Leuze electronic BCL548i User manual

BCL548i
Bar code reader
en 02-12/2012 50113410 We reserve the right to make technical changes
TECHNICAL DESCRIPTION

Leuze electronic BCL 548i
TNT 35/7-24V
© 2013
Leuze electronic GmbH + Co. KG
In der Braike 1
D-73277 Owen / Germany
Phone: [phone]
Fax: [phone]
http://www.leuze.com
[e-mail]

BCL 548i
The main menus BCL548i SF 102
Leuze electronic
GmbH & Co. KG
SW: V 1.8.0 HW:3
SN: 1009A009815 001
Device information - main menu
Information about
• Device type
• Software version
• Hardware version
• Serial number
IO1 IO2 IO3
IO4 ATT ERR
12345678
Bar code reading window - main menu
Visualization of the read bar code information.
See "Indicators in the display" on page 89.
Parameter
Parameter handling
Decoder table
Digital SWIO
Ethernet
Parameter - main menu
Configuration of the bar code reader.
See "Parameter menu" on page 95.
Language selection
o Deutsch
oEnglish
o Español
o Français
o Italiano
Language selection - main menu
Selection of the display language.
See "Language selection menu" on page 104.
Input of values
12|
<-|0123456789 save
Standard ----- Unit
126 | |
Service
Diagnostics
Status messages
Service - main menu
Scanner diagnosis and status messages.
See "Service menu" on page 105.
Actions
o Start decoding
o Start alignment
o Start auto-setup
o Start teach-in
o Code recognition start
Actions main menu
Various functions for scanner configuration and
manual operation.
See "Actions menu" on page 105.
PWR LED BUS LED
Off Device OFF Off No supply voltage
Flashes green Device ok, initialization phase Flashes green Initialization
Green, continuous light Device OK Green, continuous light Operation OK
Orange, continuous light Service mode Flashes red Communication error
Flashes red Device ok, warning set Red, continuous light Network error
Red, continuous light Device error
LNK0
LNK1
ESC
Navigate
upward/laterally
Navigate
downward/laterally
ESCAPE
leave
ENTER
confirm
Device buttons:
Delete character
Enter digit
Save input

Leuze electronic BCL 548i1
Table of contents
1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.1 Explanation of symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
1.2 Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
2 Safety notices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.1 General safety notices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.2 Safety standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.3 Approved purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
2.4 Working safely . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3 Fast commissioning / operating principle . . . . . . . . . . . . . . . . . . . 17
3.1 Mounting the BCL 548i. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.2 Device arrangement and selection of the mounting location . . . . . . . . . . . . . . . . . . . . 17
3.3 Electrical connection BCL 548i. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.4 Starting the device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.5 Commissioning the BCL 548i on the PROFINET-IO. . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.5.1 Preparing the control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.5.2 Installing the GSD file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.5.3 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.5.4 Transfer of the configuration to the IO Controller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.5.5 Configuration of the device name - device naming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
3.5.6 Check device name . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.6 Further settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.7 Bar code reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4 Device description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.1 About the bar code readers of the BCL 500iseries. . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
4.2 Characteristics of the bar code readers of the BCL 500iseries . . . . . . . . . . . . . . . . . . 25
4.4 Reading techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.4.1 Line scanner (single line). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
4.4.2 Line scanner with oscillating mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.4.3 Omnidirectional reading . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
4.5 Fieldbus systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.5.1 PROFINET-IO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.5.2 PROFINET-IO – star topology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.5.3 PROFINET-IO – line topology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.6 Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

2 BCL 548iLeuze electronic
Table of contents
4.7 External parameter memory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
4.8 autoReflAct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.9 Reference codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35
4.10 autoConfig. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
5 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.1 General specifications of the bar code readers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.1.1 Line scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
5.1.2 Oscillating-mirror scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39
5.1.3 Line scanner with deflection mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
5.2 Heating models of the bar code readers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
5.2.1 Line scanner with heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41
5.2.2 Oscillating-mirror scanner with heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
5.2.3 Line scanner with deflection mirror and heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
5.3 Dimensioned drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.3.1 Line scanner with / without heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
5.3.2 Deflection mirror scanner with / without heating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
5.3.3 Oscillating-mirror scanner with / without heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
5.4 Type overview BCL 548i. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
5.5 Reading field curves / optical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
5.6 Reading field curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49
5.6.1 High Density (N) Optics: BCL 548iSN 100/102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
5.6.2 High Density (N) Optics: BCL 548iON 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.6.3 Medium Density (M) Optics: BCL 548iSM 100/102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
5.6.4 Medium Density (M) Optics: BCL 548iOM 100. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
5.6.5 Low Density (F) Optics: BCL 548iSF 100/102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
5.6.6 Low Density (F) Optics: BCL 548iOF 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
5.6.7 Ultra Low Density (L) Optics: BCL 548iSL 102 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
5.6.8 Ultra Low Density (L) Optics: BCL 548iOL 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
5.7 Reading field curves for heating devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.7.1 High Density (N) Optics: BCL 548iSN 102 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
5.7.2 High Density (N) Optics: BCL 548iSN 100 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
5.7.3 High Density (N) Optics: BCL 548iON 100 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
5.7.4 Medium Density (M) Optics: BCL 548iSM 102 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
5.7.5 Medium Density (M) Optics: BCL 548iSM 100 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
5.7.6 Medium Density (M) Optics: BCL 548iOM 100 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
5.7.7 Low Density (F) Optics: BCL 548iSF 102 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
5.7.8 Low Density (F) Optics: BCL 548iSF 100 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5.7.9 Low Density (F) Optics: BCL 548iOF 100 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
5.7.10 Ultra Low Density (L) Optics: BCL 548iSL 102 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
5.7.11 Ultra Low Density (L) Optics: BCL 548iOL 100 H . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Leuze electronic BCL 548i3
Table of contents
6 Installation and mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
6.1 Storage, transportation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
6.2 Mounting the BCL 548i. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
6.2.1 Fastening with M4 x 6 screws . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
6.2.2 BT 56 mounting device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
6.2.3 BT 59 mounting device. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
6.3 Device arrangement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
6.3.1 Selecting a mounting location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
6.3.2 Avoiding total reflection – Line scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
6.3.3 Avoiding total reflection – oscillating/deflection-mirror scanner. . . . . . . . . . . . . . . . . . . . 75
6.3.4 Mounting location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
6.3.5 Devices with integrated heating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
6.3.6 Possible read angles between BCL 548iand bar code . . . . . . . . . . . . . . . . . . . . . . . . . . 77
6.4 Attaching laser warning sign . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
6.5 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
7 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
7.1 Safety notices for the electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
7.2 Electrical connection of the BCL 548i. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
7.2.1 PWR – Voltage supply and switching input/outputs 3 and 4 . . . . . . . . . . . . . . . . . . . . . . 80
7.2.2 SERVICE – USB interface (type A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
7.2.3 SW IN/OUT – Switching input/switching output. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
7.2.4 HOST / BUS IN for BCL 548i. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
7.2.5 BUS OUT for the BCL 548i. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
7.3 PROFINET-IO topologies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
7.3.1 PROFINET-IO wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
7.4 Cable lengths and shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
8 Display and control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
8.1 Structure of the control panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
8.2 Status display and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
8.2.1 Indicators in the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
8.2.2 LED status indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
8.2.3 Control buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
8.3 Menu description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
8.3.2 Parameter menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
8.3.3 Language selection menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
8.3.4 Service menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
8.3.5 Actions menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
8.4 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

4 BCL 548iLeuze electronic
Table of contents
9 Leuze webConfig tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
9.1 Connecting the SERVICE USB interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
9.2 Installing the required software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
9.2.1 System requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
9.2.2 Installing the USB driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
9.3 Starting the webConfig tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
9.4 Short description of the webConfig tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
9.4.1 Module overview in the Configuration menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
10 Commissioning and configuration . . . . . . . . . . . . . . . . . . . . . . . . 116
10.1 General information on the PROFINET-IO implementation of the BCL 548i. . . . . . . . 116
10.1.1 PROFINET-IO communication profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
10.1.2 Conformance Classes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
10.2 Measures to be performed prior to the initial commissioning . . . . . . . . . . . . . . . . . . . 117
10.3 Starting the device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
10.4 Configuration steps for a Siemens Simatic S7 control . . . . . . . . . . . . . . . . . . . . . . . . . 118
10.4.1 Step 1 – Preparing the control system (S7 PLC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
10.4.2 Step 2 – Installation of the GSD file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
10.4.3 Step 3 – Hardware configuration of the S7 PLC: Configuration . . . . . . . . . . . . . . . . . . . 120
10.4.4 Step 4 – Transfer of the configuration to the IO Controller (S7 PLC) . . . . . . . . . . . . . . . 121
10.4.5 Step 5 – Configuration of the device name - naming the device . . . . . . . . . . . . . . . . . . 121
10.4.6 Step 6 – Check device names . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
10.4.7 Ethernet host communication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
10.4.7.1 Manually setting the IP address............................................................................................................124
10.4.7.2 Automatically setting the IP address ....................................................................................................125
10.4.7.3 TCP/IP...................................................................................................................................................126
10.4.7.4 UDP .......................................................................................................................................................128
10.5 Commissioning via the PROFINET-IO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
10.5.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
10.6 Overview of the project modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
10.7 Decoder modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
10.7.1 Modules 1-4 – Code table extensions 1 to 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
10.7.2 Module 5 – Code type features (symbology) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
10.7.3 Module 7 – Code fragment technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
10.8 Control modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
10.8.1 Module 10 – Activations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
10.8.2 Module 11 – Reading gate control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
10.8.3 Module 12 – Multi-label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
10.8.4 Module 13 – Fragmented read result. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
10.8.5 Module 14 – Interlinked read result . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147

Leuze electronic BCL 548i5
Table of contents
10.9 Result Format. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
10.9.1 Module 20 – Decoder state. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
10.9.2 Modules 21-27 – Decoding result. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
10.9.3 Module 30 – Data formatting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
10.9.4 Module 31 – Reading gate number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
10.9.5 Module 32 – Reading gate time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
10.9.6 Module 33 – Code position. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
10.9.7 Module 34 – Reading reliability (equal scans). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
10.9.8 Module 35 – Bar code length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
10.9.9 Module 36 – Scans with information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
10.9.10 Module 37 – Decoding quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
10.9.11 Module 38 – Code direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
10.9.12 Module 39 – Number of digits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
10.9.13 Module 40 – Code type (symbology) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
10.9.14 Module 41 – Code position in the swivel range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
10.10 Data Processing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
10.10.1 Module 50 – Characteristics filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
10.10.2 Module 51 – Data filtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
10.11 Identifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
10.11.1 Module 52 – Segmentation according to the EAN process . . . . . . . . . . . . . . . . . . . . . . 163
10.11.2 Module 53 – Segmentation via fixed positions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
10.11.3 Module 54 – Segmentation according to identifier and separator . . . . . . . . . . . . . . . . . 168
10.11.4 Module 55 – String handling parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
10.12 Device Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
10.12.1 Module 60 – Device status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
10.12.2 Module 61 – Laser control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
10.12.3 Module 62 – Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
10.12.4 Module 63 – Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
10.12.5 Module 64 – Oscillating mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
10.12.6 Module 65 – Deflection mirrors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
10.13 Switching inputs/ outputs SWIO 1 … 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
10.13.1 Parameters for operating as an output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
10.13.2 Parameters for operating as an input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
10.13.3 Switch-on and switch-off functions for operation as an output . . . . . . . . . . . . . . . . . . . 180
10.13.4 Input functions for operation as an input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
10.13.5 Module 70 – Switching input/output SWIO1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
10.13.6 Module 71 – Switching input/output SWIO2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
10.13.7 Module 72 – Switching input/output SWIO3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
10.13.8 Module 73 – Switching input/output SWIO4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
10.13.9 Module 74 – SWIO status and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
10.14 Data output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
10.14.1 Module 80 – Sorting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

6 BCL 548iLeuze electronic
Table of contents
10.15 Reference code comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
10.15.1 Module 81 – Reference code comparator 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
10.15.2 Module 82 – Reference code comparator 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
10.15.3 Module 83 – Reference code comparison pattern 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
10.15.4 Module 84 – Reference code comparison pattern 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
10.16 Special Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
10.16.1 Module 90 – Status and control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
10.16.2 Module 91 – AutoReflAct (automatic reflector activation) . . . . . . . . . . . . . . . . . . . . . . . . 199
10.16.3 Module 92 – AutoControl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
10.17 Example configuration: Indirect activation via the PLC . . . . . . . . . . . . . . . . . . . . . . . . 201
10.17.1 Task . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
10.17.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
10.18 Sample configuration: Direct activation via the switching input . . . . . . . . . . . . . . . . . 203
10.18.1 Task . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
10.18.2 Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
11 Online commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
11.1 Overview of commands and parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
11.1.1 General 'online' commands. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
12 Diagnostics and troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 223
13 Type overview and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . 227
13.1 Type key . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
13.2 Type overviewBCL 548i. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
13.3 Accessory connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
13.4 Accessory USB cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 228
13.5 Accessory external parameter memory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
13.6 Accessory mounting device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
13.7 Accessory reflector for AutoReflAct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 229
13.8 Accessory ready-made cables for voltage supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
13.8.1 Contact assignment of PWR connection cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
13.8.2 Specifications of the cables for voltage supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
13.8.3 Order codes of the cables for voltage supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 230
13.9 Accessory ready-made cables for bus connection . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
13.9.1 General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
13.9.2 Contact assignments M12 PROFINET-IO connection cable KB ET… . . . . . . . . . . . . . . 231
13.9.3 Specifications M12 PROFINET-IO connection cable KB ET… . . . . . . . . . . . . . . . . . . . . 231
13.9.4 Order codes M12 PROFINET-IO connection cable KB ET… . . . . . . . . . . . . . . . . . . . . . 232

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Table of contents
14 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
14.1 General maintenance information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
14.2 Repairs, servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
14.3 Disassembling, packing, disposing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
15 Appendix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
15.1 Declaration of conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 234
15.2 ASCII character set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
15.3 Bar code samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
15.3.1 Module 0.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 239
15.3.2 Module 0.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 240

8 BCL 548iLeuze electronic
Figures and tables
Figure 2.1: Attachment of the stick-on labels with warning notices at the BCL 548i........................ 16
Figure 3.1: Connections of the BCL 548i......................................................................................... 18
Figure 3.2: Assignment of the device names to IP addresses .......................................................... 20
Figure 3.3: Assigning the device names to the configured IO devices.............................................. 21
Figure 3.4: MAC address - IP address -individual device name ....................................................... 22
Figure 4.1: Line scanner, line scanner with deflection mirror and oscillating-mirror scanner........... 24
Figure 4.2: Possible bar code orientation ........................................................................................26
Figure 4.3: Device construction ...................................................................................................... 27
Figure 4.4: Deflection principle for the line scanner ........................................................................ 28
Figure 4.5: Deflection principle for the line scanner with oscillating mirror add-on.......................... 29
Figure 4.6: Principle arrangement for omnidirectional reading ........................................................ 30
Table 4.1: Base record I&M0 ......................................................................................................... 32
Figure 4.7: PROFINET-IO in a star topology ..................................................................................... 33
Figure 4.8: PROFINET-IO in a line topology...................................................................................... 33
Figure 4.9: External parameter memory.......................................................................................... 34
Figure 4.10: Reflector arrangement for autoReflAct .......................................................................... 35
Table 5.1: Specifications of the BCL 548iline scanners without heating........................................ 37
Table 5.2: Specifications of the BCL 548ioscillating-mirror scanners without heating ................... 39
Table 5.3: Specifications of the BCL 548ideflection-mirror scanners without heating.................... 39
Table 5.4: Specifications of the BCL 548iline scanners with heating............................................. 41
Table 5.5: Specifications of the BCL 548ioscillating-mirror scanners with heating........................ 42
Table 5.6: Specifications of the BCL 548ideflection-mirror scanners with heating ........................ 43
Figure 5.1: Dimensioned drawing BCL 548iline scanner S…102 ................................................... 44
Figure 5.2: Dimensioned drawing BCL 548ideflection-mirror scanner S…100............................... 45
Figure 5.3: Dimensioned drawing BCL 548ioscillating-mirror scanner O…100.............................. 46
Table 5.7: Type overview BCL 548i............................................................................................... 47
Figure 5.4: The most important characteristics of a bar code.......................................................... 48
Figure 5.5: Zero position of the reading distance ............................................................................ 49
Table 5.8: Reading conditions ....................................................................................................... 49
Figure 5.6: "High Density" reading field curve for line scanner (with/without deflection mirror)....... 50
Figure 5.7: "High Density" reading field curve for oscillating-mirror scanners................................. 51
Figure 5.8: Lateral "High Density" reading field curve for oscillating-mirror scanners ..................... 51
Figure 5.9: "Medium Density" reading field curve for line scanner (with/without deflection mirror) . 52
Figure 5.10: "Medium Density" reading field curve for oscillating-mirror scanners ........................... 53
Figure 5.11: Lateral "Medium Density" reading field curve for oscillating-mirror scanners................ 53
Figure 5.12: "Low Density" reading field curve for line scanner (with/without deflection mirror) ....... 54
Figure 5.13: "Low Density" reading field curve for oscillating-mirror scanners ................................. 55
Figure 5.14: Lateral "Low Density" reading field curve for oscillating-mirror scanners...................... 55
Figure 5.15: "Ultra Low Density" reading field curve for line scanner without deflection mirror......... 56
Figure 5.16: "Ultra Low Density" reading field curve for oscillating-mirror scanners ......................... 57
Figure 5.17: Lateral "Ultra Low Density" reading field curve for oscillating-mirror scanners.............. 57
Figure 5.18: "High Density" reading field curve for line scanner with heating (without deflection mirror) .58
Figure 5.19: "High Density" reading field curve for line scanner with heating (with deflection mirror)......59
Figure 5.20: "High Density" reading field curve for oscillating-mirror scanners with heating............. 60

Leuze electronic BCL 548i9
Figures and tables
Figure 5.21: Lateral "High Density" reading field curve for oscillating-mirror scanners with heating . 60
Figure 5.22: "Medium Density" reading field curve for line scanner with heating (without deflection mirror) 61
Figure 5.23: "Medium Density" reading field curve for line scanner with heating (with deflection mirror) .. 62
Figure 5.24: "Medium Density" reading field curve for oscillating-mirror scanners with heating ....... 63
Figure 5.25: Lateral "Medium Density" reading field curve for oscillating-mirror scanners with heating.. 63
Figure 5.26: "Low Density" reading field curve for line scanner with heating (without deflection mirror). 64
Figure 5.27: "Low Density" reading field curve for line scanner with heating (with deflection mirror) .... 65
Figure 5.28: "Low Density" reading field curve for oscillating-mirror scanners with heating ............. 66
Figure 5.29: Lateral "Low Density" reading field curve for oscillating-mirror scanners with heating.. 66
Figure 5.30: "Ultra Low Density" reading field curve for line scanner with heating (without deflection mirror)...67
Figure 5.31: "Ultra Low Density" reading field curve for oscillating-mirror scanners with heating ..... 68
Figure 5.32: Lateral "Ultra Low Density" reading field curve for oscillating-mirror scanners with heating. 68
Figure 6.1: Device name plate BCL 548i......................................................................................... 69
Figure 6.2: Fastening options using M4x6 threaded holes .............................................................. 70
Figure 6.3: BT 56 mounting device................................................................................................. 71
Figure 6.4: Mounting example of BCL 548iwith BT 56 ................................................................... 72
Figure 6.5: Total reflection – line scanner....................................................................................... 75
Figure 6.6: Total reflection – BCL 548iwith oscillating/deflection mirror......................................... 76
Figure 6.7: Reading angle for the line scanner................................................................................ 77
Figure 7.1: Location of the electrical connections ........................................................................... 78
Figure 7.2: Connections of the BCL 548i......................................................................................... 79
Table 7.1: Pin assignment PWR..................................................................................................... 80
Figure 7.3: Switching input connection diagram SWIO_3 and SWIO_4............................................ 81
Figure 7.4: Switching output connection diagram SWIO_3 / SWIO_4 .............................................. 81
Figure 7.5: Pin assignments of SERVICE – USB interface ................................................................ 82
Figure 7.6: Pin assignment SW IN/OUT ........................................................................................... 83
Figure 7.7: Switching input connection diagram SWIO_1 and SWIO_2............................................ 83
Figure 7.8: Switching output connection diagram SWIO_1 / SWIO_2 .............................................. 84
Table 7.2: Pin assignment HOST / BUS IN BCL 548i...................................................................... 85
Figure 7.9: HOST / BUS IN cable assignments on RJ-45 ................................................................. 85
Table 7.3: Pin assignment BUS OUT .............................................................................................. 86
Figure 7.10: PROFINET-IO in a star topology ..................................................................................... 87
Figure 7.11: PROFINET-IO in a line topology ..................................................................................... 87
Table 7.4: Cable lengths and shielding .......................................................................................... 88
Figure 8.1: Structure of the control panel........................................................................................ 89
Table 8.1: Parameter handling submenu ....................................................................................... 95
Table 8.2: Decoder table submenu................................................................................................ 96
Table 8.3: Digital SWIO submenu ..................................................................................................99
Table 8.4: Ethernet submenu ...................................................................................................... 102
Figure 9.1: Connecting the SERVICE USB interface ....................................................................... 110
Figure 9.2: Device Manager with connected BCL 500i.................................................................. 112
Figure 9.3: The start page of the webConfig tool........................................................................... 113
Figure 9.4: Module overview in the webConfig tool....................................................................... 114
Figure 10.1: Connections of the BCL 548i....................................................................................... 117

10 BCL 548iLeuze electronic
Figures and tables
Table 10.1: Assignment of the device names to IP addresses ........................................................ 120
Figure 10.2: Assigning the device names to the configured IO devices............................................ 122
Figure 10.3: MAC address - IP address -individual device name ..................................................... 123
Table 10.2: Device parameters...................................................................................................... 130
Table 10.3: Module overview......................................................................................................... 135
Table 10.4: Parameters for modules 1-4 ....................................................................................... 137
Table 10.5: Parameters for module 5 ............................................................................................ 139
Table 10.6: Parameters for module 7 ............................................................................................ 140
Table 10.7: Parameters for module 10 .......................................................................................... 141
Table 10.8: Output data for module 10 .......................................................................................... 141
Table 10.9: Parameters for module 11 .......................................................................................... 143
Table 10.10: Parameters for module 12 .......................................................................................... 145
Table 10.11: Input data for module 12............................................................................................. 145
Table 10.12: Parameters for module 13 .......................................................................................... 146
Table 10.13: Input data for module 13............................................................................................. 146
Table 10.14: Parameters for module 13 .......................................................................................... 147
Table 10.15: Input data for module 20............................................................................................. 148
Table 10.16: Input data for modules 21 … 27................................................................................. 150
Table 10.17: Parameters for module 30 .......................................................................................... 152
Table 10.18: Input data for module 31............................................................................................. 153
Table 10.19: Input data for module 32............................................................................................. 154
Table 10.20: Input data for module 33............................................................................................. 154
Table 10.21: Input data for module 34............................................................................................. 155
Table 10.22: Input data for module 35............................................................................................. 155
Table 10.23: Input data for module 36............................................................................................. 156
Table 10.24: Input data for module 37............................................................................................. 156
Table 10.25: Input data for module 38............................................................................................. 157
Table 10.26: Input data for module 39............................................................................................. 157
Table 10.27: Input data for module 40............................................................................................. 158
Table 10.28: Input data for module 41............................................................................................. 159
Table 10.29: Parameters for module 50 .......................................................................................... 160
Table 10.30: Parameters for module 51 .......................................................................................... 162
Table 10.31: Parameters for module 52 .......................................................................................... 163
Table 10.32: Parameters for module 53 .......................................................................................... 165
Table 10.33: Parameters for module 54 .......................................................................................... 168
Table 10.34: Parameters for module 55 .......................................................................................... 170
Table 10.35: Input data for module 60............................................................................................. 171
Table 10.36: Output data for module 60 .......................................................................................... 171
Table 10.37: Parameters for module 61 .......................................................................................... 172
Table 10.38: Parameters for module 62 .......................................................................................... 173
Table 10.39: Input data for module 63............................................................................................. 174
Table 10.40: Output data for module 63 .......................................................................................... 174
Table 10.41: Parameters for module 64 .......................................................................................... 175
Table 10.42: Parameters for module 65 .......................................................................................... 176

Leuze electronic BCL 548i11
Figures and tables
Figure 10.4: Example 1: Start-up delay > 0 and switch-on time = 0............................................... 177
Figure 10.5: Example 2: Start-up delay > 0 and switch-on time > 0............................................... 177
Figure 10.6: Example 3: Start-up delay >0 Switch-off signal prior to lapsing of the
start-up delay ............................................................................................................. 177
Figure 10.7: Start-up delay in input mode....................................................................................... 178
Figure 10.8: Switch-on time in input mode..................................................................................... 179
Figure 10.9: Switch-off delay in input mode ................................................................................... 179
Table 10.43: Switch-on/switch-off functions ................................................................................... 180
Table 10.44: Input functions............................................................................................................ 180
Table 10.45: Parameters for module 70 – Input/Output 1 ................................................................ 181
Table 10.46: Parameters for module 71 – Input/Output 2 ................................................................ 183
Table 10.47: Parameters for module 72 – Input/Output 3 ................................................................ 185
Table 10.48: Parameters for module 73 – Input/Output 4 ................................................................ 187
Table 10.49: Input data for module 74 Input/output status and control ............................................ 189
Table 10.50: Output data for module 74 Input/output status and control.......................................... 190
Table 10.51: Parameters for module 80 .......................................................................................... 191
Table 10.52: Parameters for module 81 – Reference code comparison ........................................... 192
Table 10.53: Parameters for module 82 – Reference code comparison ........................................... 194
Table 10.54: Parameter module 83 – Reference code comparison pattern ...................................... 196
Table 10.55: Parameter module 84 – Reference code comparison pattern ...................................... 197
Table 10.56: Input data for module 90 – Status and control ............................................................ 198
Table 10.57: Parameters for module 91 – AutoreflAct ..................................................................... 199
Table 10.58: Parameters for module 92 – AutoControl .................................................................... 200
Table 10.59: Input data for module 92 – AutoControl....................................................................... 200
Table 10.60: Device parameters for example configuration 2 .......................................................... 203
Table 12.1: BCL 548ialarm and diagnostics messages................................................................. 224
Table 12.2: BCL 548ierror categories........................................................................................... 224
Table 12.1: General causes of errors............................................................................................. 225
Table 12.1: Interface error............................................................................................................. 225
Table 13.1: Type overview BCL 548i............................................................................................. 227
Table 13.2: Connectors for the BCL 548i....................................................................................... 228
Table 13.3: Cable for the BCL 548i................................................................................................ 228
Table 13.4: External parameter memory for the BCL 548i............................................................. 229
Table 13.5: Mounting devices for the BCL 548i............................................................................. 229
Table 13.6: Reflector for the BCL 548i........................................................................................... 229
Table 13.7: PWR cables for the BCL 548i...................................................................................... 230
Figure 13.1: Cable configuration PROFINET-IO connection cable..................................................... 231
Table 13.8: Bus connection cable for the BCL 548i....................................................................... 232
Figure 15.1: Bar code sample labels (module 0.3) .......................................................................... 239
Figure 15.2: Bar code sample labels (module 0.5) .......................................................................... 240

General information
Leuze electronic BCL 548i13
TNT 35/7-24V
1 General information
1.1 Explanation of symbols
The symbols used in this technical description are explained below.
Attention!
This symbol precedes text messages which must strictly be observed. Failure to comply with
this information results in injuries to personnel or damage to the equipment.
Attention Laser!
This symbol warns of possible danger caused by hazardous laser radiation.
Notice!
This symbol indicates text passages containing important information.
1.2 Declaration of conformity
The bar code readers of the BCL 500iseries have been developed and manufactured in
accordance with the applicable European standards and directives.
The BCL 500iseries is "UL LISTED" according to American and Canadian safety standards,
and fulfills the requirements of Underwriter Laboratories Inc. (UL).
Notice!
You can find the Declaration of Conformity of the devices in the appendix of the manual on
page 234.
The manufacturer of the product, Leuze electronic GmbH & Co KG in D-73277 Owen,
possesses a certified quality assurance system in accordance with ISO 9001.
UL
US
C
LISTED

Safety notices
14 BCL 548iLeuze electronic
2 Safety notices
2.1 General safety notices
Documentation
All entries in this technical description must be heeded, in particular the present chapter
"Safety notices". Keep this technical description in a safe place. It should be available at all
times.
Safety regulations
Observe the locally applicable regulations and the rules of the employer's liability insurance
association.
Repair
Repairs must only be carried out by the manufacturer or an authorized representative.
2.2 Safety standards
The bar code readers of the BCL 500iseries were developed, manufactured and tested in
accordance with the applicable safety standards. They correspond to the state of the art.
2.3 Approved purpose
Attention!
The protection of personnel and the device cannot be guaranteed if the device is operated
in a manner not complying with its intended use.
Bar code readers of the BCL 500iseries are conceived as stationary, high-speed scanners
with integrated decoders for all current bar codes used for automatic object detection.
In particular, unauthorized uses include:
• in rooms with explosive atmospheres
• operation for medical purposes
Areas of application
The bar code readers of the BCL 500iseries are especially designed for the following areas
of application:
• Storage and conveying technologies, in particular for object identification on fast-
moving conveyor belts
• Pallet transportation applications
• Automobile sector
• Omnidirectional reading

Safety notices
Leuze electronic BCL 548i15
TNT 35/7-24V
2.4 Working safely
Attention!
Access to or changes on the device, except where expressly described in this operating man-
ual, are not authorized.
Safety regulations
Observe the locally applicable legal regulations and the rules of the employer's liability insur-
ance association.
Qualified personnel
Mounting, commissioning and maintenance of the device must only be carried out by qual-
ified personnel.
Electrical work must be carried out by a certified electrician.
Attention, laser radiation!
If you look into the beam path over a longer time period, the retina of your eye may
be damaged!
Never look directly into the beam path!
Do not point the laser beam of the BCL 548iat persons!
When mounting and aligning the BCL 548i, avoid reflections of the laser beam off
reflective surfaces!
The BCL 548ibar code readers comply with safety standards EN 60825-1 for a class
2 product. They also comply with the U.S. 21 CFR 1040.10 regulations for a class II
laser product except for deviations pursuant to Laser Notice No. 50, dated July 26,
2001.
Radiant Energy: The BCL 548iuses a low power visible laser diode. The emitted wave-
length is 655nm. The average laser power is less than 1mW in accordance with the
definition of class 2 lasers.
Adjustments: Do not attempt any adjustments to or alterations of this product.
Do not remove the protective housing of the bar code reader. There are no user-
serviceable parts inside.
The scanner window is the only aperture through which light may be observed on this
product. A failure of the scanner motor, while the laser diode continues to emit a laser
beam, may cause emission levels to exceed those for safe operation. The bar code
reader has safeguards to prevent this occurrence. If, however, a stationary beam is
emitted, the failing bar code reader should be disconnected from its power source
immediately.
CAUTION: Use of controls or adjustments or performance of procedures other than
specified herein may result in hazardous light exposure.

Safety notices
16 BCL 548iLeuze electronic
The use of optical instruments or devices in combination with the device increases
the danger of eye damage!
The housing of the BCL 548iis provided with warning notices B and C above and next
to the reading window as shown in the following figure:
Figure 2.1: Attachment of the stick-on labels with warning notices at the BCL 548i
Notice!
It is important that you attach the stick-on labels supplied to the device (A in figure 2.1)! If
the signs would be covered due to the installation situation of the BCL 548i, attach them
instead in the immediate vicinity of the BCL 548iin such a way that it is not necessary to
look into the laser beam when reading the notices!
A
B
BCL 548i
Line scanner
BCL 548i
with oscillating/deflection mirror
C
AIncluded stick-on labels
BAperture label
CName plate

Fast commissioning / operating principle
Leuze electronic BCL 548i17
TNT 35/7-24V
3 Fast commissioning / operating principle
Below you will find a short description for the initial commissioning of the BCL 548i. Detailed
explanations for all listed points can be found throughout this technical description.
3.1 Mounting the BCL 548i
There are two different types of mounting arrangements for the BCL 548i:
• Using two M4x6 screws on the rear of the device or using four M4x6 screws on the
bottom of the device.
• Using a BT 56 mounting device on the two fastening grooves.
3.2 Device arrangement and selection of the mounting location
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 BCL 548iin relation to the bar code module width.
• The resulting minimum and maximum reading distance from the respective reading
field (see chapter 5.5 "Reading field curves / optical data").
• The permissible cable lengths between the BCL 548iand the host system depending
on which interface is used.
• The correct time for data output. The BCL 548ishould be positioned in such a way
that, taking into consideration the time required for data processing and the conveyor
belt speed, there is sufficient time to e.g. initiate sorting operations on the basis of the
read data.
• The display and control panel should be very visible and accessible.
• For configuring and commissioning with the webConfig tool, the USB interface should
be easily accessible.
For specific information, please refer to chapter 4.4.
Notice!
The beam exits the BCL 548ias follows for the respective devices:
- line scanner parallel to the housing base
- oscillating mirror and deflection mirror perpendicular to the housing base
The black areas in figure 6.1 are the housing base. The best read results are obtained when:
• The BCL 548iis mounted in such a way that the scanning beam is incident on the bar
code at an angle of inclination greater than ±10° … 15° to vertical.
• The reading distance lies in the middle area of the reading field.
• The bar code labels are of good print quality and have good contrast ratios.
• You do not use high-gloss labels.
• There is no direct sunlight.

Fast commissioning / operating principle
18 BCL 548iLeuze electronic
3.3 Electrical connection BCL 548i
The BCL 548iis equipped with four M12 connectors/sockets which are A- and D-coded.
Figure 3.1: Connections of the BCL 548i
The voltage supply (10 … 30VDC) is connected at the PWR M12 connector.
Available at both the PWR M12 connector as well as at the SW IN/OUT M12 socket are
four freely programmable switching inputs/outputs for custom adaptation to the
respective application. Detailed information on this topic can be found in chapter 7.2.1 and
chapter 7.2.3.
Standalone operation in PROFINET-IO
During stand-alone operation of the BCL 548i, the host interface of the superior system is
connected to HOST/BUS IN. Thus, a star structure (Ethernet structure) is possible.
Network operation in PROFINET-IO
In network operation, the superior system (PC/PLC) is connected to the host interface of
the BCL 548i. With the aid of the "switch" integrated in the BCL 548i, the bus connection
to the next participant, e.g. a BCL 548i, can occur directly via the BUS OUT socket! In addi-
tion to the classic "star topology", a "linear topology" is thus also possible
SW IN/OUT
VOUT 1
2
3
4
SWIO_1
SWIO_2
GND
FE
5
HOST / BUS IN
TD+ 1
2
3
4
RD+
RD-
TD-
SERVICE
2134
GND D+ D- U
B
PWR
SWIO_4
SWIO_3
3
2
1
4
5
GND VIN
FE
BUS OUT
TD+ 1
2
3
4
RD+
RD-
TD-
USB socket
Type A
M12 socket
(A-coded)
M12 socket
(D-coded)
M12 socket
(D-coded)
M12 plug
(A-coded)