BC5100 Bar Code Scanner

BC5100 Bar Code Scanner
BC5100 Bar Code Scanner
Customer Product Manual
Part 1076483A
Issued 8/07
NORDSON CORPORATION • DULUTH, GEORGIA • USA
www.nordson.com
For CE Declaration, refer to the LogiCommr control system manual.
Nordson Corporation welcomes requests for information, comments, and inquiries about its products. General information
about Nordson can be found on the Internet using the following address: http://www.nordson.com.
Address all correspondence to:
Nordson Corporation
Attn: Customer Service
11475 Lakefield Drive
Duluth, GA 30097
Notice
This is a Nordson Corporation publication which is protected by copyright. Original copyright date 2007.
No part of this document may be photocopied, reproduced, or translated to another language without the prior written
consent of Nordson Corporation. The information contained in this publication is subject to change without notice.
Trademarks
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ColorMax, Color-on-Demand, Control Coat, Coolwave, Cross-Cut, Dispensejet, DispenseMate, DuraBlue, Durafiber, Dura-Screen, Durasystem, Easy Coat,
Easymove Plus, Ecodry, Econo-Coat, e.dot, EFD, ESP, e stylized, ETI, Excel 2000, Fillmaster, FlexiCoat, Flex-O-Coat, Flow Sentry, Fluidmove, FoamMelt,
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PatternJet, PatternPro, PCI, Pinnacle, Powder Pilot, Powercure, Precise Coat, Primarc, Process Sentry, Pulse Spray, Quad Cure, Ready Coat, Royal Blue,
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Designations and trademarks stated in this document may be brands that, when used by third parties for their own purposes,
could lead to violation of the owners’ rights.
Part 1076483A
E 2007 Nordson Corporation
All rights reserved
Table of Contents
i
Table of Contents
E 2007 Nordson Corporation
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Qualified Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intended Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Alert Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regulations and Approvals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Personal Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fire Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Action in the Event of a Malfunction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equipment Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
2
2
2
3
3
3
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Capabilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
5
6
7
8
8
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check the Parts Inventory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Select a Scanner Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Select a Trigger Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mount the Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connect the BC5100 Components to the
LogiComm Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trigger Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjust Cut-off Distance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Startup Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
9
9
13
15
16
18
18
19
System Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BC5100 Screens . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BC5100 Screen Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection Parameter Screen Components . . . . . . . . . . . . . . . . . . . . . .
Properties Screen Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
21
23
24
25
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ii
Table of Contents
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scanner Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start the System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Change Products . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
26
26
27
28
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Clean the Scanner Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check Trigger Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optimum Read Ranges for Different Bar Code Sizes . . . . . . . . . . . . . . . .
30
30
33
34
Repair . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Replacing a Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
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Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bar Code Scanner Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trigger (Photocell) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
36
36
36
36
Appendix A: Technical Data
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scanner Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bar Code Symbologies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
A-1
A-1
A-3
A-3
A-4
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BC5100 Bar Code Scanner
1
BC5100 Bar Code Scanner
Safety
Read this section before using the equipment. This section contains
recommendations and practices applicable to the safe installation,
operation, and maintenance (hereafter referred to as “use”) of the product
described in this document (hereafter referred to as “equipment”). Additional
safety information, in the form of task-specific safety alert messages,
appears as appropriate throughout this document.
WARNING: Failure to follow the safety messages, recommendations, and
hazard avoidance procedures provided in this document can result in
personal injury, including death, or damage to equipment or property.
Qualified Personnel
Equipment owners are responsible for making sure that Nordson equipment
is installed, operated, and serviced by qualified personnel. Qualified
personnel are those employees or contractors who are trained to safely
perform their assigned tasks. They are familiar with all relevant safety rules
and regulations and are physically capable of performing their assigned
tasks.
Intended Use
Use of Nordson equipment in ways other than those described in the
documentation supplied with the equipment may result in injury to persons
or damage to property.
Some examples of unintended use of equipment include:
S
S
S
S
S
S
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using incompatible materials
making unauthorized modifications
removing or bypassing safety guards or interlocks
using incompatible or damaged parts
using unapproved auxiliary equipment
operating equipment in excess of maximum ratings
Part 1076483A
2 BC5100 Bar Code Scanner
Safety Alert Symbols
The following safety alert symbol and signal words are used throughout this
document to alert the reader to personal safety hazards or to identify
conditions that may result in damage to equipment or property. Comply with
all safety information that follows the signal word.
WARNING: Indicates a potentially hazardous situation that, if not avoided,
can result in serious personal injury, including death.
CAUTION: IIndicates a potentially hazardous situation that, if not avoided,
can result in minor or moderate personal injury.
CAUTION: (Used without the safety alert symbol) Indicates a potentially
hazardous situation that, if not avoided, can result in damage to equipment
or property.
Regulations and Approvals
Make sure all equipment is rated and approved for the environment in which
it is used. Any approvals obtained for Nordson equipment will be voided if
instructions for installation, operation, and service are not followed.
All phases of equipment installation must comply with all federal, state, and
local codes.
Personal Safety
To prevent injury follow these instructions.
S Do not operate or service equipment unless you are qualified.
S Do not operate equipment unless safety guards, doors, or covers are
intact and automatic interlocks are operating properly. Do not bypass or
disarm any safety devices.
S Keep clear of moving equipment. Before adjusting or servicing any
moving equipment, shut off the power supply and wait until the
equipment comes to a complete stop. Lock out power and secure the
equipment to prevent unexpected movement.
S Relieve (bleed off) hydraulic and pneumatic pressure before adjusting or
servicing pressurized systems or components. Disconnect, lock out, and
tag switches before servicing electrical equipment.
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BC5100 Bar Code Scanner
3
S If you receive even a slight electrical shock, shut down all electrical
equipment immediately. Do not restart the equipment until the problem
has been identified and corrected.
S Obtain and read Material Safety Data Sheets (MSDS) for all materials
used. Follow the manufacturer’s instructions for safe handling and use
of materials, and use recommended personal protection devices.
S To prevent injury, be aware of less-obvious dangers in the workplace
that often cannot be completely eliminated, such as hot surfaces, sharp
edges, energized electrical circuits, and moving parts that cannot be
enclosed or otherwise guarded for practical reasons.
Fire Safety
To avoid a fire or explosion, follow these instructions.
S Shut down all equipment immediately if you notice static sparking or
arcing. Do not restart the equipment until the cause has been identified
and corrected.
S Do not smoke, weld, grind, or use open flames where flammable
materials are being used or stored.
S Provide adequate ventilation to prevent dangerous concentrations of
volatile materials or vapors. Refer to local codes or your material MSDS
for guidance.
S Do not disconnect live electrical circuits while working with flammable
materials. Shut off power at a disconnect switch first to prevent sparking.
S Know where emergency stop buttons, shut off valves, and fire
extinguishers are located.
S Clean, maintain, test, and repair equipment according to the instructions
in your equipment documentation.
S Use only replacement parts that are designed for use with original
equipment. Contact your Nordson representative for parts information
and advice.
Action in the Event of a Malfunction
If a system or any equipment in a system malfunctions, shut off the system
immediately and perform the following steps:
S Disconnect and lock out electrical power. Close pneumatic shutoff
valves and relieve pressure.
S Identify the reason for the malfunction and correct it before restarting the
equipment.
Equipment Disposal
Dispose off equipment and materials used in operation and servicing
according to local codes.
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Part 1076483A
4 BC5100 Bar Code Scanner
System Overview
The BC5100 is a bar code scanner that monitors bar code accuracy in high
speed packaging and converting operations. The scanner detects
unreadable, missing, and incorrect codes.
This manual describes the connection, setup, and operation of the BC5100
system when used in conjunction with the LogiCommR control system.
Figure 1
System overview
1. LogiComm control module
2. Touch-screen panel
Part 1076483A
3. Machine stop relay
4. Towards the ejector
5. BC5100 scanner
6. Trigger
7. Encoder
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BC5100 Bar Code Scanner
5
The BC5100 system uses a laser diode scanner capable of 2000 scans per
second that can monitor any of the eight bar code symbologies at line
speeds up to 207 mpm (680 fpm).
When the BC5100 system is used with a LogiComm control system,
products with defective bar codes are automatically tracked and either
ejected from the production line or marked for removal. The LogiComm
control system may be programmed to stop the production line when a
defective code is detected.
The user interface for setting up and monitoring the BC5100 with the control
module is contained in the touch-screen panel.
NOTE: For specific details on installing and operating the LogiComm
control module and the touch-screen panel, refer to the appropriate
documentations.
System Components
The BC5100 system has three major components:
S Scanner
S Trigger
S LogiComm control system (control module and touch-screen panel)
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Part 1076483A
6 BC5100 Bar Code Scanner
Scanner
When a bar code moves into the field of view of the scanner, the system’s
trigger starts the read cycle. The scanner repeatedly scans the bar code as
it moves through the visible laser beam, called the scan line. Depending on
the read at the end of a trigger cycle, the system sends out any of the
following three signals:
S Match bar code
S Mismatch bar code
S No read output
Figure 2
Scanner
1. Scanner
2. Bar code
3. Scan line
NOTE: The scanner recognizes eight different bar code symbologies and
reads the codes in either ladder or picket-fence orientation. Refer to Bar
Code Symbologies given in Appendix A.
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BC5100 Bar Code Scanner
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Trigger
The BC5100 scanner uses the LA 650 trigger (photocell) to begin and end
the scan cycle. The LA 650 trigger uses a red laser beam to detect
substrates. The trigger signals the system to begin the scan cycle when it
senses the leading edge (or some other selected edge) of the product. The
scanning cycle continues until the trailing edge (or some other selected
edge) of the product is sensed.
1
2
3
4
Figure 3
LA 650 trigger
1. LED indicators
2. Cut-off point adjustment screw
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3. Receiver elements
4. Emitter
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8 BC5100 Bar Code Scanner
System Capabilities
This section explains the key applications of the BC5100 system. The key
industries in which the system is used include: folded carton manufacturing,
case sealing, and container filling.
Applications
Application
Verify bar codes on high-speed
production lines.
Verify bar codes on both constant
speed and variable speed lines.
Explanation
The scanner operates at 2000 scans per second at line speeds as
high as 207 m/min (680 ft/min) for codes in the picket-fence
orientation.
The system is not affected by changes in the line speed.
Verify bar codes in either ladder or
picket-fence orientation of the bar
code.
The system can read bar codes in either picket-fence or ladder
orientation. However, for most bar code designs, the picket-fence
orientation allows higher line speeds because more scans can be
completed during the scan cycle. For a 25 mm (1 in.) high bar code
in the ladder orientation, the maximum line speed is approximately
150 mpm (500 fpm). Refer to Figure 4.
Verify different bar codes with the
same scanner.
The system can read any of the following codes:
S
S
S
S
S
S
S
S
Code 39
Code 128
UPC/EAN
Codabar
Code 93
Pharmacode (from 2 − 16 bars)
Bobst Code (from 2 − 16 bars)
Interleaved 2 of 5
Stop the parent machine upon bad
code detection.
Whenever a bad code is detected, the LogiComm control system
can be programmed to issue a machine stop.
Eject or mark products with
detective bar codes.
Whenever a bad code is detected, the system activates an output
to the LogiComm control system. When the control module
receives a signal from the BC5100 system, it automatically tracks
the product and either ejects it or marks it for removal.
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BC5100 Bar Code Scanner
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Installation
Check the Parts Inventory
1. Verify shipment of the following components:
S one scanner and a scanner interconnect cable
S one trigger and a trigger cable
S LogiComm control system with the master control module with bead
verification capability
S mounting hardware for the major components
2. Inspect the equipment for any damage that may have occurred during
shipping. Report any problems to a Nordson representative.
Select a Scanner Location
1. Consider the following recommendations and requirements in choosing
a location for the scanner.
Location Factor
Best opportunity for scanning bar
code
Recommendation or Requirement
S Select a location where the code is fully visible to the
scanner.
S On carton folder glue machines, the best opportunity is often
just prior to or after the glue flap pre-break section.
S Consider a location soon after the feed section so that the
feeding of products can be stopped quickly when defective
bar codes are detected on the line.
Sufficient space for mounting
Refer to Technical Data, Appendix A for scanner dimensions.
Avoiding interference from glue
assist lines
Locate scanner so that no glue assist lines pass through the
scan line.
Reduction of reflected light
Locate the scanner away from direct sunlight, bright ambient, or
task lighting, or light from other equipment, such as the system’s
trigger. Minimize the amount of direct or reflected light that can
enter the scanner.
Protection of cables
Protect the connecting cable from any moving machine parts
and passing products.
Protection from dust and moisture
Choose a location that meets IP54 requirements.
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Part 1076483A
10 BC5100 Bar Code Scanner
Select a Scanner Location
(contd)
2. Position the scanner so that the bar code label will pass through the
scan line.
S If a picket-fence orientation is used, align the scan line so that half of
each bar is above the line and half below, see 1 in Figure 4.
S If a ladder orientation is used, align the scan line so that the code is
centered on the scan line, see 2 in Figure 4.
a
b
X
a
X
b
X
1
X
2
Figure 4
Correct label alignment
1. Picket-fence orientation of the bar code
a. Direction of travel
b. Scan line
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2. Ladder orientation of the bar code
a. Direction of travel
b. Scan line
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BC5100 Bar Code Scanner
11
3. Set the distance from the scanner window to the surface of the product.
S For Pharmacode and Bobst code, set the distance at 127 mm (5 in.).
S For all other codes, set the distance also at 127 mm (5 in.). Make
sure that the mounting bracket allows the distance to be adjusted
from 102 − 152 mm (4 − 6 in.).
127 mm
(5.0 in.)
1
Figure 5
Distance from scanner to product surface
1. Product surface
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Part 1076483A
12 BC5100 Bar Code Scanner
Select a Scanner Location
(contd)
4. If the product surface is shiny or reflective so that light could be reflected
from the product surface back into the scanner, slightly tilt or skew the
scanner by following one of the methods given below:
S Pitching the scanner approximately 10 degrees from the horizontal
(in either direction) as shown in Method A in Figure 6. Avoid angles
from 3 − 5 degrees, which can cause increased reflection,
or
S Skewing the scanner approximately 10 degrees from the vertical
in either direction) as shown in Method B in Figure 6.
2
3
1
Method A
Figure 6
Method B
Two ways to avoid reflected light
1. Product surface
Part 1076483A
2. Approximately 10_ from line
parallel to product surface
3. Approximately 10_ from line
perpendicular to product surface
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BC5100 Bar Code Scanner
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Select a Trigger Location
1. Consider the following recommendations and requirements in choosing
a location for the trigger:
Location Factor
Recommendation or Requirement
Sensing speed
Position the trigger lens so that it can sense the substrate
at a line speed higher than 900 m/min (2953 ft/min).
Sensing range
Position the trigger lens so that it can sense from
2 − 100 mm (0.08 − 4 in.).
Interference with scanner operation
Make sure that the light from the trigger does not shine (or
is not reflected) into the scanner.
Protection of cables
Select a location that protects cables from any moving
machine parts and passing products.
Protection from dust and water
Select a location that meets IP67 requirements.
2. Position the trigger so that the scan cycle is activated where successful
reads start occurring. See Figures 7 and 8.
1
2
3
7
4
6
5
Figure 7
Optimum location of trigger for picket-fence oriented bar codes
1. Outside limit of read range
2. Position of bar code where
successful reads start
3. Scan line
4.
5.
6.
7.
Carton or other product
Direction of line travel
Optimum location for trigger
Edge of product that activates
trigger
NOTE: For bar codes with picket-fence orientation, successful reads start
when the entire code (including quiet zones) is within the scan line.
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Part 1076483A
14 BC5100 Bar Code Scanner
Select a Trigger Location
(contd)
2
1
3
7
4
6
5
Figure 8
Optimum location of trigger for ladder oriented bar codes
1. Scan line
2. Outside limit of read range
3. Position of bar code where
successful reads start
4.
5.
6.
7.
Carton or other product
Direction of line travel
Optimum location for trigger
Edge of product that activates
trigger
NOTE: For bar codes with ladder orientation, successful reads start when
the leading edge of the code first crosses the scan line.
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BC5100 Bar Code Scanner
15
Mount the Equipment
Equipment and production line configuration may dictate a variation in the
mounting options described in this section.
1. Mount the scanner in the selected location using either the bracket
components that were ordered with the BC5100 system or brackets that
you supply.
2. Mount the trigger in the selected location. For instructions on mounting
the trigger refer to the appropriate documentation.
1
2
4
3
Figure 9
Mounting the trigger and the scanner
1. Trigger
2. Scanner
E 2007 Nordson Corporation
3. Folding carton
4. Flap guide
Part 1076483A
16 BC5100 Bar Code Scanner
Connect the BC5100 Components to the LogiComm Control System
Figure 10
System overview
1. LogiComm control module
2. Touch-screen panel
Part 1076483A
3. Machine stop relay
4. Towards the ejector
5. BC5100 scanner
6. Trigger
7. Encoder
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BC5100 Bar Code Scanner
17
Use the following instructions to connect the scanner and trigger to the
control module.
1. Connect one end of the scanner interconnect cable to the 15-pin
scanner connector. Connect the other end of the cable to the Smart
Sensor connector (high density D-SUB, 15-pin connector) on the control
module’s verification I/O bank.
2. Connect the trigger cable to the TRIGGER connector on the control
module’s verification I/O bank. If necessary, use one of the trigger
extension cables to make the connection.
3. Connect the encoder cable to the ENCODER connector on the control
module’s master I/O bank.
4. Connect the machine stop output cable from the machine stop output
relay box to the SYSTEM I/O input on the master I/O bank.
5. Connect the LogiComm control system components according to the
instructions in the LogiComm Control System manual and the
Touch-screen Panel Installation for Basic and Expanded Systems
instruction sheet.
E 2007 Nordson Corporation
Part 1076483A
18 BC5100 Bar Code Scanner
Trigger Setup
The LA 650 trigger is shipped with a default cut-off distance setting of
50 mm (1.96 in.). This gives optimal sensing performance at a sensing
distance of about 30 mm (1.18 in.). The cut-off distance is adjustable from
30 − 150 mm (1.18 − 6 in.). Objects lying beyond the cut-off distance are
ignored, even if they are highly reflective. However, it is recommended to
have a dark background or, even better, free space beyond the substrate,
especially when processing transparent plastics.
4
1
3
5
2
7
6
Figure 11
LA 650 trigger setup
1. Receiver elements
2. Lens
3. Object
4.
5.
6.
7.
Cut-off distance
Background
Sensing range
Emitted light beam
Adjust Cut-off Distance
1. Use a small screwdriver in the adjustment screw. See Figure 3 for the
cut-off point adjustment screw location.
2. Turn right to increase or left to decrease the cut-off distance.
3. Adjust the cut-off distance until the threshold is reached and the yellow
light indicator changes state.
NOTE: For optimal sensing performance, the direction of travel of the
substrate should always follow the axis from the receiver elements towards
the light emitter, see Figure 12 for the recommended direction of travel.
Figure 12 Recommended
substrate travel
Part 1076483A
E 2007 Nordson Corporation
BC5100 Bar Code Scanner
19
System Startup Check List
Before setting up the system, make sure of the following:
S The trigger and the scanner are connected to the control module.
S The touch-screen panel is turned on.
S The control module is turned on.
E 2007 Nordson Corporation
Part 1076483A
20 BC5100 Bar Code Scanner
System Setup
Follow the sequence of screens on the touch-screen panel to set the
BC5100 and the LogiComm control system for operation.
Figure 13
Sequence of screens to enter the BC5100 screens
Part 1076483A
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BC5100 Bar Code Scanner
21
BC5100 Screens
When you select BC5100 as a sensor type in the Smart Sensor Select
screen (Setup − Page 3 of 4), sensor number 6 on the Main Menu will
change in appearance.
Figure 14
E 2007 Nordson Corporation
Sensor #6 on the Main Menu
Part 1076483A
22 BC5100 Bar Code Scanner
BC5100 Screens
(contd)
Press the sensor number 6 button on the Main Menu, and the following
screen appears:
Figure 15
Part 1076483A
BC5100 screen
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BC5100 Bar Code Scanner
23
BC5100 Screen Components
The following table explains the functionality of each component in the
BC5100 menu screen.
This button/component
Does this
Active/Inactive button
Activates or deactivates bead verification for that
specific sensor.
Trigger button
Selects a trigger for use with the sensor.
Learn Code button
Obtains a good code from the next bar code, and
this code is considered good for the products in the
production line.
Inspection Parameters
button
Allows the user to set parameters for the BC5100
sensor.
Refer to Inspection Parameters.
Clear Code Error button
Resets the screen displaying the mismatched
code, and proceeds to the next code.
Properties button
Allows the user to set smart sensor properties.
Refer to Properties.
Reset Counter button
Resets the counter reading to zero.
No Match counter reading
Displays the number of products whose bar codes
do not match the learn code.
Match counter reading
Displays the number of products whose bar codes
match the learn code.
No Read counter reading
Displays the number of products whose bar codes
could not be read.
Current code
Indicates that the code responds to the following
conditions:
S
S
S
Match code
E 2007 Nordson Corporation
Match
Mismatch
No read
Indicates the reference bar code that the system
has been taught.
Part 1076483A
24 BC5100 Bar Code Scanner
Inspection Parameter Screen Components
Press the Inspection Parameters button on the BC5100 menu screen, and
the following screen appears:
Figure 16
Inspection Parameter screen
The following table explains the functionality of each component in the
BC5100 Inspection Parameter screen.
This
button/component
Does this
Pharmacode
Enabled/Disabled
Enables or disables pharmacode.
Machine Action
Allows the user to program the system response by
setting the following parameters:
S
S
On No Match
On No Read
On No Match
Enables or disables (Yes or No) the ejector to reject a
product.
On No Read
Sets the reject parameter to Yes or No.
NOTE: Under Smart Sensor Machine Stop After 1
Defect, the Machine Stop output activates a product
with a bad bar code by setting the following
conditions:
S
S
Part 1076483A
On No Match: Yes or No
On No Read: Yes or No
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BC5100 Bar Code Scanner
25
Properties Screen Components
Press the Properties button on the BC5100 menu screen, and the following
screen appears:
Figure 17
Properties screen
The following table explains the functionality of each component in the
Properties screen.
This
button/component
Does this
Trigger Settings
Select from any of the following trigger setting options:
S
S
Light On
Dark On
NOTE: Light On activates the trigger at the leading
edge of the product. The leading edge is the edge or
face of the product that the trigger senses first on the
production line. This setting is also used as the
starting point for the delay measurement.
Dark On activates the trigger at the trailing edge of the
product. The trailing edge is the product edge that
causes the trigger to stop sensing the product as the
product passes by the trigger.
Sensor Beep Control
Allows the user to program the sensor beep control
from any of the following options:
S
S
S
Software Versions
E 2007 Nordson Corporation
Beep Off
Beep On Good Read
Beep On No Read
Provides the software versions and application
version of the scanner.
Part 1076483A
26 BC5100 Bar Code Scanner
Operation
Prior to routine operation, make sure that the system learns a good bar
code. The system uses this bar code to check each product it reads. When
the leading edge (or some other selected edge) of a product activates the
trigger, the read cycle begins. The sensor repeatedly reads the target area
on the product, looking for a bar code that matches the good code the
system was taught. If a match is found, the Match counter will display a
numeric value on the BC5100 menu screen. When the No Match or No
Read counters display a numeric value, it indicates the any of the following
conditions:
S the code is either missing or significantly out of registration
S the code cannot be reliably read
S the code does not match the reference code taught to the system.
Scanner Indicators
1
Figure 18
Item
2
3
4
Scanner indicators
Indicator
Function of Key or Light
1
POWER light (red)
Turns on when power is applied to the scanner.
2
Read rate lights
Not used.
3
Status light
Not used.
4
GOOD CODE light
Turns on with each readable code.
—
Beeper (not shown)
Beeps with each bar code that is successfully read. However, a
code that can be successfully read can still be a bad code if it does
not match the reference code that was taught to the system.
Part 1076483A
E 2007 Nordson Corporation
BC5100 Bar Code Scanner
27
Start the System
1. Make sure that the LogiComm control system is powered on.
2. Start the production line and run it at jog speed.
3. Stop the line when the entire bar code is within the scan line.
4. Start the production line.
5. Press Learn Code on the BC5100 menu screen.
6. Verify that the code is the correct bar code before teaching it to the
system.
7. Press Teach Active Sensors on the Main Menu screen.
8. In the BC5100 menu screen, observe the data in the following counters:
S Match
S No Match Defects
S No Read
NOTE: If the Match counter has zero defects, go to step 9. If the
No Match Defects counter displays zero (0), repeat the Learn Code
procedure, making sure that the code used to teach the system is
good (and properly designed) and that the product is stationary
during the teach process.
9. Increase the line speed to normal operating speed. Allow the line speed
to stabilize and ensure that the feed system is stable.
NOTE: Examine the displayed bar code image. Make sure that at least one
product is sensed after the learn product before a new bar code image is
displayed. If the displayed image is very dark, the distance from the sensor
to the product needs to be adjusted. Adjust the distance until the image is
legible.
E 2007 Nordson Corporation
Part 1076483A
28 BC5100 Bar Code Scanner
Change Products
Use the following table as a checklist of possible tasks or procedures to
perform whenever there is a change in the production process, whether it is
a product changeover or some minor change.
Task or Procedure
When to Perform
Change the sensor location
When the product size or shape changes or the bar code
size or location changes, ensure that the distance from the
sensor window to the code is about 15 mm (0.59 in.).
Change the sensor angle to the product
surface
When the reflectivity changes enough to affect the
performance of the sensor.
Do a trial run
When the sensor location has changed or when the bar
code has been changed in any way.
Find the removal point for defective
products
Anytime the product size or shape changes or when the
normal operating speed has been changed.
Teach tracking distances
Anytime the distance between the trigger and the pre-eject
sensor changes. If the product size or shape changes,
change the position of the pre-eject sensor to achieve
smooth ejection or marking in the correct place.
Teach the system a good bar code
Whenever there is any change in the production process,
product design, or bar code. A new reference code must be
taught each time the system is powered up.
Part 1076483A
E 2007 Nordson Corporation
BC5100 Bar Code Scanner
29
Maintenance
WARNING: Allow only qualified personnel to perform the following tasks.
Follow the safety instructions in this document and all other related
documentation.
Clean the Scanner Windows
As part of routine operation, periodically clean the scanner windows as
described in the following procedure. The buildup of dust, dirt, or film on
either window can alter the performance of the scanner.
The frequency that cleaning is required may vary, depending on the
operating environment in which the scanner is used. At the minimum, clean
the window once a week.
1. Turn off the control module power.
WARNING: Never look directly into the laser light source or point the beam
at other people. Looking at the source of the laser beam can cause serious
injury to the eyes.
2. Clean the scanner windows with a clean, dry Q-tip or cotton cloth.
3. Turn on the control module power.
E 2007 Nordson Corporation
Part 1076483A
30 BC5100 Bar Code Scanner
Troubleshooting
WARNING: Allow only personnel with appropriate training and experience
to operate or service the equipment. The use of untrained or inexperienced
personnel to operate or service the equipment can result in injury, including
death, to themselves and others, and damage to the equipment.
WARNING: If this equipment is used with other Nordson equipment, refer
to the manuals provided with that equipment for instructions and applicable
precautions. Failure to observe this warning may result in personal injury or
death.
Troubleshooting Table
Problem
1.
System detects bad
codes when codes
are good
Possible Cause
Corrective Action
Good code not taught.
Teach a good code. This must be
done each time the system is turned
on.
Incorrect code taught.
Verify that the system was taught the
correct code and that no bar-like
printing near the actual code can be
read by the scanner as a good code.
Scanner knocked out of position.
Check the position of the scanner.
Scanner impaired by reflection.
Adjust the scanner position. Refer to
Select a Scanner Location.
Bar code printing is out of
registration or the product is
skewed.
Verify that the code position has not
shifted relative to the scanner.
Scanner lens dirty or blocked.
Clean or remove obstruction. Refer to
Clean the Scanner.
Carton flutter is causing bar code
movement.
Stabilize the carton so that the
distance from the scanner to the bar
code remains the same during the
read cycle and from one product to
the next.
Continued...
Part 1076483A
E 2007 Nordson Corporation
BC5100 Bar Code Scanner
Problem
1.
2.
System detects bad
codes when codes
are good, contd.
System starts
reporting errors at
higher line speeds
Possible Cause
31
Corrective Action
The distance of scanner to product
not within read range.
Correct scanner range. Refer to
Figure 19 to find the optimum
distance.
Trigger activating read cycle at the
wrong time.
Verify that the trigger activates the
read cycle as the bar code enters the
read range. Refer to Select a Trigger
Location.
Trigger activated more than once
per product (double-triggering).
Determine whether a cutout or some
printing is causing a second read
cycle to occur during each product. If
this is the case, relocate the trigger.
System reporting bad codes at
higher line speeds.
Refer to System Starts Reporting
Errors at Higher Line Speeds,
problem 2, given next.
Wrong colors on bar code print.
Print the code in black against a
white background. Orange, yellow, or
red codes cannot be read at all.
Alternatives to a black code are dark
gray, dark blue, or dark green.
Alternatives to a white background
are a muted beige, yellow, or red.
The bar code is not properly
designed.
Check the bar code design.
Poor trigger location.
Refer to Select a Trigger Location.
Product not stable at high line
speeds.
Stabilize the product so that the
distance from the scanner to the bar
code remains the same during the
read cycle and from one product to
the next.
Distance of scanner to product not
within read range.
Correct scanner range. Refer to
Figure 19 to find the optimum
distance.
Line speed too fast.
Refer to Check for a Sufficient
Number of Scans.
Bar code not properly designed.
Check the bar code design.
Continued...
E 2007 Nordson Corporation
Part 1076483A
32 BC5100 Bar Code Scanner
Troubleshooting Table
Problem
3.
4.
5.
System fails to detect
bad bar codes
System not rejecting
or marking products
with defective codes
System rejecting or
marking the wrong
products
(contd)
Possible Cause
Corrective Action
The trigger is out of position.
Check the alignment of the trigger
and adjust.
Trigger cable is loose or
disconnected at the LogiComm
control module.
Plug the cable back into the
appropriate connector.
Improper trigger sensitivity.
Refer to Trigger Setup.
Trigger lens dirty or blocked.
Clean or remove obstruction.
Trigger or trigger cable defective.
Replace.
Scanner not receiving power.
Check the power light on the
scanner. If it is off, first check the
continuity of the connecting cables
(the scanner cable and the
interconnect cable). If these are
good, replace the scanner.
System is detecting bad codes but
not rejecting or marking these
products.
Verify settings. Enable the reject
function at the touch-screen panel.
Reject not enabled.
Enable the reject function by pressing
the Reject Control button on the
touch-screen panel. Configure the
Reject Control settings.
Reject signal not reaching control
module.
Check that the pre-eject trigger and
encoder are working.
Problem in the LogiComm control
system.
Refer to the LogiComm Control
System manual or the embedded
Help in the touch-screen panel to
troubleshoot.
BC5100 trigger knocked out of
position.
The trigger must be returned to its
original position or the new tracking
distance must be taught to the
system.
The procedure for teaching the
tracking distances was not
correctly performed.
Clear the machine of all products and
cover the scanner window when you
teach tracking.
Problem in the LogiComm control
system.
Refer to the LogiComm Control
System manual or the embedded
Help in the touch-screen panel to
troubleshoot.
Continued...
Part 1076483A
E 2007 Nordson Corporation
BC5100 Bar Code Scanner
Problem
6.
7.
Machine stop function
not working
Machine cannot be
restarted after a stop
Possible Cause
33
Corrective Action
Machine stop not enabled.
Enable the machine stop function by
pressing the Machine Control
Settings button on the touch-screen
panel. Configure the machine stop
settings.
Problem in the LogiComm control
system.
Refer to the LogiComm Control
System manual or the embedded
Help in the touch-screen panel to
troubleshoot.
The machine-stop contacts in the
LogiComm control system need to
be reset.
Enable the machine stop function by
pressing the Machine Control
Settings button on the touch-screen
panel.
Check Trigger Operation
1. Slow down the production line until you can observe the yellow
TRIGGER LED on the control module turn on and off with each passing
product.
2. Verify that the LED turns on when the trigger detects the product’s
leading edge (or some other selected edge) and turns off when it detects
the trailing edge (or some other selected edge). If the light fails to turn
on or if it turns on and off more than once, refer to Trigger Setup under
Installation.
E 2007 Nordson Corporation
Part 1076483A
34 BC5100 Bar Code Scanner
Optimum Read Ranges for Different Bar Code Sizes
inches
0
millimeters
0
1
2
50
1:
a
b
100
2:
a
b
c
d
3
4
5
6
150
7
8
200
50
9
50
millimeters
inches
3
Figure 19
2
1
0
1
2
3
Optimum bar code size read range
1. Narrow bar width: High density
2. Narrow bar width: Low density
5 mil (0.127 mm)
7.5 mil (0.191 mm)
7.5 mil (0.191 mm)
10 mil (0.254 mm)
15 mil (0.381 mm)
20 mil (0.508 mm)
Part 1076483A
E 2007 Nordson Corporation
BC5100 Bar Code Scanner
35
Repair
WARNING: Allow only personnel with appropriate training and experience
to operate or service the equipment. The use of untrained or inexperienced
personnel to operate or service the equipment can result in injury, including
death, to themselves and others, and damage to the equipment.
WARNING: If this equipment is used with other Nordson equipment, refer
to the manuals provided with that equipment for instructions and applicable
precautions. Failure to observe this warning may result in personal injury or
death.
Replacing a Scanner
CAUTION: Failure to observe may result in equipment failure.
WARNING: Do not open the scanner housing when power is applied to the
scanner. Opening the scanner could expose you or others to eye injury from
the laser light. With the housing open, the laser light intensity can reach a
power of 7 mW.
WARNING: Never look directly into the laser light source or point the beam
at other people. Looking at the source of the laser beam can cause serious
injury to the eyes.
1. Make sure that the LogiComm control system is turned off.
2. Wait five seconds for the power supply voltage to bleed off.
3. Disconnect the scanner interconnect cable from the cordset on the
scanner.
4. Remove the scanner from its mounting and replace it with a new one.
5. Attach the cordset of the new scanner to the interconnect cable.
6. Turn on the LogiComm control system.
E 2007 Nordson Corporation
Part 1076483A
36 BC5100 Bar Code Scanner
Parts
To order parts, call the Nordson Customer Service Center or your local
Nordson representative. Use this five-column parts list, and the
accompanying illustration, to describe and locate parts correctly.
BC5100 Bar Code Scanner Parts
Part
Description
1073415
SCANNER HEAD, BAR CODE, W/ LABEL, BC5100
1059564
CABLASSY, 15POS, HI-DENSTY, DSUB, 15FT, SHLD
1072674
CABLASSY, 15POS, HI-DENSTY, DSUB, 25FT, SHLD
727268
BRACKET ASSY, TOP MOUNT, LA5100
Trigger (Photocell)
Part
Description
7301990
PHOTOCELL, LA650, NPN/PNP
7301645
BRACKET, FOR LA650 PHOTOEYE
377219
CABLE, EXT, PHOTOCELL, STR. 5M, LOGICOMM
Accessories
Part
Part 1076483A
Description
1059607
CABLEASSY, 15PIN D−SUB TO WIRES, 5 METERS
1034147
CABLEASSY, DSUB, 15POS, M/F, 15FT
1063801
ADAPTER, MACHINE STOP RELAY, LOGICOMM
1060380
LIGHT TOWER, LED, 4LIGHT W/SIREN, LOGICOMM
1059621
CABLEASSY, M/F, 7PIN DIN, LOGICOMM
377491
EJECTOR, ROTARY, 230 VAC 3PH, CCW (OP SIDE)
377490
EJECTOR, ROTARY, 400/480 VAC 3PH, CCW (OPSIDE)
379657
EJECTOR, ROTARY, 230 VAC 3PH, CW (DRV SIDE)
379656
EJECTOR, ROTARY, 400/480 VAC 3PH, CW (DRVSIDE)
E 2007 Nordson Corporation
Technical Data
A-1
Appendix A
Technical Data
Specifications
NOTE: For most bar code designs, the picket-fence orientation allows
higher line speeds because more scans can be completed during the scan
cycle.
Scanner
Item
Specification
Line speed
Up to 207 m/min (680 ft/min)
Scan rate
2000 scans/second
Maximum resolution
0.191 mm (7.5 mil or 0.0075 in.)
Minimum quiet zone
S Pharmacode/Bobst code: 7 mm
S All other codes: 5 times the width of the narrowest bar
Number of bars
S Pharmacode/Bobst code: from 2 to 16 bars
S All other codes: specification does not apply
Recommended range
S Pharmacode/Bobst code: fixed at 127 mm (5.0 in.)
S All other codes: 102−152 mm (4.0−6.0 in.)
Bar code orientation
Ladder or picket fence
Readable symbologies
S
S
S
S
S
S
S
S
Code 39
Code 128
UPC/EAN
Codabar
Code 93
Pharmacode
Bobst code
Interleaved 2 of 5
Continued...
E 2007 Nordson Corporation
Part 1076483A
A-2
Technical Data
Scanner
(contd)
Item
Specification
Orientation
Ladder or picket fence
Maximum line speed
425 m/min (1400 ft/min) in picket fence orientation
150 m/min (500 ft/min) in ladder orientation @ 25 mm (0.98 in.) bar
height
Scan rate
2000 per second
Maximum resolution
0.191 mm (0.01 in.)
Skew angle
40 degrees maximum
Pitch angle
50 degrees maximum
Distance to substrate
Pharmacode/Bobst code: 127 mm (5.0 in.) fixed
All other codes: 100 to 200 mm (3.94 to 7.87 in.) minimum distance
required
Minimum quiet zone
Pharmacode/Bobst code: 7 mm (0.28 in.)
All other codes: 5 times the width of the narrowest bar
Sensor mounting
Matte Surface: 90_ to surface for matte or non-glossy surface
Glossy surface/Reflective surface: 10_ off from line parallel to product
surface (pitching)
10_ from line perpendicular to product
surface (skewing)
Operating temperature
0_ − 60 _C (32_ − 140 _F)
Required warm up time
15 minutes minimum
Enclosure rating
IP 54
Dimensions
57.79 x 76.20 x 41.30 mm (2.28 x 3.0 x 1.63 in.). Also see figure A-1.
LogiComm connector
Smart verification sensor (15 pin D-Sub)
Light source
Semiconductor visible laser diode (650 nm nominal)
Emissions
radiated: CISPR22 EN55022: 1994 Class A
conducted: CISPR22 EN055022: 1994 Class A
Safety class
CDRH Class II
Part 1076483A
E 2007 Nordson Corporation
Technical Data
A-3
Scanner Dimensions
76.20 mm
(3.0 in.)
57.79 mm
(2.28 in.)
41.30 mm
(1.63 in.)
Figure A-1 Dimensions
Trigger
Item
Specification
Sensing Speed
More than 900 m/min (2953 ft/min) line speed
Sensing Range
2 − 100 mm (0.08 − 4 in.)
Sensing Beam
Visible red laser
Indicators
Two LED indicators indicate the following conditions:
S
S
S
S
Green steady: Power on
Green flashing: Output overload
Yellow steady: Substrate sensed
Yellow flashing: Marginal excess gain. Readjust the trigger by
moving it closer to the substrate.
Connections
5-Pin, 180_ connector plug, NPN and PNP outputs.
Operating condition
temperature
10 _C − +50 _C (+14_ − 122 _F)
E 2007 Nordson Corporation
Relative humidity: 90% (at 50 _C, non-condensing)
Part 1076483A
A-4
Technical Data
Bar Code Symbologies
Part 1076483A
E 2007 Nordson Corporation
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