Leuze BCL604i User manual

BCL 604i
Bar Code Reader
Original operating instructions
EN 2015/04 - 50129186 We reserve the right to make technical changes

Leuze electronic BCL 604i 2
© 2015
Leuze electronic GmbH + Co. KG
In der Braike 1
D-73277 Owen / Germany
Phone: [phone]
Fax: [phone]
http://www.leuze.com
[email protected]

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1 About this document. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.1 Used symbols and signal words . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
2 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.1 Intended use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 Foreseeable misuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 Competent persons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.4 Exemption of liability . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.5 Laser safety notices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.5.1 Laser safety notices– laser class 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
3 Device description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.1 Device overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.2 Performance characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
3.3 Device construction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
3.4 Connection technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.5 Display elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.5.1 Structure of the control panel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.5.2 Status display and operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.5.3 LED indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.6 Operational controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.7 External parameter memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
4 Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
4.1 autoReflAct . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
4.2 autoConfig . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5 Reading techniques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.1 Line scanner (single line). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.2 Line scanner with oscillating mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
5.3 Omnidirectional reading. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6 Mounting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.1 Device arrangement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.1.1 Selecting a mounting location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.1.2 Avoiding total reflection – Line scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.1.3 Avoiding total reflection – oscillating-mirror scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.1.4 Possible read angles between device and bar code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.2 Installing the external parameter memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
7 Electrical connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
7.2 PWR – Voltage supply and switching inputs/outputs 3 and 4 . . . . . . . . . . . . . . . . . . . . . . 29
7.3 SERVICE – USB interface (type A) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.4 SW IN/OUT – Switching input/switching output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
7.5 HOST / BUS IN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.6 BUS OUT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
7.7 PROFIBUS termination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
7.8 Cable lengths and shielding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
8 Menu description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

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8.1 The main menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8.2 Parameter menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
8.3 Language selection menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8.4 Service menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8.5 Actions menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
8.6 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
9 Commissioning – Leuze electronic webConfig tool . . . . . . . . . . . . . . . . . . . . . . 45
9.1 Connecting the service USB interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9.2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9.2.1 System requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9.2.2 Installing the USB driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9.3 Starting the webConfig tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
9.4 Short description of the webConfig tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
9.5 Module overview in the Configuration menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
10 Starting up the device - Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
10.1 General information on the PROFIBUS implementation . . . . . . . . . . . . . . . . . . . . . . . . . . 48
10.1.1Communication profile . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
10.1.2Bus-access protocol . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
10.1.3Device types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
10.1.4Expanded DP functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
10.1.5Automatic baud rate detection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
10.2 Measures to be performed prior to the initial commissioning . . . . . . . . . . . . . . . . . . . . . . 49
10.3 Setting the address . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
10.3.1Setting the device address on the display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
10.4 Commissioning via the PROFIBUS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
10.4.1General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
10.4.2Preparing the control system for consistent data transmission . . . . . . . . . . . . . . . . . . . . . 51
10.4.3General information on the GSD file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
10.4.4Permanently defined parameters/device parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
10.5 Overview of the project modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
10.6 Decoder modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
10.6.1Modules 1-4 – Code table extensions 1 to 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
10.6.2Module 5 – Code type features (symbology) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
10.6.3Module 7 – Code reconstruction technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
10.7 Control modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
10.7.1Module 10 – Activations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
10.7.2Module 11 – Reading gate control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
10.7.3Module 12 – Multi-label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
10.7.4Module 13 – Fragmented read result. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
10.7.5Module 14 – Interlinked read result . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
10.8 Result Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
10.8.1Module 20 – Decoder state . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
10.8.2Modules 21-27 – Decoding result . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
10.8.3Module 30 – Data formatting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
10.8.4Module 31 – Reading gate number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
10.8.5Module 32 – Reading gate time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
10.8.6Module 33 – Code position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
10.8.7Module 34 – Reading reliability (equal scans) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
10.8.8Module 35 – Bar code length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
10.8.9Module 36 – Scans with information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
10.8.10Module 37 – Decoding quality . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
10.8.11Module 38 – Code direction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
10.8.12Module 39 – Number of digits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
10.8.13Module 40 – Code type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

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10.8.14Module 41 – Code position in the swivel range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
10.9 Data Processing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
10.9.1Module 50 – Characteristics filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
10.9.2Module 51 – Data filtering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
10.10 Identifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
10.10.1Module 52 – Segmentation according to the EAN process . . . . . . . . . . . . . . . . . . . . . . . 73
10.10.2Module 53 – Segmentation via fixed positions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
10.10.3Module 54 – Segmentation according to identifier and separator . . . . . . . . . . . . . . . . . . 76
10.10.4Module 55 – String handling parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
10.11 Device Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
10.11.1Module 60 – Device status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
10.11.2Module 61 – Laser control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
10.11.3Module 62 – Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
10.11.4Module 63 – Alignment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
10.11.5Module 64 – Oscillating mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
10.11.6Module 65 – Deflection mirror . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
10.12 Switching inputs/ outputs SWIO 1 … 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
10.12.1Parameters for operating as an output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
10.12.2Parameters for operating as an input. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
10.12.3Switch-on and switch-off functions for operation as an output. . . . . . . . . . . . . . . . . . . . . 85
10.12.4Input functions for operation as an input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
10.12.5Module 70 – Switching input/output SWIO1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
10.12.6Module 71 – Switching input/output SWIO2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
10.12.7Module 72 – Switching input/output SWIO3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
10.12.8Module 73 – Switching input/output SWIO4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
10.12.9Module 74 – SWIO status and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
10.13 Data output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
10.13.1Module 80 – Sorting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
10.14 Reference code comparison . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
10.14.1Module 81 – Reference code comparator 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
10.14.2Module 82 – Reference code comparator 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
10.14.3Module 83 – Reference code comparison pattern 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
10.14.4Module 84 – Reference code comparison pattern 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
10.15 Special Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
10.15.1Module 90 – Status and control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
10.15.2Module 91 – AutoReflAct (automatic reflector activation) . . . . . . . . . . . . . . . . . . . . . . . . 98
10.15.3Module 92 – AutoControl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
10.16 Example configuration: Indirect activation via the PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
10.16.1Task . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
10.16.2Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
10.17 Sample configuration: Direct activation via the switching input . . . . . . . . . . . . . . . . . . . . 100
10.17.1Task . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
10.17.2Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
11 Care, maintenance and disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
11.1 Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
11.2 Servicing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
11.3 Disposing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
12 Diagnostics and troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
12.1 General causes of errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
12.2 Interface errors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
13 Service and support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
13.1 What to do should servicing be required? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Leuze electronic BCL 604i 6
14 Technical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
14.1 General specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
14.1.1 Line scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
14.1.2Oscillating-mirror scanner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
14.2 Dimensioned drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
14.3 Dimensioned drawings: Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
14.4 Reading field curves / optical data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
14.5 Reading field curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
14.5.1Medium Density (M) - optics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
14.5.2Low Density (F) - optics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
15 Ordering information and accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
15.1 Nomenclature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
15.2 Type overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
15.3 Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
16 EC Declaration of Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
17 Appendix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
17.1 ASCII character set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
17.2 Bar code samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
17.2.1Module 0.3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
17.2.2Module 0.5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

About this document
Leuze electronic BCL 604i 7
1 About this document
1.1 Used symbols and signal words
Table 1.1: Warning symbols and signal words
Table 1.2: Other symbols
Table 1.3: Terms and abbreviations
Symbol indicating dangers to persons
NOTICE Signal word for property damage
Indicates dangers that may result in property damage if the measures for dan-
ger avoidance are not followed.
Symbol for tips
Text passages with this symbol provide you with further information.
Symbols for action steps
Text passages with this symbol instruct you to perform actions.
BCL Bar code reader
CRT Code reconstruction technology

Safety
Leuze electronic BCL 604i 8
2 Safety
This sensor was developed, manufactured and tested in line with the applicable safety standards. It corre-
sponds to the state of the art.
2.1 Intended use
The device is designed as a stationary high-speed scanner with integrated decoder for all common bar
codes for automatic object detection.
Areas of application
The device is specially designed for the following areas of application:
• Object identification on fast-moving conveyor lines
• Omnidirectional reading
2.2 Foreseeable misuse
Any use other than that defined under “Intended use” or which goes beyond that use is considered
improper use.
In particular, use of the device is not permitted in the following cases:
• Rooms with explosive atmospheres
• Circuits relevant to safety
• For medicinal purposes
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 technical description of 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 stan-
dards and regulations, certified electricians are able to perform work on electrical systems and indepen-
dently detect possible dangers.
In Germany, certified electricians must fulfill the requirements of accident-prevention regulations BGV A3
(e.g. electrician foreman). In other countries, there are respective regulations that must be observed.
CAUTION
Comply with conditions and regulations!
Observe the locally applicable legal regulations and the rules of the employer's liability insurance asso-
ciation.
CAUTION
Do not modify or otherwise interfere with the device.
Do 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.
The device must not be opened. There are no user-serviceable parts inside.
Repairs must only be performed by Leuze electronic GmbH + Co. KG.

Safety
Leuze electronic BCL 604i 9
2.4 Exemption of liability
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
2.5.1 Laser safety notices– laser class 2
ATTENTION, LASER RADIATION – LASERCLASS2
Never look directly into the beam!
The device fulfills the IEC 60825-1:2007 (EN 60825-1:2007) requirements for a product in laser class 2
as well as the U.S. 21 CFR 1040.10 regulations with deviations corresponding to “Laser Notice No. 50”
from June 24th, 2007.
Never look directly into the laser beam or in the direction of reflecting laser beams.
If you look into the beam path over a longer time period, there is a risk of injury to the retina.
Do not point the laser beam of the device at persons!
Interrupt the laser beam using a non-transparent, non-reflective object if the laser beam is accidentally
directed towards a person.
When mounting and aligning the device, avoid reflections of the laser beam off reflective surfaces!
CAUTION! The use of operating or adjusting devices other than those specified here or carrying out
of differing procedures may lead to dangerous exposure to radiation.
Adhere to the applicable legal and local regulations regarding protection from laser beams.
The 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 electronic GmbH + Co. KG.
CAUTION
Affix laser information and warning signs!
Laser information and warning signs attached to the device(see figure 2.1). Also included with the device
are self-adhesive laser warning and laser information signs (stick-on labels) in multiple languages (see
figure 2.3).
Affix 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.
Affix 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.

Safety
Leuze electronic BCL 604i 10
1 Laser aperture
2 Laser warning sign
3 Laser information sign with laser parameters
Figure 2.1: Laser aperture, laser warning and information signs - line scanner
1 Laser aperture
2 Laser warning sign
3 Laser information sign with laser parameters
Figure 2.2: Laser aperture, laser warning and information signs - oscillating-mirror scanner
LASER RADIATION
DO NOT STARE INTO BEAM
CLASS 2 LASER PRODUCT
EN 60825-1:2007
Maximum Output (peak):
Pulse duration:
Wavelength:
2 mW
<150 µs
405 nm
AVOID EXPOSURE – LASER RADIATION
IS EMITTED FROM THIS APERTURE
2 3
1
LASER RADIATION
DO NOT STARE INTO BEAM
CLASS 2 LASER PRODUCT
EN 60825-1:2007
Maximum Output (peak):
Pulse duration:
Wavelength:
2 mW
<150 μs
405 nm
AVOID EXPOSURE – LASER RADIATION
IS EMITTED FROM THIS APERTURE
2 3
1

Safety
Leuze electronic BCL 604i 11
Figure 2.3: Laser warning and information signs – supplied stick-on labels
AVOID EXPOSURE – LASER RADIATION
IS EMITTED FROM THIS APERTURE
EXPOSITION DANGEREUSE – UN RAYONNEMENT
LASER EST ÉMIS PAR CETTE OUVERTURE
LASERSTRAHLUNG
NICHT IN DEN STRAHL BLICKEN
LASER KLASSE 2
DIN EN 60825-1:2008-05
Max. Leistung (peak):
Impulsdauer:
Wellenlänge:
RADIAZIONE LASER
NON FISSARE IL FASCIO
APARRECCHIO LASER DI CLASSE 2
EN 60825-1:2007
Potenza max. (peak):
Durata dell'impulso:
Lunghezza d'onda:
LASER RADIATION
DO NOT STARE INTO BEAM
CLASS 2 LASER PRODUCT
EN 60825-1:2007
Maximum Output (peak):
Pulse duration:
Wavelength:
RAYONNEMENT LASER
NE PAS REGARDER DANS LE FAISCEAU
APPAREIL À LASER DE CLASSE 2
EN 60825-1:2007
Puissance max. (crête):
Durée d`impulsion:
Longueur d`onde:
RADIACIÓN LÁSER
NO MIRAR FIJAMENTE AL HAZ
PRODUCTO LÁSER DE CLASE 2
EN 60825-1:2007
Potencia máx. (peak):
Duración del impulso:
Longitud de onda:
RADIAÇÃO LASER
NÃO OLHAR FIXAMENTE O FEIXE
EQUIPAMENTO LASER CLASSE 2
EN 60825-1:2007
Potência máx. (peak):
Período de pulso:
Comprimento de onda:
LASER RADIATION
DO NOT STARE INTO BEAM
CLASS 2 LASER PRODUCT
IEC 60825-1:2007
Complies with 21 CFR 1040.10
Maximum Output (peak):
Pulse duration:
Wavelength:
䉏⏘戟⺓
▎䦃展⏘㧮
伊䉏⏘ℶ❐
GB7247.1-2012
㦏⮶戢⒉᧤⽿⋋᧥
厘⑁㖐兼㢅梃
㽱栎
2 mW
<150 µs
405 nm
2 mW
<150 µs
405 nm
2 mW
<150 µs
405 nm
2 mW
<150
µ s
405 nm
2 mW
<150 µs
405 nm
2 mW
<150 µs
405 nm
2 mW
<150 µs
405 nm
2 mW
<150 µs
405 nm
50127630

Device description
Leuze electronic BCL 604i 12
3 Device description
3.1 Device overview
Bar code readers of the BCL 600i series are high-speed scanners with integrated decoder for all
commonly used bar codes, e.g. 2/5 Interleaved, Code 39, Code 128, EAN 8/13 etc., as well as codes from
the GS1 DataBar family.
Bar code readers of the BCL 600i series are available in various optics models and as line scanners and
oscillating mirrors.
1 Line scanner
2 Oscillating-mirror scanner
Figure 3.1: Line scanner and oscillating-mirror scanner
The extensive options for device configuration via display or software enable adaptation to a multitude of
reading tasks. Due to the large reading distance combined with the great depth of field and a very compact
construction, the device is ideally suited for package and pallet transportation systems. In general, the bar
code readers of the BCL 600i series are designed for the conveyor and storage technology market.
The interfaces (RS 232, RS 485 and RS 422) integrated in the various device models and the fieldbus
systems (Profibus DP, PROFINET-IO, Ethernet TCP/IP / UDP and Ethernet/IP) of the BCL 600i series bar
code readers offer optimum connection to the superior host system.
3.2 Performance characteristics
• Integrated fieldbus connectivity = i -> Plug-and-Play fieldbus coupling and easy networking
• Numerous interface variants facilitate connection to the superior systems
• RS 232, RS 422 as well as with integrated multiNet plus master
• RS 485 and multiNet plus slave
• alternatively, various fieldbus systems, such as
PROFINET-IO
Ethernet TCP/IP
Ethernet /IP
Ethernet
PROFIBUS DP
2
1

Device description
Leuze electronic BCL 604i 13
• Integrated code reconstruction technology (CRT) enables the identification of soiled or damaged bar
codes
• Maximum depth of field and reading distances from 400 mm to 1450 mm
• Large optical opening angle and, thus, large reading field width
• High scanning rate of 800 / 1000 scans/s for fast reading tasks
• Intuitive, backlit, multi-language display with user-friendly menu navigation
• Integrated USB 1.1 service interface
• Adjustment of all device parameters with a web browser
• Connection options for an external parameter memory
• Easy alignment- and diagnostics functions
• M12 connections with Ultra-Lock ™ technology
• Four freely programmable switching inputs/outputs for the activation or signaling of states
• Automatic monitoring of the read quality with autoControl
• Automatic recognition and setting of the bar code type using autoConfig
• Reference code comparison
• Heavy-duty housing of degree of protection IP 65

Device description
Leuze electronic BCL 604i 14
3.3 Device construction
1 Reading window
2 Control panel with display, LEDs and buttons
3 M12 connection technology
4 USB interface
5 Dovetail mounting
6 M4 mounting thread
Figure 3.2: Device construction
1
1
2
3
5
6
4
66

Device description
Leuze electronic BCL 604i 15
3.4 Connection technology
The bar code readers are connected using variously coded M12 connectors. This ensures unique connec-
tion assignments.
The additional USB interface is used for configuring the device.
For the locations of the individual device connections, please refer to the device detail shown below.
1 Service, USB socket, type A
2 SW In/Out, M12 socket (A-coded)
3 Bus Out, M12 socket (D-coded)
4 Host/Bus In, M12 socket (D-coded)
5 PWR, M12 plug (A-coded)
Figure 3.3: Location of the electrical connections
3.5 Display elements
3.5.1 Structure of the control panel
1LED PWR
2 LED NET
3 Navigation buttons
4 Escape button
5 Enter button
6 Display
Figure 3.4: Structure of the control panel
3 4 5
2
1
3
2
1
4
5
6

Device description
Leuze electronic BCL 604i 16
3.5.2 Status display and operation
Indicators in the display
Table 3.1: Status displays of the switching inputs/outputs
Bar graph
The read quality is described on a scale of 0 - 100 %. The quality is evaluated based on the “Equal Scans”
of the read result configured in the bar code reader.
Table 3.2: Status display of the USB interface
Read result
The read bar code information is displayed.
3.5.3 LED indicators
PWR LED
IO1 Switching input or switching output 1 active (function dependent on set configuration).
Default: Switching input with the “Reading gate activation” function
IO2 Switching input or switching output 2 active (function dependent on set configuration).
Default: Input with the “Teach-in” function
IO3 Switching input or switching output 3 active (function dependent on set configuration).
Default: Switching input with the “Reading gate activation” function
IO4 Switching input or switching output 4 active (function dependent on set configuration).
Default: Switching output with the “No read” function
ATT Warning (Attention)
ERR Internal device error (Error) -> The device must be sent in for inspection
USB The device is connected to a PC via the USB interface.
MS An external parameter memory is properly connected to the USB interface of the device.
Off Device OFF
• No supply voltage
Flashes green Device ok, initialization phase
• No bar code reading possible
• Voltage connected
• Self test running
• Initialization running
Green, continu-
ous light
Device OK
• Bar code reading possible
• Self test successfully finished
• Device monitoring active

Device description
Leuze electronic BCL 604i 17
NET LED
3.6 Operational controls
Navigating within the menus
Use the navigation buttons to move through the menu. Activate the desired selection with the enter
button .
Press the escape button to move up one menu level.
When one of the buttons is actuated, the display illumination is activated for 10 min.
Setting values
Set the desired value with the navigation buttons and the enter button .
An accidental incorrect entry can be corrected by selecting the left arrow button and then pressing the
enter button.
Then use the navigation buttons to select save and save the set value by pressing the enter button.
Selecting options
Set the desired option with the navigation buttons and the enter button .
Orange, continu-
ous light
Service mode
• Bar code reading possible
• Configuration via the USB service interface
• Configuration via the display
• No data on the host interface
Flashes red Device ok, warning set
• Bar code reading possible
• Temporary operating fault
Red, continuous
light
Device error / parameter enable
• No bar code reading possible
Off No supply voltage
• No communication possible
• Profibus DP communication not initialized or inactive
Flashes green Initialization
• of the device, establishing communication
Green, continu-
ous light
Operation OK
• Network mode ok
• Connection and communication to IO controller (PLC) established (data
exchange)
Flashes red Communication error
• Parameterization or configuration failed (parameter failure)
•IO error
• No data exchange
Red, continuous
light
Network error
• No communication (protocol) to IO controller established (no data exchange)
ESC

Device description
Leuze electronic BCL 604i 18
3.7 External parameter memory
The optionally available external parameter memory – based on a USB memory stick (compatible with
version 1.1) – is housed in an external hood with integrated connectors which cover the USB service inter-
face when installed (IP 65).
The external parameter memory makes it easy and reduces the time needed to replace a device on site
by providing a copy of the current parameter set of the device. This eliminates the need to configure the
exchanged device manually.
The delivery contents of the external parameter memory include the hood with integrated connectors with
unscrewable cover and the USB memory stick.
To mount, the cover of the service interface must be unscrewed. Then take the USB memory
stick and plug it into the USB connection on the device. Then, take the connector hood of the
USB memory stick and screw this over the plugged-in USB memory stick to the service interface
to close the system and ensure degree of protection IP 65.

Functions
Leuze electronic BCL 604i 19
4 Functions
General information
The integrated fieldbus connectivity = i contained in the bar code readers of the BCL 600i series facilitates
the use of identification systems which function without connection unit or gateways. The integrated
fieldbus interface considerably simplifies handling. The Plug-and-Play concept enables easy networking
and very simple commissioning: Directly connect the respective fieldbus and all configuration is performed
with no additional software.
For decoding bar codes, the bar code readers of the BCL 600i series make available the proven CRT
decoder with code reconstruction technology:
The proven code reconstruction technology (CRT) enables bar code readers of the BCL 600i series to
read bar codes with a small bar height, as well as bar codes with a damaged or soiled print image.
With the aid of the CRT decoder, bar codes can also be read without problem in other demanding situa-
tions, such as with a large tilt angle (azimuth angle or even twist angle).
Figure 4.1: Possible bar code orientation
With the BCL 604i, configuration is generally performed with the aid of the GSD file.
The device needs a suitable activation to start a read process as soon as an object is in the reading field.
This opens a time window (reading gate) in the device for the read process during which the bar code
reader has time to detect and decode a bar code.
In the basic setting, triggering takes place through an external reading cycle signal. Alternative activation
options include online commands via the host interface and the autoReflAct function. In the basic setting,
triggering takes place through an external reading cycle signal or via the PROFIBUS. An alternative option
for activation is the autoReflAct function.
In the basic setting, triggering takes place through an external reading cycle signal. Alternative activation
options include online commands via the host interface and the autoReflAct function. Through the read
operation, the device collects additional useful pieces of data for diagnosis which can also be transmitted
to the host. The quality of the read operation can be inspected using the alignment mode which is inte-
grated in the webConfig tool.
A multi-language display with buttons is used to operate the device as well as for visualization purposes.
Two LEDs provide additional optical information on the current operating state of the device.

Functions
Leuze electronic BCL 604i 20
The four freely configurable switching inputs/outputs SWIO 1 … SWIO 4 can be assigned various func-
tions and control e.g. activation of the device or external devices, such as a PLC.
System, warning and error messages provide assistance in setup/troubleshooting during commissioning
and read operation.
4.1 autoReflAct
autoReflAct stands for automatic Reflector Activation and permits an activation without additional sensors.
This is achieved by directing the scanner with reduced scanning beam towards a reflector mounted behind
the conveyor path. As long as the scanner is targeted at the reflector, the reading gate remains closed. If,
however, the reflector is blocked by an object such as a container with a bar code label, the scanner acti-
vates the read procedure, and the label on the container is read. When the path from the scanner to the
reflector has cleared, the read procedure has completed and the scanning beam is reduced and again
directed onto the reflector. The reading gate is closed.
Figure 4.2: Reflector arrangement for autoReflAct
The autoReflAct function uses the scanning beam to simulate a photoelectric sensor and thus permits an
activation without additional sensors.
You will find a matching reflector in Accessories, and more are available on request.