BSR Datalogic DS4800 User manual

DS4800
Reference Manual
BSR idware GmbH
Jakob-Haringer-Str.3
A-5020 Salzburg
Web: www.bsr.at

Datalogic Automation Srl
Via Lavino, 265
40050 - Monte S. Pietro
Bologna - Italy
DS4800 Reference Manual
Ed.: 01/2013
© 2008 – 2013 Datalogic Automation S.r.l. ALL RIGHTS RESERVED. Protected to the fullest
extent under U.S. and international laws. Copying, or altering of this document is prohibited without
express written consent from Datalogic Automation S.r.l.
Datalogic and the Datalogic logo are registered trademarks of Datalogic S.p.A. in many countries,
including the U.S.A. and the E.U.
ID-NET, Genius and X-PRESS are trademarks of Datalogic Automation S.r.l. All other brand and
product names mentioned herein are for identification purposes only and may be trademarks or
registered trademarks of their respective owners.
Datalogic shall not be liable for technical or editorial errors or omissions contained herein, nor for
incidental or consequential damages resulting from the use of this material.
18/01/13

iii
CONTENTS
REFERENCES ............................................................................................................vi
Conventions................................................................................................................. vi
Reference Documentation........................................................................................... vi
Services and Support .................................................................................................. vi
Patents.........................................................................................................................vi
SAFETY AND COMPLIANCE NOTICES...................................................................vii
Laser Safety.................................................................................................................vii
FCC Compliance ........................................................................................................viii
Power Supply..............................................................................................................viii
CE Compliance...........................................................................................................viii
Handling....................................................................................................................... ix
GENERAL VIEW.........................................................................................................xi
1RAPID CONFIGURATION ...........................................................................................1
Step 1 – Connect the System.......................................................................................1
Step 2 – Mount and Position the Scanner ....................................................................4
Step 3 – Focus the Scanner .........................................................................................6
Step 4 – X-PRESS™ Configuration..............................................................................7
Step 5 – Install Genius™ Configuration Program.......................................................11
Step 6 – Test Mode ....................................................................................................16
Advanced Scanner Configuration...............................................................................17
2INTRODUCTION ........................................................................................................18
2.1 Product Description ....................................................................................................18
2.1.1 Indicators ....................................................................................................................19
2.2 ID-NET™ ....................................................................................................................19
2.2.1 How To Setup/Configure the Scanner Network..........................................................21
2.3 X-PRESS™ Human Machine Interface ......................................................................22
2.3.1 Diagnostic Indication...................................................................................................22
2.3.2 X-PRESS™ Functions................................................................................................23
2.4 Display........................................................................................................................25
2.4.1 Display Messages.......................................................................................................26
2.5 Oscillating Mirror Models ............................................................................................29
2.6 Subzero Temperature Models ....................................................................................30
2.7 Model Description.......................................................................................................30
2.8 Accessories ................................................................................................................31
3INSTALLATION .........................................................................................................32
3.1 Package Contents ......................................................................................................32
3.2 Mechanical Installation ...............................................................................................33
3.2.1 Mounting DS4800.......................................................................................................36
3.3 Positioning ..................................................................................................................39
4CBX ELECTRICAL CONNECTIONS.........................................................................41
4.1 Power Supply..............................................................................................................42
4.2 Main Serial Interface...................................................................................................42
4.2.1 RS232 Interface..........................................................................................................43
4.2.2 RS485 Full-Duplex Interface.......................................................................................44
4.2.3 RS485 Half-Duplex Interface......................................................................................45
4.3 ID-NET™ Interface .....................................................................................................47

iv
4.3.1 ID-NET™ Cables........................................................................................................47
4.3.2 ID-NET™ Response Time ..........................................................................................48
4.3.3 ID-NET™ Network Termination..................................................................................52
4.4 Auxiliary RS232 Interface ...........................................................................................52
4.5 Inputs..........................................................................................................................53
4.5.1 Code Verifier...............................................................................................................56
4.6 Outputs .......................................................................................................................56
4.7 User Interface - Host...................................................................................................58
525-PIN CABLE ELECTRICAL CONNECTIONS........................................................59
5.1 Power Supply..............................................................................................................60
5.2 Main Serial Interface...................................................................................................60
5.2.1 RS232 Interface..........................................................................................................61
5.2.2 RS485 Full-Duplex Interface.......................................................................................62
5.2.3 RS485 Half-Duplex Interface......................................................................................63
5.3 ID-NET™ Interface .....................................................................................................65
5.3.1 ID-NET™ Cables........................................................................................................65
5.3.2 ID-NET™ Response Time ..........................................................................................66
5.3.3 ID-NET™ Network Termination..................................................................................70
5.4 Auxiliary RS232 Interface ...........................................................................................70
5.5 Inputs..........................................................................................................................71
5.5.1 Code Verifier...............................................................................................................74
5.6 Outputs .......................................................................................................................74
5.7 User Interface - Host...................................................................................................75
6TYPICAL LAYOUTS ..................................................................................................76
6.1 Point-to-Point..............................................................................................................76
6.2 Pass-Through .............................................................................................................78
6.3 ID-NET™ ....................................................................................................................80
6.4 RS232 Master/Slave...................................................................................................85
6.5 Multiplexer Layout.......................................................................................................86
7READING FEATURES...............................................................................................87
7.1 Advanced Code Reconstruction (ACR™ 4)................................................................87
7.1.1 Tilt Angle for Advanced Code Reconstruction............................................................88
7.1.2 Advanced Code Reconstruction Reading Conditions.................................................89
7.2 Linear Code Reading..................................................................................................91
7.2.1 Step-Ladder Mode......................................................................................................91
7.2.2 Picket-Fence Mode.....................................................................................................92
7.3 Performance ...............................................................................................................93
7.4 Reading Diagrams......................................................................................................94
7.4.1 Standard Models.........................................................................................................94
7.4.2 Oscillating Mirror Models ............................................................................................97
7.4.3 Subzero Models........................................................................................................100
7.4.4 Oscillating Mirror Subzero Models............................................................................103
8MAINTENANCE .......................................................................................................106
8.1 Cleaning....................................................................................................................106
9TROUBLESHOOTING .............................................................................................107
9.1 General Guidelines...................................................................................................107
10 TECHNICAL FEATURES.........................................................................................110
GLOSSARY..............................................................................................................112

v
INDEX.......................................................................................................................115

vi
REFERENCES
CONVENTIONS
This manual uses the following conventions:
“User” or “Operator” refers to anyone using a DS4800.
“Device” refers to the DS4800.
“You” refers to the System Administrator or Technical Support person using this manual to
install, mount, operate, maintain or troubleshoot a DS4800.
REFERENCE DOCUMENTATION
The documentation related to the DS4800 management is listed below:
CBX100 Installation Manual
CBX100 LT Installation Manual (for Subzero models)
CBX500 Installation Manual
CBX Accessory Manuals
Genius™ Help On Line
SERVICES AND SUPPORT
Datalogic provides several services as well as technical support through its website. Log on
to www.automation.datalogic.com and click on the links indicated for further information:
PRODUCTS
Search through the links to arrive at your product page which describes specific Info,
Features, Applications, Models, Accessories, and Downloads including the Genius™
utility program, which allows device configuration using a PC. It provides RS232 and
Ethernet interface configuration.
SERVICE
- Overview - Warranty Extensions and Maintenance Agreements
- Repair Centers
- Helpdesk
- Material Return Authorization
PATENTS
This product is covered by one or more of the following patents:
Utility patents: US5992740A; US6394352B1; US6742710B2; US6056198A; US6273336B1;
EP0789315B1; EP0959426B9; GB2345568B; JP04376353B2
Additional patents pending.

vii
SAFETY AND COMPLIANCE NOTICES
LASER SAFETY
The following information is provided to comply with the rules imposed by international
authorities and refers to the correct use of the DS4800 scanner.
Standard Regulations
This scanner utilizes a low-power laser diode. Although staring directly at the laser beam
momentarily causes no known biological damage, avoid staring at the beam as one would
with any very strong light source, such as the sun. Avoid that the laser beam hits the eye of
an observer, even through reflective surfaces such as mirrors, etc.
This product conforms to the applicable requirements of both EN 60825-1 and CDRH 21
CFR 1040 at the date of manufacture. The scanner is classified as a Class 2 laser product
according to EN 60825-1 regulations and as a Class II laser product according to CDRH
regulations.
There is a safety device, which allows the laser to be switched on only if the motor is rotating
above the threshold for its correct scanning speed.
The laser beam can be switched off through a software command (see also the Genius™
Help On Line).
WARNING
Use of controls or adjustments or performance of procedures other than
those specified herein may result in exposure to hazardous visible laser
light.
The laser light is visible to the human eye and is emitted from the window on the front of the
scanner (Figure A, 5).
Warning labels indicating exposure to laser light and the device classification are applied
onto the body of the scanner.
Disconnect the power supply when opening the device
during maintenance or installation to avoid exposure to
hazardous laser light.
The laser diode used in this device is classified as a class 3B
laser product according to EN 60825-1 regulations and as a
Class IIIb laser product according to CDRH regulations.
Any violation of the optic parts in particular can cause
radiation up to the maximum level of the laser diode (40 mW
at 630 to 680 nm).
AVOID EXPOSURE
LASER LIGHT IS EMITTED
FROM THIS APERTURE
CAUTION-CLASS 3B
LASER LIGHT WHEN OPEN
AVOID EXPOSURE TO BEAM
Warning and Device Class Labels

viii
FCC COMPLIANCE
Modifications or changes to this equipment without the expressed written approval of
Datalogic could void the authority to use the equipment.
This device complies with PART 15 of the FCC Rules. Operation is subject to the following
two conditions: (1) This device may not cause harmful interference, and (2) this device must
accept any interference received, including interference which may cause undesired
operation.
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.
POWER SUPPLY
This product is intended to be installed by Qualified Personnel only.
This accessory device is intended to be supplied by a UL Listed or CSA Certified Power Unit
with «Class 2» or LPS power source, which supplies power directly to the scanner via the 25-
pin connector.
CE COMPLIANCE
Warning:
This is a Class A product. In a domestic environment this product may cause radio
interference in which case the user may be required to take adequate measures.

ix
HANDLING
The DS4800 is designed to be used in an industrial environment and is built to withstand
vibration and shock when correctly installed, however it is also a precision product and
therefore before and during installation it must be handled correctly to avoid damage.
avoid that the scanners hit one another causing damage. They should be handled
separately.
avoid that the scanners are dropped (exceeding shock limits).
do not fine tune the positioning by striking the scanner or bracket.

x
do not weld the scanner into position which can cause electrostatic, heat or output
window damage.
do not spray paint near the scanner which can cause output window damage.

xi
GENERAL VIEW
DS4800-1000
Figure A
1
2
3 6
5
"POWER ON" LED
Indicator LEDs
Laser Beam Output Window
Push Button
4Display
Focus Adjustment
4
2
1
3
5
6

xii
DS4800-1100
Figure B
1
2
3 6
5
"POWER ON" LED
Indicator LEDs
Laser Beam Output Window
Push Button
4Display
Focus Adjustment
4
2
1
3
5
6

xiii
DS4800-1005
Figure C
1
2
3 7
6
"POWER ON" LED
Subzero Model Logo
Laser Beam Output Window
Push Button
5Display
Focus Adjustment
Indicator LEDs
4
5
1
4
6
7
2
3

xiv
5
2
1
4
6
7
3
DS4800-1105
Figure D
1
2
3 7
6
"POWER ON" LED
Subzero Model Logo
Laser Beam Output Window
Push Button
5Display
Focus Adjustment
Indicator LEDs
4

RAPID CONFIGURATION
1
1
1 RAPID CONFIGURATION
NOTE
This chapter illustrates a Stand Alone application. For other types of
installations, such as ID-NET™, Fieldbus, Pass-Through, Multiplexer
Layout, etc., refer to chapters 4, 5 and 6. For complete scanner
configuration using the Genius™ configuration program, refer to the
Context-Sensitive Help On-Line.
STEP 1 – CONNECT THE SYSTEM
To connect the system in a Stand Alone configuration, you need the hardware indicated in
Figure 1.
In this layout the data is transmitted to the Host on the main serial interface.
In Local Echo communication mode, the RS232 auxiliary interface can be used to transmit
data independently from the main interface selection.
When On-Line Operating mode is used, the scanner is activated by an External Trigger
(photoelectric sensor) when the object enters its reading zone.
Figure 1 – DS4800 in Stand Alone Layout
Figure 2 – DS4800 OM in Stand Alone Layout
DS4800
Host
PG 6000
P.S.* * Presence Sensor
(for On-Line mode)
CBX100/500
I/O, AUX
MAIN
DS4800 OM Host
PG 6000
P.S.** Presence Sensor
(for On-Line mode)
CBX100/500
I/O, AUX
MAIN

DS4800 REFERENCE MANUAL
2
1
CBX100/500 Pinout for DS4800
The table below gives the pinout of the CBX100/500 terminal block connectors. Use this
pinout when the DS4800 reader is connected by means of the CBX100/500:
CBX100/500 Terminal Block Connectors
Input Power Outputs
Vdc Power Supply Input Voltage + +V Power Source - Outputs
GND Power Supply Input Voltage - -V Power Reference - Outputs
Earth Protection Earth Ground O1+ Output 1 +
O1- Output 1 -
Inputs O2+ Output 2 +
+V Power Source – External Trigger O2- Output 2 -
I1A External Trigger A (polarity insensitive) Auxiliary Interface
I1B External Trigger B (polarity insensitive) TX Auxiliary Interface TX
-V Power Reference – External Trigger RX Auxiliary Interface RX
+V Power Source – Inputs SGND Auxiliary Interface Reference
I2A Input 2 A (polarity insensitive) ID-NET™
I2B Input 2 B (polarity insensitive) REF Network Reference
-V Power Reference – Inputs ID+ ID-NET™ network +
Shield ID- ID-NET™ network -
Shield Network Cable Shield
Main Interface
RS232 RS485 Full-Duplex RS485 Half-Duplex
TX TX+ RTX+
RTS TX- RTX-
RX *RX+
CTS *RX-
SGND SGND SGND
*Do not leave floating, see par. 4.2.2 for connection details.
CAUTION
Do not connect GND, SGND and REF to different (external) ground
references. GND, SGND and REF are internally connected through filtering
circuitry which can be permanently damaged if subjected to voltage drops
over 0.8 Vdc.

RAPID CONFIGURATION
3
1
25-pin Connector Pinout for DS4800
The table below gives the pinout of the 25-pin male D-sub connector for connection to the
power supply and input/output signals. Use this pinout when the DS4800 reader is connected
by means of the 25-pin connector:
13
2514
1
Figure 3 - 25-pin Male D-sub Connector
25-pin D-sub male connector pinout
Pin Name Function
13, 9 Vdc Power supply input voltage +
25, 7 GND Power supply input voltage -
1 CHASSIS Cable shield connected to chassis
18 I1A External Trigger A (polarity insensitive)
19 I1B External Trigger B (polarity insensitive)
6 I2A Input 2 A (polarity insensitive)
10 I2B Input 2 B (polarity insensitive)
8 O1+ Output 1 +
22 O1- Output 1 -
11 O2+ Output 2 +
12 O2- Output 2 -
20 RX Auxiliary RS232 RX
21 TX Auxiliary RS232 TX
23 ID+ ID-NET™ network +
24 ID- ID-NET™ network -
14, 15, 16, 17 NC Not Connected
Pin Name RS232
RS485
Full-Duplex
RS485
Half-Duplex
2 TX TX+ RTX+
3 RX *RX+
4 RTS TX- RTX-
5
MAIN INTERFACE
(SW SELECTABLE)
CTS *RX-
*Do not leave floating, see par. 5.2.2 for connection details.

DS4800 REFERENCE MANUAL
4
1
STEP 2 – MOUNT AND POSITION THE SCANNER
DS4800 Standard and Subzero Models
1. To mount the DS4800, use the mounting bracket to obtain the most suitable position for
the reader as shown in the figures below.
Figure 4 - Positioning with Mounting Bracket
2. When mounting the DS4800 take into consideration these three ideal label position angles:
Skew 15° to 30°, Tilt 0° and Pitch 0°.
Assure at least 15° Minimize Minimize
Figure 5 –Skew, Tilt and Pitch Angles
3. Refer to the Reading Diagrams in par. 7.4 to decide the distance your scanner should be
positioned at.
Ske
w
-45°-15° 0° 15° 45°
Pitch
S
T
P

RAPID CONFIGURATION
5
1
DS4800 OM Models
1. To mount the DS4800 OM, use the mounting bracket to obtain the most suitable position
for the reader as shown in the figures below.
Figure 6 - Positioning with Mounting Bracket
2. When mounting the DS4800 OM take into consideration these three ideal label position
angles: Skew 15° to 30°, Tilt 0° and Pitch 0°. The Skew angle refers to the most inclined
or external raster line, so that all other raster lines assure more than 15° Skew.
Assure at least 15° Minimize Minimize
Figure 7 –Skew, Tilt and Pitch Angles
3. Refer to the Reading Diagrams in par. 7.4.2 to decide the distance your scanner should
be positioned at.
S
T
P
Tilt
Skew
0° 15° 45°
-45°
-15°
alignment marks

DS4800 REFERENCE MANUAL
6
1
STEP 3 – FOCUS THE SCANNER
The reading distance depends on the focus distance of the scanner and should be set
according to the application requirements. The Focus Position is set directly through the
focus adjustment screw on the front panel of the scanner. This screw moves the internal lens
of the scanner to change the focal length of the scanner. The setting is continuous but should
not be set beyond the limits "Too Far" or "Too Near" which appear on the display at the
extremes of the focus range. Although the scanner reads across the entire focus range, there
are three guaranteed positions which correspond to the reading diagrams in par. 7.4.
1. Power up the scanner. For Subzero models, At -35 °C, a 20-minute
warm-up period is required before the scanner is ready to read
barcodes, the Ready LED blinks. Wait for the power up sequence
to finish. By default the scanner focus is in the Unlocked
position. The alternating message on the display shows the
mechanical Focus Position.
2. Using a screwdriver turn the focus adjustment screw in the desired
direction, clockwise (focus nearer to the scanner) o
r
counterclockwise (focus farther from the scanner). The focus
position in centimeters and inches is shown on the scanner display.
NOTE
The value of the Focus Position must be stored in
memory. If the mechanical position changes by more
than the allowed tolerance of the value in memory, an
alarm will be sent. See the Focus Lock function in step 4,
X-PRESS™ Configuration.
As an additional visual aid during focusing, the indicator LEDs show the relative focus
position as follows:
READ
Y
GOOD
TRIGGER
COM
STATUS
SETUP
LEARN
TEST
FOCUS
READ
Y
GOOD
TRIGGER
COM
STATUS
SETUP
LEARN
TEST
FOCUS
READ
Y
GOOD
TRIGGER
COM
STATUS
SETUP
LEARN
TEST
FOCUS

less than 30 cm

30 cm NEAR

32-38 cm
READ
Y
GOOD
TRIGGER
COM
STATUS
SETUP
LEARN
TEST
FOCUS
READ
Y
GOOD
TRIGGER
COM
STATUS
SETUP
LEARN
TEST
FOCUS
READ
Y
GOOD
TRIGGER
COM
STATUS
SETUP
LEARN
TEST
FOCUS

40 cm MEDIUM

42-58 cm

60 cm FAR
READ
Y
GOOD
TRIGGER
COM
STATUS
SETUP
LEARN
TEST
FOCUS

more than 60 cm