Leuze BCL 92 Operating Instructions

Original operating instructions
BCL 92
Bar code reader
We reserve the right to make technical changes
EN • 2020-04-28 • 50144007
© 2020 Leuze electronic GmbH + Co. KG In der Braike 1
Table of contents
1 About this document ............................................................................................5
1.1 Used symbols and signal words .............................................................................................5
1.2 Terms and abbreviations ........................................................................................................6
2 Safety .....................................................................................................................7
2.1 Intended use ........................................................................................................................... 7
2.2 Foreseeable misuse ............................................................................................................... 8
2.3 Competent persons ................................................................................................................ 8
2.4 Disclaimer ............................................................................................................................... 9
2.5 Laser safety notices................................................................................................................ 9
3 Device description ..............................................................................................10
3.1 Device overview.................................................................................................................... 10
3.1.1 About the bar code reader................................................................................................. 10
3.1.2 Stand-alone operation .......................................................................................................10
3.2 Performance characteristics .................................................................................................10
3.3 Device construction .............................................................................................................. 11
3.4 Connection technology .........................................................................................................11
3.5 Display elements .................................................................................................................. 11
Table of contents
4 Mounting..............................................................................................................12
4.1 Selecting a mounting location............................................................................................... 12
5 Electrical connection..........................................................................................14
5.1 Operating voltage ................................................................................................................. 14
5.2 Housing ground .................................................................................................................... 15
5.3 Pin assignment .....................................................................................................................15
5.4 Connecting bar code reader to MA150 connection unit....................................................... 16
5.5 Switching inputs.................................................................................................................... 18
5.6 Switching outputs.................................................................................................................. 19
5.7 Cable lengths and shielding.................................................................................................. 19
5.8 PC or terminal connection .................................................................................................... 19
6 Configuration and diagnostics software - SensorStudio...............................20
6.1 System requirements............................................................................................................ 20
6.2 Installing SensorStudio ........................................................................................................ 21
6.2.1 Downloading configuration software .................................................................................21
6.2.2 Installing the SensorStudio FDT frame ............................................................................21
6.2.3 Install the communication DTM and device DTM.............................................................. 21
6.2.4 Connecting device to PC...................................................................................................21
6.3 Starting SensorStudio.......................................................................................................... 22
6.4 Exiting SensorStudio ........................................................................................................... 23
Table of contents
6.5 Configuration parameters .....................................................................................................23
6.5.1 Decode tab ........................................................................................................................24
6.5.2 Output tab.......................................................................................................................... 27
6.5.3 Control tab.........................................................................................................................29
6.5.4 Host interface tab ..............................................................................................................30
6.5.5 Reference code tab ...........................................................................................................31
6.5.6 Switching input tab ............................................................................................................33
6.5.7 Switching output tab ..........................................................................................................34
6.6 Diagnosis .............................................................................................................................. 35
6.7 Firmware Reload................................................................................................................... 36
7 Starting up the device - Configuration..............................................................37
7.1 Measures to be performed prior to the initial commissioning ............................................... 37
7.2 Starting the device ................................................................................................................ 37
7.2.1 Power-on test ....................................................................................................................37
7.2.2 Interface ............................................................................................................................37
7.2.3 Online commands .............................................................................................................37
7.2.4 Problems ...........................................................................................................................37
7.3 Starting up with factory settings............................................................................................ 38
7.4 Setting the configuration parameters.................................................................................... 38
7.4.1 Service mode ....................................................................................................................39
7.4.2 Parameter sets ..................................................................................................................40
8 Online commands...............................................................................................41
8.1 Overview of commands and parameters .............................................................................. 41
8.2 General online commands.................................................................................................... 42
8.3 Online commands for system control ................................................................................... 47
8.4 Online commands for the parameter set operations............................................................. 48
9 Care, maintenance and disposal .......................................................................51
10 Diagnostics and troubleshooting ......................................................................52
11 Service and support ...........................................................................................53
12 Technical data .....................................................................................................54
12.1 General specifications .......................................................................................................... 54
12.2 Reading fields ....................................................................................................................... 56
12.3 Dimensioned drawings ......................................................................................................... 59
13 Order guide and accessories.............................................................................61
13.1 Type overview....................................................................................................................... 61
13.2 Accessories........................................................................................................................... 62
14 EC Declaration of Conformity ............................................................................63
15 Appendix..............................................................................................................64
15.1 Bar code samples ................................................................................................................. 64
About this document
1 About this document
1.1 Used 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
NOTE Signal word for property damage
Indicates dangers that may result in property damage if the measures for danger avoidance are not followed.
CAUTION Signal word for minor injuries
Indicates dangers that may result in minor injury if the measures for danger avoidance are not followed.
WARNING Signal 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.
About this document
1.2 Terms and abbreviations
Tab.1.3: Terms and abbreviations
BCL Bar code reader
DNC This PIN must not be connected
(Do Not Connect)
DTM Software device manager
(Device Type Manager)
EMC Electromagnetic compatibility
EN European standard
FDT Software frame for management of device managers (DTM)
(Field Device Tool)
FE Functional earth
GUI Graphical user interface
HID Device class for input devices with which users directly interact
(Human Interface Device)
NC This pin is not contacted at the device
(Not Connected)
SELV Safe Extra Low Voltage
PLC Programmable Logic Control
(corresponds to Programmable Logic Controller (PLC))
SW_IN Switching input
SW_OUT Switching output
Safety
2 Safety
This bar code reader was developed, manufactured and tested in accordance with the applicable safety standards. It corresponds to the state of the art.
2.1 Intended use
Bar code readers of the BCL92 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 BCL92 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 LeuzeelectronicGmbH+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).
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:
• 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
2.3 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 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.
Safety
1
1
2.4 Disclaimer
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
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 class1 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
Device description
3 Device description
3.1 Device 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. 2/5Interleaved, Code39, Code128, 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.
3.2 Performance characteristics
• Laser scanner with integrated decoder; lateral or frontal beam exit
• High-resolution optics
• Resolution 0.165mm…0.5mm
Reading of all common codes of module size 165…500μm (6.5…20mil) at a reading field height of ≥80mm, even with a reading distance of 25 mm for devices with lateral beam exit
• Reading distance 25mm…260mm
• Scanning rate of 600scans/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 0.8m or 3m with Sub-D connector, 15-pin
• Connection cable 0.8m with M12 connector, 12-pin
• Process and service interface RS232
Leuze electronic GmbH + Co. KG BCL 92 10
Device description
3.3 Device construction
1 BCL92 SM..0: lateral beam exit
2 BCL92 SM..2: frontal beam exit
3 Indicator diode – decode LED
4 Indicator diode – status LED
5 Connection cable with Sub-D connector, 15-pin
Connection cable with M12 connector, 12-pin
6 M2.5 mounting threads on the device side
7 M3 mounting threads on the rear of the device
Fig.3.1: Device construction of the BCL92
3.4 Connection 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 RS232
3.5 Display elements
Located on the front of the device are two LEDs that indicate the readiness for operation and the read sta­tus.
LED Display Description
Status LED
(PWR)
Green, flashing Initialization phase
Green, continuous light Operational readiness
Red, flashing 200ms Warning
Red, continuous light Error, no function
Orange, flashing 200ms Service operation
Decode LED
(GOOD READ)
Green, 200ms on Reading successful
Red, 200ms off No reading result
Orange, continuous light Reading gate active
Leuze electronic GmbH + Co. KG BCL 92 11
Mounting
4 Mounting
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
4.1 Selecting 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. KG BCL 92 12
Mounting
α
β
γ
α Azimuth angle
β Angle of inclination
γ Angle 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. KG BCL 92 13
Electrical connection
5 Electrical 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 IP54 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 IEC60742 (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 ISO13849-2, 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 MA150 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 RS232
You can configure the functions of the switching inputs or switching outputs according to your requirements via the SensorStudio configuration software (see chapter 6 "Configuration and diagnostics software - Sen­sorStudio").
5.1 Operating voltage
The operating voltage of the bar code reader is 10…30VDC.
• NEC Class2
• 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. KG BCL 92 14
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
5.2 Housing ground
To avoid electromagnetic interference, a low-impedance connection is necessary from the housing to the machine ground.
5.3 Pin assignment
Fig.5.1: Pin assignment for Sub-D connector, 15-pin
Tab.5.1: PWR/SWIO/RS232 – Sub-D connector
Pin No. Designation Assignment
1 Res. Reserved
2 SWIN1 Digital switching input1
+12…+30VDC
3 Res. Reserved
4 Res. Reserved
5 Res. Reserved
6 SWOUT2 Digital switching output2
7 Res. Reserved
8 VIN Operating voltage
+10…+30VDC
9 SWIN2 Digital switching input2
+12…+30VDC
10 SWOUT1 Digital switching output1
11 RXD RS232: RXD signal
12 TXD RS232: TXD signal
13 Res. Reserved
14 Res. Reserved
15 GNDIN Negative operating voltage
0VDC
Metal flange FE (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. KG BCL 92 15
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. Designation Assignment
1 VIN Operating voltage
2 GNDIN Negative operating voltage
3 SWIN1 Digital switching input1
4 SWOUT1 Digital switching output1
+10…+30VDC
0VDC
+12…+30VDC
5 FE Functional earth
6 n.c.
7 Res. Reserved
8 Res. Reserved
9 RXD RS232: RXD signal
10 TXD RS232: TXD signal
11 SWIN2 Digital switching input2
+12…+30VDC
12 SWOUT2 Digital switching output2
Thread (M12
connector)
FE (functional earth) Connection cable shield.
The shield of the connection cable is on the thread of the M12 connector.
5.4 Connecting bar code reader to MA150 connection unit
The signals from the bar code reader are distributed in the machine decentrally via the MA150 modular connection unit. The following components can be connected to the MA150 connection unit:
• BCL92 series bar code reader
• Photoelectric sensor/diffuse sensor to activate the bar code reader
• Voltage supply
• Serial communication RS232
NOTICE
Supply voltage!
A supply voltage of 18…30VDC is necessary if connecting via the modular connection unit.
Leuze electronic GmbH + Co. KG BCL 92 16
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
SWI1 HOST
2
3
1
4
5
7
6
Circuit diagram example for electrical installation with MA150 connection unit
1 Bar code reader BCL92
2 MA150 modular connection unit
3 Sensor (photoelectric sensor/diffuse sensor)
4 Cable, M12 connector/open cable end, 5-pin, 2m
e.g., 50108595
5 Cable, M12 socket/open cable end, 5-pin, 2m
e.g., 50104555
6 Cable, M12 socket/connector, 4-pin, 2m
e.g., 50110126
7 Cable, M12 socket/connector, 12-pin, 2m
e.g., 50130284
Fig.5.3: Circuit diagram example with MA150 connection unit
Leuze electronic GmbH + Co. KG BCL 92 17
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
5.5 Switching inputs
You can trigger a read process via switching input connections SW_IN1 and SW_IN2.
The function of switching inputs SW_IN1 and SW_IN2 is determined from the configuration, which is set, e.g., via the SensorStudio configuration software (see chapter 6 "Configuration and diagnostics software ­SensorStudio").
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 2.2kΩ pull-up resistor as defined cable termination.
1 Pull-up resistor, 2.2kΩ
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 +12VDC…+30VDC at SW IN.
Connection version NPN: standard setting (low = active); input resistance: 13.3kΩ
Connection version PNP: inverted setting (high = active); input resistance: 13.3kΩ
Fig.5.5: Switching input for connection variant PNP ("inverted" setting)
Leuze electronic GmbH + Co. KG BCL 92 18
Electrical connection
SW_OUT
2 kΩ
GND
+ 10 … + 30 V
5.6 Switching outputs
In the basic setting, switching output SWOUT1 switches on NoRead and switching output SWOUT2 switches on GoodRead.
5.7 Cable lengths and shielding
5.8 PC 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 20mA at +10…30
VDC!
Ä Observe the maximum cable lengths:
Connection Interface Max. cable length Shielding
BCL92 RS232 <3m Required
Switching inputs
Switching outputs
NOTICE
Ä Make certain that the cables of the RS232 interface are shielded should a cable extension
be necessary.
Via the RS232 service interface, you can configure the bar code reader by means of a PC or a terminal program. For this, you need an RS232 connection that establishes the RxD, TxD and GND connections between PC and bar code reader (see chapter 5.3 "Pin assignment").
<3m Not necessary
Leuze electronic GmbH + Co. KG BCL 92 19
Configuration and diagnostics software - SensorStudio
6 Configuration and diagnostics software - SensorStudio
The SensorStudio configuration software provides a graphical user interface for the operation, configura­tion and diagnostics of the device via the RS232 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 SensorStudio configuration software for products manufactured by Leuze.
The SensorStudio configuration software is offered in the following languages: German, Eng­lish, French, Italian and Spanish.
The FDT frame application of the SensorStudio supports all languages; all languages may not be supported in the device DTM (Device Type Manager).
The SensorStudio 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 BCL92 bar code reader
Procedure for the installation of the software and hardware:
Ä Install the SensorStudio 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 BCL92 in the project tree of the SensorStudio 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").
6.1 System requirements
To use the SensorStudio configuration software, you need a PC or laptop with the following specifications:
Tab.6.1: System requirements for SensorStudio installation
Operating system WindowsXP or higher (32bit, 64bit)
Computer Processor type: 1GHz or higher
Graphics card At least 1024x768 pixels
Required hard disk capacity for SensorStudio and communication DTM
NOTICE
WindowsVista
Windows7
Windows8
Serial COM interface
CD-ROM drive
Main memory (RAM): at least 64MB
Keyboard and mouse or touchpad
35MB
Administrator privileges on the PC are necessary for installing SensorStudio.
Leuze electronic GmbH + Co. KG BCL 92 20
Loading...
+ 45 hidden pages