Leuze BPS 338i User manual

We reserve the right to make technical changes
EN • 2020-11-26 • 50141265
Original operating instructions
BPS 338i
Bar Code Positioning System

© 2021
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 338i 2

Table of contents
Leuze electronic GmbH + Co. KG BPS 338i 3
Table of contents
1 About this document ............................................................................................7
1.1 Used symbols and signal words ............................................................................................. 7
2 Safety .....................................................................................................................9
2.1 Intended use ........................................................................................................................... 9
2.2 Foreseeable misuse ............................................................................................................... 9
2.3 Competent persons .............................................................................................................. 10
2.4 Disclaimer ............................................................................................................................. 10
2.5 Laser warning notices...........................................................................................................10
3 Device description ..............................................................................................11
3.1 Device overview....................................................................................................................11
3.1.1 General information...........................................................................................................11
3.1.2 Performance characteristics..............................................................................................11
3.1.3 Accessories .......................................................................................................................12
3.1.4 Device model with heating ................................................................................................12
3.2 Connection technology ......................................................................................................... 13
3.2.1 MS338 connection hood with M12 connectors.................................................................13
3.2.2 MK338 connection hood with spring-cage terminals........................................................14
3.2.3 ME338103 connection hood with cables with M12 connector.........................................16
3.3 Display elements .................................................................................................................. 16
3.3.1 LED indicators ...................................................................................................................17
3.3.2 Display indicators ..............................................................................................................20
3.4 Bar code tape ....................................................................................................................... 21
3.4.1 General information...........................................................................................................21
3.4.2 Control bar codes ..............................................................................................................24
3.4.3 Marker labels.....................................................................................................................28
3.4.4 Twin tapes .........................................................................................................................29
4 Functions.............................................................................................................30
4.1 Position measurement .......................................................................................................... 30
4.2 Speed measurement ............................................................................................................ 31
4.3 Time behavior ....................................................................................................................... 31
4.4 WebConfig tool ..................................................................................................................... 31
4.5 Evaluation of the reading quality........................................................................................... 32
5 Applications ........................................................................................................33
5.1 High-bay storage device ....................................................................................................... 34
5.2 Electrical monorail system .................................................................................................... 35
5.3 Gantry cranes ....................................................................................................................... 36
6 Mounting..............................................................................................................37
6.1 Mounting barcode tape ........................................................................................................ 37
6.1.1 Installation and application remarks ..................................................................................37
6.1.2 Cutting barcode tapes ......................................................................................................38
6.1.3 Mounting the BCB .............................................................................................................39
6.2 Mounting the barcode positioning system ........................................................................... 42
6.2.1 Mounting instructions ........................................................................................................43
6.2.2 Orientation of the BPS to the bar code tape......................................................................44
6.2.3 Mounting with the BTU 0300M-W mounting device ..........................................................45
6.2.4 Mounting with the BT300W mounting bracket.................................................................45
6.2.5 Mounting with BT56 mounting device ..............................................................................46
6.2.6 Mounting with BT300-1 mounting device .........................................................................46
6.2.7 Mounting with M4 fastening screws ..................................................................................46

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Leuze electronic GmbH + Co. KG BPS 338i 4
7 Electrical connection..........................................................................................47
7.1 External parameter memory in the connection hood ............................................................ 47
7.2 MS338 connection hood with connectors ............................................................................ 48
7.3 MK338 connection hood with spring-cage terminals ........................................................... 49
7.4 ME338103 connection hood with cables with M12 connector ............................................ 50
7.5 Pin assignment ..................................................................................................................... 51
7.5.1 PWR/SWIN/OUT ............................................................................................................51
7.5.2 HOST/BUSIN .................................................................................................................53
7.5.3 BUSOUT ..........................................................................................................................54
7.5.4 Service USB ......................................................................................................................54
7.6 EtherCAT topology ............................................................................................................... 55
7.6.1 Linear topology..................................................................................................................55
7.6.2 EtherCAT wiring ................................................................................................................56
7.7 Cable lengths and shielding.................................................................................................. 57
8 Starting up the device – Configuring EtherCAT interface ..............................58
8.1 Ethernet over EtherCAT - EoE ............................................................................................. 58
8.2 CANopen over EtherCAT - CoE ........................................................................................... 58
8.3 Starting up the device in the EtherCAT system .................................................................... 59
8.4 Device description file........................................................................................................... 59
8.5 Distributed Clock................................................................................................................... 59
8.6 Object index.......................................................................................................................... 60
8.6.1 Overview ...........................................................................................................................60
8.6.2 Definition of output data (submission data) .......................................................................61
8.6.3 Definition of input data (result data) ..................................................................................62
8.6.4 Data type ...........................................................................................................................62
8.7 Communication objects ........................................................................................................ 62
8.7.1 Object 0x1000 – Device Type ...........................................................................................62
8.7.2 Object 0x1008 – Manufacturer Device Name ...................................................................62
8.7.3 Object 0x1009 – Manufacturer Hardware Version ............................................................63
8.7.4 Object 0x100A – Manufacturer Software Version .............................................................63
8.7.5 Object 0x1018 – Identity Object ........................................................................................64
8.8 Process data objects ............................................................................................................ 65
8.8.1 Object 0x1600 – Receive-PDO (control > BPS) ASCII 8 bytes.........................................65
8.8.2 Object 0x1601 – Receive-PDO (control > BPS) ASCII 16 bytes.......................................66
8.8.3 Object 0x1602 – Receive-PDO (control > BPS) ASCII 32bytes.......................................67
8.8.4 Object 0x1620 – Fragmentation of the Receive-PDO (control > BPS) ASCII data ...........68
8.8.5
Object 0x160A – Receive-PDO (control > BPS) binary process data control command (byte) ... 69
8.8.6 Object 0x1A00 – Transmit-PDO (BPS > control) ASCII 8bytes .......................................69
8.8.7 Object 0x1A01 – Transmit-PDO (BPS > control) ASCII 16bytes .....................................71
8.8.8 Object 0x1A02 – Transmit-PDO (BPS > control) ASCII 32bytes .....................................72
8.8.9 Object 0x1A20 – Fragmentation of the Transmit-PDO (BPS > control) ASCII data..........73
8.8.10 Object 0x1A10 – Transmit-PDO (BPS > control) binary data............................................73
8.8.11 Object 0x1C00 – Sync Manager Communication Type ....................................................75
8.8.12 Object 0x1C12 – Sync Manager 2 PDO-Assignment........................................................76
8.8.13 Object 0x1C13 – Sync Manager 3 PDO-Assignment........................................................77
8.8.14 Object 0x1C32 – Sync Manager 2 Parameter...................................................................78
8.8.15 Object 0x1C33 – Sync Manager 3 Parameter...................................................................79
8.8.16 Object 0x2000-0x2002 – ASCII-answer to master ............................................................ 80
8.8.17 Object 0x2013 – Binary process data to master ...............................................................81
8.8.18 Object 0x2050 – Status ASCII answer ..............................................................................84
8.8.19 Object 0x2100-0x2102 – ASCII commands to BPS ..........................................................85
8.8.20 Object 0x2150 – Status ASCII command..........................................................................86
8.8.21 Object 0x2200 – Activation................................................................................................88
8.8.22 Object 0x2300 – Result - fragmented ASCII answers.......................................................89
8.8.23 Object 0x2400 – Result - fragmented input data...............................................................91
8.8.24 Object 0x2450 – Device status..........................................................................................93

Table of contents
Leuze electronic GmbH + Co. KG BPS 338i 5
8.8.25 Object 0x2610 – Device-specific control functions............................................................94
8.8.26 Object 0x2900 – Serial number.........................................................................................95
8.9 Online commands................................................................................................................. 95
8.9.1 General online commands ................................................................................................95
8.9.2 PT sequence .....................................................................................................................96
8.9.3 PS sequence .....................................................................................................................98
8.9.4 Communication example...................................................................................................99
8.9.5 PR sequence...................................................................................................................101
8.9.6 PC sequence...................................................................................................................102
8.10 PT sequence parameters ................................................................................................... 103
8.10.1 Digital switching input/output1........................................................................................104
8.10.2 Digital switching input/output2........................................................................................107
8.10.3 Settings for the bar code tape .........................................................................................109
8.10.4 Configuration of position monitoring................................................................................111
8.10.5 Configuration of speed monitoring ..................................................................................113
8.10.6 Configuration of the measurement value display ............................................................118
8.10.7 Configuration of the read quality .....................................................................................118
8.10.8 Output preparation for the EtherCAT interface................................................................119
9 Starting up the device – webConfig tool ........................................................120
9.1 Installing software ............................................................................................................... 120
9.1.1 System requirements ......................................................................................................120
9.1.2 Install USB driver.............................................................................................................121
9.2 Start webConfig tool ........................................................................................................... 121
9.3 Short description of the webConfigtool .............................................................................. 122
9.3.1 Overview .........................................................................................................................122
9.3.2 PROCESS function .........................................................................................................123
9.3.3 ALIGNMENT function......................................................................................................124
9.3.4 CONFIGURATION function.............................................................................................125
9.3.5 DIAGNOSIS function.......................................................................................................129
9.3.6 MAINTENANCE function.................................................................................................129
10 Diagnosis and troubleshooting .......................................................................130
10.1 What to do in case of failure? ............................................................................................. 130
10.1.1 Diagnosis with webConfig tool ........................................................................................130
10.2 Operating indicators of the LEDs........................................................................................ 131
10.3 Error messages on the display ........................................................................................... 131
10.4 Checklist for causes of errors ............................................................................................. 132
11 Care, maintenance and disposal .....................................................................134
11.1 Cleaning.............................................................................................................................. 134
11.2 Servicing ............................................................................................................................. 134
11.2.1 Firmware update .............................................................................................................134
11.2.2 BCB repair with repair kit.................................................................................................134
11.3 Disposing ............................................................................................................................ 135
12 Service and support .........................................................................................136

Table of contents
Leuze electronic GmbH + Co. KG BPS 338i 6
13 Technical data ...................................................................................................137
13.1 General specifications ........................................................................................................ 137
13.1.1 BPS without heating ........................................................................................................139
13.1.2 BPS with heating .............................................................................................................140
13.2 Bar code tape ..................................................................................................................... 140
13.3 Dimensioned drawings ....................................................................................................... 142
13.4 Dimensioned drawings: Accessories .................................................................................. 144
13.5 Dimensioned drawing barcode tape .................................................................................. 148
14 Order guide and accessories...........................................................................149
14.1 BPS338i type overview...................................................................................................... 149
14.2 Connection hoods............................................................................................................... 149
14.3 Cables accessories............................................................................................................. 149
14.4 Other accessories............................................................................................................... 150
14.5 Bar code tapes.................................................................................................................... 151
14.5.1 Standard bar code tapes .................................................................................................151
14.5.2 Special bar code tapes....................................................................................................151
14.5.3 Twin tapes .......................................................................................................................152
14.5.4 Repair tapes ....................................................................................................................152
14.5.5 Marker labels and control labels......................................................................................153
15 EC Declaration of Conformity..........................................................................154
16 Appendix............................................................................................................155
16.1 Bar code sample................................................................................................................. 155

About this document
Leuze electronic GmbH + Co. KG BPS 338i 7
1 About this document
1.1 Used symbols and signal words
Tab.1.1: Warning symbols and signal words
Symbol indicating dangers to persons
Symbol indicating dangers from harmful laser radiation
Symbol indicating possible property damage
NOTE Signal word for property damage
Indicates dangers that may result in property damage if the measures for
danger avoidance are not followed.
CAUTION Signal word for minor injuries
Indicates dangers that may result in minor injury if the measures for danger
avoidance are not followed.
WARNING Signal word for serious injury
Indicates dangers that may result in severe or fatal injury if the measures
for danger avoidance are not followed.
Tab.1.2: Other symbols
Symbol for tips
Text passages with this symbol provide you with further information.
Symbol for action steps
Text passages with this symbol instruct you to perform actions.
Symbol for action results
Text passages with this symbol describe the result of the preceding action.
Tab.1.3: Terms and abbreviations
ASCII American Standard Code for Information Interchange
BCB Bar code tape
BPS Bar code Positioning System
CAT Control Automation Technology
CFR Code of Federal Regulations
CoE CANopen over EtherCAT
DC Distributed Clock
DCP Discovery and Configuration Protocol
EMC Electromagnetic compatibility
EN European standard
ESI EtherCAT Slave Information
EoE Ethernet over EtherCAT
ETG EtherCAT Technology Group
FE Functional earth

About this document
Leuze electronic GmbH + Co. KG BPS 338i 8
GUI Graphical User Interface
HEX Hexadecimal
IO or I/O Input/Output
I&M Information&Maintenance
IP Internet Protocol
LED Light Emitting Diode
MAC Media Access Control
MVS Type of control barcode
MV0 Type of control barcode
NEC National Electric Code
NTM Network management
OSI Open Systems Interconnection model
PC Parameter Copy
PDO Process Data Object
PELV Protective Extra-Low Voltage
PR Parameter Request
PS Parameter Status
PT Parameter Transfer
RAM Random Access Memory
RT Real Time
SDO Service Data Object
PLC Programmable Logic Control
Programmable Logic Control
TCP Transmission Control Protocol
UDP User Datagram Protocol
USB Universal Serial Bus
UL Underwriters Laboratories
UV Ultraviolet
XML Extensible Markup Language

Safety
Leuze electronic GmbH + Co. KG BPS 338i 9
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300 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 high-bay storage devices
• 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 338i 10
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/EN 60825-1:2014 safety regulations for a product
of laser class1 and complies with 21 CFR 1040.10 except for conformance with IEC 60825-1
Ed. 3., as described in Laser Notice No. 56, dated May 8, 2019.
CAUTION: Opening the device can lead to dangerous exposure to radiation.
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.
Repairs must only be performed by Leuze electronic GmbH + Co. KG.