Leuze electronic BCL 95 User manual

Original operating instructions
EN 2018/08 - 50140970 We reserve the right to make technical changes
BCL 95
Bar code reader

© 2018
Leuze electronic GmbH & Co. KG
In der Braike 1
D-73277 Owen / Germany
Phone: [phone]
Fax: [phone]
http://www.leuze.com
[email protected]
Leuze electronic BCL 95 2

Table of contents
Leuze electronic BCL 95 3
Table of contents
1 About this document ............................................................................................5
1.1 Used symbols and signal words ............................................................................................. 5
1.2 Terms and abbreviations ........................................................................................................ 6
2 Safety .....................................................................................................................7
2.1 Intended use ........................................................................................................................... 7
2.2 Foreseeable misuse ............................................................................................................... 7
2.3 Competent persons ................................................................................................................ 8
2.4 Disclaimer ............................................................................................................................... 8
2.5 Laser safety notices................................................................................................................8
3 Device description ..............................................................................................12
3.1 Device overview....................................................................................................................12
3.1.1 The BCL95 bar code reader.............................................................................................12
3.1.2 Stand-alone operation .......................................................................................................12
3.2 Performance characteristics ................................................................................................. 12
3.3 Device construction .............................................................................................................. 13
3.4 Connection technology ......................................................................................................... 13
3.5 Display elements .................................................................................................................. 14
4 Mounting..............................................................................................................15
4.1 Selecting a mounting location............................................................................................... 15
5 Electrical connection..........................................................................................17
5.1 Operating voltage ................................................................................................................. 17
5.2 Housing ground .................................................................................................................... 17
5.3 Pin assignment ..................................................................................................................... 18
5.4 Switching input......................................................................................................................18
5.5 Switching output ................................................................................................................... 19
5.6 Cable lengths and shielding..................................................................................................20
5.7 PC or terminal connection .................................................................................................... 20
6 Configuration and diagnostics software - SensorStudio...............................21
6.1 System requirements............................................................................................................ 21
6.2 Installing SensorStudio ........................................................................................................ 22
6.2.1 Downloading configuration software .................................................................................22
6.2.2 Installing the SensorStudio FDT frame ............................................................................22
6.2.3 Install the communication DTM and device DTM..............................................................22
6.2.4 Connecting device to PC...................................................................................................22
6.3 Starting SensorStudio.......................................................................................................... 23
6.4 Exiting SensorStudio ........................................................................................................... 24
6.5 Configuration parameters ..................................................................................................... 24
6.5.1 Decode tab ........................................................................................................................25
6.5.2 Output tab..........................................................................................................................28
6.5.3 Control tab.........................................................................................................................30
6.5.4 Host interface tab ..............................................................................................................31
6.5.5 Reference code tab ...........................................................................................................32
6.5.6 Switching input tab ............................................................................................................34
6.5.7 Switching output tab ..........................................................................................................35
6.6 Diagnosis .............................................................................................................................. 36
6.7 Firmware Reload................................................................................................................... 37

Table of contents
Leuze electronic BCL 95 4
7 Starting up the device - Configuration..............................................................38
7.1 Measures to be performed prior to the initial commissioning ............................................... 38
7.2 Starting the device ................................................................................................................ 38
7.2.1 Power-on test ....................................................................................................................38
7.2.2 Interface ............................................................................................................................38
7.2.3 Online commands .............................................................................................................38
7.2.4 Problems ...........................................................................................................................38
7.3 Starting up with factory settings............................................................................................ 38
7.4 Setting the configuration parameters.................................................................................... 39
7.4.1 Service mode ....................................................................................................................39
7.4.2 Parameter sets ..................................................................................................................40
8 Online commands...............................................................................................41
8.1 Overview of commands and parameters .............................................................................. 41
8.2 General online commands.................................................................................................... 42
8.3 Online commands for system control ................................................................................... 45
8.4 Online commands for the parameter set operations............................................................. 46
9 Care, maintenance and disposal .......................................................................50
10 Diagnostics and troubleshooting......................................................................51
11 Service and support ...........................................................................................52
11.1 What to do should servicing be required? ............................................................................ 52
12 Technical data .....................................................................................................53
12.1 General specifications .......................................................................................................... 53
12.2 Reading fields ....................................................................................................................... 55
12.3 Dimensioned drawings ......................................................................................................... 56
13 Order guide and accessories.............................................................................58
13.1 Type overview....................................................................................................................... 58
13.2 Accessories........................................................................................................................... 58
14 EC Declaration of Conformity............................................................................59
15 Appendix..............................................................................................................60
15.1 Bar code samples ................................................................................................................. 60

About this document
Leuze electronic BCL 95 5
1 About this document
1.1 Used symbols and signal words
Tab.1.1: Warning symbols and signal words
Symbol indicating dangers to persons
Symbol indicating dangers from harmful laser radiation
Symbol indicating possible property damage
NOTE Signal word for property damage
Indicates dangers that may result in property damage if the measures for
danger avoidance are not followed.
CAUTION Signal word for minor injuries
Indicates dangers that may result in minor injury if the measures for danger
avoidance are not followed.
WARNING Signal word for serious injury
Indicates dangers that may result in severe or fatal injury if the measures
for danger avoidance are not followed.
Tab.1.2: Other symbols
Symbol for tips
Text passages with this symbol provide you with further information.
Symbol for action steps
Text passages with this symbol instruct you to perform actions.
Symbol for action results
Text passages with this symbol describe the result of the preceding action.

About this document
Leuze electronic BCL 95 6
1.2 Terms and abbreviations
Tab.1.3: Terms and abbreviations
BCL Bar code reader
DNC
(Do Not Connect)
This PIN must not be connected
DTM
(Device Type Manager)
Software device manager
EMC Electromagnetic compatibility
EN European standard
FDT
(Field Device Tool)
Software frame for management of device managers (DTM)
FE Functional earth
GUI Graphical user interface
HID
(Human Interface De-
vice)
Device class for input devices with which users directly interact
NC
(Not Connected)
This pin is not contacted at the device
PLC Programmable Logic Control
(corresponds to Programmable Logic Controller (PLC))
SW_IN Switching input
SW_OUT Switching output

Safety
Leuze electronic BCL 95 7
2 Safety
This bar code reader was developed, manufactured and tested in accordance with the applicable safety
standards. It corresponds to the state of the art.
2.1 Intended use
Bar code readers of the BCL95 series are conceived as stationary scanners with integrated decoder for all
current bar codes used for automatic object detection.
Areas of application
The bar code readers of type BCL95 are intended for the following areas of application:
• automatic analyzers
• Robotics and automation technology
• Material flow
• Labeling and packaging machines
• For space-critical bar code reading tasks
• Applications with large reading field with small modules
CAUTION
Observe intended use!
The protection of personnel and the device cannot be guaranteed if the device is operated in a
manner not complying with its intended use.
ÄOnly operate the device in accordance with its intended use.
ÄLeuzeelectronicGmbH+Co.KG is not liable for damages caused by improper use.
ÄRead these operating instructions before commissioning the device. Knowledge of the oper-
ating instructions is an element of proper use.
NOTICE
Comply with conditions and regulations!
ÄObserve the locally applicable legal regulations and the rules of the employer's liability insur-
ance association.
CAUTION
UL applications!
For UL applications, use is only permitted in Class 2 circuits in accordance with the NEC (Na-
tional Electric Code).
2.2 Foreseeable misuse
Any use other than that defined under "Intended use" or which goes beyond that use is considered im-
proper use.
In particular, use of the device is not permitted in the following cases:
• in rooms with explosive atmospheres
• in circuits which are relevant to safety
• for medical purposes
NOTICE
Do not modify or otherwise interfere with the device!
ÄDo not carry out modifications or otherwise interfere with the device. The device must not be
tampered with and must not be changed in any way.
ÄThe device must not be opened. There are no user-serviceable parts inside.
ÄRepairs must only be performed by Leuze electronicGmbH+Co.KG.

Safety
Leuze electronic BCL 95 8
NOTICE
ÄTo increase the decoding reliability, it is recommended that only the actually needed code
types be enabled.
ÄIf there are very high requirements on reading reliability, the use of additional processes is
recommended, e.g.:
ðDevice side: check digits, multiple evaluation by setting Equal Scans to min. ≥2
ðApplication side: reading moving codes
ðSystem side: plausibility checks of the bar code information
2.3 Competent persons
Connection, mounting, commissioning and adjustment of the device must only be carried out by competent
persons.
Prerequisites for competent persons:
• They have a suitable technical education.
• They are familiar with the rules and regulations for occupational safety and safety at work.
• They are familiar with the operating instructions for the device.
• They have been instructed by the responsible person on the mounting and operation of the device.
Certified electricians
Electrical work must be carried out by a certified electrician.
Due to their technical training, knowledge and experience as well as their familiarity with relevant standards
and regulations, certified electricians are able to perform work on electrical systems and independently de-
tect possible dangers.
In Germany, certified electricians must fulfill the requirements of accident-prevention regulations DGUV
(German Social Accident Insurance) provision 3 (e.g. electrician foreman). In other countries, there are re-
spective regulations that must be observed.
2.4 Disclaimer
LeuzeelectronicGmbH+Co.KG is not liable in the following cases:
• The device is not being used properly.
• Reasonably foreseeable misuse is not taken into account.
• Mounting and electrical connection are not properly performed.
• Changes (e.g., constructional) are made to the device.
2.5 Laser safety notices
WARNING
The device satisfies the requirements of IEC60825-1:2014 (EN60825-1:2014) safety regula-
tions for a product of laser class1.
ÄAdhere to the applicable legal and local regulations regarding protection from laser beams in
its latest version.
ÄThe device must not be tampered with and must not be changed in any way. There are no
user-serviceable parts inside the device. Repairs must only be performed by Leuze elec-
tronic GmbH + Co. KG.

Safety
Leuze electronic BCL 95 9
WARNING
LASER RADIATION – LASER CLASS 2
Never look directly into the beam!
The device satisfies the requirements of IEC60825-1:2007 (EN60825-1:2007) safety regula-
tions for a product of laser class2 as well as the U.S.21CFR1040.10 regulations with devia-
tions corresponding to "Laser Notice No.50" from June 24, 2007.
ÄNever look directly into the laser beam or in the direction of reflected laser beams! If you
look into the beam path over a longer time period, there is a risk of injury to the retina.
ÄDo not point the laser beam of the device at persons!
ÄInterrupt the laser beam using a non-transparent, non-reflective object if the laser beam is
accidentally directed towards a person.
ÄWhen mounting and aligning the device, avoid reflections of the laser beam off reflective
surfaces!
ÄCAUTION! The use of operating or adjusting devices other than those specified here or car-
rying out of differing procedures may lead to dangerous exposure to radiation.
The glass optics cover is the only aperture through which laser radiation may be observed
on this product.
ÄAdhere to the applicable legal and local regulations regarding protection from laser beams in
its latest version.
ÄThe device must not be tampered with and must not be changed in any way.
There are no user-serviceable parts inside the device.
ÄRepairs must only be performed by Leuze electronic GmbH + Co. KG.
WARNING
LASER RADIATION – LASER CLASS 2
ÄIf the scanner motor fails during the emission of laser radiation, the limit value of laser
class2 in accordance with IEC60825‑1 Edition2.0(2007) and Edition3.0 (2014) could be
exceeded. The device has safeguards to prevent this occurrence.
ÄIf the emitted laser beam is at a standstill, immediately disconnect the faulty bar code reader
from the voltage supply.
ÄThe BCL95 bar code reader emits scanned optical radiation at a wavelength of 655nm
(red).
ÄLooking at the device's mirror and operating at the lowest scanning rate (400scans/s) at a
viewing distance of 65mm results in pulses with a pulse duration of 120µs on the retina of
the eye. The total pulse peak power at the exit window is less than 2.1mW.
ÄThe average laser power is less than 1mW, corresponding to laser class2 in accordance
with EN60825-1, Edition2.0 (2007) and IEC60825-1, Edition2.0 (2007) and less than the
limit value of 0.39 mW for laser class1 in accordance with EN60825-1, Edition 3.0 (2014)
and IEC 60825-1, Edition 3.0 (2014).

Safety
Leuze electronic BCL 95 10
NOTICE
Laser aperture!
The glass optics cover is the only aperture through which laser radiation may be observed on
this product.
NOTICE
Affix laser information and warning signs!
Included with the device are self-adhesive laser warning and laser information signs (stick-on la-
bels) in multiple languages.
ÄAffix the laser information sheet to the device in the language appropriate for the place of
use. When using the device in the US, use the stick-on label with the "Complies with
21CFR1040.10" notice.
ÄAffix the laser information and warning signs near the device if no signs are attached to the
device (e.g. because the device is too small) or if the attached laser information and warning
signs are concealed due to the installation position.
Affix the laser information and warning signs so that they are legible without exposing the
reader to the laser radiation of the device or other optical radiation.
2
1
2
1
1 Laser aperture
2 Laser warning sign
Fig.2.1: Laser aperture and laser warning sign

Safety
Leuze electronic BCL 95 11
Fig.2.2: Laser warning and notice signs – supplied stick-on labels

Device description
Leuze electronic BCL 95 12
3 Device description
3.1 Device overview
3.1.1 The BCL95 bar code reader
The bar code reader is a laser scanner with integrated decoder for all commonly used bar codes, e.g.
2/5Interleaved, Code39, Code128, EAN etc.
• The reading field is optimized for the reading of sample tubes, reagent containers, etc., in lab automa-
tion.
• Reliable reading of 80 mm high code labels at a short distance.
• Due to the small dimensions of the unit and the variants with frontal or lateral beam exit, the bar code
reader can also be used in highly constrained spaces.
• The many possible configurations of the device allow it to be adapted to a multitude of reading tasks.
• Information on technical data and characteristics: see chapter 12 "Technical data".
3.1.2 Stand-alone operation
The bar code reader is operated as a "stand-alone" single device. The electrical connection of the operat-
ing voltage, the interface and the switching input is made via a 6-wire cable with open cable ends or via an
8-pin M12 connector.
3.2 Performance characteristics
• Laser scanner with integrated decoder; lateral or frontal beam exit
• High-resolution optics
• Resolution 0.15mm…0.5mm
Reading of all common codes of module size 165…500μm (6…20mil) at a reading field height of
≥80mm, even with a reading distance of 25 mm for devices with lateral beam exit
• Reading distance 25mm…170mm
• Scanning rate of 600scans/s facilitates reliable reading, even while in motion
• Compact design for simple integration, even in constrained spaces
• Sturdy diecast zinc housing
• Connection cable 2m with open cable end
• Pigtail with M12 connector, 8-pin
• Process and service interface RS232

Device description
Leuze electronic BCL 95 13
3.3 Device construction
1
6
3
4
5
7
6
3
4
5
7
8
8
8
8
2
1 BCL95 M0/R2 …; lateral beam exit
2 BCL95 M2/R2 …; frontal beam exit
3 Indicator diode – decode LED
4 Indicator diode – status LED
5 Laser warning sign
6 Connection cable, 6-wire with open cable end
Pigtail with M12 connector, 8-pin
7 M2.5 mounting threads on the device side
8 M3 mounting threads on the rear of the device
Fig.3.1: Device construction of the BCL95
3.4 Connection technology
6-wire connection cable with open cable end or pigtail with 8-pin M12 connection plug:
• Voltage supply
• 1 switching input
• 1 switching output
• Process and service interface RS232

Device description
Leuze electronic BCL 95 14
3.5 Display elements
Located on the front of the device are two LEDs that indicate the readiness for operation and the read sta-
tus.
LED Display Description
Status LED
(PWR)
Green, flashing Initialization phase
Green, continuous light Operational readiness
Red, flashing 200ms Warning
Red, continuous light Error, no function
Orange, flashing 200ms Service operation
Decode LED
(GOOD READ)
Green, 200ms on Reading successful
Red, 200ms off No reading result
Orange, continuous light Reading gate active

Mounting
Leuze electronic BCL 95 15
4 Mounting
ÄObserve the mounting instructions (see chapter 4.1 "Selecting a mounting location").
ÄFasten the bar code reader on the mounting threads (see chapter 3.3 "Device construction"):
• M3 mounting threads on the rear of the device
• M2.5 mounting threads on the device side
4.1 Selecting a mounting location
NOTICE
The size of the bar code module influences the maximum reading distance and the width of the
reading field.
ÄWhen selecting a mounting location and/or the bar code label, take into account the different
reading characteristics of the bar code reader with various bar code modules.
NOTICE
Observe when choosing the mounting location!
ÄMaintain the permissible environmental conditions (humidity, temperature).
ÄAvoid possible soiling of the reading window due to liquids, abrasion by boxes, or packaging
material residues.
ÄEnsure that there is the lowest possible chance of damage to the bar code reader by me-
chanical collision or jammed parts.
ÄAvoid possible ambient light influence (no direct sunlight).
In order to select the right mounting location, several factors must be considered:
• Size, orientation, and position tolerance of the bar codes on the objects to be scanned.
• The reading field of the bar code reader in relation to the bar code module width.
• The resulting minimum and maximum reading distance from the respective reading field with the re-
spective module width (see chapter 12.2 "Reading fields").
• alignment of the bar code reader for avoiding reflections.
• distance between bar code reader and host system with respect to the interface.
The best read results are obtained if the following prerequisites are fulfilled:
• The reading distance lies in the middle area of the reading field.
• There is no direct sunlight and ambient light influences are avoided
• The bar code labels are of good print quality and have good contrast ratios.
• You are not using glossy labels.
• The bar code is moved past the reading window with an angle of rotation of approx. 15°.
NOTICE
Avoid direct reflection of the laser beam!
The beam exits the bar code reader perpendicular to the reading window.
ÄThe bar code label must be rotated by >10 ° to avoid a reflection of the laser beam in the
case of glossy labels.

Mounting
Leuze electronic BCL 95 16
α
β
γ
α Azimuth angle
β Angle of inclination
γ Angle of rotation
Recommended angle of rotation: γ>10°
Fig.4.1: Definition of the reading angles

Electrical connection
Leuze electronic BCL 95 17
5 Electrical connection
CAUTION
Safety notices!
ÄThe bar code reader is completely sealed and must not be opened.
ÄBefore connecting the device, be sure that the supply voltage agrees with the value printed
on the name plate.
ÄConnection of the device and maintenance work while under voltage must only be carried
out by a qualified electrician.
ÄThe power supply unit for the generation of the supply voltage for the bar code reader and
the corresponding connection units must have a secure electrical insulation according to
IEC60742 (PELV).
ÄIf faults cannot be rectified, take the device out of operation and protect it from accidentally
being started.
CAUTION
UL applications!
For UL applications, use is only permitted in Class 2 circuits in accordance with the NEC (Na-
tional Electric Code).
NOTICE
Laying cables!
ÄLay all connection cables and signal lines within the electrical installation space or perma-
nently in cable ducts.
ÄLay the cables and lines so that they are protected against external damages.
ÄFor further information: see EN ISO 13849-2, Table D.4.
The electrical connection is established via the connection cable (see chapter 5.3 "Pin assignment"):
• 6-wire connection cable with open cable end
• Pigtail with M12 connector, 8-pin
The bar code reader is provided with the following interfaces:
• Voltage supply
• 1 switching input
• 1 switching output
• Process and service interface RS232
You can configure the functions of the switching input and the switching output according to your require-
ments via the SensorStudio configuration software (see chapter 6 "Configuration and diagnostics software
- SensorStudio").
5.1 Operating voltage
The bar code reader is designed for an operating voltage of 5V. The operating voltage is fed in via the con-
nection cable (see chapter 5.3 "Pin assignment").
• +5VDC: pin1 of the 8-pin M12 connector plug or red wire of the connection cable with open cable end
• GND: pin3 of the 8-pin M12 connector plug or violet wire of the connection cable with open cable end
5.2 Housing ground
To avoid electromagnetic interference, a low-impedance connection is necessary from the housing to the
machine ground.

Electrical connection
Leuze electronic BCL 95 18
5.3 Pin assignment
4
3
5
6
1
8
7
2
FE
Fig.5.1: Pin assignment for M12 connector, 8-pin, A-coded
Tab.5.1: RS 232 – M12 connector
Pin Signal Description IN / OUT Core color
1 +5VDC Voltage supply 5VDC IN White
2 SW IN Switching input IN Brown
3 GND Voltage supply 0VDC / Ground IN Green
4 SW OUT Switching output OUT Yellow
5 NC Not connected --- Gray
6 RS232 RxD Serial interface IN Pink
7 RS232 TxD Serial interface OUT Blue
8 FE/Shield Functional earth/shield --- Red
Tab.5.2: RS 232 – connection cable
Core color Signal Description IN / OUT
Red +5VDC Voltage supply 5VDC IN
Orange SW IN Switching input IN
Violet GND Voltage supply 0VDC / Ground IN
Black SW OUT Switching output OUT
White RS232 RxD Serial interface IN
Green RS232 TxD Serial interface OUT
Drain wire FE/Shield Functional earth/shield ---
5.4 Switching input
By means of the SW IN switching input connection, you can trigger a read process in the standard setting
(low = active) with the connection SW IN (pin2 / orange) and GND (pin3 / violet). We recommend wiring a
2.2kΩ pull-up resistor as defined cable termination.
Depending on how the switching input is actuated, you can operate it both as NPN (low = active) as well as
PNP (high = active).

Electrical connection
Leuze electronic BCL 95 19
+ 5 V DC
SW_IN
GND
4.75 … 5.5 V DC
GND
2.2 k
1
2
3
1 Pin1 / red
2 Pin2 / orange
3 Pin3 / violet
Connection version NPN: standard setting (low = active); input resistance: 36kΩ
Fig.5.2: Switching input for connection variant NPN (standard setting)
PNP actuation: With the "inverted" setting (high = active), you can trigger a read process by applying a volt-
age of +5VDC (pin1 / red) at SW IN (pin2 / orange).
+ 5 V DC
SW_IN
GND
GND
4.75 … 5.5 V DC
1
2
3
1 Pin1 / red
2 Pin2 / orange
3 Pin3 / violet
Connection version PNP: inverted setting (high = active); input resistance: 36kΩ
Fig.5.3: Switching input for connection variant PNP ("inverted" setting)
5.5 Switching output
The NPN switching output connection between SW OUT (pin4 / black) and GND (pin3 / violet) can be acti-
vated in the scanner setup.
In the basic setting, the SW OUT switching output is switched to GND if a code is detected.

Electrical connection
Leuze electronic BCL 95 20
+ 5 V DC
SW_OUT
GND
GND
+ 5 … 30 V DC
max. 20 mA !
RL
4.75 … 5.5 V DC
1
2
3
1 Pin1 / red
2 Pin4 / black
3 Pin3 / violet
Fig.5.4: Switching output
NOTICE
Maximum loading of the switching output
ÄDo not load the switching output of the code reader with more than 20mA at +5…30 VDC!
5.6 Cable lengths and shielding
ÄObserve the maximum cable lengths:
Connection Interface Max. cable length Shielding
BCL95 RS232 <3m Required
Switching input
Switching output
<3m Not necessary
NOTICE
ÄMake certain that the cables of the RS232 interface are shielded should a cable extension
be necessary.
5.7 PC or terminal connection
Via the RS232 service interface, you can configure the bar code reader by means of a PC or a terminal
program. For this, you need an RS232 connection that establishes the RxD, TxD and GND connections
between PC and bar code reader (see chapter 5.3 "Pin assignment").