Leuze BPS 307i User manual

We reserve the right to make technical changes
EN • 2020-11-26 • 50127000
Original operating instructions
BPS 307i
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 307i 2

Table of contents
Leuze electronic GmbH + Co. KG BPS 307i 3
Table of contents
1 About this document ............................................................................................6
1.1 Used symbols and signal words ............................................................................................. 6
2 Safety .....................................................................................................................8
2.1 Intended use ........................................................................................................................... 8
2.2 Foreseeable misuse ............................................................................................................... 8
2.3 Competent persons ................................................................................................................ 9
2.4 Disclaimer ............................................................................................................................... 9
2.5 Laser warning notices.............................................................................................................9
3 Device description ..............................................................................................10
3.1 Device overview....................................................................................................................10
3.1.1 General information...........................................................................................................10
3.1.2 Performance characteristics..............................................................................................10
3.1.3 Accessories .......................................................................................................................11
3.1.4 Device model with heating ................................................................................................11
3.2 Connection technology ......................................................................................................... 12
3.2.1 MS307 connection hood with M12 connectors.................................................................12
3.2.2 MK307 connection hood with spring-cage terminals........................................................12
3.2.3 KB307 connection hood with cable ..................................................................................14
3.3 Display elements .................................................................................................................. 14
3.3.1 LED indicators ...................................................................................................................14
3.3.2 Display indicators ..............................................................................................................16
3.4 Bar code tape ....................................................................................................................... 17
3.4.1 General information...........................................................................................................17
3.4.2 Control bar codes ..............................................................................................................19
3.4.3 Marker labels.....................................................................................................................23
3.4.4 Twin tapes .........................................................................................................................24
4 Functions.............................................................................................................25
4.1 Position measurement .......................................................................................................... 25
4.2 Speed measurement ............................................................................................................ 25
4.3 Time behavior ....................................................................................................................... 26
4.4 WebConfig tool ..................................................................................................................... 26
4.5 Evaluation of the reading quality........................................................................................... 27
4.6 Distance measurement to the barcode tape........................................................................ 28
5 Applications ........................................................................................................29
5.1 High-bay storage device ....................................................................................................... 30
5.2 Electrical monorail system .................................................................................................... 31
5.3 Gantry cranes ....................................................................................................................... 32

Table of contents
Leuze electronic GmbH + Co. KG BPS 307i 4
6 Mounting..............................................................................................................33
6.1 Mounting barcode tape ........................................................................................................ 33
6.1.1 Installation and application remarks ..................................................................................33
6.1.2 Cutting barcode tapes ......................................................................................................34
6.1.3 Mounting the BCB .............................................................................................................35
6.2 Mounting the barcode positioning system ........................................................................... 38
6.2.1 Mounting instructions ........................................................................................................39
6.2.2 Orientation of the BPS to the bar code tape......................................................................40
6.2.3 Mounting with the BTU 0300M-W mounting device ..........................................................40
6.2.4 Mounting with the BT300W mounting bracket.................................................................41
6.2.5 Mounting with BT56 mounting device ..............................................................................41
6.2.6 Mounting with BT300-1 mounting device .........................................................................42
6.2.7 Mounting with M4 fastening screws ..................................................................................42
7 Electrical connection..........................................................................................43
7.1 External parameter memory in the connection hood ............................................................ 43
7.2 MS307 connection hood with connectors ............................................................................ 44
7.3 MK307 connection hood with spring-cage terminals ........................................................... 44
7.4 KB307 connection hood with cable...................................................................................... 45
7.5 Pin assignment ..................................................................................................................... 46
7.5.1 PWR/SWIN/OUT (Power and switching input/output).................................................... 46
7.5.2 SSI (HOST/BUSIN) ........................................................................................................48
7.5.3 SSI connection cable.........................................................................................................49
7.5.4 Service USB ......................................................................................................................49
7.6 Cable lengths and shielding.................................................................................................. 50
8 Starting up the device – Basic configuration...................................................51
8.1 Configuring the SSI interface................................................................................................ 51
8.1.1 Principal functionality of the SSI interface .........................................................................51
8.1.2 Setting the configuration of the SSI interface ....................................................................53
8.2 Configuring the switching inputs/outputs .............................................................................. 53
8.3 Configuring the resolution for the position value................................................................... 53
8.4 Configuring speed monitoring with switching output............................................................. 53
8.5 Setting tape selection via the webConfig tool ....................................................................... 54
8.6 Configuration via the switches of the connection hood......................................................... 54
8.7 Setting configuration parameters to factory settings............................................................. 56
8.8 Key factory settings of the BPS ............................................................................................ 57
9 Starting up the device – webConfig tool ..........................................................58
9.1 Installing software ................................................................................................................. 58
9.1.1 System requirements ........................................................................................................58
9.1.2 Install USB driver...............................................................................................................58
9.2 Start webConfig tool ............................................................................................................. 59
9.3 Short description of the webConfigtool ................................................................................ 60
9.3.1 Overview ...........................................................................................................................60
9.3.2 PROCESS function ...........................................................................................................61
9.3.3 ALIGNMENT function........................................................................................................61
9.3.4 CONFIGURATION function...............................................................................................62
9.3.5 DIAGNOSIS function.........................................................................................................68
9.3.6 MAINTENANCE function...................................................................................................68

Table of contents
Leuze electronic GmbH + Co. KG BPS 307i 5
10 Diagnosis and troubleshooting .........................................................................69
10.1 What to do in case of failure? ............................................................................................... 69
10.1.1 Diagnosis with webConfig tool ..........................................................................................69
10.2 Operating indicators of the LEDs.......................................................................................... 70
10.3 Error messages on the display ............................................................................................. 70
10.4 Checklist for causes of errors ............................................................................................... 71
11 Care, maintenance and disposal .......................................................................73
11.1 Cleaning................................................................................................................................ 73
11.2 Servicing ............................................................................................................................... 73
11.2.1 Firmware update ...............................................................................................................73
11.2.2 BCB repair with repair kit...................................................................................................73
11.3 Disposing .............................................................................................................................. 74
12 Service and support ...........................................................................................75
13 Technical data .....................................................................................................76
13.1 General specifications .......................................................................................................... 76
13.1.1 BPS without heating ..........................................................................................................78
13.1.2 BPS with heating ...............................................................................................................79
13.2 Bar code tape ....................................................................................................................... 80
13.3 Dimensioned drawings ......................................................................................................... 81
13.4 Dimensioned drawings: Accessories .................................................................................... 83
13.5 Dimensioned drawing barcode tape .................................................................................... 87
14 Order guide and accessories.............................................................................88
14.1 BPS307i type overview........................................................................................................ 88
14.2 Connection hoods................................................................................................................. 88
14.3 Cables accessories............................................................................................................... 88
14.4 Other accessories................................................................................................................. 89
14.5 Bar code tapes...................................................................................................................... 89
14.5.1 Standard bar code tapes ...................................................................................................89
14.5.2 Special bar code tapes......................................................................................................90
14.5.3 Twin tapes .........................................................................................................................90
14.5.4 Repair tapes ......................................................................................................................91
14.5.5 Marker labels and control labels........................................................................................91
15 EC Declaration of Conformity............................................................................92
16 Appendix..............................................................................................................93
16.1 Bar code sample................................................................................................................... 93

About this document
Leuze electronic GmbH + Co. KG BPS 307i 6
1 About this document
1.1 Used symbols and signal words
Tab.1.1: Warning symbols and signal words
Symbol indicating dangers to persons
Symbol indicating dangers from harmful laser radiation
Symbol indicating possible property damage
NOTE Signal word for property damage
Indicates dangers that may result in property damage if the measures for
danger avoidance are not followed.
CAUTION Signal word for minor injuries
Indicates dangers that may result in minor injury if the measures for danger
avoidance are not followed.
WARNING Signal word for serious injury
Indicates dangers that may result in severe or fatal injury if the measures
for danger avoidance are not followed.
Tab.1.2: Other symbols
Symbol for tips
Text passages with this symbol provide you with further information.
Symbol for action steps
Text passages with this symbol instruct you to perform actions.
Symbol for action results
Text passages with this symbol describe the result of the preceding action.

About this document
Leuze electronic GmbH + Co. KG BPS 307i 7
Tab.1.3: Terms and abbreviations
BCB Bar code tape
BPS Bar code Positioning System
CFR Code of Federal Regulations
DAP Device Access Point
DCP Discovery and Configuration Protocol
EMC Electromagnetic compatibility
EN European standard
FE Functional earth
GSD General Station Description
GSDML Generic Station Description Markup Language
GUI Graphical User Interface
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
OSI Open Systems Interconnection model
PELV Protective Extra-Low Voltage
RT Real Time
SNMP Simple Network Management Protocol
PLC Programmable Logic Control
Programmable Logic Control
SSI Synchronous Serial Interface
(Digital Synchronous Serial Interface)
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 307i 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 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 307i 9
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.

Device description
Leuze electronic GmbH + Co. KG BPS 307i 10
3 Device description
3.1 Device overview
3.1.1 General information
The BPS 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
BPS can optionally be delivered with display and optics heating.
The following connection hoods are available for the connection of the SSI interface:
• MS307 connection hood with M12 connectors
• MK307 connection hood with spring-cage terminals
• KB307 connection hood with cable
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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
• Simultaneous position and speed measurement
• Working range: 50 to 170mm; enables flexible mounting positions
• Interfaces: PROFINET fieldbus, PROFIBUS fieldbus, SSI, RS232/RS422, RS485
• Binary inputs and outputs for control and process monitoring
• Configuration via webConfig tool or fieldbus
• Diagnosis via webConfig tool or optional display