Leuze BPS 304i Operating Instructions
BPS 304i
Bar Code Positioning System
EN 2018/01 - 50126567
We reserve the right to
make technical changes
Original operating instructions
© 2018
Leuze electronic GmbH + Co. KG
In der Braike 1
D-73277 Owen / Germany
Phone: +49 7021 573-0
Fax: +49 7021 573-199
http://www.leuze.com
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1 About this document . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.1 Used symbols and signal words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 Foreseeable misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 Competent persons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.4 Exemption of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.5 Laser warning notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 Device description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.1 Device overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.1.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.1.2 Performance characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.1.3 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.1.4 Device model with heating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2 Connection technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.2.1 MS 304 connection hood with M12 connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.2.2 MK 304 connection hood with spring-cage terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.3 Display elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.3.1 LED indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.3.2 Display indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.4 Bar code tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.4.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.4.2 Control bar codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.4.3 Marker labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.4.4 Twin tapes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.1 Position measurement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.2 Speed measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
4.3 Timing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.4 Leuze webConfig tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.5 Evaluation of the reading quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
4.6 Distance measurement to the bar code tape. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4.7 Status query of position / speed measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
5 Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
5.1 High-bay storage device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
5.2 Telpher line . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
5.3 Gantry cranes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6 Mounting and installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.1 Mounting bar code tape. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.1.1 Installation and application remarks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.1.2 Cutting bar code tapes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.1.3 Mounting the BCB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.2 Bar code positioning system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.2.1 Mounting instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.2.2 Orientation of the BPS to the bar code tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.2.3 Mounting with the BTU 0300M-W mounting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
6.2.4 Mounting with the BT 300 W mounting bracket. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.2.5 Mounting with BT 56 mounting device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
6.2.6 Mounting with BT 300-1 mounting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
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6.2.7 Mounting with M4 fastening screws. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.1 External parameter memory in the connection hood. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.2 MS 304 connection hood with connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.3 MK 304 connection hood with spring-cage terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
7.4 Pin assignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7.4.1 PWR / SW IN/OUT (Power and switching input/output) . . . . . . . . . . . . . . . . . . . . . . . . . . 45
7.4.2 HOST / BUS IN (Host/Bus input, PROFIBUS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
7.4.3 BUS OUT (bus output, PROFIBUS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
7.4.4 Service USB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
7.5 PROFIBUS topology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
7.6 Cable lengths and shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
8 Basic configuration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
8.1 Configuring the PROFIBUS interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
8.1.1 Communication profile. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
8.1.2 Bus-access processes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
8.1.3 Device types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
8.1.4 Automatic baud rate detection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
8.2 Setting the PROFIBUS address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
8.3 Starting the device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
8.4 Configuring for the Siemens SIMATIC-S7 control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
8.5 PROFIBUS project modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
8.5.1 Overview of the modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
8.5.2 Device parameter module – Permanently defined parameters . . . . . . . . . . . . . . . . . . . . 57
8.5.3 Module 1 – Position value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
8.5.4 Module 2 – Static preset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
8.5.5 Module 3 – Dynamic preset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
8.5.6 Module 4 – Input/output IO 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
8.5.7 Module 5 – Input/output IO 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
8.5.8 Module 6 – Status and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
8.5.9 Module 7 – Position limit value range 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
8.5.10Module 8 – Position limit value range 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
8.5.11Module 9 – Error handling procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
8.5.12Module 10 – Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
8.5.13Module 11 – Static speed limit value 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
8.5.14Module 12 – Static speed limit value 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
8.5.15Module 13 – Static speed limit value 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
8.5.16Module 14 – Static speed limit value 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
8.5.17Module 15 – Dynamic speed limit value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
8.5.18Module 16 – Speed status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
8.5.19Module 20 – Free resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
8.5.20Module 21 – distance to the bar code tape (BCB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
8.5.21Module 22 – Control and marker bar codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
8.5.22Module 23 – Tape value correction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
8.5.23Module 24 – Reading quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
8.5.24Module 25 – Device status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
8.5.25Module 26 – Extended status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
8.5.26Module 28 - 16-bit position value. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
9 Leuze electronic webConfig tool – Extended configuration . . . . . . . . . . . . . . . . 79
9.1 Installing software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
9.1.1 System requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
9.1.2 Install USB driver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
9.2 Start webConfig tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
9.3 Short description of the webConfig tool. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
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9.3.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
9.3.2
CONFIGURATION
9.3.3
ALIGNMENT
9.3.4
PROCESS
9.3.5
DIAGNOSTICS
9.3.6
MAINTENANCE
function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
function. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
10 Diagnostics and troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
10.1 What to do in case of failure? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
10.1.1Diagnostics with webConfig tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
10.2 Operating indicators of the LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
10.3 Error messages on the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
10.4 Checklist for causes of errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
11 Care, maintenance and disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
11.1 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
11.2 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
11.2.1Firmware update . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
11.2.2BCB repair with repair kit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
11.3 Disposing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
12 Service and support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
12.1 What to do should servicing be required? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
13 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
13.1 General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
13.1.1BPS without heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
13.1.2BPS with heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
13.2 Bar code tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
13.3 Dimensioned drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
13.4 Dimensioned drawings: Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
13.5 Dimensioned drawing bar code tape . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
14 Order guide and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
14.1 BPS 304i type overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
14.2 Connection hoods . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
14.3 Accessory terminating resistor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
14.4 Cables accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
14.5 Other accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
14.6 Bar code tapes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
15 EC Declaration of Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
16 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
16.1 BCB bar code tape with 40 mm grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
16.2 Bar code tape BCB8 with 30 mm grid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Leuze electronic BPS 304i 5
1 About this document
1.1 Used symbols and signal words
Table 1.1: Warning symbols and signal words
Symbol indicating dangers to persons
Symbol indicating dangers from harmful laser radiation
NOTE 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
BCB Bar code tape (general or specific BCB type with 40 mm grid)
BCB8 Bar code tape (BCB type with 30 mm grid)
BPS Bar code Positioning System
CFR Code of Federal Regulations
DAP Device Access Point
DCP Discovery and Configuration Protocol
EMC Electromagnetic compatibility
EN European standard
FE Functional earth
GSD General Station Description
GSDML Generic Station Description Markup Language
Symbol for action steps
Text passages with this symbol instruct you to perform actions.
GUI Graphical User Interface
IO or I/O Input/Output
I&M Information & Maintenance
IP Internet Protocol
LED Light Emitting Diode
MAC Media Access Control
MVS Type of control bar code
MV0 Type of control bar code
Leuze electronic BPS 304i 6
About this document
NEC National Electric Code
OSI Open Systems Interconnection model
PELV Protective Extra-Low Voltage
PNO PROFIBUS Nutzerorganisation e.V. (PROFIBUS User Organization)
RT Real Time
SNMP Simple Network Management Protocol
PLC Programmable Logic Control
Programmable Logic Control
TCP Transmission Control Protocol
UDP User Datagram Protocol
USB Universal Serial Bus
UL Underwriters Laboratories
UV Ultraviolet
XML Extensible Markup Language
Leuze electronic BPS 304i 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 an optical measuring system which uses visible red laser light to determine its position relative to a permanently mounted bar code tape.
All accuracy details for the BPS 300 measurement system refer to the position relative to the permanently
mounted bar code tape.
Areas of application
The BPS is designed for positioning in the following areas of application:
• Telpher line
• Travel and lifting axes of high-bay storage devices
• Repositioning units
• Gantry crane bridges and their trolleys
•Elevators
CAUTION
Observe intended use!
Only operate the device in accordance with its 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.
Leuze electronic GmbH + Co. KG is not liable for damages caused by improper use.
Read the operating instructions before commissioning the device.
Knowledge of the operating instructions is an element of proper use.
Safety
NOTICE
Comply with conditions and regulations!
Observe the locally applicable legal regulations and the rules of the employer's liability insurance asso-
ciation.
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
• for medical purposes
• as own safety component in accordance with the machinery directive
Use as safety-related component within the safety function is possible, if the component combi-
nation is designed correspondingly by the machine manufacturer.
NOTICE
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.
Leuze electronic BPS 304i 8
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 original operating instructions 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 DGUV
(German Social Accident Insurance) provision 3 (e.g. electrician foreman). In other countries, there are
respective regulations that must be observed.
2.4 Exemption of liability
Leuze electronic GmbH + Co. KG is not liable in the following cases:
Safety
• 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 warning notices
ATTENTION, LASER RADIATION – LASERCLASS2
Never look directly into the beam!
The device satisfies the requirements of IEC 60825-1:2007 (EN 60825-1:2007) safety regulations for a
product of laser class 2 as well as the U.S. 21 CFR 1040.10 regulations with deviations corresponding
to “Laser Notice No. 50” from June 24, 2007.
Never look directly into the laser beam or in the direction of reflected 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.
Observe the applicable statutory and local laser protection regulations.
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.
Leuze electronic BPS 304i 9
Safety
2
1
3
NOTICE
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 2.2).
Affix the laser information sheet to the device in the language appropriate for the place of use.
When using the device in the U.S.A., 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.
1 Laser aperture
2 Laser warning sign
3 Laser information sign with laser parameters
Figure 2.1: Laser aperture, laser warning and information signs
Leuze electronic BPS 304i 10
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 (avg):
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
1,8 mW
<150 µs
655 nm
1,8 mW
<150 µs
655 nm
1.8 mW
<150 µs
655 nm
1,8 mW
<150
µ
s
655 nm
1,8 mW
<150 µs
655 nm
1,8 mW
<150 µs
655 nm
<1 mW
<150 µs
655 nm
1.8 mW
<150 µs
655 nm
50120562-02
Safety
Figure 2.2: Laser warning and information signs – supplied stick-on labels
Leuze electronic BPS 304i 11
3 Device description
000040 000044 000048 000052 000056
000060 000064 000068
4
0000480000
0000556
1
2
4
3
3.1 Device overview
3.1.1 General information
The BPS bar code positioning system uses visible red laser light to determine its position and its speed
value relative to a bar code tape that is affixed along the travel path. This takes place in the following steps:
• Read a code on the bar code tape (see figure 3.1)
• Determine the position of the read code in the scanning beam
• Calculate the position to within less than a millimeter using the code information and the code position relative to the device's center.
The position and speed values are then output to the controller via the host interface.
The BPS consists of device housing and interface connection hood for the connection to the control. The
BPS can optionally be delivered with display and optics heating.
The following connection hoods are available for the connection of the PROFIBUS interface:
• MS 304 connection hood with M12 connectors
• MK 304 connection hood with spring-cage terminals
Device description
1 Bar code tape
2 Connection hood
3 Device housing
4 Middle of the scanning beam (device middle, output position value)
Figure 3.1: Device construction, device arrangement and beam exit
3.1.2 Performance characteristics
The most important performance characteristics of the bar code positioning system:
• Positioning with submillimeter accuracy from 0 to 10,000 m
• For the control at high traverse rates of up to 10 m/s
• Simultaneous position and speed measurement
• Working range: 50 to 170 mm; enables flexible mounting positions
• Interfaces: PROFINET fieldbus, PROFIBUS fieldbus, SSI, RS 232/RS 422, RS 485
• Binary inputs and outputs for control and process monitoring
• Configuration via webConfig tool or fieldbus
• Diagnostics via webConfig tool or optional display
• Optional model with display
• Optional model with heating for use to -35 °C
Leuze electronic BPS 304i 12
3.1.3 Accessories
Special accessories are available for the bar code positioning system. The accessories are optimally
matched to the BPS:
• Highly flexible, scratch-, smudge- and UV-resistant bar code tape
• Mounting devices for precise mounting with one screw (easy-mount)
• Modular connection technology via connection hoods with M12 connectors or spring-cage terminals
3.1.4 Device model with heating
The bar code positioning system is optionally available as a model with integrated heating. In this case,
heating is permanently installed ex works.
NOTICE
No self-installation of the heating!
Self-installation of the heating on-site by the user is not possible.
The heating consists of two parts:
• Front cover heater
• Housing heater
Device description
Features of the integrated heating:
• Extends the application range of the BPS to -35 °C
• Supply voltage 18 … 30 VDC
• BPS release through an internal temperature switch (start-up delay of about 30 min for 24 V DC and
minimum ambient temperature of -35 °C)
• Required conductor cross-section for the power supply: At least 0.75 mm
2
NOTICE
Do not use ready-made cables!
It is not possible to use ready-made cables.
The current consumption of the BPS is too high for the ready-made cables.
Function
When the supply voltage is applied to the BPS, a temperature switch initially only supplies the heating with
current (front cover heater and housing heater). During the heating phase (around 30 min), when the
inside temperature rises above 15 °C, the temperature switch connects the BPS to the supply voltage. This
is followed by the self test and the changeover to read operation. The PWR LED lights up, showing overall
readiness for operation.
When the inside temperature reaches approx. 18 °C, another temperature switch turns the housing heater
off and, if necessary, back on again (if the inside temperature drops below 15 °C). This does not interrupt
the read operation.
The front cover heater remains activated until an inside temperature of 25 °C is reached. At temperatures
above this, the front cover heater switches off and, with a switching hysteresis of 3 °C, back on again at
an inside temperature below 22 °C.
3.2 Connection technology
For the electrical connection of the BPS, the following connection variants are available:
• MS 304 connection hood with M12 connectors
• MK 304 connection hood with spring-cage terminals
The voltage supply (18 … 30 VDC) is connected acc. to the connection type selected.
Two freely programmable switching inputs/switching outputs for individual adaptation to the respective
application are also available here.
Leuze electronic BPS 304i 13
3.2.1 MS 304 connection hood with M12 connectors
1
3
4
2
The MS 304 connection hood features three M12 connector plugs and a Mini-B type USB socket as a
service interface for configuration and diagnostics of the BPS.
Contained in the MS 304 are the address switches for setting the PROFIBUS address and the
integrated parameter memory for easily exchanging the BPS. Both the settings as well as the
PROFIBUS address are stored in the MS 304 and automatically transmitted to the device on
every device start-up.
Device description
1 PWR / SW IN/OUT: M12 plug (A-coded)
2 SERVICE: Mini-B USB socket (behind protective cap)
3 HOST / BUS IN: M12 plug (B-coded), PROFIBUS 0
4 BUS OUT: M12 socket (B-coded), PROFIBUS 1
Figure 3.2: MS 304 connection hood, connections
NOTICE
Shielding connection
The shielding connection is done via the M12 connector housing.
3.2.2 MK 304 connection hood with spring-cage terminals
The MK 304 connection hood makes it possible to connect the BPS directly and without additional connectors. The MK 304 features three cable bushings in which the shielding connection for the interface cable
is also located. A Mini-B type USB socket is used for service purposes and for configuration and diagnostic
of the BPS.
Contained in the MK 304 are the address switches for setting the PROFIBUS address and the
integrated parameter memory for easily exchanging the BPS. Both the settings as well as the
PROFIBUS address are stored in the MK 304 and automatically transmitted to the device on
every device start-up.
Leuze electronic BPS 304i 14
1 3x cable bushing, M16 x 1.5
1
2
1 1
≈ 55 mm ≈ 8 mm ≈ 15 mm
1 2
2 SERVICE: Mini-B USB socket (behind protective cap)
Figure 3.3: Connection hood MK 304, connections
Cable fabrication and shielding connection
Remove approx. 78 mm of the connection cable sheathing.
15 mm of sheath of the shielded line must be freely accessible.
Lead the individual wires into the terminals according to the diagram.
Device description
NOTICE
Do not use wire-end sleeves!
When fabricating cables, we recommend against using wire-end sleeves.
The shield is automatically contacted when the cable is lead into the metal screw fitting and fas-
tened when the cord grip is closed.
1 Diameter of contact area, cable: 6 … 9.5 mm
2 Diameter of contact area, shield: 5 … 9.5 mm
Figure 3.4: Cable fabrication for connection hoods with spring-cage terminals
3.3 Display elements
The BPS is available optionally with display, two control buttons and LEDs or with only two LEDs as indicators on the device housing.
3.3.1 LED indicators
The device housing features the following multicolor LED indicators as primary display element:
•PWR
•BUS
Leuze electronic BPS 304i 15
1PWR LED
1
3 4
2
2LED BUS
3 Display
4 Control buttons
Figure 3.5: Indicators on the device housing
Device description
Table 3.1: Meaning of the LED indicators on the device housing
LED Color, state Description
LED 1
PWR
Off Device is switched off
• No supply voltage
Green, flashing Device is being initialized
• Supply voltage connected
• Initialization running
• No measurement value output
Green, continuous light Device in operation
• Initialization finished
• Measurement value output
Red, flashing Warning set
• No measurement (e.g. no bar code tape)
Red, continuous light Device error
• Device function is limited
• Details via event log
(see chapter 10.1.1 "Diagnostics with webConfig tool")
Orange, continuous
light
Service active
• No data on the host interface
• Configuration via USB service interface
LED 2
BUS
Off No supply voltage
Green, flashing
• Establishing communication to the master
• Device waiting for communication to be re-established
• No cyclical data exchange
Green, continuous light
• Communication with master established
• Cyclical data exchange active
Red, flashing
• Parameterization or configuration failed
• Communication error detected (DP Error)
• No cyclical data exchange
Leuze electronic BPS 304i 16
3.3.2 Display indicators
1 2
The optional display of the BPS is only used as a display element. The display has the following features:
• Monochromatic with white background lighting
• Double line, 128 x 32 pixels
• Display language: English
Two control buttons can be used to control which values appear in the display.
The background lighting is activated by pressing any control button and is automatically deactivated after
ten minutes have passed.
The display shows the content on two lines:
• The upper display line shows the selected function as an English term.
• The lower display line shows the data of the selected function.
Device description
1 Display
2 Control buttons
Figure 3.6: Display on the device housing
Display functions
The following functions can be displayed and activated in the display:
• Position value
•
Position Value
• Position value in mm
Display with “.” as decimal separator character (e.g.,
• Reading quality
•
Quality
• 0 … 100%
• Device status
•
BPS Info
•
System OK
• I/O status
Status of the inputs/outputs
•
I/O status
•
IO1 In:0
In/Out depending on configuration, 0/1 for state of the I/O
• Device address for host communication
/
Warning
/
IO2 Out:0
/
Error
+ 34598.7 mm
)
•
BPS Address
• Decimal value of the PROFIBUS address, e.g.
• Version information
Software and hardware version of the device
•
Version
•
SW: V1.3.0 HW:1
Leuze electronic BPS 304i 17
126
NOTICE
Laser activation by selecting
If measurement is stopped, the laser is activated by selecting
The display is controlled via the control buttons:
• – Enter: activate or deactivate the display shift function
• – Down: scroll through functions (downwards)
Example: Representation of the I/O status on the display
1. Press button : Display flashes
Quality
!
Quality
Device description
.
2. Press button : Display changes from position value (
3. Press button : Display changes from reading quality (
4. Press button : Display changes from device status (
5. Press button : I/O status displayed, display stops flashing
Display during device start-up
During device start-up, a start-up display first appears which is briefly followed by the display with the
version information.
The standard display after starting up the BPS is
3.4 Bar code tape
3.4.1 General information
The bar code tape is available in different variants:
• BCB bar code tape with 40 mm grid
Code128 with character set C, increasing in increments of 4 (e.g., 000004, 000008, … )
• Bar code tape BCB8 with 30 mm grid
Code128 with character set C, increasing in increments of 3 (e.g. 000003, 000006, … )
A bar code tape consists of a sequence of individual position labels in one of the two grids. Defined cut
marks are provided for cutting the BCB.
The bar code tape is delivered on a roll. A roll contains up to 200 m of BCB, with the wrapping direction
from the outside to the inside (smallest number on the outside). If more than 200 m of BCB is ordered, the
total length is divided into rolls of 200 m.
Bar code tapes with special requirements with respect to height, length and value range can be ordered
from Leuze electronic (see chapter 14.6 "Bar code tapes").
Position Value
BPS Info
Position Value
Quality
.
) to reading quality (
) to device status (
) to I/O status
BPS Info
Quality
)
)
NOTICE
Value range for BCB with special requirements!
When ordering bar code tapes with special requirements, make certain that the value range contains
only values that are divisible by three (BCB8 with 30 mm grid) or four (BCB with 40 mm grid).
It may otherwise not be possible to purchase and use repair tapes.
NOTICE
Only one BCB type per system!
In a given system, use either only BCB8 with 30 mm grid or only BCB with 40 mm grid.
If different BCB types are used in one system, the BPS cannot ensure an exact position determination.
Leuze electronic BPS 304i 18
NOTICE
1 2
000040 000044 000048 000052
40
BCB8
BCB8
BCB8 BCB8
BCB8
000018 000021 000024 000027 000030
1 2
30
Configure the BPS for the used BCB type!
The used BCB type must be set in the BPS configuration with the
Tape selection
chapter 8.5.2 "Device parameter module – Permanently defined parameters".
On delivery, the BPS is set for BCB with a 40 mm grid.
If the BCB8 with a 30 mm grid is used, the
If the used BCB type does not correspond to the
Tape selection
Tape selection
must be adjusted in the BPS configuration.
configured in the BPS, exact position
determination cannot be performed by the BPS.
BCB bar code tape with 40 mm grid
Device description
parameter; see
1 Position label with position value
2 Cut mark
Figure 3.7: Bar code tape with 40 mm grid
The standard height of 47 mm can be adapted. Other BCB height (25 mm) and special heights on request.
With a standard bar code tape and a repair tape with 40 mm grid, the printed numerical values
are divisible by four without a remainder.
Bar code tape BCB8 with 30 mm grid
1 Position label with position value
2 Cut mark
Figure 3.8: Bar code tape with 30 mm grid
Leuze electronic BPS 304i 19
Device description
2
000040 000044 000048 0150000 015004
1
The standard height of 47 mm can be adapted. Other BCB heights (25 mm and 30 mm) and special
heights on request.
With a standard bar code tape and repair tape with 30 mm grid, the printed numerical values are
divisible by three without a remainder.
For bar code tapes with 30 mm grid, the designation
the position value.
3.4.2 Control bar codes
With the help of control bar codes that are affixed on top of the bar code tape at appropriate positions, functions in the BPS can be activated or deactivated, e.g., for changing various position values at switches.
Code type Code128 with character set B is used for the control bar code.
The
MVS
label is a control bar code for the direction-independent switching of the position values from one
bar code tape to another in the middle of the control bar code label.
• If, upon reaching the changeover position in the middle of the
the new BCB section in the scanning beam, the position value of the first BCB section is still output
after the middle of the
The
MV0
label is a control bar code for the deactivation of the position output.
• If the BPS detects the middle of the
MV0
label.
Arrangement of the control bar codes
The control bar code is attached in such a way that it replaces one position bar code or seamlessly
connects two bar code tapes with different value ranges to one another (see figure 3.9).
MVS
label for half of the label width.
MV0
label, no position values are output after the middle of the
BCB8
is printed in plain text in addition to
MVS
label, the BPS does not detect
1 Control bar code
2 The control bar code is decoded in the marked scans
Figure 3.9: Arrangement of the MVS control bar code
Leuze electronic BPS 304i 20
1 Control bar code
000040 000044
0
1
2
2 End of position determination from the middle of the control bar code
Figure 3.10: Arrangement of the MV0 control bar code
Device description
NOTICE
Distance between two control bar codes!
Make certain that there is only one control bar code (or marker label) in the scanning beam at a time.
The minimum distance between two control bar codes is determined by the distance between the BPS
and bar code tape and the resulting length of the scanning beam.
The control bar codes are simply affixed over the existing bar code tape.
A control bar code should cover an entire position bar code and must have the correct grid dimension (see
figure 3.11):
• 30 mm with BCB8 bar code tapes
• 40 mm with BCB bar code tapes
Keep the gap between the BCBs that are switched between as small as possible.
Leuze electronic BPS 304i 21
Device description
1
2
000040 000044 000048 015000 015004
000040 000044 000048 015004
1 Control bar code perfectly affixed on the bar code tape
2 Control bar code at small gap between two bar code tapes
Figure 3.11: Correct positioning of the control bar code
NOTICE
Gaps in bar code tape
Avoid polished and high-gloss surfaces.
Keep the gaps between the two bar code tapes and the control bar code as small as possible.
Measurement value switching between two bar code tapes with different value ranges
MVS
or
MV0
The
control bar code is used to switch between two bar code tapes.
NOTICE
1 m minimum distance of the bar code values for measurement value switching!
For different BCB value ranges, make certain that the minimum distance of 1 m between the preceding
position bar code (before the control bar code) and the subsequent position bar code (after the control
bar code) is maintained.
Example (BCB with 40 mm grid): If the last position bar code on the BCB before the control bar code
is
75120
, the following position bar code on the BCB after the control bar code must be at least
If the minimum distance between the bar code values is not maintained, position determination may
be faulty.
• The end of the preceding bar code tape and the start of the subsequent bar code tape can end and
begin, respectively, with completely different position bar codes.
• BCB changeover by means of a control bar code always occurs at the same position, i.e., it serves to
change from the preceding tape to the subsequent tape and vice versa.
• If the center of the BPS reaches the transition point of the control bar code, the device switches to
the second BCB, provided the next position label is in the BPS's scanning beam (see figure 3.12).
The output position value is thereby always uniquely assigned to one BCB.
75220
.
Leuze electronic BPS 304i 22
Device description
000040 000044 000048 0150000 015004
1
2
3
4
If the BPS does not detect the new BCB section upon reaching the changeover position, the posi-
tion-value output is dependent on the used control bar code.
MVS
control bar code: The position value of the first BCB is output beyond the middle of the
MVS
label for half of the label width.
MV0
control bar code: No position values are output after the middle of the
MV0
label.
• When the control label is passed, the new BCB value is output relative to the middle of the device or
label.
1 Scanning beam
2 Middle of the control bar code
3 Middle of the BPS
4 Direction of movement
Figure 3.12: Changeover position with
3.4.3 Marker labels
Marker labels, which are affixed at the appropriate locations on top of the bar code tape, can be used to
trigger various functions in the superior control. The BPS detects the defined marker labels in the scanning
beam, decodes them, and makes them available to the control.
NOTICE
Distance between two marker labels!
Make certain that there is only one marker label (or control bar code) in the scanning beam at a time.
The minimum distance between two marker labels is determined by the distance between the BPS and
bar code tape and the resulting length of the scanning beam.
Definition of the marker label
The following combinations of letters and numbers may be used as marker labels:
First character: A … Z, a … z
Second character: Digit from 0 … 9
Third character: Digit from 0 … 9
MVS
control bar code for BCB changeover
Structure of the marker labels
Code type Code128 with character set B is used for the marker labels.
Arrangement when using the marker label with positioning
The marker label must be attached to the bar code tape aligned with the grid of the actual coding. A posi-
Leuze electronic BPS 304i 23
tion code should be visible before and after the marker label.
Figure 3.13: System arrangement of marker labels
000040 000044 000048 0000052 000056
1
1
2
Arrangement when using the marker label without positioning
The marker label must be positioned within the BPS's detection range.
3.4.4 Twin tapes
Twin tapes are jointly manufactured bar code tapes with the same value range.
Device description
1 Marker label
NOTICE
A twin tape always consists of two bar code tapes!
When ordering a twin tape, two bar code tapes are always included with an order.
Twin tapes are used if positioning with two bar code tapes is necessary, e.g., with crane systems or elevators.
Because they are manufactured jointly, both tapes have the same length tolerance. As a result, differences
in length and code position are minimal. By having the same code position on both tapes, improved
synchronization can be achieved during positioning compared to bar code tapes that are manufactured
separately.
1 Twin bar code tape 1
2 Twin bar code tape 2
Figure 3.14: Twin tape with double numbering
Twin tapes are always delivered in pairs on two rolls.
If twin tapes are replaced, both tapes are to be replaced.
Twin tapes can be ordered from Leuze electronic (see chapter 14.6 "Bar code tapes").
Leuze electronic BPS 304i 24
4 Functions
This chapter describes the functions of the BPS and the parameters for adaptation to the respective application conditions and requirements.
Main functions:
• Position measurement
• Speed measurement
The following parameters are relevant for the timing of the position and speed measurement:
• Measurement value preparation
Configurable response time
• Measurement error tolerance
Configurable time-based error suppression
4.1 Position measurement
The output value of the position measurement is calculated from the measurement and the settings for
resolution, preset, offset, etc.
The most important individual parameters for the position measurement are:
Parameter Description Range/Values
Functions
Position resolution The parameter specifies the resolution of the position value.
It acts only on the host interface.
The resolution has no effect on the set parameter values
such as offset or preset.
Unit The parameter specifies the measurement unit of the mea-
sured position and speed.
The selection of the measurement unit affects all parameters with measurement units.
Offset The offset is used to correct the position value by a fixed
amount.
If the offset is activated, the offset is added to the position
value. This yields a new output value:
Output value = position value + offset
Preset Like the offset, the preset is used to correct the position
value.
With preset, a preset value is specified. The value is
accepted during a corresponding event (switching input or
fieldbus).
If the preset is activated, this has priority over the offset.
0.001 mm
0.01 mm
0.1 mm
1 mm
10 mm
or
Free resolution
Metric (mm)
or
inch (1/100 in)
1 mm
or
inch/100
1 mm
or
inch/100
4.2 Speed measurement
The current speed is ascertained and output on the basis of the respective position values.
The most important individual parameters for the speed measurement are:
Leuze electronic BPS 304i 25
Functions
Parameter Description Range/Values
Speed resolution The parameter defines the resolution of the speed value. It
Averaging The parameter specifies the averaging time of the calcu-
4.3 Timing
The BPS of the 300i series operate with a scanning rate of 1000 scans per second. A measurement value
is ascertained every 1 ms.
The following parameters are relevant for the timing of the position and speed measurement:
Parameter Description Range/Values
Integration depth The integration depth affects the measurement of position
affects only the fieldbus output.
lated speed values in steps.
and speed. The
number of sequential measurements that the BPS uses for
position determination.
The integration results in smoothing of the output measurement value.
An
integration depth
measurement values) results in a response time of 8 ms.
integration depth
of 8 (position determination with 8
parameter specifies the
1 mm/s
10 mm/s
100 mm/s
1000 mm/s
or
Free resolution
Steps:
2 ms, 4 ms,
8 ms,
16 ms, 32 ms,
64 ms, 128 ms
Factory setting:
8
Error delay time Errors that occur are suppressed for the configured time.
If no valid position or speed value can be ascertained in the
configured
output.
If the error persists after the
value of the
ter is then output (standard).
4.4 Leuze webConfig tool
The webConfig configuration tool offers a graphical user interface for the display of process data, configuration and diagnostics of the BPS via a PC; see chapter 9 "Leuze electronic webConfig tool – Extended
configuration".
4.5 Evaluation of the reading quality
The BPS can signal the reading quality of the BPS. The reading quality is displayed in % values.
The parameters for the evaluation of the reading quality are set in the interface-specific configuration; see
chapter 8.5.23 "Module 24 – Reading quality".
The values of the reading quality are displayed via the optional display (
munication protocol and via the webConfig tool; see chapter 9.3.3 "ALIGNMENT function".
The evaluation of the reading quality provides the following information, e.g.:
• The reading quality is constantly bad: Soiling of the BPS optics
• The reading quality is always bad at certain position values: Soiling of the BCB
error delay time
, the last valid value is always
error delay time
elapses, the
Position/Speed value in case of error
parame-
Quality
Factory setting:
50 ms
), the serial com-
Leuze electronic BPS 304i 26
4.6 Distance measurement to the bar code tape
Within the reading field, the BPS can output the current distance from the read head to the BCB. The
distance from the position label closest to the reference point is output.
see chapter 8.5.20 "Module 21 – distance to the bar code tape (BCB)"
The distance measurement value is output via:
•The
ALIGNMENT
only available in the
• The host interface (input data)
function (
Service
Quality
menu) in the webConfig tool (see chapter 9.3.3); this function is
operating mode.
4.7 Status query of position / speed measurement
The following status information can be transmitted to the PROFINET master:
Module 6 (see chapter 8.5.8) and module 16 (see chapter 8.5.18) in the PROFIBUS configuration signal
status information of the position/speed measurement.
The following status information can be transmitted to the PROFIBUS master:
• Status information for position measurement: Input data 0.0 … 1.7; see chapter 8.5.8 "Module 6 –
Status and control"
• Status information for speed measurement: Input data 0.0 … 1.5; see chapter 8.5.18 "Module 16 –
Speed status"
Functions
Leuze electronic BPS 304i 27
5 Applications
Wherever systems are moved automatically, it is necessary to uniquely determine their respective positions. In addition to mechanical measuring sensors, optical methods are particularly well suited for position
determination as they can be used to determine position without mechanical wear and slippage.
Compared to common optical measurement techniques, the Leuze electronic Bar code Positioning
System (BPS) is able to measure a position with absolute sub-millimeter accuracy, i.e. independent of
reference points. As a result, it is able to provide a unique position value at any time. With the highly flexible
and hard-wearing Bar Code Tape (BCB), the system can even be used without problem in systems with
curves or guide tolerances. And this at lengths of up to 10,000 meters.
The product family of Leuze electronic bar code positioning systems convinces with a variety of advantages:
• The laser simultaneously scans three bar codes and, as a result, is able to determine the position
with sub-millimeter accuracy. The wide reading field makes accurate position determination possible
even in the event of minor damage to the tape.
• With the systems' flexible depth of field, it is also possible to bridge over mechanical deviations.
• Due to the large reading distance combined with the great depth of field, a large opening angle and a
very compact construction, the device is ideally suited for the conveyor and storage technology market.
• The BPS devices are capable of simultaneously measuring position and speed and are thus also
suitable for control tasks in your automation applications.
• Using a mounting device, the BPS can be mounted with millimeter accuracy with just one screw. If
mounted using a mounting device, a new device is automatically aligned correctly should it be necessary to exchange a device (easy-mount).
• The unique labeling of the bar code tape allows the system to be put back into operation without
problem even after a brief voltage drop without, e.g., needing to utilize a reference point.
• The Leuze electronic bar code tape is very robust, highly flexible and, thanks to the self-adhesive
back, can be easily integrated into your overall mechanical system. It can be fit optimally to both vertical as well as horizontal curved paths and thereby reliably facilitates trouble-free and reproducible
measurement at any point in your system with sub-millimeter accuracy.
Applications
Typical applications for the BPS include:
• High-bay storage device (see chapter 5.1)
• Telpher line (see chapter 5.2)
• Gantry cranes (see chapter 5.3)
Leuze electronic BPS 304i 28
5.1 High-bay storage device
Applications
Figure 5.1: High-bay storage device
Simultaneous position and speed measurement for regulation tasks
Precise positioning with a reproducibility of
0.15 mm
Control at high traverse rates of up to 10 m/s
Leuze electronic BPS 304i 29
5.2 Telpher line
Applications
Figure 5.2: Telpher line
The working range from 50 - 170 mm allows for flexible mounting positions and reliable position detec-
tion at varying distances
Control codes for changing to different position values at switches
Leuze electronic BPS 304i 30
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