Leuze electronic BCL548i User Manual

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BCL548i

Bar code reader

en 02-12/2012 50113410

We reserve the right to

make technical changes

TECHNICAL DESCRIPTION

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 info@leuze.de

Leuze electronic BCL 548i

TNT 35/7-24V

BCL 548i

LNK0

LNK1

Navigate

upward/laterally

Navigate

downward/laterally ESCAPE

leave

ENTER

confirm

Device buttons:

Delete character

Enter digit

Save input

The main menus

ESC

Input of values

12|

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

BCL548i SF 102

Leuze electronic GmbH & Co. KG SW: V 1.8.0 HW:3 SN: 1009A009815 001

IO1 IO2 IO3 IO4 ATT ERR

12345678

Parameter

Parameter handling Decoder table Digital SWIO Ethernet

Language selection o Deutsch oEnglish o Español o Français o Italiano

Ser vi ce

Diagnostics Status messages

Device information - main menu

Information about

• Device type

• Software version

• Hardware version

• Serial number

Bar code reading window - main menu

Visualization of the read bar code information. See "Indicators in the display" on page 89.

Parameter - main menu

Configuration of the bar code reader. See "Parameter menu" on page 95.

Language selection - main menu

Selection of the display language. See "Language selection menu" on page 104.

Service - main menu

Scanner diagnosis and status messages. See "Service menu" on page 105.

Actions o Start decoding o Start alignment o Start auto-setup o Start teach-in o Code recognition start

Actions main menu

Various functions for scanner configuration and manual operation. See "Actions menu" on page 105.

PWR LED BUS LED

Off Device OFF Off No supply voltage Flashes green Device ok, initialization phase Flashes green Initialization Green, continuous light Device OK Green, continuous light Operation OK Orange, continuous light Service mode Flashes red Communication error Flashes red Device ok, warning set Red, continuous light Network error Red, continuous light Device error

Table of contents

1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.1 Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

1.2 Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

2 Safety notices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.1 General safety notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.2 Safety standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.3 Approved purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

2.4 Working safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

3 Fast commissioning / operating principle . . . . . . . . . . . . . . . . . . . 17

3.1 Mounting the BCL 548i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.2 Device arrangement and selection of the mounting location . . . . . . . . . . . . . . . . . . . . 17

3.3 Electrical connection BCL 548i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3.4 Starting the device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.5 Commissioning the BCL 548i on the PROFINET-IO. . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.5.1 Preparing the control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.5.2 Installing the GSD file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

3.5.3 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3.5.4 Transfer of the configuration to the IO Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

3.5.5 Configuration of the device name - device naming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

3.5.6 Check device name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

3.6 Further settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

3.7 Bar code reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

4 Device description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

4.1 About the bar code readers of the BCL 500i series. . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

4.2 Characteristics of the bar code readers of the BCL 500i series . . . . . . . . . . . . . . . . . . 25

4.4 Reading techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

4.4.1 Line scanner (single line). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

4.4.2 Line scanner with oscillating mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

4.4.3 Omnidirectional reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

4.5 Fieldbus systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4.5.1 PROFINET-IO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

4.5.2 PROFINET-IO – star topology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

4.5.3 PROFINET-IO – line topology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

4.6 Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Leuze electronic BCL 548i 1

Table of contents

4.7 External parameter memory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

4.8 autoReflAct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

4.9 Reference codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

4.10 autoConfig. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

5 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

5.1 General specifications of the bar code readers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

5.1.1 Line scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

5.1.2 Oscillating-mirror scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

5.1.3 Line scanner with deflection mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

5.2 Heating models of the bar code readers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

5.2.1 Line scanner with heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

5.2.2 Oscillating-mirror scanner with heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

5.2.3 Line scanner with deflection mirror and heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

5.3 Dimensioned drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

5.3.1 Line scanner with / without heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

5.3.2 Deflection mirror scanner with / without heating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

5.3.3 Oscillating-mirror scanner with / without heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

5.4 Type overview BCL 548i. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

5.5 Reading field curves / optical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

5.6 Reading field curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

5.6.1 High Density (N) Optics: BCL 548i SN 100/102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

5.6.2 High Density (N) Optics: BCL 548i ON 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

5.6.3 Medium Density (M) Optics: BCL 548i SM 100/102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

5.6.4 Medium Density (M) Optics: BCL 548i OM 100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

5.6.5 Low Density (F) Optics: BCL 548i SF 100/102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

5.6.6 Low Density (F) Optics: BCL 548i OF 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

5.6.7 Ultra Low Density (L) Optics: BCL 548i SL 102. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

5.6.8 Ultra Low Density (L) Optics: BCL 548i OL 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

5.7 Reading field curves for heating devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

5.7.1 High Density (N) Optics: BCL 548i SN 102 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

5.7.2 High Density (N) Optics: BCL 548i SN 100 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

5.7.3 High Density (N) Optics: BCL 548i ON 100 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60

5.7.4 Medium Density (M) Optics: BCL 548i SM 102 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

5.7.5 Medium Density (M) Optics: BCL 548i SM 100 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

5.7.6 Medium Density (M) Optics: BCL 548i OM 100 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

5.7.7 Low Density (F) Optics: BCL 548i SF 102 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

5.7.8 Low Density (F) Optics: BCL 548i SF 100 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65

5.7.9 Low Density (F) Optics: BCL 548i OF 100 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

5.7.10 Ultra Low Density (L) Optics: BCL 548i SL 102 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

5.7.11 Ultra Low Density (L) Optics: BCL 548i OL 100 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

2 BCL 548i Leuze electronic

Table of contents

6 Installation and mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

6.1 Storage, transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

6.2 Mounting the BCL 548i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

6.2.1 Fastening with M4 x 6 screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

6.2.2 BT 56 mounting device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

6.2.3 BT 59 mounting device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73

6.3 Device arrangement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

6.3.1 Selecting a mounting location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

6.3.2 Avoiding total reflection – Line scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

6.3.3 Avoiding total reflection – oscillating/deflection-mirror scanner. . . . . . . . . . . . . . . . . . . . 75

6.3.4 Mounting location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

6.3.5 Devices with integrated heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

6.3.6 Possible read angles between BCL 548i and bar code . . . . . . . . . . . . . . . . . . . . . . . . . . 77

6.4 Attaching laser warning sign . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

6.5 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

7 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

7.1 Safety notices for the electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

7.2 Electrical connection of the BCL 548i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

7.2.1 PWR – Voltage supply and switching input/outputs 3 and 4 . . . . . . . . . . . . . . . . . . . . . . 80

7.2.2 SERVICE – USB interface (type A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

7.2.3 SW IN/OUT – Switching input/switching output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

7.2.4 HOST / BUS IN for BCL 548i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

7.2.5 BUS OUT for the BCL 548i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

7.3 PROFINET-IO topologies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

7.3.1 PROFINET-IO wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

7.4 Cable lengths and shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

8 Display and control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

8.1 Structure of the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

8.2 Status display and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

8.2.1 Indicators in the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

8.2.2 LED status indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

8.2.3 Control buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

8.3 Menu description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

8.3.2 Parameter menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

8.3.3 Language selection menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

8.3.4 Service menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

8.3.5 Actions menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

8.4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Leuze electronic BCL 548i 3

Table of contents

9 Leuze webConfig tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

9.1 Connecting the SERVICE USB interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

9.2 Installing the required software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

9.2.1 System requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

9.2.2 Installing the USB driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

9.3 Starting the webConfig tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

9.4 Short description of the webConfig tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

9.4.1 Module overview in the Configuration menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

10 Commissioning and configuration . . . . . . . . . . . . . . . . . . . . . . . . 116

10.1 General information on the PROFINET-IO implementation of the BCL 548i . . . . . . . . 116

10.1.1 PROFINET-IO communication profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

10.1.2 Conformance Classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117

10.2 Measures to be performed prior to the initial commissioning . . . . . . . . . . . . . . . . . . . 117

10.3 Starting the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

10.4 Configuration steps for a Siemens Simatic S7 control . . . . . . . . . . . . . . . . . . . . . . . . . 118

10.4.1 Step 1 – Preparing the control system (S7 PLC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .118

10.4.2 Step 2 – Installation of the GSD file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

10.4.3 Step 3 – Hardware configuration of the S7 PLC: Configuration . . . . . . . . . . . . . . . . . . . 120

10.4.4 Step 4 – Transfer of the configuration to the IO Controller (S7 PLC) . . . . . . . . . . . . . . . 121

10.4.5 Step 5 – Configuration of the device name - naming the device . . . . . . . . . . . . . . . . . . 121

10.4.6 Step 6 – Check device names . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

10.4.7 Ethernet host communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

10.4.7.1 Manually setting the IP address............................................................................................................124

10.4.7.2 Automatically setting the IP address ....................................................................................................125

10.4.7.3 TCP/IP ...................................................................................................................................................126

10.4.7.4 UDP.......................................................................................................................................................128

10.5 Commissioning via the PROFINET-IO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

10.5.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

10.6 Overview of the project modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .134

10.7 Decoder modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

10.7.1 Modules 1-4 – Code table extensions 1 to 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

10.7.2 Module 5 – Code type features (symbology) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

10.7.3 Module 7 – Code fragment technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

10.8 Control modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

10.8.1 Module 10 – Activations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

10.8.2 Module 11 – Reading gate control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

10.8.3 Module 12 – Multi-label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

10.8.4 Module 13 – Fragmented read result. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

10.8.5 Module 14 – Interlinked read result . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

4 BCL 548i Leuze electronic

Table of contents

10.9 Result Format. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

10.9.1 Module 20 – Decoder state. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

10.9.2 Modules 21-27 – Decoding result. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

10.9.3 Module 30 – Data formatting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

10.9.4 Module 31 – Reading gate number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

10.9.5 Module 32 – Reading gate time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

10.9.6 Module 33 – Code position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

10.9.7 Module 34 – Reading reliability (equal scans). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

10.9.8 Module 35 – Bar code length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

10.9.9 Module 36 – Scans with information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

10.9.10 Module 37 – Decoding quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

10.9.11 Module 38 – Code direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

10.9.12 Module 39 – Number of digits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

10.9.13 Module 40 – Code type (symbology) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

10.9.14 Module 41 – Code position in the swivel range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

10.10 Data Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

10.10.1 Module 50 – Characteristics filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

10.10.2 Module 51 – Data filtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

10.11 Identifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

10.11.1 Module 52 – Segmentation according to the EAN process . . . . . . . . . . . . . . . . . . . . . . 163

10.11.2 Module 53 – Segmentation via fixed positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

10.11.3 Module 54 – Segmentation according to identifier and separator . . . . . . . . . . . . . . . . . 168

10.11.4 Module 55 – String handling parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

10.12 Device Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

10.12.1 Module 60 – Device status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

10.12.2 Module 61 – Laser control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

10.12.3 Module 62 – Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

10.12.4 Module 63 – Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

10.12.5 Module 64 – Oscillating mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

10.12.6 Module 65 – Deflection mirrors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

10.13 Switching inputs/ outputs SWIO 1 … 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

10.13.1 Parameters for operating as an output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

10.13.2 Parameters for operating as an input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

10.13.3 Switch-on and switch-off functions for operation as an output . . . . . . . . . . . . . . . . . . . 180

10.13.4 Input functions for operation as an input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180

10.13.5 Module 70 – Switching input/output SWIO1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

10.13.6 Module 71 – Switching input/output SWIO2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

10.13.7 Module 72 – Switching input/output SWIO3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

10.13.8 Module 73 – Switching input/output SWIO4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

10.13.9 Module 74 – SWIO status and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

10.14 Data output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

10.14.1 Module 80 – Sorting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

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Table of contents

10.15 Reference code comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

10.15.1 Module 81 – Reference code comparator 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192

10.15.2 Module 82 – Reference code comparator 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

10.15.3 Module 83 – Reference code comparison pattern 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

10.15.4 Module 84 – Reference code comparison pattern 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

10.16 Special Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

10.16.1 Module 90 – Status and control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198

10.16.2 Module 91 – AutoReflAct (automatic reflector activation) . . . . . . . . . . . . . . . . . . . . . . . . 199

10.16.3 Module 92 – AutoControl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

10.17 Example configuration: Indirect activation via the PLC . . . . . . . . . . . . . . . . . . . . . . . . 201

10.17.1 Task . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

10.17.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

10.18 Sample configuration: Direct activation via the switching input . . . . . . . . . . . . . . . . .203

10.18.1 Task . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

10.18.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

11 Online commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

11.1 Overview of commands and parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

11.1.1 General 'online' commands. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

12 Diagnostics and troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 223

13 Type overview and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . 227

13.1 Type key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

13.2 Type overviewBCL 548i . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

13.3 Accessory connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

13.4 Accessory USB cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228

13.5 Accessory external parameter memory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

13.6 Accessory mounting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

13.7 Accessory reflector for AutoReflAct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229

13.8 Accessory ready-made cables for voltage supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

13.8.1 Contact assignment of PWR connection cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

13.8.2 Specifications of the cables for voltage supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

13.8.3 Order codes of the cables for voltage supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230

13.9 Accessory ready-made cables for bus connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

13.9.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

13.9.2 Contact assignments M12 PROFINET-IO connection cable KB ET… . . . . . . . . . . . . . . 231

13.9.3 Specifications M12 PROFINET-IO connection cable KB ET… . . . . . . . . . . . . . . . . . . . .231

13.9.4 Order codes M12 PROFINET-IO connection cable KB ET… . . . . . . . . . . . . . . . . . . . . . 232

6 BCL 548i Leuze electronic

Table of contents

14 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

14.1 General maintenance information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

14.2 Repairs, servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

14.3 Disassembling, packing, disposing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

15 Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

15.1 Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234

15.2 ASCII character set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

15.3 Bar code samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

15.3.1 Module 0.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239

15.3.2 Module 0.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

Leuze electronic BCL 548i 7

Figures and tables

Figure 2.1: Attachment of the stick-on labels with warning notices at the BCL 548i........................ 16

Figure 3.1: Connections of the BCL 548i......................................................................................... 18

Figure 3.2: Assignment of the device names to IP addresses .......................................................... 20

Figure 3.3: Assigning the device names to the configured IO devices.............................................. 21

Figure 3.4: MAC address - IP address -individual device name ....................................................... 22

Figure 4.1: Line scanner, line scanner with deflection mirror and oscillating-mirror scanner........... 24

Figure 4.2: Possible bar code orientation ........................................................................................26

Figure 4.3: Device construction ......................................................................................................27

Figure 4.4: Deflection principle for the line scanner ........................................................................ 28

Figure 4.5: Deflection principle for the line scanner with oscillating mirror add-on.......................... 29

Figure 4.6: Principle arrangement for omnidirectional reading ........................................................ 30

Table 4.1: Base record I&M0 .........................................................................................................32

Figure 4.7: PROFINET-IO in a star topology ..................................................................................... 33

Figure 4.8: PROFINET-IO in a line topology...................................................................................... 33

Figure 4.9: External parameter memory.......................................................................................... 34

Figure 4.10: Reflector arrangement for autoReflAct .......................................................................... 35

Table 5.1: Specifications of the BCL 548i line scanners without heating ........................................ 37

Table 5.2: Specifications of the BCL 548i oscillating-mirror scanners without heating ................... 39

Table 5.3: Specifications of the BCL 548i deflection-mirror scanners without heating.................... 39

Table 5.4: Specifications of the BCL 548i line scanners with heating ............................................. 41

Table 5.5: Specifications of the BCL 548i oscillating-mirror scanners with heating ........................ 42

Table 5.6: Specifications of the BCL 548i deflection-mirror scanners with heating ........................ 43

Figure 5.1: Dimensioned drawing BCL 548i line scanner S…102................................................... 44

Figure 5.2: Dimensioned drawing BCL 548i deflection-mirror scanner S…100............................... 45

Figure 5.3: Dimensioned drawing BCL 548i oscillating-mirror scanner O…100.............................. 46

Table 5.7: Type overview BCL 548i ............................................................................................... 47

Figure 5.4: The most important characteristics of a bar code.......................................................... 48

Figure 5.5: Zero position of the reading distance ............................................................................49

Table 5.8: Reading conditions ....................................................................................................... 49

Figure 5.6: "High Density" reading field curve for line scanner (with/without deflection mirror)....... 50

Figure 5.7: "High Density" reading field curve for oscillating-mirror scanners................................. 51

Figure 5.8: Lateral "High Density" reading field curve for oscillating-mirror scanners ..................... 51

Figure 5.9: "Medium Density" reading field curve for line scanner (with/without deflection mirror) . 52

Figure 5.10: "Medium Density" reading field curve for oscillating-mirror scanners ........................... 53

Figure 5.11: Lateral "Medium Density" reading field curve for oscillating-mirror scanners................ 53

Figure 5.12: "Low Density" reading field curve for line scanner (with/without deflection mirror) ....... 54

Figure 5.13: "Low Density" reading field curve for oscillating-mirror scanners ................................. 55

Figure 5.14: Lateral "Low Density" reading field curve for oscillating-mirror scanners...................... 55

Figure 5.15: "Ultra Low Density" reading field curve for line scanner without deflection mirror ......... 56

Figure 5.16: "Ultra Low Density" reading field curve for oscillating-mirror scanners .........................57

Figure 5.17: Lateral "Ultra Low Density" reading field curve for oscillating-mirror scanners.............. 57

Figure 5.18: "High Density" reading field curve for line scanner with heating (without deflection mirror).58

Figure 5.19: "High Density" reading field curve for line scanner with heating (with deflection mirror)......59

Figure 5.20: "High Density" reading field curve for oscillating-mirror scanners with heating............. 60

8 BCL 548i Leuze electronic

Figures and tables

Figure 5.21: Lateral "High Density" reading field curve for oscillating-mirror scanners with heating . 60 Figure 5.22: "Medium Density" reading field curve for line scanner with heating (without deflection mirror) 61 Figure 5.23: "Medium Density" reading field curve for line scanner with heating (with deflection mirror) .. 62

Figure 5.24: "Medium Density" reading field curve for oscillating-mirror scanners with heating ....... 63

Figure 5.25: Lateral "Medium Density" reading field curve for oscillating-mirror scanners with heating.. 63 Figure 5.26: "Low Density" reading field curve for line scanner with heating (without deflection mirror). 64

Figure 5.27: "Low Density" reading field curve for line scanner with heating (with deflection mirror) ....65

Figure 5.28: "Low Density" reading field curve for oscillating-mirror scanners with heating ............. 66

Figure 5.29: Lateral "Low Density" reading field curve for oscillating-mirror scanners with heating.. 66 Figure 5.30: "Ultra Low Density" reading field curve for line scanner with heating (without deflection mirror)...67

Figure 5.31: "Ultra Low Density" reading field curve for oscillating-mirror scanners with heating..... 68

Figure 5.32: Lateral "Ultra Low Density" reading field curve for oscillating-mirror scanners with heating. 68

Figure 6.1: Device name plate BCL 548i......................................................................................... 69

Figure 6.2: Fastening options using M4x6 threaded holes .............................................................. 70

Figure 6.3: BT 56 mounting device................................................................................................. 71

Figure 6.4: Mounting example of BCL 548i with BT 56 ................................................................... 72

Figure 6.5: Total reflection – line scanner....................................................................................... 75

Figure 6.6: Total reflection – BCL 548i with oscillating/deflection mirror......................................... 76

Figure 6.7: Reading angle for the line scanner................................................................................ 77

Figure 7.1: Location of the electrical connections ........................................................................... 78

Figure 7.2: Connections of the BCL 548i......................................................................................... 79

Table 7.1: Pin assignment PWR..................................................................................................... 80

Figure 7.3: Switching input connection diagram SWIO_3 and SWIO_4............................................ 81

Figure 7.4: Switching output connection diagram SWIO_3 / SWIO_4 .............................................. 81

Figure 7.5: Pin assignments of SERVICE – USB interface ................................................................ 82

Figure 7.6: Pin assignment SW IN/OUT ........................................................................................... 83

Figure 7.7: Switching input connection diagram SWIO_1 and SWIO_2............................................ 83

Figure 7.8: Switching output connection diagram SWIO_1 / SWIO_2 .............................................. 84

Table 7.2: Pin assignment HOST / BUS IN BCL 548i ...................................................................... 85

Figure 7.9: HOST / BUS IN cable assignments on RJ-45 ................................................................. 85

Table 7.3: Pin assignment BUS OUT .............................................................................................. 86

Figure 7.10: PROFINET-IO in a star topology ..................................................................................... 87

Figure 7.11: PROFINET-IO in a line topology ..................................................................................... 87

Table 7.4: Cable lengths and shielding .......................................................................................... 88

Figure 8.1: Structure of the control panel........................................................................................ 89

Table 8.1: Parameter handling submenu ....................................................................................... 95

Table 8.2: Decoder table submenu ................................................................................................ 96

Table 8.3: Digital SWIO submenu ..................................................................................................99

Table 8.4: Ethernet submenu ...................................................................................................... 102

Figure 9.1: Connecting the SERVICE USB interface ....................................................................... 110

Figure 9.2: Device Manager with connected BCL 500i.................................................................. 112

Figure 9.3: The start page of the webConfig tool........................................................................... 113

Figure 9.4: Module overview in the webConfig tool....................................................................... 114

Figure 10.1: Connections of the BCL 548i....................................................................................... 117

Leuze electronic BCL 548i 9

Figures and tables

Table 10.1: Assignment of the device names to IP addresses ........................................................120

Figure 10.2: Assigning the device names to the configured IO devices............................................ 122

Figure 10.3: MAC address - IP address -individual device name ..................................................... 123

Table 10.2: Device parameters ...................................................................................................... 130

Table 10.3: Module overview......................................................................................................... 135

Table 10.4: Parameters for modules 1-4 ....................................................................................... 137

Table 10.5: Parameters for module 5 ............................................................................................ 139

Table 10.6: Parameters for module 7 ............................................................................................ 140

Table 10.7: Parameters for module 10 .......................................................................................... 141

Table 10.8: Output data for module 10 ..........................................................................................141

Table 10.9: Parameters for module 11 .......................................................................................... 143

Table 10.10: Parameters for module 12 .......................................................................................... 145

Table 10.11: Input data for module 12............................................................................................. 145

Table 10.12: Parameters for module 13 .......................................................................................... 146

Table 10.13: Input data for module 13............................................................................................. 146

Table 10.14: Parameters for module 13 .......................................................................................... 147

Table 10.15: Input data for module 20............................................................................................. 148

Table 10.16: Input data for modules 21 … 27................................................................................. 150

Table 10.17: Parameters for module 30 .......................................................................................... 152

Table 10.18: Input data for module 31............................................................................................. 153

Table 10.19: Input data for module 32............................................................................................. 154

Table 10.20: Input data for module 33............................................................................................. 154

Table 10.21: Input data for module 34............................................................................................. 155

Table 10.22: Input data for module 35............................................................................................. 155

Table 10.23: Input data for module 36............................................................................................. 156

Table 10.24: Input data for module 37............................................................................................. 156

Table 10.25: Input data for module 38............................................................................................. 157

Table 10.26: Input data for module 39............................................................................................. 157

Table 10.27: Input data for module 40............................................................................................. 158

Table 10.28: Input data for module 41............................................................................................. 159

Table 10.29: Parameters for module 50 .......................................................................................... 160

Table 10.30: Parameters for module 51 .......................................................................................... 162

Table 10.31: Parameters for module 52 .......................................................................................... 163

Table 10.32: Parameters for module 53 .......................................................................................... 165

Table 10.33: Parameters for module 54 .......................................................................................... 168

Table 10.34: Parameters for module 55 .......................................................................................... 170

Table 10.35: Input data for module 60............................................................................................. 171

Table 10.36: Output data for module 60 .......................................................................................... 171

Table 10.37: Parameters for module 61 .......................................................................................... 172

Table 10.38: Parameters for module 62 .......................................................................................... 173

Table 10.39: Input data for module 63............................................................................................. 174

Table 10.40: Output data for module 63 .......................................................................................... 174

Table 10.41: Parameters for module 64 .......................................................................................... 175

Table 10.42: Parameters for module 65 .......................................................................................... 176

10 BCL 548i Leuze electronic

Figures and tables

Figure 10.4: Example 1: Start-up delay > 0 and switch-on time = 0............................................... 177

Figure 10.5: Example 2: Start-up delay > 0 and switch-on time > 0............................................... 177

Figure 10.6: Example 3: Start-up delay >0 Switch-off signal prior to lapsing of the

start-up delay ............................................................................................................. 177

Figure 10.7: Start-up delay in input mode....................................................................................... 178

Figure 10.8: Switch-on time in input mode..................................................................................... 179

Figure 10.9: Switch-off delay in input mode ................................................................................... 179

Table 10.43: Switch-on/switch-off functions................................................................................... 180

Table 10.44: Input functions............................................................................................................ 180

Table 10.45: Parameters for module 70 – Input/Output 1................................................................ 181

Table 10.46: Parameters for module 71 – Input/Output 2................................................................ 183

Table 10.47: Parameters for module 72 – Input/Output 3................................................................ 185

Table 10.48: Parameters for module 73 – Input/Output 4................................................................ 187

Table 10.49: Input data for module 74 Input/output status and control ............................................ 189

Table 10.50: Output data for module 74 Input/output status and control.......................................... 190

Table 10.51: Parameters for module 80 .......................................................................................... 191

Table 10.52: Parameters for module 81 – Reference code comparison ........................................... 192

Table 10.53: Parameters for module 82 – Reference code comparison ........................................... 194

Table 10.54: Parameter module 83 – Reference code comparison pattern ...................................... 196

Table 10.55: Parameter module 84 – Reference code comparison pattern ...................................... 197

Table 10.56: Input data for module 90 – Status and control ............................................................ 198

Table 10.57: Parameters for module 91 – AutoreflAct ..................................................................... 199

Table 10.58: Parameters for module 92 – AutoControl .................................................................... 200

Table 10.59: Input data for module 92 – AutoControl....................................................................... 200

Table 10.60: Device parameters for example configuration 2 .......................................................... 203

Table 12.1: BCL 548i alarm and diagnostics messages ................................................................. 224

Table 12.2: BCL 548i error categories ........................................................................................... 224

Table 12.1: General causes of errors ............................................................................................. 225

Table 12.1: Interface error............................................................................................................. 225

Table 13.1: Type overview BCL 548i ............................................................................................. 227

Table 13.2: Connectors for the BCL 548i ....................................................................................... 228

Table 13.3: Cable for the BCL 548i ................................................................................................ 228

Table 13.4: External parameter memory for the BCL 548i ............................................................. 229

Table 13.5: Mounting devices for the BCL 548i ............................................................................. 229

Table 13.6: Reflector for the BCL 548i........................................................................................... 229

Table 13.7: PWR cables for the BCL 548i ...................................................................................... 230

Figure 13.1: Cable configuration PROFINET-IO connection cable..................................................... 231

Table 13.8: Bus connection cable for the BCL 548i ....................................................................... 232

Figure 15.1: Bar code sample labels (module 0.3) .......................................................................... 239

Figure 15.2: Bar code sample labels (module 0.5) .......................................................................... 240

Leuze electronic BCL 548i 11

1 General information

1.1 Explanation of symbols

The symbols used in this technical description are explained below.

Attention!

This symbol precedes text messages which must strictly be observed. Failure to comply with this information results in injuries to personnel or damage to the equipment.

Attention Laser!

This symbol warns of possible danger caused by hazardous laser radiation.

Notice!

This symbol indicates text passages containing important information.

1.2 Declaration of conformity

The bar code readers of the BCL 500i series have been developed and manufactured in accordance with the applicable European standards and directives.

The BCL 500i series is "UL LISTED" according to American and Canadian safety standards, and fulfills the requirements of Underwriter Laboratories Inc. (UL).

General information

Notice!

You can find the Declaration of Conformity of the devices in the appendix of the manual on page 234.

The manufacturer of the product, Leuze electronic GmbH & Co KG in D-73277 Owen, possesses a certified quality assurance system in accordance with ISO 9001.

LISTED

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Safety notices

2 Safety notices

2.1 General safety notices

Documentation

All entries in this technical description must be heeded, in particular the present chapter "Safety notices". Keep this technical description in a safe place. It should be available at all times.

Safety regulations

Observe the locally applicable regulations and the rules of the employer's liability insurance association.

Repair

Repairs must only be carried out by the manufacturer or an authorized representative.

2.2 Safety standards

The bar code readers of the BCL 500i series were developed, manufactured and tested in accordance with the applicable safety standards. They correspond to the state of the art.

2.3 Approved purpose

Attention!

The protection of personnel and the device cannot be guaranteed if the device is operated in a manner not complying with its intended use.

Bar code readers of the BCL 500i series are conceived as stationary, high-speed scanners with integrated decoders for all current bar codes used for automatic object detection.

In particular, unauthorized uses include:

• in rooms with explosive atmospheres

• operation for medical purposes

Areas of application

The bar code readers of the BCL 500i series are especially designed for the following areas of application:

• Storage and conveying technologies, in particular for object identification on fastmoving conveyor belts

• Pallet transportation applications

• Automobile sector

• Omnidirectional reading

14 BCL 548i Leuze electronic

2.4 Working safely

Attention!

Access to or changes on the device, except where expressly described in this operating manual, are not authorized.

Safety regulations

Observe the locally applicable legal regulations and the rules of the employer's liability insurance association.

Qualified personnel

Mounting, commissioning and maintenance of the device must only be carried out by qualified personnel. Electrical work must be carried out by a certified electrician.

Attention, laser radiation!

If you look into the beam path over a longer time period, the retina of your eye may be damaged!

Never look directly into the beam path!

Do not point the laser beam of the BCL 548i at persons!

When mounting and aligning the BCL 548i, avoid reflections of the laser beam off reflective surfaces!

The BCL 548i bar code readers comply with safety standards EN 60825-1 for a class 2 product. They also comply with the U.S. 21 CFR 1040.10 regulations for a class II laser product except for deviations pursuant to Laser Notice No. 50, dated July 26,

2001.

Radiant Energy: The BCL 548i uses a low power visible laser diode. The emitted wavelength is 655nm. The average laser power is less than 1mW in accordance with the definition of class 2 lasers.

Adjustments: Do not attempt any adjustments to or alterations of this product.

Do not remove the protective housing of the bar code reader. There are no userserviceable parts inside.

The scanner window is the only aperture through which light may be observed on this product. A failure of the scanner motor, while the laser diode continues to emit a laser beam, may cause emission levels to exceed those for safe operation. The bar code reader has safeguards to prevent this occurrence. If, however, a stationary beam is emitted, the failing bar code reader should be disconnected from its power source immediately.

Safety notices

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CAUTION: Use of controls or adjustments or performance of procedures other than specified herein may result in hazardous light exposure.

Leuze electronic BCL 548i 15

Safety notices

BCL 548i Line scanner

BCL 548i

with oscillating/deflection mirror

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

The use of optical instruments or devices in combination with the device increases the danger of eye damage!

The housing of the BCL 548i is provided with warning notices B and C above and next to the reading window as shown in the following figure:

Figure 2.1: Attachment of the stick-on labels with warning notices at the BCL 548i

Notice!

It is important that you attach the stick-on labels supplied to the device (A in figure 2.1)! If the signs would be covered due to the installation situation of the BCL 548i, attach them instead in the immediate vicinity of the BCL 548i in such a way that it is not necessary to look into the laser beam when reading the notices!

16 BCL 548i Leuze electronic

Fast commissioning / operating principle

3 Fast commissioning / operating principle

Below you will find a short description for the initial commissioning of the BCL 548i. Detailed explanations for all listed points can be found throughout this technical description.

3.1 Mounting the BCL 548i

There are two different types of mounting arrangements for the BCL 548i:

• Using two M4x6 screws on the rear of the device or using four M4x6 screws on the bottom of the device.

• Using a BT 56 mounting device on the two fastening grooves.

3.2 Device arrangement and selection of the mounting location

In order to select the right mounting location, several factors must be considered:

• Size, orientation, and position tolerance of the bar codes on the objects to be scanned.

• The reading field of the BCL 548i in relation to the bar code module width.

• The resulting minimum and maximum reading distance from the respective reading field (see chapter 5.5 "Reading field curves / optical data").

• The permissible cable lengths between the BCL 548i and the host system depending on which interface is used.

• The correct time for data output. The BCL 548i should be positioned in such a way that, taking into consideration the time required for data processing and the conveyor belt speed, there is sufficient time to e.g. initiate sorting operations on the basis of the read data.

• The display and control panel should be very visible and accessible.

• For configuring and commissioning with the webConfig tool, the USB interface should be easily accessible.

For specific information, please refer to chapter 4.4.

Notice!

The beam exits the BCL 548i as follows for the respective devices:

- line scanner parallel to the housing base

- oscillating mirror and deflection mirror perpendicular to the housing base The black areas in figure 6.1 are the housing base. The best read results are obtained when:

• The BCL 548i is mounted in such a way that the scanning beam is incident on the bar code at an angle of inclination greater than ±10° … 15° to vertical.

• The reading distance lies in the middle area of the reading field.

• The bar code labels are of good print quality and have good contrast ratios.

• You do not use high-gloss labels.

• There is no direct sunlight.

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Fast commissioning / operating principle

SW IN/OUT

VOUT

SWIO_1

SWIO_2

GND

HOST / BUS IN

TD+

RD+

RD-

TD-

SERVICE

2134

GND D+ D-

PWR

SWIO_4

SWIO_3

GND VIN

BUS OUT

TD+

RD+

RD-

TD-

USB socket

Type A

M12 socket

(A-coded)

M12 socket

(D-coded)

M12 socket

(D-coded)

M12 plug (A-coded)

3.3 Electrical connection BCL 548i

The BCL 548i is equipped with four M12 connectors/sockets which are A- and D-coded.

Figure 3.1: Connections of the BCL 548i

The voltage supply (10 … 30 VDC) is connected at the PWR M12 connector.

Available at both the PWR M12 connector as well as at the SW IN/OUT M12 socket are four freely programmable switching inputs/outputs for custom adaptation to the respective application. Detailed information on this topic can be found in chapter 7.2.1 and chapter 7.2.3.

Standalone operation in PROFINET-IO

During stand-alone operation of the BCL 548i, the host interface of the superior system is connected to HOST/BUS IN. Thus, a star structure (Ethernet structure) is possible.

Network operation in PROFINET-IO

In network operation, the superior system (PC/PLC) is connected to the host interface of the BCL 548i. With the aid of the "switch" integrated in the BCL 548i, the bus connection to the next participant, e.g. a BCL 548i, can occur directly via the BUS OUT socket! In addition to the classic "star topology", a "linear topology" is thus also possible

18 BCL 548i Leuze electronic

3.4 Starting the device

LNK0

LNK1

 Connect the supply voltage +10 … 30V DC (typ. +24 V DC); the BCL 548i starts up and

the bar code reading window appears on the display:

Fast commissioning / operating principle

First, you need to assign its individual device name to the BCL 548i. The PLC must communicate this device name to the participant during the "device naming". Further information may be found below and in chapter "Step 5 – Configuration of the device name - naming the device" on page 121.

By default, parameter enabling is deactivated and you cannot change any settings. If you wish to carry out the configuration via the display, you must activate parameter enabling. Further information can be found in chapter "Parameter enabling" on page 107.

3.5 Commissioning the BCL 548i on the PROFINET-IO

 Complete the necessary steps for commissioning a Siemens-S7 control as described

below.

Further information regarding the individual commissioning steps is provided in see chapter

10.4 "Configuration steps for a Siemens Simatic S7 control".

3.5.1 Preparing the control system

 In the first step, assign an IP address to the IO Controller (S7 PLC) and prepare the control

for a consistent data transmission.

Notice!

If an S7 control is used, you need to ensure that Simatic-Manager Version 5.4 + service pack 5 (V5.4+SP5) or higher is used.

3.5.2 Installing the GSD file

For the subsequent configuration of the IO devices, e.g., BCL 548i, the corresponding GSD file must be loaded first. All data in modules required for operating the BCL 548i is described in this file. These are input and output data and device parameters for the functioning of the BCL 548i and the definition of the control and status bits.

 Install the GSD file associated with the BCL 548i in the PROFINET-IO Manager of your

control.

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Leuze electronic BCL 548i 19

Fast commissioning / operating principle

3.5.3 Configuration

 Configure the PROFINET-IO system with the HW Config of the SIMATIC Manager by

inserting the BCL 548i into your project.

Figure 3.2: Assignment of the device names to IP addresses

Here, an IP address is assigned to a unique "device name".

3.5.4 Transfer of the configuration to the IO Controller

 Transfer the PROFINET-IO configuration to the IO Controller (S7 PLC).

After the correct transfer to the IO Controller (S7 PLC), the PLC automatically carries out the following activities:

• Check device names

• Assignment of the IP addresses that were configured in the HW Config to the IO devices

• Establishment of a connection between the IO Controller and configured IO devices

• Cyclical data exchange

Notice!

Participants that have not been "named" cannot be contacted yet at this point in time!

20 BCL 548i Leuze electronic

Fast commissioning / operating principle

3.5.5 Configuration of the device name - device naming

PROFINET-IO defines the "naming of the device" as the creation of a name-based relationship for a PROFINET-IO device.

Assigning the device names to the configured IO devices

 Select the respective bar code scanner BCL 548i for the "device naming" based on its

MAC address.

The unique "device name" (which must match the participant in the HW Config) is then assigned to this participant.

Notice!

Multiple BCL 548i can be distinguished by the MAC addresses displayed. The MAC address may be found on the name plate of the respective bar code scanner.

Figure 3.3: Assigning the device names to the configured IO devices

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Fast commissioning / operating principle

Assignment of MAC address - IP address -individual device name

 At this point, assign an IP address (suggested by the PLC), a subnet mask and, if required,

a router address, and assign this data to the named participant ("device name").

Figure 3.4: MAC address - IP address -individual device name

From now on, and when programming, only the unique "device name" (max. 255 characters) is used.

3.5.6 Check device name

 After completing the configuration phase, recheck the "device names" that have been

assigned. Please ensure that these names are unique and that all participants are located in the same subnet.

22 BCL 548i Leuze electronic

3.6 Further settings

Modul 0,5

6677889900

Carry out further settings via the PROFINET-IO Controller, such as the control of the decoding and processing of the read data and the configuration of the connected switching inputs and outputs, using the parameters provided by the GSD file.

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

A detailed description of the modules can be found beginning on chapter 10.6.

3.7 Bar code reading

With the aid of the "Action menu", you can instruct the BCL 548i to read a bar code.

Fast commissioning / operating principle

Actions

o Start decoding o Start alignment o Start auto-setup o Start teach-in

To test, you can use the following bar code in the 2/5 Interleaved format. The bar code module here is 0.5:

The read information appears in the display and is simultaneously passed on to the superior system (PLC or PC).

Please check the incoming data of the bar code information there.

Alternatively, you can connect a photoelectric sensor or a 24 V DC switching signal to the SW IN/OUT socket for read activation. To do this, however, you must appropriately configure the switching input (see chapter 7.2.3 "SW IN/OUT – Switching input/switching output").

In the main menu, use the buttons to select the Actions menu item. Activate the Actions menu with . Then select Start decod- ing with and press again to start the bar code reading oper- ation.

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Leuze electronic BCL 548i 23

Device description

Line scanner

Oscillating-mirror scanner /

Line scanner with deflection mirror

4 Device description

4.1 About the bar code readers of the BCL 500i series

Bar code readers of the BCL 500i series are high-speed scanners with integrated decoder for all commonly used bar codes, e.g. 2/5 Interleaved, Code 39, Code 128, EAN 8/13 etc., as well as codes from the GS1 DataBar family.

Bar code readers of the BCL 500i series are available in various optics models as well as line scanners, line scanners with deflection mirrors, oscillating mirrors and also optionally as heated models.

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

The extensive options for device configuration via display or software enable adaptation to a multitude of reading tasks. Due to the large reading distance combined with the great depth of field and a very compact construction, the device is ideally suited for package and pallet transportation systems. In general, the bar code readers of the BCL 500i series are designed for the conveyor and storage technology market.

The interfaces (RS 232, RS 485 and RS 422) integrated in the various device models and

24 BCL 548i Leuze electronic

the fieldbus systems (PROFIBUS DP, PROFINET-IO and Ethernet) of the bar code readers of the BCL 500i series offer optimum connection to the superior host system.

Device description

4.2 Characteristics of the bar code readers of the BCL 500i series

Performance features:

• Integrated fieldbus connectivity = i -> Plug-and-Play fieldbus coupling and easy networking

• Numerous interface variants facilitate connection to the superior systems

• RS 232, RS 422 as well as with integrated multiNet plus master

• RS 485 and multiNet plus slave

alternatively, various fieldbus systems, such as

•PROFIBUS DP

•PROFINET-IO

•Ethernet

• Integrated code fragment technology (CRT) enables the identification of soiled or damaged bar codes

• Maximum depth of field and reading distances from 200mm to 2400mm

• Large optical opening angle and, thus, large reading field width

• High scanning rate from 800 - 1200 scans/s for fast reading tasks

• Intuitive, backlit, multi-language display with user-friendly menu navigation

•Integrated USB 1.1 service interface

• Adjustment of all device parameters with a web browser

• Connection options for an external parameter memory

• Easy alignment- and diagnosis functions

• M12 connections with Ultra-Lock™ technology

• Four freely programmable switching inputs/outputs for the activation or signaling of states

• Automatic monitoring of the read quality with autoControl

• Automatic recognition and setting of the bar code type using autoConfig

• Reference code comparison

• Optional heating models to -35°C

• Heavy-duty housing of protection class IP 65

Notice!

Information on technical data and characteristics can be found in chapter 5.

General information

The integrated fieldbus connectivity = i contained in the bar code readers of the BCL 500i series facilitates the use of identification systems which function without connector unit or gateways. The integrated fieldbus interface considerably simplifies handling. The Plug-andPlay concept enables easy networking and very simple commissioning: Directly connect the respective fieldbus and all configuration is performed with no additional software.

For decoding bar codes, the bar code readers of the BCL 500i series make available the proven CRT decoder with code fragment technology:

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Device description

The proven code fragment technology (CRT) enables bar code readers of the BCL 500i series to read bar codes with a small bar height, as well as bar codes with a damaged or soiled print image.

With the aid of the CRT decoder, bar codes can also be read without problem in other demanding situations, such as with a large tilt angle (azimuth angle or even twist angle).

Figure 4.2: Possible bar code orientation

With the BCL 548i, configuration is generally performed with the aid of the GSD file.

The BCL 548i needs a suitable activation to start a read process as soon as an object is in the reading field. This opens a time window ("reading gate") in the BCL 548i for the read process during which the bar code reader has time to detect and decode a bar code.

In the basic setting, triggering takes place through an external reading cycle signal. Alternative activation options include online commands via the host interface and the autoReflAct function.

Through the read operation, the BCL 548i collects additional useful pieces of data for diagnosis which can also be transmitted to the host. The quality of the read operation can be inspected using the alignment mode which is integrated in the webConfig tool.

A multi-language display with buttons is used to operate the BCL 548i as well as for visualization purposes. Two LEDs provide additional optical information on the current operating state of the device.

The four freely configurable switching inputs/outputs "SWIO 1 … SWIO 4" can be assigned various functions and control e.g. activation of the BCL 548i or external devices, such as a PLC.

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

26 BCL 548i Leuze electronic

4.3 Device construction

USB interface

M12 connection

technology

Reading window

Dovetail mounting and 4 mounting threads

Dovetail mounting and 2 mounting threads

Display, LEDs

and buttons

Figure 4.3: Device construction

Device description

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Device description

4.4 Reading techniques

4.4.1 Line scanner (single line)

A line (scan line) scans the label. Due to the opt. opening angle, the reading field width is dependent on the read distance. Through the movement of the object, the entire bar code is automatically transported through the scan line.

The integrated code fragment technology permits twisting of the bar code (tilt angle) within certain limits. These are dependent on the transport speed, the scanning rate of the scanner and the bar code properties.

Areas of application of the line scanner

The line scanner is used:

• when the bars of the bar code are printed in the conveying direction ('ladder arrangement').

• with bar codes having very short bar lengths.

• when the ladder code is turned out of the vertical position (tilt angle).

• when the scanning distance is large.

Figure 4.4: Deflection principle for the line scanner

28 BCL 548i Leuze electronic

4.4.2 Line scanner with oscillating mirror

The oscillating mirror deflects the scan line additionally to both sides across the scan direction at a randomly adjustable oscillation frequency. In this way, the BCL 548i can also scan larger areas or spaces for bar codes. The reading field height (and the scan line length useful for evaluation) depends on the reading distance due to the optical beam width of the oscillating mirror.

Areas of application of the line scanner with oscillating mirror

For line scanners with oscillating mirror, oscillation frequency, start/stop position etc. are adjustable. It is used:

• when the position of the label is not fixed, e.g. on pallets – various labels can, thus, be detected at various positions.

• when the bars of the bar code are printed perpendicular to the conveying direction ('picket fence arrangement').

• when reading stationary objects.

• when the bar code is turned out of the horizontal position.

• when the scanning distance is large.

• when a large reading field (reading window) has to be covered.

Device description

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

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Device description

4.4.3 Omnidirectional reading

In order to read arbitrarily oriented bar codes on an object, at least 2 bar code readers are necessary. If the bar code is not printed over-square, i.e. bar length > code length, bar code readers with integrated code fragment technology are necessary.

Figure 4.6: Principle arrangement for omnidirectional reading

30 BCL 548i Leuze electronic

4.5 Fieldbus systems

Various product variants of the BCL 500i series are available for connecting to different fieldbus systems such as PROFIBUS DP, PROFINET-IO and Ethernet.

4.5.1 PROFINET-IO

The BCL 548i is designed as a PROFINET-IO device (acc. to IEEE 802.3). It supports a transmission rate of up to 100 Mbit/s (100Base TX/FX), full duplex, as well as auto-negotiation and auto-crossover.

The functionality of the device is defined via parameter sets which are clustered in modules. These modules are contained in a GSDML file.

Each BCL 548i is sealed with a unique MAC-ID. This information is used to assign a unique, plant-specific device name ("NameOfStation") to the device via the "Discovery and Configuration Protocol (DCP)". When configuring a PROFINET-IO system, the assignment of the device names to the configured IO devices creates a name-based relationship for the participating IO devices ("device naming"). Further information can be found in section "Commissioning and configuration" on page 116.

The BCL 548i features multiple M12 connectors / sockets for the electrical connection of the supply voltage, the interface and the switching inputs and outputs. Additional information on the electrical connection can be found in chapter 7.

The BCL 548i supports:

• PROFIBUS-IO device functionality based on the PROFIBUS profile for identification systems

• Modular structure of the IO data

•PROFINET-IO RT (Real Time) communication

• Standard Fast Ethernet (100 Mbit/s) connections (M12 technology)

• Integrated Ethernet switch/ 2 Ethernet ports

• PROFINET-IO Conformance Class B (CC-B)

• I&M support: I&M 0-4

• Diagnostics/alarms

Device description

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For further details, see chapter 10!

Leuze electronic BCL 548i 31

Device description

Identification & Maintenance Functions

The BCL 548i supports the base record I&M0:

Contents Index Data type Description Value

Header 0 10 bytes

MANUFACTURER_ID 10 UNSIGNED16

ORDER_ID 12 ASCII string 20 bytes Leuze order no.

SERIAL_NUMBER 32 ASCII string 16 bytes Unique device serial number Device-dependent

HARDWARE_REVISION 48 UNSIGNED16

SOFTWARE_REVISION 50 1xCHAR, 3xUNSIGNED8

REVISION_COUNTER 54 UNSIGNED16

PROFILE_ID 56 UNSIGNED16 PROFIBUS application profile number

PROFILE_SPECIFIC_TYPE 58 UNSIGNED16

IM_VERSION 60 2xUNSIGNED8 Implemented I&M version V 1.1 0x01,0x01

IM_SUPPORTED 62 Bit[16] Optional I&M records available 0

Table 4.1: Base record I&M0

The BCL 548i supports further protocols and services for communication:

• TCP / IP (Client / Server)

•UDP

•DCP

•ARP

•PING

Further information on commissioning can be found in chapter 10.

Manufacturer specific Manufacturer specific

Leuze PNO manufacturer ID Leuze manufacturer ID

Hardware revision number, e.g. "0…65535"

Software version number, e.g. V130 correspond to "V1.3.0"

Is incremented when updating individual modules. This function is not supported

Info about subchannels and submodules Not relevant

338

Device-dependent

0xF600 (Generic Device)

0x01,0x01

32 BCL 548i Leuze electronic

4.5.2 PROFINET-IO – star topology

PC / PLC host interface

Other network participants

BCL 548i

"myBCL 548i_1"

PC / PLC host interface

BCL 548i

"myBCL 548i_1"

to other network participants

BCL 548i

"myBCL 548i_2"

BCL 548i

"myBCL 548i_3

The BCL 548i can be operated as a single device (standalone) with individual device name in a star topology. The PLC must communicate this device name to the participant during the "device naming".

Figure 4.7: PROFINET-IO in a star topology

4.5.3 PROFINET-IO – line topology

The innovative further development of the BCL 548i with integrated switch functionality offers the option of connecting multiple bar code readers of type BCL 548i to one another without direct connection to a switch. In addition to the classic "star topology", a "linear topology" is thus also possible.

Device description

Leuze electronic BCL 548i 33

Figure 4.8: PROFINET-IO in a line topology

Each participant in this network requires its own unique device name that is assigned by the PLC during the "device naming". For specific information, please refer to chapter "Step 5 – Configuration of the device name - naming the device" on page 121.

The maximum length of a segment (connection from the hub to the last participant) is limited to 100m.

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Device description

USB memory stick

4.6 Heater

For low-temperature applications to min. -35°C (e.g. in cold storage), the bar code readers of the BCL 548i series can optionally be permanently fitted with a built-in heating and these bar code readers purchased as separate device models.

4.7 External parameter memory

The optionally available external parameter memory – based on a USB memory stick (compatible with version 1.1) – is housed in an external hood with integrated connectors which cover the USB service interface when installed (IP 65).

The external parameter memory simplifies the timesaving onsite exchange of a BCL 548i by providing a copy of the current parameter set of the BCL 548i and by storing the device name as well. This eliminates the need to configure the exchanged device manually and, in particular, a new naming of the device – the control can immediately access the exchanged BCL 548i.

The delivery contents of the external parameter memory include the hood with integrated connectors with unscrewable cover and the USB memory stick.

Figure 4.9: External parameter memory

Notice!

To mount, the cover of the service interface must be unscrewed. Then take the USB memory stick and plug it into the USB connection on the BCL 548i. Then, take the connector hood of the USB memory stick and screw this over the plugged-in USB memory stick to the service interface to close the system and ensure protection class IP 65.

34 BCL 548i Leuze electronic

4.8 autoReflAct

AutoReflAct stands for Automatic Reflector Activation and permits an activation without

additional sensors. This is achieved by directing the scanner with reduced scanning beam towards a reflector mounted behind the conveyor path. As long as the scanner is targeted at the reflector, the reading gate remains closed. If, however, the reflector is blocked by an object such as a container with a bar code label, the scanner activates the read procedure, and the label on the container is read. When the path from the scanner to the reflector has cleared, the read procedure has completed and the scanning beam is reduced and again directed onto the reflector. The reading gate is closed.

Notice!

You will find a matching reflector in Accessories, and more are available on request.

Device description

Figure 4.10: Reflector arrangement for autoReflAct

The autoReflAct function uses the scanning beam to simulate a photoelectric sensor and thus permits an activation without additional sensory mechanism.

4.9 Reference codes

The BCL 548i offers the possibility of storing one or two reference codes.

It is possible to store the reference codes by means of teach-in (display command), via the webConfig tool, via online commands or PROFINET-IO.

The BCL 548i can compare read bar codes with one and/or both reference codes and execute user-configurable functions depending on the comparison result.

Leuze electronic BCL 548i 35

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Device description

4.10 autoConfig

With the autoConfig function, the BCL 548i offers the user who only wishes to simultaneously read one code type (symbology) with one number of digits an extremely simple and convenient configuration option.

After starting the autoConfig function via the display, switching input or from a superior control, it is sufficient to position a bar code label with the desired code type and number of digits in the reading field of the BCL 548i.

Afterward, bar codes with the same code type and number of digits are recognized and decoded.

Notice!

The settings made via display or webConfig configuration tool push the parameters set in the PROFINET-IO only temporarily into the background. They are overwritten during integration into the PROFINET-IO or when the parameter enable is deactivated!

Device settings for operating the BCL 548i on the PROFINET-IO are managed and configured exclusively by the PROFINET-IO Controller (PLC). Permanent changes must be carried out here!

Detailed information on this topic can be found in chapter 10 "Commissioning and configuration" on page 116.

36 BCL 548i Leuze electronic

Specifications

5 Specifications

5.1 General specifications of the bar code readers

5.1.1 Line scanner

Typ e BCL 548i

PROFINET-IO

Typ e Line scanner without heating

Optical data

Light source Laser diode  = 650nm / 655nm (red light) Beam exit Front Scanning rate 1000 scans/s (adjustable in the range 800 … 1200 scans/s) Beam deflection By means of rotating polygon wheel Useful opening angle Max. 60 ° Optics models / resolution High Density (N): 0.25 … 0.5 mm

Medium Density (M): 0.35 … 0.8mm Low Density (F): 0.5 … 1.0mm

Ultra Low Density (L): 0.7 … 1.0mm Read distance see reading field curves Laser safety class 2 acc. to EN 60825-1,

CDRH (U.S. 21 CFR 1040.10)

Bar code data

Code types 2/5 Interleaved, Code 39, Code 128, EAN 128, EAN / UPC,

Codabar, Code 93, GS1 DataBar Omnidirectional Bar code contrast (PCS) >= 60 % External light tolerance 2000 lx (on the bar code) Number of bar codes per scan

Electrical data

Interface type 2x PROFINET-IO

Protocols PROFINET-IO RT-communication

Baud rate 10/100MBaud

Table 5.1: Specifications of the BCL 548i line scanners without heating

on 2x M12 (D)

DCP

TCP/IP (Client/ Server) / UDP

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Leuze electronic BCL 548i 37

Specifications

Type BCL 548i

PROFINET-IO

Type Line scanner without heating

Data formats

Service interface USB 1.1 compatible, A-coded Switching input / switching output

Operating voltage 10 … 30VDC (Class II, Safety Class III) Power consumption Max. 10W

Operating and display elements

Display Monochromatic graphical display, 128 x 64 pixel, with background

Keyboard 4 buttons LEDs 2 LEDs for power (PWR) and bus state (BUS), two-colored (red/green)

Mechanical data

Protection class IP 65 (with screwed-on M12 connectors or mounted caps) Weight 1.1kg Dimensions (WxHxD) 63 x 123.5 x 106.5 mm Housing diecast aluminum

Environmental data

Operating temperature range 0°C … +40°C Storage temperature range -20°C … +70°C Air humidity Max. 90% rel. humidity, non-condensing Vibration IEC 60068-2-6, test FC Shock IEC 60068-2-27, test Ea Continuous shock IEC 60068-2-29, test Eb Electromagnetic compatibility

Table 5.1: Specifications of the BCL 548i line scanners without heating

1) This is a Class A product. In a domestic environment this product may cause radio interference, in which case the operator may be required to take adequate measures.

4 switching inputs/outputs, freely programmable functions

- Switching input: 10 … 30V DC depending on supply voltage, I max. = 8mA

- Switching input: 10 … 30V DC, depending on supply voltage, I max. = 60mA (short-circuit proof)

Switching inputs/outputs are protected against polarity reversal!

lighting

EN 55022; IEC 61000-6-2 (contains IEC 61000-4-2, -3, -4, -5 and -6)

Attention!

For UL applications, use is permitted exclusively in Class 2 circuits according to NEC (National Electric Code).

The BCL 548i bar code readers are designed in accordance with safety class III for supply by PELV (protective extra-low voltage with reliable disconnection).

38 BCL 548i Leuze electronic

5.1.2 Oscillating-mirror scanner

Technical data same as for line scanner without heating with the following differences:

Specifications

Typ e BCL 548i

Typ e Oscillating-mirror scanner without heating

Optical data

Beam exit Lateral zero position at an angle of 90° Beam deflection Via rotating polygon wheel (horizontal) and stepping motor with mirror

Oscillation frequency 0 … 10Hz

Max. swivel angle ±20 °(adjustable) Reading field height See reading field curves

Electrical data

Power consumption Max. 14W

Mechanical data

Weight 1.5kg Dimensions (Wx H x D) 84 x173 x 147mm

Table 5.2: Specifications of the BCL 548i oscillating-mirror scanners without heating

PROFINET-IO

(vertical)

(adjustable, max. frequency is dependent on set swivel angle)

5.1.3 Line scanner with deflection mirror

Technical data same as for line scanner without heating with the following differences:

Typ e BCL 548i

Typ e Line scanner with deflection mirror without heating

Optical data

Beam exit Lateral zero position at an angle of 90° Beam deflection Via rotating polygon wheel (horizontal) and deflection mirror (vertical) Max. optical adjustment range of the beam exit

Electrical data

Power consumption Max. 11W

Mechanical data

Weight 1.4kg Dimensions (Wx H x D) 84 x173 x 147mm

Table 5.3: Specifications of the BCL 548i deflection-mirror scanners without heating

PROFINET-IO

±10° (adjustable via display or software)

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Leuze electronic BCL 548i 39

Specifications

5.2 Heating models of the bar code readers

The BCL 548i bar code readers are optionally available as models with integrated heating. In this case, heating is permanently installed ex works. Self-installation onsite by the user is not possible!

Features

• Integrated heating (permanently installed)

• Extends the application range of the BCL 548i to -35°C

• Supply voltage 24V DC ±20 %

• BCL 548i enabling through an internal temperature switch (switch-on delay about 30 min for 24V DC and minimum ambient temperature of -35 °C)

• Necessary conductor cross-section for the voltage supply: at least 0.75 mm²; the use of ready-made cables is, thus, not possible.

Construction

The heating consists of two parts:

• The front cover heater

• The housing heater

Function

When the 24V DC supply voltage is applied to the BCL 548i, a temperature switch initially only connects the heating to electrical power (front cover heater and housing heater). During the heating phase (around 30min), when the inside temperature rises above 15°C, the temperature switch connects the BCL 548i 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 approximately 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.

Electrical connection

The required core cross-section of the connection cable for the voltage supply must be at least 0.75 mm².

Attention!

The voltage supply must not be looped through from one device to the next.

40 BCL 548i Leuze electronic

Specifications

Power consumption

The energy requirement depends on the model:

• the line scanner with heating typically consumes 40W and a maximum of 50W power.

• the line scanner with oscillating mirror and heating typically consumes 60W and a maximum of 75W.

These values are based on operation with unconnected switching outputs.

5.2.1 Line scanner with heating

Technical data same as for line scanner without heating with the following differences:

Typ e BCL 548i

PROFINET-IO

Typ e Line scanner with heating

Electrical data

Operating voltage 24 V DC ±20 % Power consumption Max. 50W Structure of the heating Housing heating and separate heating of the optics glass Warmup time Min. 30min at +24 VDC and an ambient temperature of -35° C Min. conductor cross-section

Environmental data

Operating temperature range -35°C … +40 °C Storage temperature range -20°C … +70 °C

Table 5.4: Specifications of the BCL 548i line scanners with heating

Conductor cross-section of at least 0.75mm² for the supply-voltage supply line. Wiring through of the voltage supply to multiple heating devices is not permissible. standard, M12 ready-made cable not usable (insufficient conductor cross-section)

Leuze electronic BCL 548i 41

TNT 35/7-24V

Specifications

5.2.2 Oscillating-mirror scanner with heating

Technical data same as for line scanner without heating with the following differences:

Type BCL 548i

Type Oscillating-mirror scanner with heating

Optical data

Useful opening angle Max. 50 ° Max. swivel angle ±12°(adjustable)

Electrical data

Operating voltage 24VDC ±20% Power consumption Max. 75W Structure of the heating Housing heating and separate heating of the optics glass Warmup time Min. 30min at +24VDC and an ambient temperature of -35° C Min. conductor cross-section

Environmental data

Operating temperature range -35°C … +40°C Storage temperature range -20°C … +70°C

Table 5.5: Specifications of the BCL 548i oscillating-mirror scanners with heating

PROFINET-IO

Conductor cross-section of at least 0.75mm² for the supply-voltage supply line. Wiring through of the voltage supply to multiple heating devices is not permissible. Standard, M12 ready-made cable not usable (insufficient conductor cross-section)

42 BCL 548i Leuze electronic

5.2.3 Line scanner with deflection mirror and heating

Technical data same as for line scanner without heating with the following differences:

Specifications

Typ e BCL 548i

Typ e Deflection mirror scanner with heating

Optical data

Useful opening angle Max. 50 ° Max. adjustment range ±10 °(adjustable via display or software)

Electrical data

Operating voltage 24 V DC ±20 % Power consumption Max. 75W Structure of the heating Housing heating and separate heating of the optics glass Warmup time Min. 30min at +24 VDC and an ambient temperature of -35° C Min. conductor cross-section

Environmental data

Operating temperature range -35°C … +40 °C Storage temperature range -20°C … +70 °C

Table 5.6: Specifications of the BCL 548i deflection-mirror scanners with heating

PROFINET-IO

TNT 35/7-24V

Leuze electronic BCL 548i 43

Specifications

A – Optical axis

5.3 Dimensioned drawings

5.3.1 Line scanner with / without heating

Figure 5.1: Dimensioned drawing BCL 548i line scanner S…102

44 BCL 548i Leuze electronic

5.3.2 Deflection mirror scanner with / without heating

A – Optical axis B – Optical adjustment range C – Opening angle

The opening angle is reduced on devices with heating, see "Reading field curves for heating devices" on page 58.

Specifications

Figure 5.2: Dimensioned drawing BCL 548i deflection-mirror scanner S…100

Leuze electronic BCL 548i 45

TNT 35/7-24V

Specifications

A – Optical axis B – Optical swivel range C – Opening angle

The optical swivel range and the opening angle are reduced on devices with heating, see "Reading field curves for heating devices" on page 58.

5.3.3 Oscillating-mirror scanner with / without heating

46 BCL 548i Leuze electronic

Figure 5.3: Dimensioned drawing BCL 548i oscillating-mirror scanner O…100

5.4 Type overview BCL 548i

BCL 548i family

(PROFINET-IO on 2x M 12 D-coded)

Type designation Description Part no.

High Density Optics (m = 0.25 … 0.5mm)

BCL 548i SN 100 Line scanner with deflection mirror 50113185 BCL 548i SN 102 Line scanner, beam exit at the front 50113183 BCL 548i ON 100 Oscillating-mirror scanner 50113199 BCL 548i SN 100 H Line scanner with deflection mirror, with heating 50113186 BCL 548i SN 102 H Line scanner, beam exit at the front, with heating 50113184 BCL 548i ON 100 H Oscillating-mirror scanner with heating 50113200

Medium Density Optics (m = 0.35 … 1.0mm)

BCL 548i SM 100 Line scanner with deflection mirror 50113189 BCL 548i SM 102 Line scanner, beam exit at the front 50113187 BCL 548i OM 100 Oscillating-mirror scanner 50113201 BCL 548i SM 100 H Line scanner with deflection mirror, with heating 50113190 BCL 548i SM 102 H Line scanner, beam exit at the front, with heating 50113188 BCL 548i OM 100 H Oscillating-mirror scanner with heating 50113202

Low Density Optics (m = 0.5 … 1.0mm)

BCL 548i SF 100 Line scanner with deflection mirror 50113197 BCL 548i SF 102 Line scanner, beam exit at the front 50113195 BCL 548i OF 100 Oscillating-mirror scanner 50113205 BCL 548i SF 100 H Line scanner with deflection mirror, with heating 50113198 BCL 548i SF 102 H Line scanner, beam exit at the front, with heating 50113196 BCL 548i OF 100 H Oscillating-mirror scanner with heating 50113206

Specifications

Ultra Low Density Optics (m = 0.7 … 1.0mm)

BCL 548i SL 102 Line scanner, beam exit at the front 50113191 BCL 548i OL 100 Oscillating-mirror scanner 50113203 BCL 548i SL 102 H Line scanner, beam exit at the front, with heating 50113192 BCL 548i OL 100 H Oscillating-mirror scanner with heating 50113204

Table 5.7: Type overview BCL 548i

Leuze electronic BCL 548i 47

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Specifications

M = Module: The narrowest line or space of a bar code in mm. Z

= Wide element: Wide lines and spaces are a multiple (ratio) of the

module. Module x Ratio = Z

(Normal Ratio 1 : 2.5).

= Quiet zone: The quiet zone should be at least 10 times the

module, but not less than 2.5mm.

L = Code length: The length of the bar code in mm including the start

and stop characters. The quiet zone is included depending on the code definition.

= Bar length: Height of the elements in mm.

5.5 Reading field curves / optical data

Bar code characteristics

Notice!

Please note that the size of the bar code module influences the maximum reading distance and the width of the reading field. Therefore, when selecting a mounting location and/or the bar code label, take into account the different reading characteristics of the scanner with various bar code modules.

Figure 5.4: The most important characteristics of a bar code

The range in which the bar code can be read by the BCL 548i (the so-called reading field) depends on the quality of the printed bar code and its dimensions.

Therefore, above all, the module of a bar code is decisive for the size of the reading field.

Notice!

A rule of thumb: The smaller the module of the bar code is, the smaller the maximum reading distance and reading field width will be.

48 BCL 548i Leuze electronic

5.6 Reading field curves

Zero position

Distance acc. to reading field curves

Notice!

Please notice that the real reading fields are also influenced by factors such as labeling material, printing quality, scanning angle, printing contrast etc., and may thus deviate from the reading fields specified here.

The zero position of the reading distance always refers the front edge of the housing of the beam exit and is shown in figure 5.5 for the two housing types of the BCL 548i.

Specifications

Figure 5.5: Zero position of the reading distance

Reading conditions for the reading field curves

Bar code type 2/5 Interleaved Ratio 1:2,5

Leuze electronic BCL 548i 49

ANSI specification class A Reading rate > 75%

Table 5.8: Reading conditions

TNT 35/7-24V

Specifications

Read distance [mm]

Reading field width [mm]

5.6.1 High Density (N) Optics: BCL 548i SN 100/102

400

300

200

100

-100

-200

-300

-400 0-100 200100 300 400 500 600 700 800 900 1000

BCL 500/501/504/508/548i SN 100/102

m = 0,3

m = 0,35

m = 0,25

m = 0,3

m = 0,35

m = 0,5

Figure 5.6: "High Density" reading field curve for line scanner (with/without deflection mirror)

The reading field curve applies for the reading conditions stated in table 5.8.

50 BCL 548i Leuze electronic

5.6.2 High Density (N) Optics: BCL 548i ON 100

0-100 100 200 300 400 500 600 700 800 900 1000

100

200

300

400

-100

-200

-300

-400

BCL 500/501/504/508/548i ON 100

m = 0,25

m = 0,3

m = 0,35

m = 0,5

m = 0,35

m = 0,3

m = 0,25

m = 0,5

Read distance [mm]

Reading field width [mm]

Read distance [mm]

Reading field height [mm]

Figure 5.7: "High Density" reading field curve for oscillating-mirror scanners

Specifications

400

300

200

100

-100

-200

-300

-400

-100

0 100

200 300 400 500 600 700 800 900 1000

Figure 5.8: Lateral "High Density" reading field curve for oscillating-mirror scanners

The reading field curves apply for the reading conditions stated in table 5.8.

Leuze electronic BCL 548i 51

BCL 500/501/504/508/548i ON 100

m = 0,3

m = 0,5

m = 0,35

m = 0,25

m = 0,3

m = 0,35

m = 0,5

TNT 35/7-24V

Specifications

Read distance [mm]

Reading field width [mm]

5.6.3 Medium Density (M) Optics: BCL 548i SM 100/102

400

300

200

100

-100

-200

-300

-400

BCL 500/501/504/508/548i SM 100/102

m = 0,5

m = 0,35

100 200-100 0 300 400 500 600 700 800 900 1000 1100

m = 0,8 … 1,0

Figure 5.9: "Medium Density" reading field curve for line scanner (with/without deflection mirror)

The reading field curves apply for the reading conditions stated in table 5.8.

m = 0,35

m = 0,5

m = 0,8 … m = 1,0

52 BCL 548i Leuze electronic

5.6.4 Medium Density (M) Optics: BCL 548i OM 100

0-100 100 200 300 400 500 600 700 800 900 1000 1100

100

200

300

400

-100

-200

-300

-400

BCL 500/501/504/508/548i OM 100

m = 0,35

m = 0,5

m = 0,8 … m = 1,0

m = 0,5

m = 0,35

m = 0,8 … 1,0

Read distance [mm]

Reading field width [mm]

0 100

-100

200 300 400 500 600 700 800 900 11001000

100

200

300

400

-100

-200

-300

-400

BCL 500/501/504/508/548i OM 100

m = 0,35

m = 0,5

m = 0,8 … m = 1,0

m = 0,5

m = 0,35

m = 0,8 … 1,0

Read distance [mm]

Reading field height [mm]

Figure 5.10: "Medium Density" reading field curve for oscillating-mirror scanners

Specifications

Figure 5.11: Lateral "Medium Density" reading field curve for oscillating-mirror scanners

The reading field curves apply for the reading conditions stated in table 5.8.

Leuze electronic BCL 548i 53

TNT 35/7-24V

Specifications

100 200-100 0 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700

100

-100

-200

-300

-400

-500

-600

-700

200

300

400

500

600

700

BCL 500/501/504/508/548i SF 100/102

m = 1,0

m = 0,8

m = 0,5

m = 0,8

m = 1,0

Read distance [mm]

Reading field width [mm]

5.6.5 Low Density (F) Optics: BCL 548i SF 100/102

Figure 5.12: "Low Density" reading field curve for line scanner (with/without deflection mirror)

The reading field curves apply for the reading conditions stated in table 5.8.

54 BCL 548i Leuze electronic

5.6.6 Low Density (F) Optics: BCL 548i OF 100

Read distance [mm]

Reading field width [mm]

Read distance [mm]

Reading field height [mm]

Specifications

700

600

500

400

300

200

100

-100

-200

-300

-400

-500

-600

-700 0-100 100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 17001600

BCL 500/501/504/508/548i OF 100

m = 0,5

m = 0,8

Figure 5.13: "Low Density" reading field curve for oscillating-mirror scanners

700

600

500

400

300

200

100

BCL 500/501/504/508/548i OF 100

m = 0,5

m = 0,8

m = 1,0

m = 0,5

m = 0,8

m = 1,0

-100

-200

-300

-400

-500

-600

-700

-100

m = 0,5

0 100

200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 17001600

m = 1,0

m = 0,8

Figure 5.14: Lateral "Low Density" reading field curve for oscillating-mirror scanners

The reading field curves apply for the reading conditions stated in table 5.8.

Leuze electronic BCL 548i 55

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Specifications

Read distance [mm]

Reading field width [mm]

5.6.7 Ultra Low Density (L) Optics: BCL 548i SL 102

800

600

400

200

-200

-400

-600

-800 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 26000

BCL 500/501/504/508/548i SL 102

m = 0,7

m = 0,8

m = 1,0

Figure 5.15: "Ultra Low Density" reading field curve for line scanner without deflection mirror

The reading field curves apply for the reading conditions stated in table 5.8.

m = 0,7

m = 0,8

m = 1,0

56 BCL 548i Leuze electronic

5.6.8 Ultra Low Density (L) Optics: BCL 548i OL 100

Read distance [mm]

Reading field width [mm]

200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 26000

-200

-400

-600

-800

-1000

1000

200

400

600

800

BCL 500/501/504/508/548i OL 100

m = 0,7

m = 0,8

m = 1,0

m = 0,8

m = 0,7

Read distance [mm]

Reading field height [mm]

Specifications

800

600

400

200

-200

-400

-600

-800 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 26000

BCL 500/501/504/508/548i OL 100

m = 0,7

m = 0,8

Figure 5.16: "Ultra Low Density" reading field curve for oscillating-mirror scanners

m = 0,7

m = 0,8

m = 1,0

Figure 5.17: Lateral "Ultra Low Density" reading field curve for oscillating-mirror scanners

The reading field curves apply for the reading conditions stated in table 5.8.

Leuze electronic BCL 548i 57

TNT 35/7-24V

Specifications

100 200-100 0 300 400 500 600 700 800 900 1000

100

200

300

400

-100

-200

-300

-400

BCL 500/501/504/508/548i SN 102 H

m = 0,25

m = 0,3

m = 0,35

m = 0,5

m = 0,35

m = 0,3

m = 0,25

m = 0,5

Read distance [mm]

Reading field width [mm]

5.7 Reading field curves for heating devices

The reading field curves of the heating devices differ to some extent from the normal reading curves due to the optics heating and are somewhat reduced in the reading field width as well as in the reading field height!

• The maximum opening angle for all oscillating and deflection mirror devices (BCL 548i…100 H) is reduced to ±28° (without heating = ±30°).

• In addition, the maximum swivel range for all oscillating mirror devices (BCL 548i O…100 H) is reduced to ±12° (without heating = ±20°). The deflection mirror models (BCL 548i S…100 H) are not affected by this limitation.

• The reading field curves and opening angles are unchanged for all line scanners with heating (BCL 548i S…102 H).

For details, please refer to the following reading field curves for the heating devices.

5.7.1 High Density (N) Optics: BCL 548i SN 102 H

58 BCL 548i Leuze electronic

Figure 5.18: "High Density" reading field curve for line scanner with heating (without deflection mirror)

The reading field curve applies for the reading conditions stated in table 5.8.

5.7.2 High Density (N) Optics: BCL 548i SN 100 H

100 200-100 0 300 400 500 600 700 800 900 1000

100

200

300

400

-100

-200

-300

-400

BCL 500/501/504/508/548i SN 100 H

m = 0,25

m = 0,3

m = 0,35

m = 0,5

m = 0,35

m = 0,3

m = 0,25

m = 0,5

Read distance [mm]

Reading field width [mm]

Figure 5.19: "High Density" reading field curve for line scanner with heating (with deflection mirror)

The reading field curve applies for the reading conditions stated in table 5.8.

Specifications

Leuze electronic BCL 548i 59

TNT 35/7-24V

Specifications

Read distance [mm]

Reading field width [mm]

0 100

-100

200 300 400 500 600 700 800 900 1000

100

200

300

400

-100

-200

-300

-400

BCL 500/501/504/508/548i ON 100 H

m = 0,25

m = 0,3

m = 0,35

m = 0,5

m = 0,35

m = 0,3

m = 0,25

m = 0,5

= ±12˚

Read distance [mm]

Reading field height [mm]

5.7.3 High Density (N) Optics: BCL 548i ON 100 H

BCL 500/501/504/508/548i ON 100 H

m = 0,3

m = 0,5

m = 0,35

m = 0,25

-100

-200

-300

-400

400

300

200

100

1000-100 200 300 400 500 600 700 800 900 1000

Figure 5.20: "High Density" reading field curve for oscillating-mirror scanners with heating

m = 0,25

m = 0,3

m = 0,35

m = 0,5

Figure 5.21: Lateral "High Density" reading field curve for oscillating-mirror scanners with heating

60 BCL 548i Leuze electronic

The reading field curves apply for the reading conditions stated in table 5.8.

5.7.4 Medium Density (M) Optics: BCL 548i SM 102 H

100 200-100 0 300 400 500 600 700 800 900 1000 1100

100

200

300

400

-100

-200

-300

-400

BCL 500/501/504/508/548i SM 102 H

m = 0,35

m = 0,5

m = 0,8 … m = 1,0

m = 0,5

m = 0,35

m = 0,8 … 1,0

Read distance [mm]

Reading field width [mm]

Figure 5.22: "Medium Density" reading field curve for line scanner with heating (without deflection mirror)

The reading field curves apply for the reading conditions stated in table 5.8.

Specifications

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Specifications

Read distance [mm]

Reading field width [mm]

5.7.5 Medium Density (M) Optics: BCL 548i SM 100 H

BCL 500/501/504/508/548i SM 100 H

m = 0,35

m = 0,5

m = 0,8 … m = 1,0

m = 0,5

m = 0,35

m = 0,8 … 1,0

-100

-200

-300

-400

400

300

200

100

100 200-100 0 300 400 500 600 700 800 900 1000 1100

Figure 5.23: "Medium Density" reading field curve for line scanner with heating (with deflection mirror)

The reading field curves apply for the reading conditions stated in table 5.8.

62 BCL 548i Leuze electronic

5.7.6 Medium Density (M) Optics: BCL 548i OM 100 H

1000-100 200 300 400 500 600 700 800 900 1000 1100

100

200

300

400

-100

-200

-300

-400

BCL 500/501/504/508/548i OM 100 H

m = 0,35

m = 0,5

m = 0,8 … m = 1,0

m = 0,5

m = 0,35

m = 0,8 … 1,0

Read distance [mm]

Reading field width [mm]

0 100

-100

200 300 400 500 600 700 800 900 11001000

100

200

300

400

-100

-200

-300

-400

BCL 500/501/504/508/548i OM 100 H

m = 0,35

m = 0,5

m = 0,8 … m = 1,0

m = 0,5

m = 0,35

m = 0,8 … 1,0

= ±12˚

Read distance [mm]

Reading field height [mm]

Figure 5.24: "Medium Density" reading field curve for oscillating-mirror scanners with heating

Specifications

Figure 5.25: Lateral "Medium Density" reading field curve for oscillating-mirror scanners with heating

The reading field curves apply for the reading conditions stated in table 5.8.

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Specifications

100 200-100 0 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700

100

-100

-200

-300

-400

-500

-600

-700

200

300

400

500

600

700

BCL 500/501/504/508/548i SF 102 H

m = 1,0

m = 0,8

m = 0,5

m = 0,8

m = 1,0

Read distance [mm]

Reading field width [mm]

5.7.7 Low Density (F) Optics: BCL 548i SF 102 H

Figure 5.26: "Low Density" reading field curve for line scanner with heating (without deflection mirror)

The reading field curves apply for the reading conditions stated in table 5.8.

64 BCL 548i Leuze electronic

5.7.8 Low Density (F) Optics: BCL 548i SF 100 H

Read distance [mm]

Reading field width [mm]

Specifications

700

600

500

400

300

200

100

-100

-200

-300

-400

-500

-600

-700 100 200-100 0 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700

BCL 500/501/504/508/548i SF 100 H

m = 0,5

m = 0,8

m = 0,5

m = 0,8

m = 1,0

Figure 5.27: "Low Density" reading field curve for line scanner with heating (with deflection mirror)

The reading field curves apply for the reading conditions stated in table 5.8.

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Specifications

1000-100 200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 1600 1700

100

-100

-200

-300

-400

-500

-600

-700

200

300

400

500

600

700

BCL 500/501/504/508/548i OF 100 H

m = 1,0

m = 0,8

m = 0,5

m = 0,8

m = 1,0

Read distance [mm]

Reading field width [mm]

Read distance [mm]

Reading field height [mm]

5.7.9 Low Density (F) Optics: BCL 548i OF 100 H

Figure 5.28: "Low Density" reading field curve for oscillating-mirror scanners with heating

700

600

500

400

300

200

100

-100

-200

-300

-400

-500

-600

-700 0 100

-100

Figure 5.29: Lateral "Low Density" reading field curve for oscillating-mirror scanners with heating

The reading field curves apply for the reading conditions stated in table 5.8.

66 BCL 548i Leuze electronic

BCL 500/501/504/508/548i OF 100 H

= ±12˚

m = 0,8

m = 0,5

200 300 400 500 600 700 800 900 1000 1100 1200 1300 1400 1500 17001600

m = 0,5

m = 0,8

m = 1,0

5.7.10 Ultra Low Density (L) Optics: BCL 548i SL 102 H

Read distance [mm]

Reading field width [mm]

Specifications

800

600

400

200

-200

-400

-600

-800 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 26000

BCL 500/501/504/508/548i SL 102 H

m = 0,7

m = 0,8

m = 0,7

m = 0,8

m = 1,0

Figure 5.30: "Ultra Low Density" reading field curve for line scanner with heating (without deflection mirror)

The reading field curves apply for the reading conditions stated in table 5.8.

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Specifications

Read distance [mm]

Reading field width [mm]

200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 26000

-200

-400

-600

-800

-1000

1000

200

400

600

800

BCL 500/501/504/508/548i OL 100 H

m = 0,7

m = 0,8

m = 1,0

±12˚

m = 1,0

m = 0,8

m = 0,7

Read distance [mm]

Reading field height [mm]

5.7.11 Ultra Low Density (L) Optics: BCL 548i OL 100 H

800

600

400

200

-200

-400

-600

-800 200 400 600 800 1000 1200 1400 1600 1800 2000 2200 2400 26000

BCL 500/501/504/508/548i OL 100 H

m = 0,7

m = 0,8

m = 0,7

m = 0,8

m = 1,0

Figure 5.31: "Ultra Low Density" reading field curve for oscillating-mirror scanners with heating

68 BCL 548i Leuze electronic

Figure 5.32: Lateral "Ultra Low Density" reading field curve for oscillating-mirror scanners with heating

The reading field curves apply for the reading conditions stated in table 5.8.

6 Installation and mounting

6.1 Storage, transportation

Attention!

When transporting or storing, package the device s o th at it i s pr otected against collision and humidity. Optimum protection is achieved when using the original packaging. Heed the required environmental conditions specified in the technical data.

Unpacking

 Check the packaging for any damage. If damage is found, notify the post office or shipping

agent as well as the supplier.

 Check the delivery contents using your order and the delivery papers:

• Delivered quantity

• Device type and model as indicated on the nameplate

• Laser warning signs

• Brief manual

The name plate provides information as to what BCL type your device is. For specific information, please refer to chapter 5.

Name plates of the bar code readers of the BCL 500i series

Installation and mounting

Figure 6.1: Device name plate BCL 548i

 Save the original packaging for later storage or shipping.

If you have any questions concerning your shipment, please contact your supplier or your local Leuze electronic sales office.

 Observe the applicable local regulations when disposing of the packaging materials.

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Installation and mounting

6.2 Mounting the BCL 548i

The BCL 548i bar code readers can be mounted in two different ways:

• Using two M4x6 screws on the rear of the device or using four M4x6 screws on the bottom of the device.

• Using a BT 56 mounting device on the two fastening grooves.

6.2.1 Fastening with M4 x 6 screws

Figure 6.2: Fastening options using M4x6 threaded holes

70 BCL 548i Leuze electronic

6.2.2 BT 56 mounting device

Clamping jaws for mounting on the BCL 548i

Clamp profile for mounting to round or oval pipes Ø16…20mm

A Rod holder, turnable 360° B Rods Ø 16 … 20mm

All dimensions in mm

The BT 56 mounting device is available for mounting the BCL 548i using the fastening grooves. It is designed for rod installation (Ø 16mm to 20mm). For ordering instructions, please refer to chapter "Type overview and accessories" on page 227.

BT 56 mounting device

Installation and mounting

Figure 6.3: BT 56 mounting device

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Installation and mounting

Figure 6.4: Mounting example of BCL 548i with BT 56

72 BCL 548i Leuze electronic

6.2.3 BT 59 mounting device

Clamping jaws for mounting on the BCL 548i

A Holder, turnable 360° B ITEM joint, angle adjustable ±90° C M 8x16 screw cylinder, M 8 wave washer, M 8

sliding block, connectors for ITEM profile (2x)

alle Maße in mm

The BT 59 mounting device offers you an additional fastening option. For ordering instructions, please refer to chapter "Type overview and accessories" on page 227.

BT 59 mounting device

Installation and mounting

Leuze electronic BCL 548i 73

BT 59 mounting device

Notice!

When mounting, ensure that the scanning beam is not reflected directly back to the scanner by the label which is being read. For further information, see the notices in chapter 6.3! Please refer to chapter 5.6 for the permissible minimum and maximum distances between the BCL 548i and the labels to be read.

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Installation and mounting

6.3 Device arrangement

6.3.1 Selecting a mounting location

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 BCL 548i in relation to the bar code module width.

• The resulting minimum and maximum reading distance from the respective reading field (see chapter 5.5 "Reading field curves / optical data").

• The permissible cable lengths between the BCL 548i and the host system depending on which interface is used.

• The display and control panel should be very visible and accessible.

• For configuring and commissioning with the webConfig tool, the USB interface should be easily accessible.

For specific information, please refer to chapter 4.4.

Notice!

The beam exits the BCL 548i as follows for the respective devices:

- line scanner parallel to the housing base

- oscillating mirror and deflection mirror perpendicular to the housing base The black areas in figure 6.1 are the housing base. The best read results are obtained when:

• The BCL 548i is mounted in such a way that the scanning beam is incident on the bar code at an angle of inclination greater than ±10° … 15° to vertical.

• The reading distance lies in the middle area of the reading field.

• The bar code labels are of good print quality and have good contrast ratios.

• You do not use high-gloss labels.

• There is no direct sunlight.

74 BCL 548i Leuze electronic

Installation and mounting

Bar code

The BCL 548i should be mounted in such a way that the scanning beam is incident on the bar code at an angle of inclination greater than ±10° … 15° to vertical.

…

6.3.2 Avoiding total reflection – Line scanner

The bar code label must be positioned at an angle of inclination greater than ±10° … 15° from vertical in order to avoid total reflection of the laser beam (see figure 6.5)!

Total reflection occurs whenever the laser light of the bar code reader is directly incident on the surface of the bar code at an angle of 90°. The light directly reflected by the bar code may overload the bar code reader and thereby cause non-readings!

Figure 6.5: Total reflection – line scanner

6.3.3 Avoiding total reflection – oscillating/deflection-mirror scanner

For the BCL 548i with oscillating/deflection mirror, the laser beam exits at an angle of 90° to vertical.

For the BCL 548i with deflection mirror, it is also possible to use software to adjust the direction of the beam by ±10°.

For the BCL 548i with oscillating mirror, the swivel range of ±20° (±12° for devices with heating) is to be taken into account.

This means that in order to be on the safe side and to avoid total reflection, the BCL 548i with oscillating/deflection mirror must be inclined upward or downward 20° … 30°!

Notice!

Mount the BCL 548i with oscillating/deflection mirror in such a way that the outlet window of the bar code reader is parallel to the object. This will result in an angle of inclination of approx. 25°.

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Leuze electronic BCL 548i 75

Installation and mounting

Bar code

The BCL 548i should be mounted in such a way that the scanning beam is incident on the bar code at an angle of inclinatio n greater than ±25° to vertical.

Figure 6.6: Total reflection – BCL 548i with oscillating/deflection mirror

6.3.4 Mounting location

 When selecting a mounting location, pay attention to:

• Maintaining the required environmental conditions (temperature, humidity).

• Possible soiling of the reading window due to liquids, abrasion by boxes, or packaging material residues.

• Lowest possible chance of damage to the BCL 548i by mechanical collision or jammed parts.

• Possible extraneous light (no direct sunlight or sunlight reflected by the bar code).

6.3.5 Devices with integrated heating

 For devices with integrated heating, also observe the following points:

• Mount the BCL 548i in a way which provides maximum thermal isolation, e.g. using rubber-bonded metal.

• Mount in such a way that the device is protected from draft and wind; mount additional shields if necessary.

Notice!

When installing the BCL 548i in a protective housing, it must be ensured that the scanning beam can exit the protective housing without obstruction.

76 BCL 548i Leuze electronic

Installation and mounting

6.3.6 Possible read angles between BCL 548i and bar code

The optimum alignment of the BCL 548i is accomplished when the scan line scans the code bars almost at a right angle (90°). All read angles that are possible between the scan line and bar code must be taken account (figure 6.7).

Figure 6.7: Reading angle for the line scanner

 Tilt  Angle of inclination (Pitch)  Skew

In order to avoid total reflection, the skew  should be greater than 10°

6.4 Attaching laser warning sign

Attention Laser!

Follow the safety notices in chapter 2.

 It is important that you attach the sticky labels supplied to the device (laser warning signs

and laser emission symbol)! If the signs would be covered due to the installation situation of the BCL 548i, attach them instead in the immediate vicinity of the BCL 548i in such a way that it is not necessary to look into the laser beam when reading the notices!

6.5 Cleaning

 Clean the glass window of the BCL 548i with a soft cloth after mounting. Remove all pack-

aging remains, e.g. carton fibers or Styrofoam balls. In doing so, avoid leaving fingerprints on the front cover of the BCL 548i.

Attention!

Do not use aggressive cleaning agents such as thinner or acetone for cleaning the device.

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Electrical connection

7 Electrical connection

The BCL 548i bar code readers are connected using variously coded M12 connectors. This ensures unique connection assignments.

The additional USB interface is used for configuring the device.

For the locations of the individual device connections, please refer to the device detail shown below.

Notice!

The corresponding mating connectors and ready-made cables are available as accessories for all cables. For additional information, refer to chapter chapter 13.

Figure 7.1: Location of the electrical connections

7.1 Safety notices for the electrical connection

Attention!

Do not open the device yourself under any circumstances! There is otherwise a risk of uncontrolled emission of laser radiation from the device. The housing of the BCL 548i contains no parts that need to be adjusted or maintained by the user.

Before connecting the device, be sure that the supply voltage agrees with the value printed on the name plate.

Connection of the device and cleaning must only be carried out by a qualified electrician.

Ensure that the functional earth (FE) is connected correctly. Unimpaired operation is only guaranteed when the functional earth is connected properly.

If faults cannot be corrected, the device should be removed from operation and protected against possible use.

Attention!

For UL applications, use is permitted exclusively in Class 2 circuits according to NEC (National Electric Code).

The BCL 548i bar code readers are designed in accordance with safety class III for supply by PELV (protective extra-low voltage with reliable disconnection).

78 BCL 548i Leuze electronic

Notice!

USB socket

Type A

M12 socket

(A-coded)

M12 socket

(D-coded)

M12 socket

(D-coded)

M12 plug (A-coded)

Protection class IP65 is achieved only if the connectors and caps are screwed into place!

7.2 Electrical connection of the BCL 548i

As a PROFINET-IO participant, the BCL 548i is equipped with four M 12 plugs / sockets which are A- and D-coded.

The voltage supply (PWR) as well as the four freely configurable switching inputs/outputs (SW IN/OUT and PWR) are connected there.

"HOST / BUS IN" is available as a PROFINET-IO interface for connecting to the host system.

By means of the implemented switch function in the BCL 548i, an additional second "BUS OUT" PROFINET-IO interface is available for creating a scanner network (linear topology).

A USB connection serves as a "SERVICE" interface.

Electrical connection

SERVICE

GND D+ D-

2134

BUS OUT

RD+

TD+

Figure 7.2: Connections of the BCL 548i

Described in detail in the following are the individual connections and pin assignments.

RD-

TD-

HOST / BUS IN

TD+

RD+

RD-

VOUT

TD-

SW IN/OUT

SWIO_1

SWIO_2

GND VIN

GND

PWR

SWIO_3

SWIO_4

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Electrical connection

PWR

SWIO_4

SWIO_3

GND VIN

M12 plug (A-coded)

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

PWR (5-pin plug, A-coded)

Pin Name Remark

1 VIN Positive supply voltage +10 … +30 V DC

2 SWIO_3 Configurable switching input / output 3

3 GND Negative supply voltage 0VDC

4 SWIO_4 Configurable switching input / output 4

5 FE Functional earth

Thread FE Functional earth (housing)

Table 7.1: Pin assignment PWR

Supply voltage

Attention!

For UL applications, use is permitted exclusively in Class 2 circuits according to NEC (National Electric Code).

The BCL 548i bar code readers are designed in accordance with safety class III for supply by PELV (protective extra-low voltage with reliable disconnection).

Connecting functional earth FE

 Ensure that the functional earth (FE) is connected correctly. Unimpaired operation is only

guaranteed when the functional earth is connected properly. All electrical disturbances (EMC couplings) are discharged via the functional earth connection.

Switching input / output

The BCL 548i is equipped with four freely programmable, opto-decoupled switching inputs and outputs SWIO_1 … SWIO_4.

The switching inputs can be used to activate various internal functions of the BCL 548i (decoding, autoConfig, …). The switching outputs can be used to signal the state of the BCL 548i and to implement external functions independent of the superior control.

The two switching inputs/outputs SWIO_1 and SWIO_2 are located on the SW IN/OUT M12 socket and are described in chapter 7.2.3. The other two (SWIO_3 and SWIO_4) of the four freely configurable switching inputs/outputs are located on the PWR M12 connector.

Notice!

In general, configuration of the bar code reader takes place on the PROFINET-IO via the corresponding GSD file. Alternatively, you can temporarily set the respective function as input or output via the display or with the aid of the webConfig configuration tool for the purpose of testing the respective functionality. After reconnecting to the PROFINET-IO or after deactivating parameter enabling, the parameter settings set by the PROFINET-IO are again active!

80 BCL 548i Leuze electronic

Electrical connection

Switching input

Switching output from controller (deactivated)

Switching input to controller

Switching output

Switching output from controller

Switching input to controller (deactivated)

Described in the following is the external wiring for use as a switching input or output; the respective function assignments to the switching inputs/outputs can be found in chapter 10.

Function as switching input

Figure 7.3: Switching input connection diagram SWIO_3 and SWIO_4

 If you use a sensor with a standard M12 connector, please note the following:

• Pins 2 and 4 must not be operated as switching outputs if sensors which function as inputs are also connected to these pins.

If, for example, the inverted sensor output is connected to pin 2, and pin 2 of the bar code reader is, at the same time, configured as an output (and not as an input), the switching output malfunctions.

Attention!

The maximum input current must not exceed 8mA!

Function as switching output

Figure 7.4: Switching output connection diagram SWIO_3 / SWIO_4

Attention!

Each configured switching output is short-circuit proof! Do not load the respective switching output of the BCL 548i with more than 60mA at +10 … +30VDC in normal operation!

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Electrical connection

SERVICE

2134

GND D+ D-

Notice!

Both switching inputs/outputs SWIO_3 and SWIO_4 are configured by default in such a way that:

• Switching input SWIO_3 activates the reading gate

• Switching output SWIO_4 switches on "No Read"

7.2.2 SERVICE – USB interface (type A)

SERVICE – USB interface (type A )

Pin Name Remark

1 VB Positive supply voltage +5V DC

2D-Data -

3D+Data +

4GNDGround

Figure 7.5: Pin assignments of SERVICE – USB interface

Attention!

Maximum load of the +5V DC supply voltage of the USB interface is 200mA!

 Ensure adequate shielding.

The entire connection cable must absolutely be shielded acc. to the USB specifications. Cable length must not exceed 3m.

 Use the Leuze-specific USB service cable (see chapter 13 "Type overview and acces-

sories") for the connection and use a service PC to configure.

Notice!

IP 65 is achieved only if the connectors and caps are screwed into place. Alternatively, a parameter memory in the form of a USB memory stick certified by Leuze electronic GmbH + Co. can be connected to the provided USB service interface. With this Leuze memory stick, protection class IP 65 is also ensured.

82 BCL 548i Leuze electronic

7.2.3 SW IN/OUT – Switching input/switching output

SW IN/OUT

VOUT

SWIO_1

SWIO_2

GND

M12 socket

(A-coded)

Diffuse reflection light scanner

Switching output from controller (deactivated)

Switching input to controller

Output

SW IN/OUT (5-pin socket, A-coded)

Pin Name Remark

1VOUT

Voltage supply for sensors (VOUT identical to VIN at PWR IN)

2SWIO_1Configurable switching input / output 1

3GNDGND for the sensors

4SWIO_2Configurable switching input / output 2

5FEFunctional earth

Thread FE Functional earth (housing)

Figure 7.6: Pin assignment SW IN/OUT

The BCL 548i is equipped with four freely programmable, opto-decoupled switching inputs and outputs SWIO_1 … SWIO_4.

The two switching inputs/outputs SWIO_1 and SWIO_2 are located on the SW IN/OUT M12 socket. The other two (SWIO_3 and SWIO_4) of the four freely configurable switching inputs/ outputs are located on the PWR M 12 connector and are described in chapter 7.2.1.

Described in the following is the external wiring for use as a switching input or output; the respective function assignments to the switching inputs/outputs can be found in chapter 10.

Function as switching input

Electrical connection

Figure 7.7: Switching input connection diagram SWIO_1 and SWIO_2

 If you use a sensor with a standard M12 connector, please note the following:

• Pins 2 and 4 must not be operated as switching outputs if sensors which function as inputs are also connected to these pins.

Attention!

The maximum input current must not exceed 8mA!

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Electrical connection

Switching output

Switching output from controller

Switching input to controller (deactivated)

Function as switching output

Figure 7.8: Switching output connection diagram SWIO_1 / SWIO_2

Attention!

Each configured switching output is short-circuit proof! Do not load the respective switching output of the BCL 548i with more than 60mA at +10 … +30VDC in normal operation!

Notice!

Both switching inputs/outputs SWIO_1 and SWIO_2 are configured by default in such a way that they function as switching inputs:

• Switching input SWIO_1 activates the start reading gate function

• Switching input SWIO_2 activates the reference code teach-in function

The functions of the individual switching inputs/outputs are programmed via the display or via configuration in the webConfig tool under the Switching input or Switching output heading.

For further information, see also "Commissioning and configuration" on page 116.

84 BCL 548i Leuze electronic

7.2.4 HOST / BUS IN for BCL 548i

HOST / BUS IN

TD+

RD+

RD-

TD-

M12 socket

(D-coded)

TD+

RD+

RD-

TD-

BCL548 HOST / BUS IN RJ 45

TD+ (1) TD- (2)

RD+ (3)

RD- (6)

Twisted pair

The BCL 548i makes either the PROFINET-IO interface available as host interface.

HOST / BUS IN (4-pin socket, D-coded)

Thread FE Functional earth (housing)

Table 7.2: Pin assignment HOST / BUS IN BCL 548i

 For the host connection of the BCL 548i, the "KB ET - … - SA-RJ45" ready-made cables

are preferred, see table 13.8 "Bus connection cable for the BCL 548i" on page 232.

PROFINET-IO cable assignments

Electrical connection

Pin Name Remark

1TD+ Transmit Data +

2RD+ Receive Data +

3TD- Transmit Data -

4RD- Receive Data -

Figure 7.9: HOST / BUS IN cable assignments on RJ-45

Notice for connecting the PROFINET-IO interface!

Ensure adequate shielding. The entire connection cable must be shielded and earthed. The RD+/RD- and TD+/TD- wires must be stranded in pairs. Use CAT 5 cable for the connection.

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Electrical connection

BUS OUT

TD+

RD+

RD-

TD-

M12 socket

(D-coded)

7.2.5 BUS OUT for the BCL 548i

To set up a PROFINET-IO network with other participants with linear topology, the BCL 548i makes available another PROFINET-IO RT interface. The use of this interface drastically reduces the cabling requirements, as only the first BCL 548i requires a direct connection to the switch, via which it can communicate with the host. All other BCL 548i are connected in series to the first BCL 548i, see figure 7.11.

Table 7.3: Pin assignment BUS OUT

 For the connection of two BCL 548i, the "KB ET - … - SSA" ready-made cables are pre-

ferred, see table 13.8 "Bus connection cable for the BCL 548i" on page 232.

If you use user-configurable cables, note the following:

Notice!

Ensure adequate shielding. The entire connection cable must be shielded and earthed. The signal lines must be stranded in pairs. Use CAT 5 cable for the connection.

BUS OUT (4-pin socket, D-coded)

Pin Name Remark

1TD+ Transmit Data +

2RD+ Receive Data +

3TD- Tr a nsmit Data -

4RD- Receive Data -

Thread FE Functional earth (housing)

Note!

For the BCL 548i as standalone device or as the last participant in a linear topology, termination on the BUS OUT socket is not mandatory!

86 BCL 548i Leuze electronic

7.3 PROFINET-IO topologies

PC / PLC host interface

Other network participants

BCL 548i

myBCL 548i_1

PC / PLC host interface

to other network participants

BCL 548i

myBCL 548i_2

(device name 2)

BCL 548i

myBCL 548i_3

(device name 3)

I/O

PWR

I/O

PWR

I/O

PWR

BCL 548i

myBCL 548i_1

(device name 1)

The BCL 548i can be operated as a single device (standalone) with individual device name in a PROFINET-IO star topology. The PLC must communicate this device name to the participant during the "device naming" (see section "Step 5 – Configuration of the device name - naming the device" on page 121).

Figure 7.10: PROFINET-IO in a star topology

The innovative further development of the BCL 548i with integrated switch functionality offers the option of networking multiple bar code readers of type BCL 548i with one another. In addition to the classic "star topology", a "linear topology" is thus also possible.

This makes wiring the network easy and inexpensive as participants are connected to one another in parallel.

The maximum length of a segment (connection from one participant to the next) is limited to 100m.

Electrical connection

Leuze electronic BCL 548i 87

Figure 7.11: PROFINET-IO in a line topology

Up to 254 bar code readers can be networked. They must all be located in the same subnet.

To do this, the individual "device name" is assigned to each participating BCL 548i through "device naming", using the control's configuration tool. Detailed information can be found in section "Step 5 – Configuration of the device name - naming the device" on page 121.

Information on the necessary configuration steps can be found in chapter 10.

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Electrical connection

7.3.1 PROFINET-IO wiring

A Cat. 5 Ethernet cable should be used for wiring.

For the connection technology transition from M12 to RJ45, a "KDS ET M12 /

RJ 45 W - 4P" adapter is available that lets you connect standard network cables.

If no standard network cables are to be used (e.g. due to lacking IP… protection class), you can use the "KB ET - … - SA" user-configurable cable on the BCL 548i, see table 13.8 "Bus connection cable for the BCL 548i" on page 232.

The individual BCL 548i devices in a linear topology are connected with the "KB ET - … -

SSA" cable, see table 13.8 "Bus connection cable for the BCL 548i" on page 232.

For unavailable cable lengths, you can configure your cables yourself. When doing so, make certain that you connect TD+ on the M 12 connector with RD+ on the RJ-45 connector and TD- on the M12 connector with RD- on the RJ-45 connector, respectively, etc.

Notice!

Use the recommended connectors / sockets or the ready-made cables (see chapter 13 "Type overview and accessories").

7.4 Cable lengths and shielding

 Observe the following maximum cable lengths and shielding types:

Connection Interface Max. cable length Shielding

BCL – service

BCL – host

Network from the first BCL to the last BCL

BCL – power supply unit

Switching input

Switching output

Table 7.4: Cable lengths and shielding

USB 3 m

PROFINET-IO RT 100 m absolutely required, shielded

PROFINET-IO RT

the maximum segment length

must not exceed 100m for

100Base-TX Twisted Pair

(min.Cat.5)

30m not necessary

10m not necessary

shielding absolutely

necessary acc. to USB

specifications

absolutely required, shielded

88 BCL 548i Leuze electronic

8 Display and control panel

IO1 IO2 IO3 IO4 ATT ERR

LNK0

USB

12345678

LNK1

LED

Control buttons

Read result

Bar graph

Status display Link states

USB interface

8.1 Structure of the control panel

Figure 8.1: Structure of the control panel

Display and control panel

8.2 Status display and operation

8.2.1 Indicators in the display

Status displays of the switching inputs/outputs

IO1 Switching input or switching output 1 active (function dependent on set configuration).

Default: Switching input with the "Reading gate activation" function

IO2 Switching input or switching output 2 active (function dependent on set configuration).

Default: Input with the "Teach-in" function

IO3 Switching input or switching output 3 active (function dependent on set configuration).

Default: Switching input with the "Reading gate activation" function

IO4 Switching input or switching output 4 active (function dependent on set configuration).

ATT Warning (Attention) ERR Internal device error (Error) -> The device must be sent in for inspection

Bar graph

The read quality is described on a scale of 0 - 100%. The quality is evaluated based on the "Equal Scans" of the read result configured in the bar code reader.

Default: Switching output with the "No read" function

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Display and control panel

Status display of the USB interface

USB The BCL 548i is connected to a PC via the USB interface. MS An external parameter memory is properly connected to the USB interface of the

BCL 548i.

Read result

The read bar code information is displayed.

Link states

Displays the link states (LNK0 and LNK1) of the PROFINET-IO interface.

• LNK0: physical connection to the HOST / BUS IN port

• LNK1: physical connection to the BUS OUT port

8.2.2 LED status indicators

PWR LED

off Device OFF

flashes green Device ok, initialization phase

- no supply voltage

- no bar code reading possible

- voltage connected

- self test running

- initialization running

green continuous light Device ok

- bar code reading possible

- self test successfully finished

- device monitoring active

orange continuous light Service mode

- bar code reading possible

- configuration via the USB service interface

- configuration via the display

- no data on the host interface

flashes red Device ok, warning set

- bar code reading possible

- temporary operating fault

red continuous light Device error / parameter enable

- no bar code reading possible

90 BCL 548i Leuze electronic

BUS LED

ESC

off No supply voltage

- no communication possible

- PROFINET-IO communication not initialized or inactive

flashes green Initialization

- of the BCL 548i, establishing communication

green continuous light Operation ok

- Network operation ok

- Connection and communication to IO Controller (PLC) established ("data exchange")

flashes red Communication error

bus error

- Parameterization or configuration failed ("parameter failure")

-IO error

- no data exchange

red continuous light Network error

bus error

- No communication (protocol) to IO Controller established ("no data exchange")

Display and control panel

8.2.3 Control buttons

Up Navigate upward/laterally.

Down Navigate downward/laterally.

ESC

ESC Exit menu item.

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ENTER Confirm/enter value, change menu levels.

Navigating within the menus

The menus within a level are selected with the up/down buttons .

The selected menu item is activated with the enter button .

Press the ESC button to move up one menu level.

When one of the buttons is actuated, the display illumination is activated for 10min.

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Display and control panel

Setting values

If input of a value is possible, the display looks like this:

0000|

<-|0123456789 save Standard ----- Unit 0000 | |

Use the and buttons to set the desired value. An accidental, incorrect entry can be corrected by selecting

Then use the buttons to select save and save the set value by pressing .

Selecting options

If options can be selected, the display looks like this:

oOFF

ON Standard ----- Unit OFF | |

Select the desired option with the buttons. Activate the option by pressing .

<-| and then pressing .

92 BCL 548i Leuze electronic

8.3 Menu description

After voltage is applied to the bar code reader, a startup screen is displayed for several seconds. The display then shows the bar code reading window with all status information.

8.3.1 The main menus

Display and control panel

BCL548i SF 102

Leuze electronic GmbH & Co. KG SW: V 1.3.1 HW:1 SN: 0704-081894 001

Network settings Channel 1:

Addr: 192.168.60.101 Mask: 255.255.255.0 Gateway: 0.0.0.0 DevName: BCL 548i

IO1 IO2 IO3 IO4 ATT ERR

LNK0

LNK1

12345678

Parameter 1

Parameter handling Decoder table Digital SWIO Ethernet

Language selection o Deutsch o English o Español o Français o Italiano

Device information - main menu

This menu item contains detailed information on

• Device type

• Software version

• Hardware version

• Serial number

Network settings - main menu

• Display of the network settings

see "Ethernet" on page 102.

Bar code reading window - main menu

• Visualization of the read bar code information

• Status overview of the switching inputs/outputs

• Bar graphs for read quality of the current bar code

see "Indicators in the display" on page 89.

Parameter - main menu

• Configuration of the bar code reader.

see "Parameter menu" on page 95.

Language selection - main menu

• Selection of the display language.

see "Language selection menu" on page 104.

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Display and control panel

Ser vi ce

Diagnostics

Status messages

Actions

o Start decoding o Start alignment o Start auto-setup o Start teach-in

Service - main menu

• Scanner diagnosis and status messages

see "Service menu" on page 105.

Actions main menu

• Various functions for scanner configuration and manual operation

see "Actions menu" on page 105.

Notice!

The rear cover of this manual includes a fold-out page with the complete menu structure.

It describes the menu items in brief.

A detailed description of the individual parameters can be found in the description of the PROFINET-IO GSD modules (see chapter 10.6 "Overview of the project modules").

Attention!

If parameters are changed via the display during bus operation, the BCL 548i is separated from the PROFINET-IO at the moment parameter enabling is activated via the display. Parameters set by the PROFINET-IO are moved to the background, and changes to parameters can be made via the display. When parameter enabling is exited, the BCL 548i is automatically reconnected to the PROFINET-IO. Upon connection to the PROFINET-IO, the BCL 548i receives all parameters from the PROFINET-IO Controller (PLC).

Changes made via the display are overwritten!

Device settings for operating the BCL 548i on the PROFINET-IO are managed and configured exclusively by the PROFINET-IO Controller (PLC).

94 BCL 548i Leuze electronic

8.3.2 Parameter menu

Parameter handling

The Parameter handling submenu is used to lock and release the parameter input via the display and for resetting to default values.

Table 8.1: Parameter handling submenu

Display and control panel

Level 3 Level 4 Level 5 Selection/configuration option

Parameter enabling

Parameters to default

Description

OFF/ON

The standard setting ( changes. If parameter enabling is activated ( manually.

As long as parameter enabling is activated, the BCL 548i is disconnected from the PROFINET-IO.

By pressing the enter button after selecting

Parameters to default

standard settings without any further security prompts. In this case, English is selected as the display language.

OFF

) prevents unintended parameter

), parameters can be changed

, all parameters are reset to their

Standard

OFF

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Display and control panel

Decoder table

In the Decoder table submenu, 4 different code type definitions can be stored. Bar codes that have been read can o nly be decoded if they correspond to one of the definitions stored here.

Table 8.2: Decoder table submenu

Level 3 Level 4 Level 5 Selection/configuration option

Max. no. of labels

Decoder 1 Symbology

(Code type)

Number of digits Interval mode OFF/ON

Digits 1 0 to 64 characters

Digits 2 0 to 64 characters

Digits 3 0 to 64 characters

Digits 4 0 to 64 characters

Digits 5 0 to 64 characters

Reading reliability Value from 2 to 100

Description

Value between 0 and 64

The value set here specifies the maximum number of labels that should be detected for each reading gate.

No code Code 2 of 5 interleaved Code 39 Code 32 Code UPC Code EAN Code 128 EAN Addendum Codabar Code 93 GS1 DataBar Omnidirectional GS1 DataBar Limited GS1 DataBar Expanded

No code

If all subsequent decoders are deactivated.

With the and 2 define a range of character numbers that are to be read.

First decodable number of characters or lower range limit.

Second decodable number of characters or upper range limit.

Third decodable number of characters.

Fourth decodable number of characters.

Fifth decodable number of characters.

Number or scans required to reliably detect a label.

is configured, the current and

setting, the values in digits 1

Standard

Code 2/5i

OFF

96 BCL 548i Leuze electronic

Table 8.2: Decoder table submenu

Display and control panel

Level 3 Level 4 Level 5 Selection/configuration option

Check digit method Standard

Check digit transm. Standard

Decoder 2 Symbology as decoder 1 Code 39

Number of digits

Reading reliability

Check digit method

Check digit transm.

Decoder 3 Symbology as decoder 1 Code 128

Number of digits

Reading reliability

Check digit method

Check digit transm.

Interval mode OFF/ON ON

Digits 1 0 to 64 characters 4

Digits 2 0 to 64 characters 30

Digits 3 0 to 64 characters 0

Digits 4 0 to 64 characters 0

Digits 5 0 to 64 characters 0

Interval mode OFF/ON ON

Digits 1 0 to 64 characters 4

Digits 2 0 to 64 characters 63

Digits 3 0 to 64 characters 0

Digits 4 0 to 64 characters 0

Digits 5 0 to 64 characters 0

Description

No check

Depending on the symbology (code type) selected for the decoder, further calculation algorithms can be selected here. Check digit method used for the decoding of the bar code that has been read.

Standard

If method intended for the respective code type is used.

Not standard

Specifies whether the check digit is transmitted. Standard means that the transmission matches the standard intended for the respective code type.

Value from 2 to 100 4

as decoder 1 Standard

Value from 2 to 100 4

as decoder 1 Standard

is set, the check digit

Standard

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Display and control panel

Table 8.2: Decoder table submenu

Level 3 Level 4 Level 5 Selection/configuration option

Decoder 4 Symbology as decoder 1 Code UPC

Number of digits

Reading reliability

Check digit method

Check digit transm.

Interval mode OFF/ON OFF

Digits 1 0 to 64 characters 8

Digits 2 0 to 64 characters 0

Digits 3 0 to 64 characters 0

Digits 4 0 to 64 characters 0

Digits 5 0 to 64 characters 0

Description

Value from 2 to 100 4

as decoder 1 Standard

Standard

98 BCL 548i Leuze electronic

Leuze electronic BCL548i User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1 General information

1.1 Explanation of symbols

1.2 Declaration of conformity

2 Safety notices

2.1 General safety notices

2.2 Safety standards

2.3 Approved purpose

2.4 Working safely

3 Fast commissioning / operating principle

3.1 Mounting the BCL 548i

3.2 Device arrangement and selection of the mounting location

3.3 Electrical connection BCL 548i

3.4 Starting the device

3.5 Commissioning the BCL 548i on the PROFINET-IO

3.5.1 Preparing the control system

3.5.2 Installing the GSD file

3.5.3 Configuration

3.5.4 Transfer of the configuration to the IO Controller

3.5.5 Configuration of the device name - device naming

3.5.6 Check device name

3.6 Further settings

3.7 Bar code reading

4 Device description

4.1 About the bar code readers of the BCL 500i series

4.2 Characteristics of the bar code readers of the BCL 500i series

4.4 Reading techniques

4.4.1 Line scanner (single line)

4.4.2 Line scanner with oscillating mirror

4.4.3 Omnidirectional reading

4.5 Fieldbus systems

4.5.1 PROFINET-IO

4.5.2 PROFINET-IO – star topology

4.5.3 PROFINET-IO – line topology

4.6 Heater

4.7 External parameter memory

4.8 autoReflAct

4.9 Reference codes

4.10 autoConfig

5 Specifications

5.1 General specifications of the bar code readers

5.1.1 Line scanner

5.1.2 Oscillating-mirror scanner

5.1.3 Line scanner with deflection mirror

5.2 Heating models of the bar code readers

5.2.1 Line scanner with heating

5.2.2 Oscillating-mirror scanner with heating

5.2.3 Line scanner with deflection mirror and heating

5.3 Dimensioned drawings

5.3.1 Line scanner with / without heating

5.3.2 Deflection mirror scanner with / without heating

5.3.3 Oscillating-mirror scanner with / without heating

5.4 Type overview BCL 548i

5.5 Reading field curves / optical data

5.6 Reading field curves

5.6.1 High Density (N) Optics: BCL 548i SN 100/102

5.6.2 High Density (N) Optics: BCL 548i ON 100

5.6.3 Medium Density (M) Optics: BCL 548i SM 100/102

5.6.4 Medium Density (M) Optics: BCL 548i OM 100

5.6.5 Low Density (F) Optics: BCL 548i SF 100/102

5.6.6 Low Density (F) Optics: BCL 548i OF 100

5.6.7 Ultra Low Density (L) Optics: BCL 548i SL 102

5.6.8 Ultra Low Density (L) Optics: BCL 548i OL 100

5.7 Reading field curves for heating devices

5.7.1 High Density (N) Optics: BCL 548i SN 102 H

5.7.2 High Density (N) Optics: BCL 548i SN 100 H

5.7.3 High Density (N) Optics: BCL 548i ON 100 H

5.7.4 Medium Density (M) Optics: BCL 548i SM 102 H

5.7.5 Medium Density (M) Optics: BCL 548i SM 100 H

5.7.6 Medium Density (M) Optics: BCL 548i OM 100 H

5.7.7 Low Density (F) Optics: BCL 548i SF 102 H

5.7.8 Low Density (F) Optics: BCL 548i SF 100 H

5.7.9 Low Density (F) Optics: BCL 548i OF 100 H

5.7.10 Ultra Low Density (L) Optics: BCL 548i SL 102 H

5.7.11 Ultra Low Density (L) Optics: BCL 548i OL 100 H

6 Installation and mounting

6.1 Storage, transportation