15.1 Bar code samples ................................................................................................................. 64
Leuze electronic GmbH + Co. KGBCL 924
About this document
1About this document
1.1Used symbols and signal words
Tab.1.1: Warning symbols and signal words
Symbol indicating dangers to persons
Symbol indicating dangers from harmful laser radiation
Symbol indicating possible property damage
NOTESignal word for property damage
Indicates dangers that may result in property damage if the measures for
danger avoidance are not followed.
CAUTIONSignal word for minor injuries
Indicates dangers that may result in minor injury if the measures for danger
avoidance are not followed.
WARNINGSignal word for serious injury
Indicates dangers that may result in severe or fatal injury if the measures
for danger avoidance are not followed.
Tab.1.2: Other symbols
Symbol for tips
Text passages with this symbol provide you with further information.
Symbol for action steps
Text passages with this symbol instruct you to perform actions.
Symbol for action results
Text passages with this symbol describe the result of the preceding action.
Leuze electronic GmbH + Co. KGBCL 925
About this document
1.2Terms and abbreviations
Tab.1.3: Terms and abbreviations
BCLBar code reader
DNCThis PIN must not be connected
(Do Not Connect)
DTMSoftware device manager
(Device Type Manager)
EMCElectromagnetic compatibility
ENEuropean standard
FDTSoftware frame for management of device managers (DTM)
(Field Device Tool)
FEFunctional earth
GUIGraphical user interface
HIDDevice class for input devices with which users directly interact
(Human Interface Device)
NCThis pin is not contacted at the device
(Not Connected)
SELVSafe Extra Low Voltage
PLCProgrammable Logic Control
(corresponds to Programmable Logic Controller (PLC))
SW_INSwitching input
SW_OUTSwitching output
Leuze electronic GmbH + Co. KGBCL 926
Safety
2Safety
This bar code reader was developed, manufactured and tested in accordance with the applicable safety
standards. It corresponds to the state of the art.
2.1Intended use
Bar code readers of the BCL92 series are conceived as stationary scanners with integrated decoder for all
current bar codes used for automatic object detection.
Areas of application
Bar code readers of the BCL92 series are designed for the following areas of application:
• Automatic analyzers
• Robotics and automation technology
• Material flow
• Labeling and packaging machines
• For space-critical bar code reading tasks
• Applications with large reading field with small modules
CAUTION
Observe intended use!
The protection of personnel and the device cannot be guaranteed if the device is operated in a
manner not complying with its intended use.
Ä Only operate the device in accordance with its intended use.
Ä LeuzeelectronicGmbH+Co.KG is not liable for damages caused by improper use.
Ä Read these operating instructions before commissioning the device. Knowledge of the oper-
ating instructions is an element of proper use.
NOTICE
Comply with conditions and regulations!
Ä Observe the locally applicable legal regulations and the rules of the employer's liability insur-
ance association.
CAUTION
UL applications!
For UL applications, use is only permitted in LPS/Class 2 circuits in accordance with the NEC
(National Electric Code).
Leuze electronic GmbH + Co. KGBCL 927
Safety
2.2Foreseeable misuse
Any use other than that defined under "Intended use" or which goes beyond that use is considered improper use.
In particular, use of the device is not permitted in the following cases:
• in rooms with explosive atmospheres
• in circuits which are relevant to safety
• for medical purposes
NOTICE
Do not modify or otherwise interfere with the device!
Ä Do not carry out modifications or otherwise interfere with the device. The device must not be
tampered with and must not be changed in any way.
Ä The device must not be opened. There are no user-serviceable parts inside.
Ä Repairs must only be performed by Leuze electronic GmbH + Co. KG.
NOTICE
Ä To increase the decoding reliability, it is recommended that only the actually needed code
types be enabled.
Ä If there are very high requirements on reading reliability, the use of additional processes is
recommended, e.g.:
ð Device side: check digits, multiple evaluation by setting Equal Scans to min. ≥2
ð Application side: reading moving codes
ð System side: plausibility checks of the bar code information
2.3Competent persons
Connection, mounting, commissioning and adjustment of the device must only be carried out by competent
persons.
Prerequisites for competent persons:
• They have a suitable technical education.
• They are familiar with the rules and regulations for occupational safety and safety at work.
• They are familiar with the operating instructions for the device.
• They have been instructed by the responsible person on the mounting and operation of the device.
Certified electricians
Electrical work must be carried out by a certified electrician.
Due to their technical training, knowledge and experience as well as their familiarity with relevant standards
and regulations, certified electricians are able to perform work on electrical systems and independently detect possible dangers.
In Germany, certified electricians must fulfill the requirements of accident-prevention regulations DGUV
(German Social Accident Insurance) provision 3 (e.g. electrician foreman). In other countries, there are respective regulations that must be observed.
Leuze electronic GmbH + Co. KGBCL 928
Safety
1
1
2.4Disclaimer
LeuzeelectronicGmbH+Co.KG is not liable in the following cases:
• The device is not being used properly.
• Reasonably foreseeable misuse is not taken into account.
• Mounting and electrical connection are not properly performed.
• Changes (e.g., constructional) are made to the device.
2.5Laser safety notices
ATTENTION
LASER RADIATION – CLASS 1 LASER PRODUCT
The device satisfies the requirements of IEC/EN 60825-1:2014 safety regulations for a product
of laser class1 and complies with 21 CFR 1040.10 except for conformance with IEC 60825-1
Ed. 3., as described in Laser Notice No. 56, dated May 8, 2019.
Ä Observe the applicable statutory and local laser protection regulations.
Ä The device must not be tampered with and must not be changed in any way.
There are no user-serviceable parts inside the device.
Repairs must only be performed by Leuze electronic GmbH + Co. KG.
NOTICE
Laser aperture!
The glass optics cover is the only aperture through which laser radiation may be observed on
this product.
1 Laser aperture
Fig.2.1: Laser aperture
Leuze electronic GmbH + Co. KGBCL 929
Device description
3Device description
3.1Device overview
3.1.1
3.1.2
About the bar code reader
The bar code reader is a laser scanner with integrated decoder for all commonly used bar codes, e.g.
2/5Interleaved, Code39, Code128, EAN etc.
• The reading field is optimized for the reading of sample tubes, reagent containers, etc., in laboratory
automation.
• Reliable reading of 80 mm high code labels at a short distance.
• Due to the small dimensions of the unit and the variants with frontal or lateral beam exit, the bar code
reader can also be used in highly constrained spaces.
• The many possible configurations of the device allow it to be adapted to a multitude of reading tasks.
• Information on technical data and characteristics: see chapter 12 "Technical data".
Stand-alone operation
The bar code reader is operated as a "stand-alone" single device. The electrical connection of the operating voltage, the interface and the switching input is made via a 12-pin M12 connector or via a 15-pin Sub-D
connector.
3.2Performance characteristics
• Laser scanner with integrated decoder; lateral or frontal beam exit
• High-resolution optics
• Resolution 0.165mm…0.5mm
Reading of all common codes of module size 165…500μm (6.5…20mil) at a reading field height of
≥80mm, even with a reading distance of 25 mm for devices with lateral beam exit
• Reading distance 25mm…260mm
• Scanning rate of 600scans/s facilitates reliable reading, even while in motion
• Compact design for simple integration, even in constrained spaces
• Two switching inputs and two switching outputs
• Sturdy diecast zinc housing
• Connection cable 0.8m or 3m with Sub-D connector, 15-pin
• Connection cable 0.8m with M12 connector, 12-pin
• Process and service interface RS232
Leuze electronic GmbH + Co. KGBCL 9210
Device description
3.3Device construction
1BCL92 SM..0: lateral beam exit
2BCL92 SM..2: frontal beam exit
3Indicator diode – decode LED
4Indicator diode – status LED
5Connection cable with Sub-D connector, 15-pin
Connection cable with M12 connector, 12-pin
6M2.5 mounting threads on the device side
7M3 mounting threads on the rear of the device
Fig.3.1: Device construction of the BCL92
3.4Connection technology
Connection cable with 15-pin Sub-D connector or connection cable with 12-pin M12 connector:
• Voltage supply
• Two switching inputs
• Two switching outputs
• Process and service interface RS232
3.5Display elements
Located on the front of the device are two LEDs that indicate the readiness for operation and the read status.
LEDDisplayDescription
Status LED
(PWR)
Green, flashingInitialization phase
Green, continuous lightOperational readiness
Red, flashing 200msWarning
Red, continuous lightError, no function
Orange, flashing 200msService operation
Decode LED
(GOOD READ)
Green, 200ms onReading successful
Red, 200ms offNo reading result
Orange, continuous lightReading gate active
Leuze electronic GmbH + Co. KGBCL 9211
Mounting
4Mounting
Ä Observe the mounting instructions (see chapter 4.1 "Selecting a mounting location").
Ä Fasten the bar code reader on the mounting threads (see chapter 3.3 "Device construction"):
• M3 mounting threads on the rear of the device
• M2.5 mounting threads on the device side
4.1Selecting a mounting location
NOTICE
The size of the bar code module influences the maximum reading distance and the width of the
reading field.
Ä When selecting a mounting location and/or the bar code label, take into account the different
reading characteristics of the bar code reader with various bar code modules.
NOTICE
Observe when choosing the mounting location!
Ä Maintain the permissible environmental conditions (humidity, temperature).
Ä Avoid possible soiling of the reading window due to liquids, abrasion by boxes, or packaging
material residues.
Ä Ensure that there is the lowest possible chance of damage to the bar code reader by me-
chanical collision or jammed parts.
Ä Avoid possible ambient light influence (no direct sunlight).
In order to select the right mounting location, several factors must be considered:
• Size, orientation, and position tolerance of the bar codes on the objects to be scanned.
• The reading field of the bar code reader in relation to the bar code module width.
• The resulting minimum and maximum reading distance from the respective reading field with the respective module width (see chapter 12.2 "Reading fields").
• alignment of the bar code reader for avoiding reflections.
• distance between bar code reader and host system with respect to the interface.
The best read results are obtained if the following prerequisites are fulfilled:
• The reading distance lies in the middle area of the reading field.
• There is no direct sunlight and protect against ambient light effects.
• The bar code labels are of good print quality and have good contrast ratios.
• You are not using glossy labels.
• The bar code is moved past the reading window with an angle of rotation of approx. 15°.
Leuze electronic GmbH + Co. KGBCL 9212
Mounting
α
β
γ
αAzimuth angle
βAngle of inclination
γAngle of rotation
Fig.4.1: Definition of the reading angles
NOTICE
Avoid direct reflection of the laser beam!
The beam exits the bar code reader perpendicular to the reading window.
Ä The bar code label must be rotated by >10 ° to avoid a reflection of the laser beam in the
case of glossy labels.
Recommended angle of rotation: γ>10°
Leuze electronic GmbH + Co. KGBCL 9213
Electrical connection
5Electrical connection
CAUTION
Safety notices!
Ä The bar code reader is completely sealed and must not be opened.
Ä Do not try to open the device under any circumstances, as this avoids both degree of pro-
tection IP54 and the warranty.
Ä Before connecting the device, be sure that the supply voltage agrees with the value printed
on the name plate.
Ä Connection of the device and maintenance work while under voltage must only be carried
out by a qualified electrician.
Ä The power supply unit for the generation of the supply voltage for the bar code reader and
the corresponding connection units must have a secure electrical insulation according to
IEC60742 (SELV).
Ä If faults cannot be rectified, take the device out of operation and protect it from accidentally
being started.
CAUTION
UL applications!
For UL applications, use is only permitted in LPS/Class 2 circuits in accordance with the NEC
(National Electric Code).
NOTICE
Laying cables!
Ä Lay all connection cables and signal lines within the electrical installation space or perma-
nently in cable ducts.
Ä Lay the cables and lines so that they are protected against external damages.
Ä For further information: see ISO13849-2, Table D.4.
The electrical connection is established via the connection cable (see chapter 5.3 "Pin assignment"):
• Connection cable with Sub-D connector, 15-pin
• Connection cable with M12 connector, 12-pin
NOTICE
You can optionally use an MA150 modular connection unit for the electrical connection.
The bar code reader is provided with the following interfaces:
• Voltage supply
• Two switching inputs
• Two switching outputs
• Process and service interface RS232
You can configure the functions of the switching inputs or switching outputs according to your requirements
via the SensorStudio configuration software (see chapter 6 "Configuration and diagnostics software - SensorStudio").
5.1Operating voltage
The operating voltage of the bar code reader is 10…30VDC.
• NEC Class2
• Protection class III with SELV Power Supply
The operating voltage is fed in via the connection cable (see chapter 5.3 "Pin assignment").
Leuze electronic GmbH + Co. KGBCL 9214
Electrical connection
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
Res
.
Res.
Res.
Res.
SWIN1
SWIN2
SWOUT1
RXD
TXD
Res.
Res.
GNDIN
Res.
SWOUT2
VIN
5.2Housing ground
To avoid electromagnetic interference, a low-impedance connection is necessary from the housing to the
machine ground.
5.3Pin assignment
Fig.5.1: Pin assignment for Sub-D connector, 15-pin
Tab.5.1: PWR/SWIO/RS232 – Sub-D connector
Pin No.DesignationAssignment
1Res.Reserved
2SWIN1Digital switching input1
+12…+30VDC
3Res.Reserved
4Res.Reserved
5Res.Reserved
6SWOUT2Digital switching output2
7Res.Reserved
8VINOperating voltage
+10…+30VDC
9SWIN2Digital switching input2
+12…+30VDC
10SWOUT1Digital switching output1
11RXDRS232: RXD signal
12TXDRS232: TXD signal
13Res.Reserved
14Res.Reserved
15GNDINNegative operating voltage
0VDC
Metal flangeFE (functional earth)Connection cable shield.
The shield of the connection cable is on the metal
flange of the Sub-D connector.
Leuze electronic GmbH + Co. KGBCL 9215
Electrical connection
4
11
3
2
1
10
9
8
12
5
6
7
Fig.5.2: Pin assignment for M12 connector, 12-pin, A-coded
Tab.5.2: PWR/SWIO/RS232 - M12 connector
Pin No.DesignationAssignment
1VINOperating voltage
2GNDINNegative operating voltage
3SWIN1Digital switching input1
4SWOUT1Digital switching output1
+10…+30VDC
0VDC
+12…+30VDC
5FEFunctional earth
6n.c.
7Res.Reserved
8Res.Reserved
9RXDRS232: RXD signal
10TXDRS232: TXD signal
11SWIN2Digital switching input2
+12…+30VDC
12SWOUT2Digital switching output2
Thread (M12
connector)
FE (functional earth)Connection cable shield.
The shield of the connection cable is on the
thread of the M12 connector.
5.4Connecting bar code reader to MA150 connection unit
The signals from the bar code reader are distributed in the machine decentrally via the MA150 modular
connection unit. The following components can be connected to the MA150 connection unit:
• BCL92 series bar code reader
• Photoelectric sensor/diffuse sensor to activate the bar code reader
• Voltage supply
• Serial communication RS232
NOTICE
Supply voltage!
A supply voltage of 18…30VDC is necessary if connecting via the modular connection unit.
Leuze electronic GmbH + Co. KGBCL 9216
Electrical connection
DC 18 V … 30 V
P
WR/SWIO3/SWIO4
PWR/SWIO1-4/
RS232-422
PWR/SWI1
RS 232
SWIO3
MA 150
Art.-No.
01301095
SWIO4
PWR
PWR/SWIO
IDENT
SWO2
SWI1HOST
2
3
1
4
5
7
6
Circuit diagram example for electrical installation with MA150 connection unit
1Bar code reader BCL92
2MA150 modular connection unit
3Sensor (photoelectric sensor/diffuse sensor)
4Cable, M12 connector/open cable end, 5-pin, 2m
e.g., 50108595
5Cable, M12 socket/open cable end, 5-pin, 2m
e.g., 50104555
6Cable, M12 socket/connector, 4-pin, 2m
e.g., 50110126
7Cable, M12 socket/connector, 12-pin, 2m
e.g., 50130284
Fig.5.3: Circuit diagram example with MA150 connection unit
Leuze electronic GmbH + Co. KGBCL 9217
Electrical connection
+ 12 ... + 30 V DC
SW_IN 1/SW_IN 2
GND
+ 12 … + 30 V DC
GND
1
+ 12 ... + 30 V DC
SW_IN 1/SW_IN 2
GND
GND
+ 12 … + 30 V DC
5.5Switching inputs
You can trigger a read process via switching input connections SW_IN1 and SW_IN2.
The function of switching inputs SW_IN1 and SW_IN2 is determined from the configuration, which is set,
e.g., via the SensorStudio configuration software (see chapter 6 "Configuration and diagnostics software SensorStudio").
Depending on how the switching input is actuated, you can operate it both as NPN (low = active) as well as
PNP (high = active).
NPN actuation
• Standard setting (low = active)
• We recommend wiring a 2.2kΩ pull-up resistor as defined cable termination.
1Pull-up resistor, 2.2kΩ
Fig.5.4: Switching input for connection variant NPN (standard setting)
PNP actuation
With the "inverted" setting (high = active), you can trigger a read process by applying a voltage of
+12VDC…+30VDC at SW IN.
Connection version NPN: standard setting (low = active); input resistance: 13.3kΩ
Fig.5.5: Switching input for connection variant PNP ("inverted" setting)
Leuze electronic GmbH + Co. KGBCL 9218
Electrical connection
SW_OUT
2 kΩ
GND
+ 10 … + 30 V
5.6Switching outputs
In the basic setting, switching output SWOUT1 switches on NoRead and switching output SWOUT2
switches on GoodRead.
5.7Cable lengths and shielding
5.8PC or terminal connection
Fig.5.6: Switching output
NOTICE
Maximum loading of the switching output!
Ä Do not load the switching output of the bar code reader with more than 20mA at +10…30
VDC!
Ä Observe the maximum cable lengths:
ConnectionInterfaceMax. cable lengthShielding
BCL92RS232<3mRequired
Switching inputs
Switching outputs
NOTICE
Ä Make certain that the cables of the RS232 interface are shielded should a cable extension
be necessary.
Via the RS232 service interface, you can configure the bar code reader by means of a PC or a terminal
program. For this, you need an RS232 connection that establishes the RxD, TxD and GND connections
between PC and bar code reader (see chapter 5.3 "Pin assignment").
<3mNot necessary
Leuze electronic GmbH + Co. KGBCL 9219
Configuration and diagnostics software - SensorStudio
6Configuration and diagnostics software - SensorStudio
The SensorStudio configuration software provides a graphical user interface for the operation, configuration and diagnostics of the device via the RS232 service interface.
A device that is not connected to the PC can be configured offline.
Configurations can be saved and reopened as projects for transferring back to the device at a later time.
NOTICE
Only use the SensorStudio configuration software for products manufactured by Leuze.
The SensorStudio configuration software is offered in the following languages: German, English, French, Italian and Spanish.
The FDT frame application of the SensorStudio supports all languages; all languages may not
be supported in the device DTM (Device Type Manager).
The SensorStudio configuration software is designed according to the FDT/DTM concept:
• You make the individual configuration settings for the bar code reader in the Device Type Manager
(DTM).
• The individual DTM configurations of a project can be called up via the frame application of the Field
Device Tool (FDT).
• Communication DTM for bar code readers: LeCommInterface
• Device DTM for the BCL92 bar code reader
Procedure for the installation of the software and hardware:
Ä Install the SensorStudio configuration software on the PC.
Ä Install the communication and device DTM. Communication and device DTM are included in the Le-
AnalysisCollectionSetup installation package.
Ä Create device DTM for BCL92 in the project tree of the SensorStudio FDT frame.
Ä Connect bar code reader to PC (see chapter 5.8 "PC or terminal connection").
Ä Activate service interface on bar code reader (see chapter 7.4.1 "Service mode").
6.1System requirements
To use the SensorStudio configuration software, you need a PC or laptop with the following specifications:
Tab.6.1: System requirements for SensorStudio installation
Operating systemWindowsXP or higher (32bit, 64bit)
ComputerProcessor type: 1GHz or higher
Graphics cardAt least 1024x768 pixels
Required hard disk capacity for SensorStudio and
communication DTM
NOTICE
WindowsVista
Windows7
Windows8
Serial COM interface
CD-ROM drive
Main memory (RAM): at least 64MB
Keyboard and mouse or touchpad
35MB
Administrator privileges on the PC are necessary for installing SensorStudio.
Leuze electronic GmbH + Co. KGBCL 9220
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