 Oscillating-mirror scanner
Figure 3.1: Line scanner 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 bar
code readers of the BCL 600i series are 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-IO, Ether net TCP/IP / UDP and Ethernet/IP) of the BCL 600i series bar
code readers offer optimum connection to the superior host system.
3.2 Performance characteristics
• Integrated fieldbus connectivity = i -> Plug-and-Play fieldbus coupling and easy networking
• Numerous interface variants facilitate connection to the superior systems
• RS 232, RS 422 as well as with integrated multiNet plus master
• RS 485 and multiNet plus slave
• alternatively, various fieldbus systems, such as
PROFINET-IO
Ethernet TCP/IP
Ethernet /IP
Ethernet
PROFIBUS DP
Leuze electronic BCL 604i 12
Device description
• Integrated code reconstruction technology (CRT) enables the identification of soiled or damaged bar
codes
• Maximum depth of field and reading distances from 400 mm to 1450 mm
• Large optical opening angle and, thus, large reading field width
• High scanning rate of 800 / 1000 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 diagnostics functions
• M12 connections with Ultra-Lock ™ technology
• Four freely programmable switching inputs/outputs for the activation or signaling of states
• Automatic monitoring of the read quality with autoControl
• Automatic recognition and setting of the bar code type using autoConfig
• Reference code comparison
• Heavy-duty housing of degree of protection IP 65
Leuze electronic BCL 604i 13
3.3 Device construction
1
1
2
3
5
6
4
66
Device description
1 Reading window
2 Control panel with display, LEDs and buttons
3 M12 connection technology
4 USB interface
5 Dovetail mounting
6 M4 mounting thread
Figure 3.2: Device construction
Leuze electronic BCL 604i 14
3.4 Connection technology
3 4 5
2
1
3
2
1
4
5
6
The bar code readers are connected using variously coded M12 connectors. This ensures unique connection assignments.
The additional USB interface is used for configuring the device.
For the locations of the individual device connections, please refer to the device detail shown below.
1 Service, USB socket, type A
2 SW In/Out, M12 socket (A-coded)
3 Bus Out, M12 socket (D-coded)
4 Host/Bus In, M12 socket (D-coded)
5 PWR, M12 plug (A-coded)
Figure 3.3: Location of the electrical connections
Device description
3.5 Display elements
3.5.1 Structure of the control panel
1LED PWR
2 LED NET
3 Navigation buttons
4 Escape button
5 Enter button
6 Display
Figure 3.4: Structure of the control panel
Leuze electronic BCL 604i 15
3.5.2 Status display and operation
Indicators in the display
le 3.1: Status displays of the switching inputs/outputs
Tab
Device description
IO1
Switching input or switching output 1 active (function dependent on set configuration).
Default: Switching input with the “Reading gate activation” function
IO2 Switching input or switching output 2 active (function dependent on set configuration).
Default: Input with the “Teach-in” function
IO3 Switching input or switching output 3 active (function dependent on set configuration).
Default: Switching input with the “Reading gate activation” function
IO4 Switching input or switching output 4 active (function dependent on set configuration).
Default: Switching output with the “No read” function
ATT Warning (Attention)
ERR Internal device error (Error) -> The device must be sent in for inspection
Bar graph
The read quality is described on a scale of 0 - 100 %. The quality is evaluated based on the “Equal Scans”
of the read result configured in the bar code reader.
Table 3.2: Status display of the USB interface
USB The device is connected to a PC via the USB interface.
MS An external parameter memory is properly connected to the USB interface of the device.
Read result
The read bar code information is displayed.
3.5.3 LED indicators
PWR LED
Off Device OFF
Flashes green Device ok, initialization phase
Green, continuous light
• No supply voltage
• No bar code reading possible
• Voltage connected
• Self test running
• Initialization running
Device OK
• Bar code reading possible
• Self test successfully finished
• Device monitoring active
Leuze electronic BCL 604i 16
Device description
Orange, continuous light
Service mode
• Bar code reading possible
• Configuration via the USB service interface
• Configuration via the display
• No data on the host interface
Flashes red Device ok, warning set
• Bar code reading possible
• Temporary operating fault
Red, continuous
light
Device error / parameter enable
• No bar code reading possible
NET LED
Off No supply voltage
• No communication possible
• Profibus DP communication not initialized or inactive
Flashes green Initialization
• of the device, establishing communication
Green, continuous light
Operation OK
• Network mode ok
• Connection and communication to IO controller (PLC) established (data
exchange)
Flashes red Communication error
Red, continuous
Network error
light
3.6 Operational controls
Navigating within the menus
Use the navigation buttons to move through the menu. Activate the desired selection with the enter
button .
Press the escape button to move up one menu level.
When one of the buttons is actuated, the display illumination is activated for 10 min.
Setting values
Set the desired value with the navigation buttons and the enter button .
An accidental incorrect entry can be corrected by selecting the left arrow button and then pressing the
enter button.
Then use the navigation buttons to select save and save the set value by pressing the enter button.
Selecting options
Set the desired option with the navigation buttons and the enter button .
• Parameterization or configuration failed (parameter failure)
•IO error
• No data exchange
• No communication (protocol) to IO controller established (no data exchange)
ESC
Leuze electronic BCL 604i 17
3.7 External parameter memory
The optionally available external parameter memory – based on a USB memory stick (compatible with
version 1.1) – is housed in an external hood with integrated connectors which cover the USB service interface when installed (IP 65).
The external parameter memory makes it easy and reduces the time needed to replace a device on site
by providing a copy of the current parameter set of the device. This eliminates the need to configure the
exchanged device manually.
The delivery contents of the external parameter memory include the hood with integrated connectors with
unscrewable cover and the USB memory stick.
To mount, the cover of the service interface must be unscrewed. Then take the USB memory
stick and plug it into the USB connection on the device. Then, take the connector hood of the
USB memory stick and screw this over the plugged-in USB memory stick to the service interface
to close the system and ensure degree of protection IP 65.
Device description
Leuze electronic BCL 604i 18
4 Functions
General information
The integrated fieldbus connectivity = i contained in the bar code readers of the BCL 600i series facilitates
the use of identification systems which function without connection unit or gateways. The integrated
fieldbus interface considerably simplifies handling. The Plug-and-Play concept enables easy networking
and very simple commissioning: Directly connect the respective fieldbus and all configuration is performed
with no additional software.
For decoding bar codes, the bar code readers of the BCL 600i series make available the proven CRT
decoder with code reconstruction technology:
The proven code reconstruction technology (CRT) enables bar code readers of the BCL 600i series to
read bar codes with a small bar height, as well as bar codes with a damaged or soiled print image.
With the aid of the CRT decoder, bar codes can also be read without problem in other demanding situations, such as with a large tilt angle (azimuth angle or even twist angle).
Functions
Figure 4.1: Possible bar code orientation
With the BCL 604i, configuration is generally performed with the aid of the GSD file.
The device needs a suitable activation to start a read process as soon as an object is in the reading field.
This opens a time window (reading gate) in the device for the read process during which the bar code
reader has time to detect and decode a bar code.
In the basic setting, triggering takes place through an external reading cycle signal. Alternative activation
options include online commands via the host interface and the autoReflAct function. 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.
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 device collects additional useful pieces of data for diagnosis which can also be transmitted
to the host. The quality of the read operation can be inspected using the alignment mode which is integrated in the webConfig tool.
A multi-language display with buttons is used to operate the device as well as for visualization purposes.
Two LEDs provide additional optical information on the current operating state of the device.
Leuze electronic BCL 604i 19
The four freely configurable switching inputs/outputs SWIO 1 … SWIO 4 can be assigned various functions and control e.g. activation of the device or external devices, such as a PLC.
System, warning and error messages provide assistance in setup/troubleshooting during commissioning
and read operation.
4.1 autoReflAct
autoReflAct st a nds for automatic Reflector Activation and permits an activation without additional sensors.
This is achieved by directing the scanner with reduced scanning beam towards a reflector mounted behind
the conveyor path. As long as the scanner is targeted at the reflector, the reading gate remains closed. If,
however, the reflector is blocked by an object such as a container with a bar code label, the scanner activates the read procedure, and the label on the container is read. When the path from the scanner to the
reflector has cleared, the read procedure has completed and the scanning beam is reduced and again
directed onto the reflector. The reading gate is closed.
You will find a matching reflector in Accessories, and more are available on request.
Functions
Figure 4.2: Reflector arrangement for autoReflAct
The autoReflAct function uses the scanning beam to simulate a photoelectric sensor and thus permits an
activation without additional sensors.
Leuze electronic BCL 604i 20
4.2 autoConfig
With the autoConfig function, the device offers an extremely simple and convenient configuration option
to users who only want to read one code type (symbology) with one number of digits at a time.
After starting the autoConfig function via the display, switching input or from a superior control, it is sufficient to position a bar code label with the desired code type and number of digits in the reading field of the
device.
Afterward, bar codes with the same code type and number of digits are recognized and decoded.
The settings made via display or webConfig configuration tool push the parameters set in the
Profibus only temporarily into the background. They are overwritten during integration into the
Profibus or when the parameter enable is deactivated!
Device settings for operating the device on the Profibus are managed and configured exclusively
by the Profibus controller (PLC). Permanent changes must be carried out here!
For further information, see chapter 10 "Starting up the device - Configuration".
Functions
Leuze electronic BCL 604i 21
5 Reading techniques
5.1 Line scanner (single line)
A line (scan line) scans the label. Due to the opt. opening angle, the reading field width is dependent on
the read distance. Through the movement of the object, the entire bar code is automatically transported
through the scan line.
The integrated code reconstruction technology permits twisting of the bar code (tilt angle) within certain
limits. These are dependent on the transport speed, the scanning rate of the scanner and the bar code
properties.
Areas of application of the line scanner
The line scanner is used:
• when the bars of the bar code are printed in the conveying direction ('ladder arrangement').
• with bar codes having very short bar lengths.
• when the ladder code is turned out of the vertical position (tilt angle).
• when the reading distance is large.
Reading techniques
Figure 5.1: Deflection principle for the line scanner
5.2 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 device can also scan larger areas or spaces for
bar codes. The reading field height (and the scan line length useful for evaluation) depends on the reading
distance due to the optical opening angle of the oscillating mirror.
Leuze electronic BCL 604i 22
Reading techniques
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 bar code are printed perpendicular to the conveying direction (“picket fence
arrangement”).
• when reading stationary objects.
• when the bar code is turned out of the horizontal position.
• when the reading distance is large.
• when a large reading field (reading window) has to be covered.
Figure 5.2: Deflection principle for the line scanner with oscillating mirror add-on
5.3 Omnidirectional reading
In order to read arbitrarily oriented bar codes on an object, at least 2 bar code readers are necessary. If
the bar code is not printed over-square, i.e. bar length > code length, bar code readers with integrated code
reconstruction technology are necessary.
Figure 5.3: Principle arrangement for omnidirectional reading
Leuze electronic BCL 604i 23
6 Mounting
The bar code readers can be mounted in different ways:
• Using two M4x6 screws on the rear of the device or using four M4x6 screws on the bottom of the
device (see figure 3.2).
• Using a BT 56 mounting device on the two fastening grooves (see figure 14.3).
• Using a BT 59 mounting device on the two fastening grooves (see figure 14.4).
6.1 Device arrangement
6.1.1 Selecting a mounting location
In order to select the right mount
• Size, orientation, and position tolerance of the bar codes on the objects to be scanned.
• The reading field of the device in relation to the bar code module width.
• The resulting minimum and maximum reading distance from the respective reading field (see
chapter 14.4 "Reading field curves / optical data").
• The permissible cable lengths between the device and the host system depending on which interface
is used.
• The correct time for data output. The device should be positioned in such a way that, taking into consideration the time required for data processing and the conveyor belt speed, there is sufficient time
to e.g. initiate sorting operations on the basis of the read data.
• The display and control panel should be very visible and accessible.
• For configuring and commissioning with the webConfig tool, the USB interface should be easily
accessible.
• Maintaining the required environmental conditions (temperature, humidity).
• Possible soiling of the reading window due to liquids, abrasion by boxes, or packaging material residues.
• Lowest possible chance of damage to the device by mechanical collision or jammed parts.
• Possible extraneous light (no direct sunlight or sunlight reflected by the bar code).
Mounting
ing location, several factors must be considered:
With the line scanner, the beam exits the device parallel to the housing base; with the oscillating
mirror, the beam exits perpendicular to the housing base. The housing base is the black surface.
The best read results are obtained when:
• The device is mounted in such a way that the scanning beam is incident on the bar code at an angle
of inclination greater than ±10° … 15° to vertical.
• The reading distance lies in the middle area of the reading field.
• The bar code labels are of good print quality and have good contrast ratios.
• You do not use high-gloss labels.
• There is no direct sunlight.
6.1.2 Avoiding total reflection – Line scann
The bar code label must be positioned at an angle of inclination greater than ±10° … 15° from vertical in
order to avoid total reflection of the laser beam (see figure 6.1)!
Total reflection occurs whenever the laser light of the bar code reader is directly incident on the surface of
the bar code at an angle of 90°. The light directly reflected by the bar code may overload the bar code
reader and thereby cause non-readings!
er
Leuze electronic BCL 604i 24
1 Zero position
x
1
2
x
1
2
2Bar code
x Distance acc. to reading field curves
a ±10 … 15°
Figure 6.1: Total reflection – line scanner
6.1.3 Avoiding total reflection – oscillating-mirror scanner
For the device with oscillating mirror, the laser beam exits at an angle of 90° to vertical.
In addition, the swivel range of ±20° is to be taken into account.
This means that in order to be on the safe side and to avoid total reflection, the device with oscillating mirror
must be inclined upward or downward 20° … 30°!
Mounting
1 Zero position
2Bar code
x Distance acc. to reading field curves
a±25°
Figure 6.2: Total reflection – oscillating-mirror scanner
Leuze electronic BCL 604i 25
6.1.4 Possible read angles between device and bar code
The optimum alignment of th
e device is accomplished when the scan line scans the code bars almost at
a right angle (90°). All read angles that are possible between the scan line and bar code must be taken
account (see figure 6.3).
Mounting
a Azimuth angle (tilt)
b Inclination angle (pitch)
g Rotation angle (skew)
In order to avoid total reflection, the skew g should be greater than 10 °
Figure 6.3: Reading angle for the line scanner
6.2 Installing the external parameter memory
Remove the cover of the USB connection on the device.
Insert the USB memory stick into the USB connection and then cover it with the connector hood to
ensure degree of protection IP 65.
The USB memory stick can be inserted regardless of whether or not the device is connected to supply
voltage.
• After the USB memory stick has been inserted and supply voltage applied, the following message
appears on the display.
Memory stick connected: Export internal configuration?
Use the navigation buttons to select OK and activate with the enter button .
The configuration is now transferred to the external parameter memory and is from now on updated immediately when the configuration is changed via display or online commands.
• The display of MS under the device address indicates that the USB memory stick is correctly connected and functional.
Replacing a defective device
Uninstall the defective device.
Remove the external parameter memory from the defective device by unscrewing the protection hood.
Leuze electronic BCL 604i 26
Mounting
Mount the external parameter memory on the new device.
Install and start up the new device.
The following message appears on the display again:
• Memory stick connected: Export internal configuration?
Use the navigation buttons to select Cancel and activate with the enter button .
Make sure you select Cancel. Otherwise, the configuration in the external parameter memory is
lost!
The configuration is now imported from the external parameter memory and the device is immediately
operational without any further configuration.
Leuze electronic BCL 604i 27
7 Electrical connection
3 4 5
2
1
CAUTION
Do not open the device yourself under any circumstances! There is otherwise a risk of uncontrolled
emission of laser radiation from the device. The housing of the device contains no parts that need to
be adjusted or maintained by the user.
Before connecting the device, be sure that the supply voltage agrees with the value printed on the
name plate.
Connection of the device and cleaning must only be carried out by a qualified electrician.
Ensure that the functional earth (FE) is connected correctly. Unimpaired operation is only guaranteed
when the functional earth is connected properly.
If faults cannot be corrected, the device should be removed from operation and protected against pos-
sible commissioning.
CAUTION
For UL applications, use is only permitted in Class 2 circuits in accordance with the NEC (National Electric Code). The bar code readers are designed in accordance with safety class III for supply by PELV
(protective extra-low voltage with reliable disconnection).
Electrical connection
CAUTION
Degree of protection IP 65 is achieved only if the connectors and caps are screwed into place!
7.1 Overview
As a PROFIBUS participant, the device is equipped with four M12 plugs/sockets which are A- and Bcoded.
The voltage supply (PWR) as well as the four freely configurable switching inputs/outputs (SW IN/OUT and
PWR) are connected there.
The device is designed for use in PROFIBUS DP. An incoming DP IN - PROFIBUS DP is available as a
HOST / BUS IN interface for connecting to the PLC. An outgoing DP OUT - PROFIBUS DP is present as
another second physical BUS OUT interface for setting up the PROFIBUS DP network.
An USB connection is used as a SERVICE interface.
1 Service, USB socket, type A
2 SW In/Out, M12 socket (A-coded)
3 Bus Out, M12 socket (B-coded)
4 Host/Bus In, M12 socket (B-coded)
5 PWR, M12 plug (A-coded)
Figure 7.1: Connections of the device
Described in detail in the following are the individual connections and pin assignments.
Leuze electronic BCL 604i 28
7.2 PWR – Voltage supply and switching inputs/outputs 3 and 4
2
3
1
4
5
FE
Figure 7.2: PWR, M12 plug (A-coded)
Table 7.1: Pin assignments - PWR
Pin Name Comment
1 VIN Positive supply voltage +10 ... +30 V DC
2 SWIO_3 Configurable switching input / output 3
3 GND Negative supply voltage 0 V DC
4 SWIO_4 Configurable switching input / output 4
5 FE Functional earth
Electrical connection
Thread FE Functional earth (housing)
Supply voltage
CAUTION
For UL applications, use is only permitted in Class 2 circuits in accordance with the NEC (National Electric Code).
CAUTION
The BCL 604i bar code readers are designed in accordance with safety class III for supply by PELV
(protective extra-low voltage with reliable disconnection).
Connecting functional earth FE
Ensure that the functional earth (FE) is connected correctly. Unimpaired operation is only guaranteed
when the functional earth is connected properly. All electrical disturbances (EMC couplings) are discharged via the functional earth connection.
Switching input/output
The device is equipped with four freely programmable, opto-decoupled switching inputs and outputs
SWIO_1 … SWIO_4.
The switching inputs can be used to activate various internal functions of the device (decoding,
autoConfig, …). The switching outputs can be used to signal the state of the device and to implement
external functions independent of the superior control.
The two switching inputs/outputs SWIO_1 and SWIO_2 are located on the SW IN/OUT M12 socket (see
chapter 7.4). The other two (SWIO_3 and SWIO_4) of the four freely configurable switching inputs/outputs
are located on the PWR M12 plug.
In general, configuration of the bar code reader takes place on the PROFIBUS via the corre-
sponding GSD file. Alternatively, you can temporarily set the respective function as input or out-
put via the display or with the aid of the webConfig configuration tool for the purpose of testing
the respective functionality. After reconnecting to the PROFIBUS or after deactivating parameter
enabling, the parameter settings set by the PROFIBUS are again active!
The external wiring as switching input and switching output is described in the following. For the respective
function assignment to the switching inputs/outputs see chapter 10.
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Function as switching input
1
2
3
Electrical connection
1
2
3
1 Switching input
2 Switching output from controller (deactivated)
3 Switching input to controller
Figure 7.3: Switching input connection diagram SWIO_3 and SWIO_4
If you use a sensor with a standard M12 connector, please note the following:
Pins 2 and 4 must not be operated as switching outputs if sensors which function as inputs are also
connected to these pins.
If, for example, the inverted sensor output is connected to pin 2, and pin 2 of the bar code reader is, at
the same time, configured as an output (and not as an input), the switching output malfunctions.
CAUTION
The maximum input current must not exceed 8 mA!
Function as switching output
1 Switching output
2 Switching input from controller
3 Switching output to controller (deactivated)
Figure 7.4: Switching output connection diagram SWIO_3 / SWIO_4
NOTICE
Each configured switching output is short-circuit proof! Do not load the respective switching output of the
device with more than 60 mA at +10 … +30 V DC in normal operation!
By default, the two switching inputs/outputs SWIO_3 and SWIO_4 are configured so that switch-
ing input SWIO_3 activates the reading gate and switching output SWIO_4 switches on “No
Read”.
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7.3 SERVICE – USB interface (type A)
4
3
1
2
1
3
2
4
5
FE
Figure 7.5: Service, USB, type A
Table 7.2: Pin assignments of SERVICE – USB interface
Pin Name Comment
1 VB Positive supply voltage +5 V DC
2 D- Data -
3 D+ Data -
4 GND Ground
NOTICE
Maximum load of the +5 V DC supply voltage of the USB interface is 200 mA!
Ensure adequate shielding.
The entire interconnection cable must absolutely be shielded acc. to the USB specifications. Cable
length must not exceed 3 m.
Use the Leuze-specific USB service cable (see chapter 15 "Ordering information and accessories") for
the connection and use a service PC to configure.
Electrical connection
NOTICE
IP 65 is achieved only if the connectors and caps are screwed into place.
7.4 SW IN/OUT – Switching input/switching output
Figure 7.6: SW IN/OUT, M12 socket (A-coded)
Table 7.3: Pin assignment SW IN/OUT
Pin Name Comment
1 VOUT Voltage supply for sensors
(VOUT identical to VIN at PWR IN)
2SWIO_
1
3 GND GND for the sensors
Configurable switching input / output 1
4SWIO_
Configurable switching input / output 2
2
5 FE Functional earth
Leuze electronic BCL 604i 31
Thread FE Functional earth (housing)
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