Accu-Sort 10 User manual

Revision: 1.1 Release Date: 01/23/01
Model 10
Bar Code Scanner
OPERATIONS AND MAINTENANCE MANUAL

I
INTRODUCTION
This is the Operations and Maintenance Manual for the Model 10. It provides
details on everything you need to know to unpack, set up, operate, maintain, and
troubleshoot your system.
This note box is used throughout this manual to indicate supplementary
information important to the current topic.
MANUAL REVISIONS
This Operations and Maintenance Manual is under revision control. Any
addendums or other documents associated with this manual are under separate
revision controls. A revision number is changed by 0.1 whenever technical
information is changed or added to a document. Any revision between 0.1 and
0.9 is automatically considered preliminary. Any document with a revision
greater than 0.9 has been officially released by the Accu-Sort Systems ECN
process. The document revision history can be found in the Revision History
section at the end of this manual.
DISCLAIMER
Information in this manual is subject to change without notice. No part of this
document is to be reproduced or utilized in any form or by any means, electronic
or mechanical, including photocopying, recording, or by an information storage
and retrieval system without the prior written consent of Accu-Sort Systems, inc.
All drawings and specifications contained in this manual are the property of
Accu-Sort Systems, inc. and shall not be reproduced, copied or used in whole or
in part as the basis for the sale or manufacture of devices without written
permission.
Copyright©2000 Accu-Sort Systems, inc.
All Rights Reserved

II
WARRANTY
Accu-Sort Systems, inc. warrants that its scanner and component parts will be
free from defects in material and workmanship for a period of one year from the
date of shipment (15 months for distributors to account for stocking of units). All
new replacement units will also be warranted for the remainder of the original
one-year time period. Unless otherwise stated, warranty for products not
manufactured by ASI is limited to the manufacturer’s warranty. Accu-Sort’s sole
obligation with respect to damage (whether direct, incidental or consequential,
resulting from the use or performance of the unit) is to replace the defective units
thereof.
Service requests due to misuse, abuse, neglect, changes in the original
specifications, or service calls not related to the Accu-Sort equipment, will be
charged at the then current service rate plus all travel related expenses.
•If the unit fails within two weeks of shipping (Out Of Box Failure):
Standard units and custom units with only custom software are replaced within
48 hours with new units. Units with custom hardware will be replaced in 72
hours with new units. If the defective unit is not returned within 30 days, the
customer will be contacted. If the defective unit is not returned after 45 days,
the customer will be invoiced for that unit. Accu-Sort will issue an RA#
(return authorization number) for each defective unit.
•If the unit fails after two weeks of shipment, but before the end of the
warranty period:
These procedures are the same as Out Of Box Failures, except Accu-Sort will
send refurbished units instead of new units. These refurbished units will be
warranted for 90 days from date of shipment or the balance of the original one-
year warranty, whichever is greater.
•If the unit fails after the original warranty period (Out Of Warranty
Failures):
These procedures are the same as Out Of Box Failures, except Accu-Sort will
send refurbished units instead of new units. These refurbished units will be
warranted for 90 days from date of shipment. All out of warranty defective
units will be replaced for a fixed price. Contact the Accu-Sort Customer
Service Department for the current prices.
Additional details on the coverage, support, and services available for your bar
code scanning and automated systems equipment is available from:
Accu-Sort Systems, inc.
2800 Crystal Drive 511 School House Road 2398 North Penn Road
Hatfield, PA 19440 Telford, PA 18969 Hatfield, PA 19440
Phone: [phone]
1-800-BAR-CODE
FAX:
Internet: www.accusort.com
Telford Main..........[phone]
Customer Service...[phone]
Systems..................[phone]
Sales.......................[phone]
Acct/Mktg..............[phone]
TMS.......................[phone]
North Penn.............[phone]

III
CUSTOMER SERVICE
If you have any problems or questions that require Accu-Sort’s help, direct your
calls to the Customer Service Department.
Accu-Sort Customer Service: phone: [phone]
1-800-BAR-CODE
(ask for Customer Service)
fax: [phone]
To ensure that Accu-Sort’s response is prompt and accurate, please have the
following information ready to give the Customer Service Department when
calling:
•Product Serial Number
•Product Type or name
•Detailed description of the question or problem
•Customer contact name and phone number
Product Type Serial Number
Model 10 Serial Tag
Serial Number Breakdown:
WWXXXXXX
WW - Two digit year of manufacture
XXXXXX - Six digit sequential build number
The WWXXXXXX fields are bar coded with a Code 128 type bar code.

IV
SAFETY RECOMMENDATIONS AND PRECAUTIONS
The Model 10 is an electronic microprocessor-based bar code scanner. Please
follow the safety precautions and warnings found throughout this manual in order
to prevent personal injury or damage to the unit. Failure to follow these
precautions may void your warranty.
This equipment has been tested and found to comply with the limits for a Class A digital
device, pursuant to part 15 of the FCC Rules. These limits are designed to provide
reasonable protection against harmful interference when the equipment is operated in a
commercial environment. This equipment generates, uses, and can radiate radio frequency
energy and, if not installed and used in accordance with the instruction manual may cause
harmful interference to radio communications. Operation of this equipment in a residential
area is likely to cause harmful interference in which case the user will be required to
correct the interference at his own expense.
The following note boxes are displayed throughout this manual to indicate safety
concerns and/or warnings.
This note box is used to alert the user they are about to perform an action
involving a dangerous level of voltage, or to warn against an action that could
cause electrical shock.
This note box is used to provide precautions and/or guidelines, warning the user
that personal injury or damage to the unit may occur during the task they are
performing.
WHEN UNPACKING AND MOUNTING
•Do not drop the unit, internal damage may result
•Do not touch the exit window glass. Fingerprints on the glass may diminish
scanner performance. If the window becomes dirty, refer to Exit Window
Cleaning in Chapter 6.
WARNING
This is a Class A product. In a domestic environment this product can cause radio
interference in which case the user may be required to take adequate measures.
(ref. CISPR 22 = EN 55 022:1995)
WARNING
In order to maintain Electromagnetic Compatibility (EMC) Compliance
interconnecting cables must be connected using a 360°

shield connection of all
the interface cables with a conductive strain relief for RF shielding purposes
(i.e.:’metalized’ ’D’ sub-strain relief). This applies to all I/O cables connected
through ’D’ sub-connectors.
CAUTION – Use of controls or adjustments or performance of procedures other
than those specified herein may result in hazardous laser light exposure.

V
GENERAL PRECAUTIONS
Please follow these precautions:
Do not attempt to open the housing. This product contains no user-serviceable
parts. Disassembly of the product will void the warranty. Refer any service to the
Accu-Sort Customer Service Department.
Laser power up to 7 mW could be accessible inside the unit.
•Avoid staring at the laser beam. Staring at the laser beam for prolonged
periods could result in eye damage (see illustration page vi).
•Any service should be performed so as not to violate compliance with the
Code of Federal Regulations, Title 21, Part 1040, Section 10 (21 CFR
1040.10), as administered by the Center for Devices and Radiological
Health, a service of the Food and Drug Administration under the Department
of Health and Human Services. Do not attempt to defeat any safety
provisions.
•Do not create any obstructions of airflow to the unit. Keep the area around
the unit clean to provide for cooling.
•Learn where the disconnect switches or circuit breakers are for your area.
(Ensure that others using the equipment know this also.)
•Use shielded interface cables with this product. To maintain FCC
compliance, the cable shield must make a 360ÛFRQQHFWLRQWRWKHVKLHOGHG
mating connector.
•Before performing any type of maintenance, turn off power to the unit and
disconnect the power cord.
•Be certain your hands and the floor of your work area are dry before
touching electrical equipment or connecting cords.
•Routinely check all connections to your Model 10. If a cable is damaged in
any way, replace it.
•Check mounting hardware periodically for tightness and stability.
GROUNDING THE MODEL 10
The system must be grounded electrically at all times. Please follow these
precautions:
•Ensure your AC power outlet has a properly grounded receptacle.
•Do not turn on the system until all components are properly cabled and
grounded with three-conductor AC power cords.

VI
LABEL LOCATIONS
The following labels identify areas of the Model 10 that require special
precautions or handling, or provide general information.
Model 10 Labels and Locations

Solutions with Vision
Chapter One
Introduction
CHECKING THE PACKING SLIP.......................................................................................................................1-3
GENERAL DESCRIPTION OF SYSTEM OPERATION........................................................................................... 1-7
BLOCK DIAGRAM OF MODEL 10 SYSTEM.......................................................................................................1-9
PRODUCT SPECIFICATIONS.........................................................................................................................1-10
FEATURES ....................................................................................................................................1-11
READ CHARTS ........................................................................................................................................... 1-12
GENERAL PURPOSE ...................................................................................................................... 1-12
HIGH DENSITY ..............................................................................................................................1-13
Chapter Two
Configuring the System
WIRING AND TERMINATING CONNECTIONS..................................................................................................... 2-3
OBJECT-SENSING SIGNAL DEVICE ...................................................................................................2-4
Chapter Three
Installation
INSTALLATION REQUIREMENTS...................................................................................................................... 3-3
POWER........................................................................................................................................... 3-3
MOUNTING REQUIREMENTS.............................................................................................................3-4
MOUNTING THE MODEL 10............................................................................................................................ 3-6
MULTIPURPOSE MOUNTING BRACKET .............................................................................................. 3-6
UNIVERSAL MOUNTING SHIPKIT .......................................................................................................3-8
BALL AND SOCKET MOUNT ............................................................................................................ 3-10
MOUNTING EXAMPLES................................................................................................................................3-13
SIDE READ ................................................................................................................................... 3-13
TOP READ ....................................................................................................................................3-14
BACK READ .................................................................................................................................. 3-15
Chapter Four
Start-Up and Operation
DISPLAY PANEL............................................................................................................................................4-3
BAR GRAPH DISPLAY ......................................................................................................................4-3
START-UP TASKS......................................................................................................................................... 4-8
Chapter Five
Troubleshooting
TROUBLESHOOTING ..................................................................................................................................... 5-3
PRELIMINARY STEPS ....................................................................................................................... 5-3
TROUBLESHOOTING TABLES ............................................................................................................ 5-3
Table of Contents

MODEL 10 OPERATIONS AND MAINTENANCE MANUAL
Accu-Sort Systems
Chapter Six
Maintenance
MAINTENANCE TASKS................................................................................................................................... 6-3
EXIT WINDOW CLEANING................................................................................................................. 6-3
EXTERIOR CLEANING.......................................................................................................................6-3
CHECK CONNECTIONS FOR TIGHTNESS............................................................................................ 6-3
Chapter Seven
Basic Operating Examples
APPLICATION EXAMPLES............................................................................................................................... 7-3
LABEL PRINTING VERIFICATION........................................................................................................ 7-3
BAR CODE VERIFICATION ................................................................................................................7-3
PC BOARD TRACKING.....................................................................................................................7-4
PRODUCT COUNTING ...................................................................................................................... 7-4
PRODUCT IDENTIFICATION ............................................................................................................... 7-5
AUTOMATED BLOOD ANALYZER .......................................................................................................7-5
Appendix A
ASCII Communications
ASCII COMMUNICATIONS.............................................................................................................................A-3
STANDARD RS485 MULTIDROP COMMUNICATIONS...........................................................................A-3
MESSAGE FORMATS........................................................................................................................A-4
MESSAGE SEQUENCING ..................................................................................................................A-5
TIMING ...........................................................................................................................................A-5
MULTIDROP PROTOCOL EXAMPLES..................................................................................................A-7
PROTOCOLS USED WITH RS232, CURRENT LOOP, AND 422 ............................................................A-8
ASCII CHART ..............................................................................................................................................A-9
Glossary
Index
Revision History

MODEL 10 SERIAL TAG ...................................................................................................................................III
MODEL 10 LABELS AND LOCATIONS.................................................................................................................VI
PARTS TABLE...............................................................................................................................................1-6
TYPICAL MODEL 10 INSTALLATION (MATERIAL HANDLING)..............................................................................1-8
TYPICAL MODEL 10 INSTALLATION (EMBEDDED)............................................................................................1-8
BOTTOM LABEL OF MODEL 10 WITH MODEL CONFIGURATION.........................................................................1-9
MODEL 10 DIMENSIONS .............................................................................................................................1-10
GENERAL PURPOSE READ CHART...............................................................................................................1-12
HIGH DENSITY READ CHART.......................................................................................................................1-13
CABLE PIN CONFIGURATIONS .......................................................................................................................2-3
POWER CONNECTION EXAMPLE....................................................................................................................3-3
MOUNTING SCREW SELECTION.....................................................................................................................3-4
MOUNTING CONTACT POINTS .......................................................................................................................3-5
MOUNTING COLUMN WITH MULTIPURPOSE MOUNTING BRACKET....................................................................3-6
MULTIPURPOSE MOUNTING BRACKET ...........................................................................................................3-7
UNIVERSAL MOUNTING SHIPKIT ....................................................................................................................3-8
UNIVERSAL MOUNTING SHIPKIT MOUNTING HOLES........................................................................................3-8
UNIVERSAL MOUNTING SHIPKIT ....................................................................................................................3-9
UNIVERSAL MOUNTING BRACKET..................................................................................................................3-9
BALL AND SOCKET MOUNT .........................................................................................................................3-10
BALL & SOCKET MOUNT TERMS .................................................................................................................3-11
MODEL 10 LED DESCRIPTIONS....................................................................................................................4-3
FIVE SEGMENT LED BAR GRAPH DISPLAY ....................................................................................................4-3
MODE 1 SEGMENT VALUES ..........................................................................................................................4-4
MODE 2 SEGMENT VALUES ..........................................................................................................................4-5
ACCU-SORT DIAGNOSTIC CODE....................................................................................................................4-6
LABEL PRINTING VERIFICATION APPLICATION ................................................................................................7-3
BAR CODE VERIFICATION APPLICATION.........................................................................................................7-3
PC BOARD TRACKING APPLICATION..............................................................................................................7-4
PRODUCT COUNTING APPLICATION...............................................................................................................7-4
PRODUCT IDENTIFICATION APPLICATION........................................................................................................7-5
AUTOMATED BLOOD ANALYZER APPLICATION................................................................................................7-5
RS485 COMMUNICATIONS EXAMPLE ............................................................................................................A-3
MASTER/SLAVE TIMING DIAGRAM .................................................................................................................A-5
ASCII CHART ..............................................................................................................................................A-9
Table of Figures

MODEL 10 OPERATIONS AND MAINTENANCE MANUAL
Accu-Sort Systems

Chapter One Contents
Chapter One
Introduction
1Heading 2
CHECKING THE PACKING SLIP................................................................... 1-3
GENERAL DESCRIPTION OF SYSTEM OPERATION ....................................... 1-7
BLOCK DIAGRAM OF MODEL 10 SYSTEM................................................... 1-9
PRODUCT SPECIFICATIONS...................................................................... 1-10
FEATURES .......................................................................................... 1-11
READ CHARTS........................................................................................ 1-12
GENERAL PURPOSE ............................................................................ 1-12
HIGH DENSITY..................................................................................... 1-13

1-2 MODEL 10 OPERATIONS AND MAINTENANCE MANUAL
Accu-Sort Systems

INTRODUCTION 1-3
Solutions with Vision
CHECKING THE PACKING SLIP
Enclosed in plastic on the outside of your box is a packing slip. The packing slip
lists the parts of your order.
As soon as you open the box, check the equipment against the packing slip to
ensure you received everything you ordered. If any equipment is missing or has
been damaged during shipment, contact Accu-Sort immediately at 1-800-BAR-
CODE (refer to Customer Service).
The Model 10 packaging was specifically designed to protect the unit during
shipment. Do not throw it away. Save all the packaging materials in case you
have to transport your unit to a different building.
Depending upon your needs, you may have one or more of the pieces of
equipment shown in the following table:

1-4 MODEL 10 OPERATIONS AND MAINTENANCE MANUAL
Accu-Sort Systems
DRAWINGS ARE NOT TO SCALE
Model 10 Part Number Description
1000001001 Scanner with Internal Logic
Model 10 Options
1. Optical Setup 1000022760 General Purpose 10 mil min. (300 scans/sec)
1000024871 High Density (200 scans/sec)
2. Customization 1000022761
3. Mirror Wheel 1000003008 Straight (6-sided)
1000003727 Raster (6-sided) 1/2" @ 5.0"
1000003728 Raster (6-sided) !/4" @ 5.0"
4. Supply Voltage Logic Board
1000004679 5 VDC
1000004680 Variable Custom Supply Voltage (10.0 - 30.0 VDC)
5. Cable Configuration 1000008758 1 Meter, 20 Compatible 15pin
1000008759 1 Meter, EM-50 Compatible
1000008760 1 Meter, Flying Leads, 15 Conductors
OTS Distributor Units 1000025466 General Purpose, 10 mil min, .5@5 Raster, EM (300 Scans/Second) 5VDC
1000025467 General Purpose, 10 mil min, .5@5 Raster, FF (300 Scans/Second) 5VDC
1000025468 General Purpose, 10 mil min, .5@5 Raster, FF (300 Scans/Second) 24VDC
1000025469 High Density, 5 mil min, .5@5 Raster, EM (200 Scans/Second) 5VDC
1000025470 High Density, 5 mil min, .5@5 Raster, FF (200 Scans/Second) 5VDC
1000025471 High Density, 5 mil min, .5@5 Raster, FF (200 Scans/Second) 24VDC
1000025472 General Purpose, 10 mil min, .25@5 Raster, EM (300 Scans/Second) 5VDC
1000025473 General Purpose, 10 mil min, .25@5 Raster, FF (300 Scans/Second) 5VDC
1000025474 General Purpose, 10 mil min, .25@5 Raster, FF (300 Scans/Second) 24VDC
1000025475 High Density, 5 mil min, .25@5 Raster, EM (200 Scans/Second) 5VDC
1000025476 High Density, 5 mil min, .25@5 Raster, FF (200 Scans/Second) 5VDC
1000025477 High Density, 5 mil min, .25@5 Raster, FF (200 Scans/Second) 24VDC
Model 10 Accessories
Interface Boxes/Expansion Modules
1000017362 Small Scanner Interface without relays
1000017365 Small Scanner Interface with relays
1000017376 Small Scanner Interface with solid state relays
1000015791 Scanner Expansion Module
Power Supplies 1000022163 110V AC Power Supply (for Small Scanner Interface)
1000015618 220V AC Power Supply (for Small Scanner Interface)
1000017369 120V AC 5V DC Programming Kit
1000017371 220V AC 5V DC Programming Kit
1000017370 110V AC 12V DC Programming Kit (for Optional Input Voltage)
1000017372 220V AC 12V DC Programming Kit (for Optional Input Voltage)

INTRODUCTION 1-5
Solutions with Vision
DRAWINGS ARE NOT TO SCALE
Part Number Description
Photoeyes 1000020527 Standard 9 Pin D Connector Photoeye Kit
Mounting Equipment 1000003614 Bracket Mounting, Universal
1000003627 Universal Mounting Shipkit (includes 1000003614)
1000003656 Ball and Socket Mount Kit
1000018197 Mounting Structure Assembly
1000018208 Mounting Kit
Displays 1000016277 External Display
1000016281 External Display w/ 10 Ft. Cable
1000016280 110V External Power Supply for Display
1000016283 220V External Power Supply for Display

1-6 MODEL 10 OPERATIONS AND MAINTENANCE MANUAL
Accu-Sort Systems
DRAWINGS ARE NOT TO SCALE
Part Number Description
Lamp Enclosures 1000017045 Single Green Lamp Enclosure
1000017046 Single Red Lamp Enclosure
1000017047 Dual Lamp Enclosure
Communication Interfaces 1000015450 15 pin port DeviceNet
1000015843 External Serial to Ethernet Converter Kit (Plugs into 15 pin connector on scanner)
Model 10 Documentation 1000025606 Small Scanners Installation Software and User Documentation CD-ROM
Parts Table

INTRODUCTION 1-7
Solutions with Vision
GENERAL DESCRIPTION OF SYSTEM OPERATION
The Model 10 combines impressive optical performance with useful electrical
features in a rugged IP-65 / NEMA 4 rated enclosure. Its compact size, zero
clearance cable exit, and flexible software parameters ease integration into
existing as well as new designs.
Fault tolerant inputs and outputs provide protection against field miswiring. Solid
state relay outputs interface directly with PLCs requiring either current sourcing
or sinking.
Versatile mounting features including M3 metric threaded holes allow mounting
on two sides and require no additional brackets.
Installation is simplified with visual diagnostics designed to verify scanning
efficiency.
The Model 10 features:
•Lowest cost Accu-Sort solution
•Widest scan angle for its size
•Easy integration
•Easy installation
•2 Optical setups
•Material Handling and Embedded applications
The system contains:
•NEMA 4 / IP-65 enclosure
•Integrated pigtail cable
•Bar graph LEDs
•Individual LEDs
•Diagnostic Pushbutton
•2M on board FLASH memory
•Diagnostic bar code support
•Windows Setup Program
Typical applications include:
•Automatic Teller Machines
•Library access control systems
•Medical specimen tracking systems
•Document handling machines
•Label printer verification
•Semiconductor wire bonding machines

1-8 MODEL 10 OPERATIONS AND MAINTENANCE MANUAL
Accu-Sort Systems
Typical Model 10 Installation (Material Handling)
Typical Model 10 Installation (Embedded)
The installation of the Model 10 as an embedded laser normally requires that the
end product be certified to the regulations of the Center for Devices and
Radiological Health (CDRH).