Datalogic AccuLazr AL5010 User manual

AL5010
Product Line Manual

AccuLazr™ AL5010 Product Line Manual
PN 1000068393 2.1 | CMS 11-0023 | 2013.01.31 | RAY
Document Revision Control
This document is under revision control in accordance with Datalogic’s Quality
System. Any addenda 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.
Copyright Information
Copyright © 2011-2012 DATALOGIC. All rights reserved.
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 prior written consent of
Datalogic Systems, Inc. All drawings and specifications contained in this manual
are the property of Datalogic Systems, Inc. and shall not be reproduced, copied
or used in whole or in part as the basis for the sale or manufacture of products
without the written permission.
Datalogic and DRX® are registered trademarks and the AS logotype, 1-800-
BAR-CODE™ is a trademark of Datalogic.
All other company or product names are mentioned for purposes of identification
only, and may be trademarks of their respective owners.
Disclaimer Information
The information contained in this manual is subject to change without notice.
Supplemental information or documentation may be required for certain
applications or usage.
The examples and diagrams in this manual are included solely for illustrative
purposes. Because of the many variables and requirements associated with any
particular installation, Datalogic cannot assume responsibility or liability for
actual use based on the examples and diagrams.
No patent liability is assumed by Datalogic with respect to use of information,
circuits, equipment, or software described in this manual.
In no event will DATALOGIC. be responsible or liable for indirect or
consequential damages resulting from the use or application of this equipment.
Datalogic 511 School House Rd. Telford, PA 18969 1-800-BAR-CODE™

AccuLazr™ AL5010 Product Line Manuals Contents iii
Contents
Preface
Intended Audience ......................................................................................... vii
Thank You...................................................................................................... vii
Overview of Contents.................................................................................... viii
Other Sources of Information........................................................................ viii
Conventions .................................................................................................. viii
Customer Service ......................................................................................... viii
1 Introduction
AL5010 Product Line Overview .......................................................................9
The AL5010 Scan Head ................................................................................10
The AL5010 Mounting Base ..........................................................................10
The AL5010 Interface Module.......................................................................11
AccuLazr™ User Interface.............................................................................12
Typical AL5010 Mid-Range Bar Code Reading Applications ........................13
Options and Accessories ...............................................................................14
2 Safety
Symbols .........................................................................................................15
General Precautions ......................................................................................16
Unpacking, Mounting and Installation Recommendations ............................16
Compliance Requirements ............................................................................17
Electrical Safety .............................................................................................17
Electrical Grounding Requirements...............................................................18
Electrostatic Discharge ..................................................................................18
Basic Rules for ESD Control..........................................................................18
Laser Safety...................................................................................................19
Safety Labels and Locations..........................................................................20
3 Mechanical Installation
Prerequisites ..................................................................................................21
Tools Required...............................................................................................21
Additional Information ....................................................................................21
Unpacking Instructions ..................................................................................21
Installation Sequence.....................................................................................22
Orientation Considerations ............................................................................23
Read Range...................................................................................................23
Bar Code Orientation to Scanning Area .......................................................24
General Mounting Guidelines ........................................................................25
Reader Positioning.........................................................................................25
Dimensions and Clearances..........................................................................26
Attaching the Mounting Base.........................................................................26
Attaching the Universal Mounting Bracket (UMB) .........................................27
Installing an AL5010 Scan Head ...................................................................28
Mounting the Trigger Photoeye .....................................................................29
Mounting the Tachometer..............................................................................30
Mounting the Interface Module ......................................................................31
Mounting the I/O Modules..............................................................................34
00b-AL5010_Table of Contents_R10.doc Accu-Sort Systems, Inc.

iv Contents AccuLazr™ AL5010 Product Line Manuals
4 Electrical Installation
Prerequisites ..................................................................................................37
Tools Required.............................................................................................. 37
Additional Information ....................................................................................37
Installation Sequence(s) ................................................................................38
Installing Multiple Readers.............................................................................38
General Electrical Installation Guidelines and Precautions...........................39
Cable and Conduit Connections ....................................................................40
Wiring the AL5010 Interface Modules............................................................41
Power Requirements .....................................................................................45
Power Supply Connections............................................................................45
Trigger Connections.......................................................................................46
Tachometer Connections...............................................................................47
Serial Communications Connections (COM1 and COM2) ............................48
Ethernet Communications Connections ........................................................50
I/O Module Connections ................................................................................51
DeviceNet ......................................................................................................53
Profibus ..........................................................................................................53
Connecting the AL5010 .................................................................................53
Wiring to the AL5010 without an Interface Module........................................54
Check Installation...........................................................................................55
5 Setup
Getting Started...............................................................................................57
AccuLazr User Interface Basics.....................................................................60
Getting Help ...................................................................................................60
Modify Settings ..............................................................................................61
Configuration ...........................................................................................62
Bar Codes................................................................................................63
Modulo Checks........................................................................................65
Stripping/Padding ....................................................................................66
Match Codes ...........................................................................................67
Serial Communications ...........................................................................68
Network ...................................................................................................71
Trigger .....................................................................................................74
Relay .......................................................................................................75
Tracking...................................................................................................76
FAST Monitor™.......................................................................................77
Advanced.................................................................................................79
Save / Retrieve ..............................................................................................80
Diagnostics ....................................................................................................81
Monitor.....................................................................................................82
Log Viewer...............................................................................................83
Update Firmware.....................................................................................90
6 Operations
First-time Startup ...........................................................................................91
Default Parameters ........................................................................................91
First-time Setup..............................................................................................92
Check Operations using Test Mode ..............................................................92
Operations Checklist......................................................................................93
Control Panel Indicators ................................................................................94
Backup / Restore Procedures........................................................................99
Checking Operations with User Interface ....................................................100
Accu-Sort Systems, Inc. 00b-AL5010_Table of Contents_R10.doc

AccuLazr™ AL5010 Product Line Manuals Contents v
Standalone Operation ..................................................................................102
Tracking Operation ......................................................................................103
Dual X-Scanning Operation .........................................................................104
Multiple-Reader Network Operation ............................................................105
Scanning Array / Tunnel Operation .............................................................106
7 Maintenance
Laser Shutoff Procedure..............................................................................107
Maintenance Tasks......................................................................................108
Cleaning Exit Window ..................................................................................109
Cleaning Trigger Photoeye ..........................................................................110
Cleaning Tachometer...................................................................................110
Tighten Mounting Hardware ........................................................................111
Checking Interface Module Connections.....................................................111
Verify Reader Operation ..............................................................................112
Verify Photoeye Operation...........................................................................112
Verify Tachometer Operation.......................................................................112
8 Troubleshooting
Test Mode ....................................................................................................113
Status Indicators ..........................................................................................113
Control Panel Indicators ..............................................................................114
Diagnostics ..................................................................................................117
Log Viewer ...................................................................................................120
Update Firmware .........................................................................................126
Troubleshooting Tables ..............................................................................131
9 Service
Replacement Procedures ............................................................................129
AL5010 Field Replaceable Units (FRUs) Spare Parts ...............................130
Interface Module FRU Spare Parts .............................................................131
Appendices
A Specifications
Al5010 Technical Specifications ..................................................................133
Basic Interface Module Technical Specifications ........................................133
Enhanced Interface Module Technical Specifications ................................134
Power Supply...............................................................................................134
Output Modules............................................................................................135
Input Modules ..............................................................................................135
Certifications ................................................................................................136
B Read Charts
AL5010 Read Charts ...................................................................................137
C User Interface
AccuLazr User Interface ..............................................................................149
Modify Settings ............................................................................................150
Configuration .........................................................................................151
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vi Contents AccuLazr™ AL5010 Product Line Manuals
Bar Codes..............................................................................................153
Modulo Checks......................................................................................155
Stripping/Padding ..................................................................................156
Match Code Patterns.............................................................................157
Serial Communications .........................................................................161
Network .................................................................................................166
Trigger ...................................................................................................170
Relay .....................................................................................................172
Tracking.................................................................................................174
FAST Monitor™.....................................................................................176
Advanced...............................................................................................177
Save / Retrieve ............................................................................................179
Diagnostics ..................................................................................................181
Monitor...................................................................................................182
Log Viewer.............................................................................................184
Update Firmware...................................................................................185
D Networking Guide
.................................................................................................................... 187
E FAST Monitor Configuration
.....................................................................................................................207
F Installation Drawings
.....................................................................................................................209
G Test Label for Adjustable Raster Setup
.....................................................................................................................231
Accu-Sort Systems, Inc. 00b-AL5010_Table of Contents_R10.doc

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00c-AL5010_Preface_R20.doc Accu-Sort Systems, Inc.

viii Preface AccuLazr™ AL5010 Product Line Manuals
Conventions
WARNINGS or CAUTIONS: This symbol identifies a hazard or
procedure that, if incorrectly performed, could cause personal injury or
result in equipment damage. It is also used to bring the user’s attention to
details that are considered IMPORTANT.
HIGH VOLTAGE CAUTION: This symbol alerts the user they are about
to perform an action involving, either a dangerous level of voltage, or to
warn against an action that could result in damage to devices or electrical
shock.
LASER CAUTION: This symbol alerts the user they are about to perform
an action involving possible exposure to laser light radiation.
ESD CAUTION: This symbol identifies a procedure that requires you take
measures to prevent Electrostatic Discharge (ESD) e.g., use an ESD wrist
strap. Circuit boards are most at risk. Please follow ESD procedures.
NOTES: This symbol draws attention to details or procedures that may be
useful in improving, maintaining, or enhancing the performance of the
hardware or software being discussed.
NOTE REGARDING DIMENSIONAL REFERENCES: This manual
provides all dimensional references in inches and in most cases Metric
referenced in brackets, for example 10 inches [254 mm].
Customer Service
Training
Accu-Sort Systems offers a complete set of training courses to help you and
your staff get the most out of your investment. We can help you develop a
training plan that provides thorough training for both your project team and
your end users. We will work with you to organize courses appropriate to
your job or area of responsibility. Training professionals can show you how
to plan your training throughout the implementation process so that the right
amount of information is delivered to key people when they need it the most.
You can attend courses at our training center, or you can arrange for our
trainers to teach at your facility. In addition, we can tailor standard courses or
develop custom courses to meet your needs.
Support
From on–site support to central support, our team of experienced
professionals provides the help and information you need to keep your
equipment working for you. This team includes your Account Manager and
Accu-Sort’s large staff of support specialists with expertise in your business
area and managing your hardware and software environment.
NOTE: If you have any problems or questions that require Accu-Sort's
assistance, direct your calls to Customer Service at 1-800-BAR-CODE™ or
[phone].
Accu-Sort Systems, Inc. 00c-AL5010_Preface_R20.doc

AccuLazr™ AL5010 Product Line Manual Introduction 1
1 Introduction
This chapter presents an introductory description of the AccuLazr™ AL5010
laser barcode scanner product line including:
 AL5010 Product Line Overview
 AccuLazr User Interface
AL5010 Product Line Overview
The AL5010 line of laser barcode readers is designed with industrial and
manufacturing applications in mind, providing high-speed scanning and high
reliability in a rugged industrial enclosure. The entire AL5010 product line
offers a large depth of field that provides accurate barcode reading from as
little as 4 inches up to 48 inches.
The AccuLazr AL5010 Mid-Range Laser Barcode Readers include:
 AL5010 Scan Head
 AL5010 Mounting Base
 AccuLazr Interface Module (optional)
 Power Supply Module (optional)
AL5010 Barcode Reader AccuLazr Basic Interface Module
01-AL5010_Introduction_R20.doc Accu-Sort Systems, Inc.

2 Introduction AccuLazr™ AL5010 Product Line Manuals
AL5010 Scan Head
The AL5010 Scan Head incorporates the optics and laser module(s) for
scanning barcodes as well as the decoding engine and parameter storage
module. The control panel provides several LED status indicators and three
function buttons.
There are five models of the AL5010 Scan Head (each available with
optional adjustable raster):
 One-laser models for standard and high-density
 Two-laser models for standard, near-focus high-density and high-density
An optional Adjustable Raster (adjustable up to 20-degrees above or below
0-degrees, variable DOF) is available in the existing scan head housing. No
bolt-on additions are required.
AL5010 Mounting Base
The AL5010 Mounting Base provides for the mounting of the AL5010 as well
as the wiring interface between the scan head and AccuLazr Interface
Module. It includes a parameter storage module that enables parameters to
be uploaded/downloaded with the ‘hot-swappable’ scan head.
Accu-Sort Systems, Inc. 01-AL5010_Introduction_R20.doc

AccuLazr™ AL5010 Product Line Manual Introduction 3
AccuLazr Interface Module
The AccuLazr Interface Module is fully compatible with the AL5010 line of
barcode readers and is available in both a Basic and Enhanced version.
The AccuLazr Basic Interface Module provides the following connections:
 Scanner (15-pin and RJ45)
 Ethernet / EtherNet/IP (1)
 Serial ports (2)
 Trigger Input
 Power
The Enhanced Interface Module provides the following additional
connections:
 Tach Input
 Up to four Opto22 I/O modules
 Fieldbus communications (either DeviceNet or Profibus)
01-AL5010_Introduction_R20.doc Accu-Sort Systems, Inc.

4 Introduction AccuLazr™ AL5010 Product Line Manuals
AccuLazr™ User Interface
The AccuLazr User Interface lets you configure an AL5010 through a series
of intuitive, user-friendly menus, tools and dialog boxes accessed via a web
browser. Context sensitive help is available to assist with use of the software.
With the user interface, you can:
 Integrate AL5010 to your system and application without custom
software.
 Modify output messages to accommodate your system needs.
 Add or modify the barcode symbologies read by AL5010.
 Define up to four (4) relay input/outputs.
 Monitor AL5010 performance using diagnostic tools.
 Fine-tune optional adjustable raster.
You can easily configure your AL5010 reader by using a desktop or laptop
computer, an Ethernet network connection and the browser-based interface.
Accu-Sort Systems, Inc. 01-AL5010_Introduction_R20.doc

AccuLazr™ AL5010 Product Line Manual Introduction 5
Typical AL5010 Mid-Range Barcode Reading Applications
Use the AL5010 in the following applications:
 single-reader applications (side or top)
 pick module scanning
 multi-sided scanning
 retail distribution centers
 industrial manufacturing
With optional Adjustable Raster:
 pallet scanning
 hard-to-read barcodes
 plastic shrink-wrapped barcodes
 unknown label positioning
01-AL5010_Introduction_R20.doc Accu-Sort Systems, Inc.

6 Introduction AccuLazr™ AL5010 Product Line Manuals
Accu-Sort Systems, Inc. 01-AL5010_Introduction_R20.doc
Options and Accessories
Contact your sales representative for assistance in determining which
options and accessories will be applicable to your application.
If you know which items are needed, contact Accu-Sort’s Customer Service
Department (ask for the Spare Parts Coordinator) between 8 AM and
4:30PM (EST) Monday through Friday at 1-800-BAR-CODE (Fax: 215-723-
1515).

AccuLazr™ AL5010 Product Line Manuals Safety 7
2 Safety
Please follow the safety precautions and warnings found in this manual when
installing, setting up, operating, maintaining, troubleshooting or replacing any
Accu-Sort products, parts, or related equipment. Following these precautions
will prevent personal injury or damage to the unit. Failure to follow these
precautions may also void your warranty.
This section provides important information regarding safety and your
AL5010, especially involving issues regarding:
 General Precautions during Mounting and Installation
 Compliance Requirements
 Electrical Safety
 Electrical Grounding Requirements
 Electrostatic Discharge Precautions and Control
 Laser Safety
Contact Accu-Sort at 1-800-BAR-CODE™ if you need more information.
Symbols
Throughout this manual, special safety alerts are indicated by the following
symbols:
WARNINGS or CAUTIONS: This symbol identifies a hazard or
procedure that, if incorrectly performed, could cause personal injury or
result in equipment damage.
HIGH VOLTAGE CAUTION: This symbol alerts the user they are about
to perform an action involving, either a dangerous level of voltage, or to
warn against an action that could result in damage to devices or electrical
shock.
LASER CAUTION: This symbol alerts the user they are about to perform
an action involving possible exposure to laser light radiation.
ESD CAUTION: This symbol identifies a procedure that requires you take
measures to prevent Electrostatic Discharge (ESD) e.g., use an ESD wrist
strap. Circuit boards are most at risk. Please follow ESD procedures.
Alerts help you to:
 Identify a hazard and its consequences
 Avoid a hazard by taking adequate safety precautions
 Get the most out of your bar code solution
02-AL5010_Safety_R20.doc Accu-Sort Systems, Inc.

8 Safety AccuLazr™ AL5010 Product Line Manuals
General Precautions
Installation and Service by Qualified Service Technician Only
WARNING: All procedures involving exposure to the inside of the
AL5010 Interface Module must be performed by a trained
technician because of possible exposure to emitted laser radiation,
high voltage, and could reduce the effectiveness of the device’s IP
rating. There are no user-serviceable parts inside. Do not attempt
to open the unit or perform any installation/service procedures
unless you are a trained technician! DO NOT REMOVE the
faceplate from the scan head enclosure. Opening the AL5010 will
void the factory warranty.
Refer all servicing and advanced troubleshooting to a qualified service
technician. Technical training is available from Accu-Sort Systems.
Furthermore, even trained technicians should always reference the specific
product documentation for more detailed service procedures that may not be
described in the AL5010 Product Manual.
Unpacking, Mounting and Installation Recommendations
CAUTION: Firmly fasten mounting structures in place before installing the
equipment to any mounting structure. Avoid using freestanding mounting
structures. If your application requires a freestanding mounting structure,
avoid making the structure top-heavy.
 Follow all procedures regarding electrical safety, laser safety, and
electrostatic discharge safety (ESD) as outlined in this manual.
 Save all packing material in case you have to transport your readers.
 Use steel or aluminum as a mounting structure. An Accu-Sort mounting
structure is recommended for optimum system performance.
 Check mounting hardware periodically for tightness and stability.
 Do not use sheet rock, plaster board, wood, or other unstable mounting
surfaces.
 Do not use mounting surfaces that are subject to high vibrations.
 Do not create any obstructions of airflow around the modules. Keep the
area around the modules clean to provide for cooling. (Refer to specific
product manuals for minimum clearances.)
 Avoid dropping the readers during unpacking and installation.
 Do not touch the window glass of the scan head.
Accu-Sort Systems, Inc. 02-AL5010_Safety_R20.doc

AccuLazr™ AL5010 Product Line Manuals Safety 9
Compliance Requirements
FCC NOTICE: The AL5010 has been tested and found to comply with the
limits for a Class A digital device, pursuant to Title 47, Part 15 of the FCC
Rules. These limits are designed to provide a 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
manuals, 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.
WARNING: These are Class A products. In a domestic environment, these
products can cause radio interference, in which case the user may be required
to take adequate measures. (Ref. CISPR 22 = EN 55 022:1995.)
IMPORTANT: Follow the guidelines below to maintain Electromagnetic
Compatibility (EMC) Compliance:
 Interconnecting cables must be twisted pair cables.
 All shielded I/O cables shall have the shield terminated to the chassis.
 NOTE: DRAIN WIRE SHIELDING IS NOT ADEQUATE.
 Do not remove the shielding covers.
 Refer to the details on making custom cables as provided in the specific
technical manual for the component.
Electrical Safety
AL5010 must be installed in accordance with Canadian Electrical Code, Part I,
CSA C22.1; CSA C22.2 No. 0; and the National Electrical Code, NFPA 70.
For complete requirements, National Electrical Code, ANSI/NFPA 70,
Canadian Electrical Code, Part I, C22.1, or other national standard must be
consulted.
 For PERMANENTLY CONNECTED EQUIPMENT/RACK MOUNTED,
incorporate a readily accessible disconnect device in the fixed wiring.
 For PLUGGABLE EQUIPMENT/RACK MOUNTED, install the socket-
outlet near the equipment so it is easily accessible.
 Make sure that all personnel who work with the equipment know where
the disconnect switches or circuit breakers are located.
 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 power cords, plugs, wiring, and cable connections for
any signs of exposed wire or deteriorating insulation. If you notice any
damage, make arrangements with service personnel to repair or replace
the damaged item immediately.
02-AL5010_Safety_R20.doc Accu-Sort Systems, Inc.

10 Safety AccuLazr™ AL5010 Product Line Manuals
Electrical Grounding Requirements
Before applying power to any device, ALL components MUST be electrically
grounded. Follow these precautions:
 Ensure all AC power outlets have a properly grounded receptacle.
 ALL components MUST be properly cabled and grounded with three-
conductor AC power cords.
 Use the correct power cord for your country.
 Reference specific grounding instructions for each component.
 Do not use a two-prong adapter.
 Do not cut/remove the round grounding prong from any plug.
 Do not use an extension cord to defeat any ground.
Electrostatic Discharge
ESD CAUTION: Measures must be taken to prevent Electrostatic
Discharge (ESD) at all times when handling any product, equipment, unit or
part (e.g. use a grounded ESD wrist strap). It should be noted that circuit
boards are at greatest risk to damage from ESD. Please follow standard
ESD precautions!
Electrostatic discharge (ESD), the transfer of static electricity from one object
to another, is an often-unnoticeable hazard to electronic components.
Boards and other devices with integrated circuits are particularly sensitive to
ESD damage. Product failures may not occur until days or weeks after the
component was damaged.
Static damage to units can take the form of upset failures or catastrophic
failures (direct and latent).
An upset failure occurs when an electrostatic discharge is not significant
enough to cause total failure, but may result in intermittent gate leakage,
causing loss of software or incorrect storage of information.
Direct catastrophic failures occur when a unit is damaged to the point where
it is permanently damaged.
Basic Rules for ESD Control
Below are some keys to effectively control unnecessary ESD damage when
working with ESD-sensitive devices:
 Define an ESD protective area and work on the ESD-sensitive devices in
this area only.
 Define static sensitivity of devices to be handled in ESD protective area.
 Establish suitable static control program that limits static generation to
less than the damage threshold of the most sensitive device and
provides a safe, defined path for static charge dissipation.
 Prevent contamination of the protective area by unnecessary non-static
controlled materials.
 Audit the ESD protective area regularly to ensure that static control is
maintained. Document the findings for future reference.
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AccuLazr™ AL5010 Product Line Manuals Safety 11
 Refer to the specific ESD precautions for each component.
Laser Safety
The AL5010 uses visible laser diodes and emits a “moving” red beam. Do
not stare into the AL5010’s exit window at the laser light source. Avoid
unintentional exposure to laser light whenever possible. The laser light level
does not constitute a health hazard, however staring at the laser light for
prolonged periods could result in eye damage.
The following appears next to the AL5010 laser exit window:
WARNING! LASER LIGHT EMITTED FROM THIS APERTURE
Warning on AL5010 Laser Exit Window to Avoid Exposure
WARNING: Use of controls, adjustments, or procedures other than those
specified in this document may result in hazardous laser light exposure.
The AL5010 Line Scanning Bar Code Reader is rated as a Class 1 Laser
Product by the International Electrotechnical Commission. Compliances are
as follows: Class 1 Laser Product (IEC-60825-1) 2007.
Before performing any maintenance or service procedures, perform
the laser shutoff procedure provided in Chapter 7.
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12 Safety AccuLazr™ AL5010 Product Line Manuals
Safety Labels and Locations
Refer to the following figures for specific label locations and warnings. When
operating, repairing, or replacing an AL5010, note all label content on the
unit. These labels provide special precautions for operation, usage
specifications, product identification, and service information.
WARNING: LASER LIGHT EMITTED FROM THIS APERTURE.
Label Placement AL5010 Scan Head
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