Leuze BPS 3007i User manual

We reserve the right to make technical changes
EN • 2023-02-23 • 50148853
Original operating instructions
BPS 3007i
Bar code positioning system

© 2023
Leuze electronic GmbH + Co. KG
In der Braike 1
73277 Owen / Germany
Phone: [phone]
Fax: [phone]
www.leuze.com
[email protected]
Leuze electronic GmbH + Co. KG BPS 3007i 2

Table of contents
Leuze electronic GmbH + Co. KG BPS 3007i 3
Table of contents
1 About this document ............................................................................................5
1.1 Used symbols and signal words .............................................................................................5
2 Safety .....................................................................................................................6
2.1 Intended use ...........................................................................................................................6
2.2 Foreseeable misuse................................................................................................................6
2.3 Competent persons.................................................................................................................7
2.4 Disclaimer ...............................................................................................................................7
2.5 Laser warning notices .............................................................................................................7
3 Device description ................................................................................................8
3.1 Device overview......................................................................................................................8
3.1.1 General information.............................................................................................................8
3.1.2 Performance characteristics................................................................................................8
3.1.3 Accessories .........................................................................................................................9
3.2 Connection technology ...........................................................................................................9
3.2.1 MS3007 connection hood with M12 connectors.................................................................9
3.2.2 MK3007 connection hood with spring-cage terminals........................................................9
3.3 Display elements...................................................................................................................11
3.4 Bar code tape........................................................................................................................12
3.4.1 General information...........................................................................................................12
3.4.2 Twin tapes .........................................................................................................................13
4 Applications ........................................................................................................14
4.1 High-bay storage device .......................................................................................................15
4.2 Electrical monorail system ....................................................................................................16
4.3 Gantry cranes .......................................................................................................................17
5 Mounting..............................................................................................................18
5.1 Mounting barcode tape ........................................................................................................18
5.1.1 Installation and application remarks ..................................................................................18
5.1.2 Cutting barcode tapes ......................................................................................................19
5.1.3 Mounting the BCB .............................................................................................................20
5.2 Mounting the barcode positioning system............................................................................23
5.2.1 Mounting instructions.........................................................................................................24
5.2.2 Orientation of the BPS to the bar code tape......................................................................24
5.2.3 Mounting with the BTU 0300M-W mounting device ..........................................................25
5.2.4 Mounting with the BT300W mounting bracket.................................................................26
5.2.5 Mounting with M4 fastening screws...................................................................................26
6 Electrical connection..........................................................................................27
6.1 MS3007 connection hood with connectors ..........................................................................27
6.2 MK3007 connection hood with spring-cage terminals .........................................................28
6.3 Pin assignment .....................................................................................................................29
6.3.1 PWR/SWIN/OUT (Power and switching input/output)....................................................29
6.3.2 SSI (HOST/BUSIN) ........................................................................................................30
6.4 Cable lengths and shielding..................................................................................................31
7 Starting up the device – Basic configuration...................................................32
7.1 Configuring the SSI interface ................................................................................................32
7.1.1 Principal functionality of the SSI interface .........................................................................32
7.2 Configuration via the switches of the connection hood.........................................................33

Table of contents
Leuze electronic GmbH + Co. KG BPS 3007i 4
8 Diagnosis and troubleshooting .........................................................................34
8.1 What to do in case of failure? ...............................................................................................34
8.2 Operating indicators of the LEDs ..........................................................................................34
8.3 Checklist for causes of errors ...............................................................................................34
9 Care, maintenance and disposal .......................................................................36
9.1 Cleaning................................................................................................................................36
9.2 Servicing ...............................................................................................................................36
9.2.1 Firmware update................................................................................................................36
9.2.2 BCB repair with repair kit...................................................................................................36
9.3 Disposing ..............................................................................................................................37
10 Service and support ...........................................................................................38
11 Technical data .....................................................................................................39
11.1 General specifications...........................................................................................................39
11.1.1 BPS ...................................................................................................................................41
11.2 Bar code tape........................................................................................................................41
11.3 Dimensioned drawings..........................................................................................................42
11.4 Dimensioned drawings: Accessories ....................................................................................44
11.5 Dimensioned drawing barcode tape ....................................................................................46
12 Order guide and accessories.............................................................................47
12.1 Type overview.......................................................................................................................47
12.2 Connection hoods .................................................................................................................47
12.3 Cables accessories...............................................................................................................47
12.4 Other accessories .................................................................................................................47
12.5 Bar code tapes......................................................................................................................48
12.5.1 Standard bar code tapes ...................................................................................................48
12.5.2 Special bar code tapes......................................................................................................48
12.5.3 Twin tapes .........................................................................................................................49
12.5.4 Repair tapes ......................................................................................................................49
13 EC Declaration of Conformity............................................................................50
14 Appendix..............................................................................................................51
14.1 Bar code sample ...................................................................................................................51

About this document
Leuze electronic GmbH + Co. KG BPS 3007i 5
1 About this document
1.1 Used symbols and signal words
Tab.1.1: Warning symbols and signal words
Symbol indicating dangers to persons
Symbol indicating dangers from harmful laser radiation
Symbol indicating possible property damage
NOTE Signal word for property damage
Indicates dangers that may result in property damage if the measures for dan-
ger avoidance are not followed.
CAUTION Signal word for minor injuries
Indicates dangers that may result in minor injury if the measures for danger
avoidance are not followed.
WARNING Signal word for serious injury
Indicates dangers that may result in severe or fatal injury if the measures for
danger avoidance are not followed.
Tab.1.2: Other symbols
Symbol for tips
Text passages with this symbol provide you with further information.
Symbol for action steps
Text passages with this symbol instruct you to perform actions.
Symbol for action results
Text passages with this symbol describe the result of the preceding action.
Tab.1.3: Terms and abbreviations
BCB Bar code tape
BPS Bar code positioning system
EMC Electromagnetic compatibility
EN European standard
FE Functional earth
IO or I/O Input/Output
LED Light Emitting Diode
NEC National Electric Code
PELV Protective Extra-Low Voltage
SSI Synchronous Serial Interface
(Digital Synchronous Serial Interface)
USB Universal Serial Bus
UV Ultraviolet

Safety
Leuze electronic GmbH + Co. KG BPS 3007i 6
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 an optical measuring system which uses visible red laser light of laser class1 to determine its
position relative to a permanently mounted barcode tape.
All accuracy details for the BPS3000i measurement system refer to the position relative to the permanently
mounted bar code tape.
CAUTION
Use only approved bar code tapes!
The bar code tapes approved by Leuze and listed on the Leuze website as accessories are an
essential part of the measurement system.
Bar code tapes not approved by Leuze are not allowed.
The use of such bar code tapes is contrary to the intended use.
Areas of application
The BPS is designed for positioning in the following areas of application:
• Electrical monorail system
• Travel and lifting axes of stacker cranes
• Repositioning units
• Gantry crane bridges and their trolleys
• Elevators
CAUTION
Observe intended use!
The protection of personnel and the device cannot be guaranteed if the device is operated in a
manner not complying with its intended use.
ÄOnly operate the device in accordance with its intended use.
ÄLeuzeelectronicGmbH+Co.KG is not liable for damages caused by improper use.
ÄRead these operating instructions before commissioning the device. Knowledge of the oper-
ating instructions is an element of proper use.
NOTICE
Comply with conditions and regulations!
ÄObserve the locally applicable legal regulations and the rules of the employer's liability insur-
ance association.
2.2 Foreseeable misuse
Any use other than that defined under "Intended use" or which goes beyond that use is considered im-
proper use.
In particular, use of the device is not permitted in the following cases:
• in rooms with explosive atmospheres
• for medical purposes
• as own safety component in accordance with the machinery directive
NOTICE
Use as safety-related component within the safety function is possible, if the component combi-
nation is designed correspondingly by the machine manufacturer.

Safety
Leuze electronic GmbH + Co. KG BPS 3007i 7
NOTICE
Do not modify or otherwise interfere with the device!
ÄDo not carry out modifications or otherwise interfere with the device. The device must not be
tampered with and must not be changed in any way.
ÄThe use of a bar code tape not approved by Leuze is equivalent to an intervention in or
change to the device/measurement system.
ÄThe device must not be opened. There are no user-serviceable parts inside.
ÄRepairs must only be performed by LeuzeelectronicGmbH+Co.KG.
2.3 Competent persons
Connection, mounting, commissioning and adjustment of the device must only be carried out by competent
persons.
Prerequisites for competent persons:
• They have a suitable technical education.
• They are familiar with the rules and regulations for occupational safety and safety at work.
• They are familiar with the operating instructions for the device.
• They have been instructed by the responsible person on the mounting and operation of the device.
Certified electricians
Electrical work must be carried out by a certified electrician.
Due to their technical training, knowledge and experience as well as their familiarity with relevant standards
and regulations, certified electricians are able to perform work on electrical systems and independently de-
tect possible dangers.
In Germany, certified electricians must fulfill the requirements of accident-prevention regulations DGUV
(German Social Accident Insurance) provision 3 (e.g. electrician foreman). In other countries, there are re-
spective regulations that must be observed.
2.4 Disclaimer
LeuzeelectronicGmbH+Co.KG is not liable in the following cases:
• The device is not being used properly.
• Reasonably foreseeable misuse is not taken into account.
• Mounting and electrical connection are not properly performed.
• Changes (e.g., constructional) are made to the device.
2.5 Laser warning notices
ATTENTION
LASER RADIATION – CLASS 1 LASER PRODUCT
The device satisfies the requirements of IEC 60825-1:2014 / EN 60825-1:2014+A11:2021 safety
regulations for a product of laser class1 as well as the U.S.21CFR1040.10 regulations with
deviations corresponding to Laser Notice No.56 from May 8, 2019.
ÄObserve the applicable statutory and local laser protection regulations.
ÄThe device must not be tampered with and must not be changed in any way.
There are no user-serviceable parts inside the device.
CAUTION! Opening the device can lead to dangerous exposure to radiation!
Repairs must only be performed by LeuzeelectronicGmbH+Co.KG.

Device description
Leuze electronic GmbH + Co. KG BPS 3007i 8
3 Device description
3.1 Device overview
3.1.1 General information
The BPS3000i barcode positioning system uses visible red laser light to determine its position and its
speed value relative to a barcode tape that is affixed along the travel path. This takes place in the following
steps:
• Read a code on the barcode tape (see following figure)
• Determine the position of the read code in the scanning beam
• Calculate the position to within less than a millimeter using the code information and the code position
relative to the device's center.
The position and speed values are then output to the controller via the host interface.
The BPS consists of device housing and interface connection hood for the connection to the control. The
connection hood must be ordered separately.
The following connection hoods are available for the connection of the SSI interface:
• MS3007 connection hood with M12 connectors
• MK3007 connection hood with spring-cage terminals
000040 000044 000048 000052 000056 000060 000064 000068
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8
8
8
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0000
0000
0000
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0000
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5
2
0000
56
56
56
56
56
56
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0000
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1
2
4
3
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1 Bar code tape
2 Connection hood
3 Device housing
4 Middle of the scanning beam (device middle, output position value)
Fig.3.1: Device construction, device arrangement and beam exit
3.1.2 Performance characteristics
The most important performance characteristics of the barcode positioning system:
• Positioning with submillimeter accuracy from 0 to 10,000m
• For the control at high traverse rates of up to 10m/s
• Working range: 50 to 170mm; enables flexible mounting positions
• Interface: SSI

Device description
Leuze electronic GmbH + Co. KG BPS 3007i 9
3.1.3 Accessories
Special accessories are available for the bar code positioning system. The accessories are optimally
matched to the BPS:
• Highly flexible, scratch-, smudge- and UV-resistant barcode tape
• Mounting devices for precise mounting with one screw (easy-mount)
• Modular connection technology via connection hoods with M12 connectors or spring-cage terminals
3.2 Connection technology
For the electrical connection of the BPS, the following connection variants are available:
• MS3007 connection hood with M12 connectors
• MK3007 connection hood with spring-cage terminals
The voltage supply (18…30VDC) is connected acc. to the connection type selected.
3.2.1 MS3007 connection hood with M12 connectors
The MS3007 connection hood features two M12 connector plugs and a Mini-Btype USB socket.
NOTICE
The configuration switches and the integrated parameter memory for the simple replacement of
the BPS are located in the MS3007.
1
34
2
1 PWR/SW IN/OUT: M12 plug (A-coded)
2 Mini-B USB socket (behind protective cap)
3 HOST/BUSIN: M12 plug (B-coded), SSI
4 BUS OUT: not equipped
Fig.3.2: MS3007 connection hood, connections
NOTICE
Shielding connection
ÄThe shielding connection is done via the M12 connector housing.
3.2.2 MK3007 connection hood with spring-cage terminals
The MK3007 connection hood makes it possible to connect the BPS directly and without additional con-
nectors.
• The MK3007 features cable bushings in which the shielding connection for the interface cable is also
located, and
• a Mini-Btype USB socket.

Device description
Leuze electronic GmbH + Co. KG BPS 3007i 10
NOTICE
The configuration switches and the integrated parameter memory for simple replacement of the
BPS are located in the MK3007.
1
2
1 1
1 3x cable bushing, M16x1.5
2 Mini-B USB socket (behind protective cap)
Fig.3.3: Connection hood MK3007, connections
Cable fabrication and shielding connection
ÄRemove approx.78mm of the connection cable sheathing. 15mm of sheath of the shielded line must
be freely accessible.
ÄLead the individual wires into the terminals according to the diagram.
NOTICE
Do not use wire-end sleeves!
ÄWhen fabricating cables, we recommend against using wire-end sleeves.
NOTICE
The shield is automatically contacted when the cable is lead into the metal screw fitting and fas-
tened when the cord grip is closed.
≈ 55 mm ≈ 8 mm≈ 15 mm
1 2
1 Diameter of contact area, cable: 6…9.5mm
2 Diameter of contact area, shield: 5…9.5mm
Fig.3.4: Cable fabrication for connection hoods with spring-cage terminals