Datalogic DS6400 User manual

DS6400
Reference Manual

Datalogic Automation Srl
Via Lavino, 265
40050 - Monte S. Pietro
Bologna - Italy
DS6400 Reference Manual
Ed.: 11/2013
© 2003 –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.
Genius, PackTrack, Step-a-Head, FLASH, ACR, and ID-NET 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.
19/11/13

iii
CONTENTS
REFERENCES ..........................................................................................................vi
Reference Documentation .........................................................................................vi
Support Through The Website ...................................................................................vi
Patents ......................................................................................................................vi
COMPLIANCE..........................................................................................................vii
Electrical Safety........................................................................................................ vii
Laser Safety.............................................................................................................. vii
Power Supply............................................................................................................viii
CE Compliance..........................................................................................................ix
FCC Compliance........................................................................................................ix
GENERAL VIEW ........................................................................................................x
GUIDE TO INSTALLATION.....................................................................................xiv
Point-to-Point Installation......................................................................................... xiv
Master/Slave Lonworks Installation...........................................................................xv
1INTRODUCTION ........................................................................................................1
1.1 Product Description.....................................................................................................1
1.2 Applications ................................................................................................................2
1.3 Model Description.......................................................................................................3
1.4 Oscillating Mirror Models.............................................................................................4
1.5 Indicators....................................................................................................................6
1.6 Keypad and Display....................................................................................................6
1.6.1 Internal Net.................................................................................................................7
1.6.2 Test Mode...................................................................................................................7
1.6.3 PackTrack (Auto)........................................................................................................8
1.7 Auto PackTrack™ Calibration for Reading Station Using Scanner Menu ....................9
1.7.1 Auto PackTrack Conditions and Limits........................................................................9
1.7.2 Auto PackTrack Parameter Descriptions...................................................................10
1.7.3 Auto PackTrack Setup ..............................................................................................11
1.8 Accessories ..............................................................................................................14
2INSTALLATION........................................................................................................16
2.1 Package Contents.....................................................................................................16
2.2 Mechanical Mounting................................................................................................17
2.2.1 Mounting the Scanner...............................................................................................17
2.2.2 Mounting the Scanner with Accessories....................................................................20
2.3 Positioning the Scanner............................................................................................22
2.3.1 16° Skew Positioning ................................................................................................23
2.3.2 45° Skew Positioning ................................................................................................24
3CBX ELECTRICAL CONNECTIONS........................................................................25
3.1 Power Supply............................................................................................................27
3.2 Main Serial Interface.................................................................................................27
3.2.1 RS232 Interface........................................................................................................28
3.2.2 RS485 Full-Duplex Interface.....................................................................................29
3.2.3 RS485 Half-Duplex Interface.....................................................................................30
3.3 Auxiliary RS232 Interface..........................................................................................32
3.4 Inputs........................................................................................................................33

iv
3.4.1 Code Verifier.............................................................................................................37
3.5 Outputs.....................................................................................................................37
3.6 User Interface - Host.................................................................................................40
4CUSTOM CABLE ELECTRICAL CONNECTIONS...................................................41
4.1 Power Supply............................................................................................................43
4.2 Main Serial Interface.................................................................................................43
4.2.1 RS232 Interface........................................................................................................44
4.2.2 RS485 Full-Duplex Interface.....................................................................................45
4.2.3 RS485 Half-Duplex Interface.....................................................................................46
4.3 Auxiliary Interface .....................................................................................................48
4.4 Inputs........................................................................................................................48
4.4.1 Code Verifier.............................................................................................................51
4.5 Outputs.....................................................................................................................51
4.6 User Interface...........................................................................................................53
5LONWORKS CONNECTIONS .................................................................................54
5.1 Network Termination.................................................................................................55
5.2 Lonworks Interface....................................................................................................55
6FIELDBUS CONNECTIONS.....................................................................................58
6.1 Ethernet Interface .....................................................................................................58
6.2 Ethernet Interface (older models)..............................................................................59
6.3 DeviceNet Interface ..................................................................................................61
6.4 Profibus Interface......................................................................................................62
7TYPICAL LAYOUTS.................................................................................................63
7.1 Local Lonworks Network...........................................................................................63
7.1.1 Small Synchronized Network ....................................................................................64
7.1.2 Multidata Network.....................................................................................................66
7.1.3 Fieldbus Networks ....................................................................................................67
8SOFTWARE CONFIGURATION...............................................................................69
8.1 Genius™ Installation.................................................................................................69
8.2 Guide to Rapid Configuration....................................................................................69
8.2.1 Wizard for Quick Reader Setup.................................................................................69
8.2.2 Genius™ Network Setup Through Master.................................................................72
8.2.3 Alternative Slave Address Assignment......................................................................77
8.3 Advanced Genius™ Configuration ............................................................................77
8.3.1 Genius™ Shortcuts for Network Configuration..........................................................78
8.4 Parameter Default Values.........................................................................................80
9READING FEATURES .............................................................................................84
9.1 DS6400 FLASH™ Dynamic Focus............................................................................84
9.1.1 Fixed Mode...............................................................................................................84
9.1.2 Continuous Mode......................................................................................................84
9.1.3 Triggered Mode.........................................................................................................85
9.1.4 D-FLASH™ Mode .....................................................................................................85
9.2 Advanced Code Reconstruction (ACR™ 4)...............................................................86
9.2.1 Tilt Angle for Advanced Code Reconstruction...........................................................86
9.3 PackTrack™ .............................................................................................................87
9.3.1 Auto PackTrack™ Calibration for Reading Station Using DLAPC .............................89
9.3.2 Manual PackTrack™ Calibration for DS6400 Scanner Using SPY ............................96
9.3.3 PackTrack™ Calibration for DS6400 Oscillating Mirror Models.................................99
9.4 Performance...........................................................................................................100

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9.4.1 Reading Conditions.................................................................................................100
9.5 Reading Diagrams..................................................................................................102
9.5.1 DS6400 Standard Model.........................................................................................103
9.5.2 DS6400 Oscillating Mirror Model.............................................................................113
10 MAINTENANCE .....................................................................................................123
10.1 Cleaning..................................................................................................................123
10.2 External Memory Backup & Restore .......................................................................123
10.3 Automatic Scanner Replacement (ASR) .................................................................123
10.3.1 ASR Network Configuration ....................................................................................124
10.3.2 Scanner Replacement Procedure ...........................................................................124
11 TROUBLESHOOTING............................................................................................125
12 TECHNICAL FEATURES.......................................................................................128
AALTERNATIVE LAYOUTS.....................................................................................130
Point-to-Point..........................................................................................................130
ID-NET™ Gateway .................................................................................................132
Pass Through .........................................................................................................133
RS232 Master/Slave...............................................................................................134
Multiplexer ..............................................................................................................136
GLOSSARY............................................................................................................137
INDEX.....................................................................................................................140

vi
REFERENCES
REFERENCE DOCUMENTATION
The documentation related to the DS6400 management is listed below:
CBX100/CBX500 Installation Manuals
PWR series power supply unit Installation Manuals
Document about the Ethernet connectivity
Document about the Profibus connectivity
ID-NET™ Fixed Baudrate Application Note
GFC-60 90° deflecting mirror
GFC-600 90° deg. mirror close distance
Help On-Line in PDF format
SUPPORT THROUGH THE WEBSITE
Datalogic provides several services as well as technical support through its website. Log on
to www.datalogic.com and click on the Industrial Automation links for further information:
Products - Industrial Automation - Identification
Select your product from the links on the Identification page. The product page
describes specific Info, Features, Applications, Models, Accessories, and Downloads
including documentation, software drivers, and the Genius™utility program, which
allows device configuration using a PC through Serial and Ethernet interfaces.
Support & Services - Industrial Automation
Several links from the Industrial Automation list take you to additional services such as:
Service Program which contains Maintenance Agreements and Warranty Extensions;
Repair Centers; On-Line RMA Return Material Authorizations; Technical Support through
email or phone, Partner Program; Downloads for additional downloads.
PATENTS
This product is covered by one or more of the following patents:
U.S. patents: Re. 36,251; 5,992,740; 6,049,406; 6,347,740 B1; 6,394,352 B1; 6,443,360 B1;
6,629,639 B2; 6,742,710 B2; 7,161,685 B1; 7,195,162 B2.
European patents: 652,530 B1; 786,734 B1; 789,315 B1; 851,376 B1; 959,426 B9;
1,300,798 B1;1,217,571 B1; 1,363,228 B1; 1.607,901 B1.
Japanese patents: 3,793,585 B2; 4,033,958 B2; 4,129,302 B2; 4,376,353 B2; 4,451,592 B2.

vii
COMPLIANCE
ELECTRICAL SAFETY
This product conforms to the applicable requirements contained in the European Standard for
electrical safety EN-60950 at the date of manufacture.
WARNING
This symbol refers to operations that must be performed by qualified
personnel only. Example: opening the device.
LASER SAFETY
The following information is provided to comply with the rules imposed by international
authorities and refers to the correct use of the DS6400 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 EN60825-1 and
CDRH 21 CFR1040 at the date of manufacture. The reader is classified as a Class 2 laser
product according to EN60825-1 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.
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 head of the
scanner (Figure A).

viii
Warning labels indicating exposure to laser light and the device classification are applied
onto the body of the scanner (Figure A):
AVOID EXPOSURE
LASER RADIATION IS EMITTED FROM THIS APERTURE
AVOID EXPOSURE –LASER LIGHT
IS EMITTED FROM THIS APERTURE
Laser Safety Label for Oscillating Mirror and Standard Models
DS6400
CAUTION-CLASS 3B
LASER LIGHT
WHEN OPEN
AVOID EXPOSURE
TO BEAM
LASER LIGHT - DO NOT STARE INTO BEAM
CLASS 2 LASER PRODUCT
MAX. OUTPUT RADIATION 1 mW
EMITTED WAVE LENGTH 630~680 nm
EN60825-1:2001
Warning and Device Class Label
The identification label is applied onto the bottom part of the scanner (Figure A, 2):
N2468
DATALOGIC AUTOMATION S.r.l. - Via Lavino, 265
40050 Monte San Pietro (BO) ITALY
MANUFACTURED VOLT Amp.
JANUARY 2005 15-30 DC 1.5-0.7
MODEL No.
SERIAL No.
Thisproductconformstotheapplicablerequirements
of 21CFR 1040 at the date of manufacture.
Device Identification Label
Disconnect the power supply when opening the device during maintenance or installation to
avoid exposure to hazardous laser light.
The laser diodes used in this device are classified as Class 3B laser products according to
EN 60825-1 regulations and as Class IIIb laser products according to CDRH regulations. Any
violation of the optic parts in particular can cause radiation up to the maximum level of the
laser diode (35 mW at 630~680 nm).
POWER SUPPLY
This product is intended to be installed by Qualified Personnel only.
For all DS6400 models:
This device is intended to be supplied by a UL Listed Power Unit marked “Class 2” or LPS
power source, which supplies power directly to the scanner via the 25/26-pin connector.
This scanner must be supplied by a Class II Power Supply Unit conforming to the
EN 60950 safety regulation.

ix
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.
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.

x
GENERAL VIEW
DS6400
Figure A - DS6400
Laser Safety Label
Warning and Device Class Label
Identification Label
Connector Panel
Display and Keypad Panel
Laser Beam Output Window
1
3
7
6
5
2
Service Cap
4
6
4
3
1
2
7
5

xi
DS6400
Figure B - DS6400 Oscillating Mirror Version
Laser Safety Label
1
Laser Beam Output Window
2
Figure C –Display and Keypad Panel
Programming Keypad
Phase On LED
TX Data LED
Power On LED
LCD Display
1
2
3
5
4
2
3
4
5
1
1
2

xii
Figure D –Connector Panel for Master/Slave Models
Main/Aux. Interface 25-pin D-Sub male connector
1
Lonworks 9-pin male connector
2
Lonworks 9-pin female connector
3
Figure E –Connector Panel for Ethernet Models
Main/Aux. Interface 26-pin D-Sub male connector
1
Ethernet 4-pin female connector
2
Lonworks 9-pin female connector
3
Figure F –Connector Panel for (older) Ethernet Models
Main/Aux. Interface 26-pin D-Sub male connector
1
RJ45 modular connector for Ethernet Interface
2
Lonworks 9-pin female connector
3
3
2
1
3
2
1
2
1
3

xiii
Figure F –Connector Panel for DeviceNet Models
Main/Aux. Interface 26-pin D-Sub male connector
1
DeviceNet 5-pin male connector
2
Lonworks 9-pin female connector
3
Figure G –Connector Panel for Profibus Models
Main/Aux. Interface 26-pin D-Sub male connector
1
Profibus 9-pin female connector (white)
2
Lonworks 9-pin female connector
3
1
3
2
1
3
2

xiv
GUIDE TO INSTALLATION
POINT-TO-POINT INSTALLATION
The following can be used as a checklist to verify all the necessary steps to complete
installation of the DS6400 scanner.
1) Read all information in the section “Compliance” at the beginning of this manual.
2) Correctly mount the scanner using the bracket provided according to the information in
par. 2.2 and position it at the correct reading distance according to your model as shown
in par. 2.3 and par. 9.5.
3) Make electrical connections to your DS6400 scanner by:
a) Connecting the DS6400 scanner to the CBX100/CBX500 by means of one of the
CAB-Sxx (or CAB-F0x depending on the model) cables provided as an accessory
(see par. 1.8).
b) Providing correct and complete system cabling through the CBX100/CBX500
according to the signals necessary for the layout of your application (trigger, inputs,
outputs).
Cabling: Power, Interface, Inputs, Outputs, etc. For further details, see chapter 3
(chapter 4 for custom cabling).
Alternative Layouts: Point-to-Point, Pass Through, RS232 Master/Slave,
Multiplexer. See appendix A for layout references.
4) Configure the DS6400 scanner by installing and running the Genius™ configuration
program from the CD-ROM provided. See chapter 8 and the Help On-Line for details.
The main steps are:
Select the codes to be read
Set-up the communication parameters
When PackTrack™ is required, set the PS Offset and Position parameters
Define data formatting parameters
NOTE
Fine tuning of the scanner position for barcode reading can be
accomplished by performing a test through the SPY configuration tool in
Genius™.
5) Exit the configuration program and run your application.
The installation is now complete.

xv
MASTER/SLAVE LONWORKS INSTALLATION
The following can be used as a checklist to verify all the steps necessary to complete
installation of the DS6400 scanner in a Master/Slave Lonworks network.
1) Read all information in the section “Compliance” at the beginning of this manual.
2) Correctly mount the scanner using the bracket provided according to the information in
par. 2.2 and position it at the correct reading distance according to your model as shown
in par. 9.5.
3) Make electrical connections to your DS6400 scanner by:
a) Connecting the DS6400 Master scanner to the CBX100/CBX500 by means of one of
the CAB-Sxx (or CAB-F0x depending on the model) cables provided as an accessory
(see par. 1.8).
b) Correctly terminating the DS6400 Master reader according to the information given in
par. 5.1 and par. 7.1.
c) Completing the system wiring adding as many slave scanners as required by your
system layout (refer to par. 7.1).
d) Correctly terminating the last DS6400 Slave reader of the network according to the
information given in par. 5.1 and par. 7.1.
4) Install and run the Genius™ configuration program from the CD-ROM provided.
Configure the Local Lonworks Network using one of the procedures given below:
Configure the entire network through the Master as described in par. 8.2.2;
Configure the Master as described in par. 8.2.2 and locally define each slave scanner
address as described in par. 8.2.3.
Define each scanner, master and slaves (with their addresses), by using the scanner
keypad according to the information given in par. 1.6.1.
5) Configure the Master scanner through the Genius™ program. The main steps are:
Select the codes to be read
Set-up the communication parameters
When PackTrack™ is required, perform PackTrack™ calibration, see par. 9.3.1.
Define data formatting parameters
6) Configure each Slave scanner through the Master scanner using Genius™. The main
steps are:
Select the codes to be read
When PackTrack™ is required, perform PackTrack™ calibration, see par. 9.3.1.
NOTE
Fine tuning of the scanner position for barcode reading can be
accomplished by performing a test through the SPY configuration tool in
Genius™.

xvi
7) Send the configuration to the Master.
8) Perform the External Memory Backup Procedure for system backup purposes (see par.
10.2). For backward compatibility you can perform the ASR Network Configuration
procedure for system backup purposes (see par. 10.3.1).
9) Exit the configuration program and run your application.
The installation is now complete.

INTRODUCTION
1
1
1 INTRODUCTION
1.1 PRODUCT DESCRIPTION
The DS6400 is a high performance laser scanner in a complete range of industrial bar code
readers offering an innovative and modular solution in terms of reading performance,
connectivity and maintenance, in addition to a completely new hardware and software
platform.
The DS6400 has been specifically designed for simple installation, easy use and flexibility.
An innovative mechanical design together with the Datalogic patented Step-a-HeadTM feature
make it possible to rotate the reader head and the decoder base independently from each
other. Step-a-HeadTM enables the DS6400 to always be installed in the ideal position, by
modifying the orientation of the connector panel while leaving the laser window in the desired
position. The need for space is minimized and installation is easier.
The DS6400 has an innovative linear motor designed to control the focus position of the
scanner via software. This dynamic system, called FLASHTM,is able to move the focus
position rail to rail, from the minimum position to the maximum position, in less than 10 msec.
In typical applications, where a DOF <1 meter is required, the focus position is adjusted in 4
msec.
The DS6400 can read all most popular barcodes even in the most difficult conditions, thanks
to a new generation decoder and code reconstruction technology (ACR™ 4).
This reader is also offered in a model with an integrated SW programmable oscillating mirror.
Great attention has been given to built-in connectivity for market standards. A Local
Lonworks network for scanner connectivity (all versions), and a Fieldbus network (Ethernet,
DeviceNet, or Profibus) for host connectivity (dedicated versions) have been integrated in the
decoder base.
Some of the main features of DS6400 are listed below:
scanning speed up to 1200 scans/sec;
2 serial communication interfaces
reading all popular codes;
supply voltage from 15 to 30 Vdc;
electrical connection through connectors;
high speed Lonworks connectivity for Master/Slave layout;
Fieldbus models (Ethernet, Profibus) with built-in connectivity;
programmable in several different operating modes to suit the most various barcode
reading system requirements;
light source: solid state laser diode; the light emitted has a wavelength between
630~680nm.
IP64 protection class of the enclosure (IP50 for older RJ45 Ethernet models).

DS6400 REFERENCE MANUAL
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1
1.2 APPLICATIONS
The DS6400 barcode reader is specifically designed for industrial applications and for all
cases requiring high reading performance such as:
code reconstruction
reading of codes covered by plastic film
reading of codes with a wide depth of field
reading of high resolution codes positioned at long distances from the reader
code reading on fast moving objects
DS6400 is designed for both single-reader layouts and multi-reader layouts. For typical
layouts see chapter 7 and appendix A.
Feature
Benefit
ACR™
Advanced Code Reconstruction technology
allows the reading of low aspect ratio labels
placed anywhere on a parcel and enhances the
readability of poorly printed or damaged codes.
PackTrack™
PackTrack™ is a Datalogic patented parcel
tracking system which improves the reading
features in omnidirectional stations. In particular,
PackTrack™ manages 6-sided reading systems
when it is impossible to detect the real position of
the code on the parcel, thus overcoming the need
for external accessories essential in traditional
tracking systems.
FLASH™
A dynamic focus system controlled by software
which is able to move the focus position from the
absolute minimum position to the absolute
maximum position, in less than 10 msec., typical
applications can be adjusted in 4 msec.
Modular solution with
separated head and base and
Step-a-Head™feature
Possibility to select the combination of head and
base that best fits the needs of the application.
Great scalability of the offer.
Down time cost reduction, since the decoder base
works even if the head has been removed.
Easy maintenance. In case of replacement of the
head, all the configuration parameters are stored
in the base, and the scanner is automatically
configured.
Easy installation with the minimum room needed.
Reading on pallets or large
objects where a long reading
distance / wide reading field
are needed
DS6400 with FLASHTM dynamic focusing system.
Reading parcels on conveyors
DS6400 implements the Packtrack™ functionality
which leads to an increase of the plant production
as a result of the augmented system throughput.

INTRODUCTION
3
1
Feature
Benefit
Master working as a
Multiplexer on high speed
Lonworks bus
Great competitiveness of the offer, since the cost
of an external multiplexer is saved;
High data transfer on an industrial, reliable bus
running at 1,2 Mbit/sec.
Genius™ Configuration SW
Reduced learning time, with an easy wizard
approach;
Multilanguage platform;
All the configuration parameters stored into the
scanner;
Not dependent on the Physical interface.
Energy Saving
A software parameter group which allows
management of the energy saving feature. In
particular, it allows turning on/off the motor and
laser of all network scanners according to the
selected digital input, encoder, or communication
channel.
The time required to restart the system is less
than 1 minute independently from the number of
scanners connected.
It is suggested to use this parameter for example
when the conveyor is stopped for a lengthy
period.
1.3 MODEL DESCRIPTION
The DS6400 scanner is available in versions that differ in regard to the following
characteristics:
Optical Model (Head)
Decoder Model (Base)
Optical Model (Head)
0 = Standard
5 = Oscillating Mirror
Decoder Model (Base)
10 = Master/Slave
11 = Profibus
12 = Ethernet
15 = Devicenet
DS6400 - 10X - 0YY

DS6400 REFERENCE MANUAL
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1
1.4 OSCILLATING MIRROR MODELS
Oscillating mirror models are used when coverage of a large reading area is required, mainly
in picket fence applications.
The DS6400 scanner mounts a dedicated optic head with integrated oscillating mirror driven
by a linear motor. The speed, the precision, the repeatability, and the reliability of this driving
technology assure high level performance.
The oscillating mirror is completely software controlled and software programmable. The
Genius™ software tool allows adjusting the linear motor speed (oscillating frequency) and
the upper and lower limits of the oscillation by defining the top and bottom line limit angles.
When the oscillating mirror is programmed to read barcode labels at very small angles,
position the reader to assure at least 10° for the Skew angle (see par. 2.3). This angle refers
to the most inclined or external laser line, so that all other laser lines assure more than 10°
Skew. This avoids the direct reflection of the laser light emitted by the reader.
10°
Figure 1 –Oscillating Mirror Skew Angle
Otherwise, the scanner can be mounted at an angle of inclination of 17.5° in order to attain
symmetrical deflection ranges.
17.5°
107.5°
Figure 2 - Oscillating Mirror Reading Position
In the above case, the zone where the scan line is perpendicular to the reflecting surface
corresponds to a neutral zone at the center of the reading field.