Leuze BPS 8 User manual

BPS 8
Bar Code Positioning System
en 03-2018/01 50105556 We reserve the right to make technical changes
Original operating instructions

Leuze electronic BPS 8 1
Table of contents
1 About this document ......................................................................................................... 4
1.1 Used symbols and signal words .......................................................................................... 4
2 Safety .................................................................................................................................. 6
2.1 Intended use ........................................................................................................................ 6
2.2 Foreseeable misuse............................................................................................................. 7
2.3 Competent persons.............................................................................................................. 7
2.4 Exemption of liability ............................................................................................................ 8
2.5 Laser safety notices ............................................................................................................. 8
3 Technical data of BPS 8 .................................................................................................. 11
3.1 General specifications BPS 8 ............................................................................................ 11
3.2 Dimensioned drawings....................................................................................................... 13
3.3 Reading field curves .......................................................................................................... 15
4 MA 8… / MA 2xxi connection units................................................................................. 16
4.1 MA 8.1 connection unit ...................................................................................................... 17
4.2 MA 8-01 / MA 8-02 connection unit.................................................................................... 18
4.3 MA 2xxi connection unit ..................................................................................................... 20
5 Bar code tape ................................................................................................................... 21
5.1 General information ........................................................................................................... 21
5.2 Control bar codes............................................................................................................... 23
5.3 Marker bar codes ............................................................................................................... 27
5.4 Technical data of the BCB8 bar code tape ........................................................................ 29
5.5 Dimensioned drawing for position, control and marker bar codes ..................................... 30
6 Mounting and installation ............................................................................................... 31
6.1 Mounting the bar code tape ............................................................................................... 31
6.1.1 Installation and application remarks ............................................................................................ 31
6.1.2 Cutting bar code tapes................................................................................................................. 33
6.1.3 Mounting the BCB........................................................................................................................ 36
6.1.4 BCB repair with repair kit ............................................................................................................. 39
6.2 Mounting the BPS 8 ........................................................................................................... 41
6.2.1 BT 8-01 mounting device............................................................................................................. 43
6.2.2 BT 8-0 mounting device............................................................................................................... 44
6.3 Device arrangement...........................................................................................................45

Leuze electronic BPS 8 2
Table of contents
7 Electrical connection ....................................................................................................... 48
7.1 Safety notices for the electrical connection........................................................................ 48
7.2 Electrical connection BPS 8............................................................................................... 49
7.2.1 BPS 8 - PWR IN - Voltage supply, RS 232, Switching input/output ............................................ 49
7.3 Electrical connection via connection unit MA 8.1 ............................................................... 51
7.3.1 Electrical connection MA 8.1 ....................................................................................................... 51
7.3.2 PWR IN HOST/RS 232 connector – voltage supply and RS 232 ................................................ 52
7.3.3 SW IN/OUT socket – switching input and switching output......................................................... 53
7.3.4 BCL socket – connecting the BPS 8 to the MA 8.1 ..................................................................... 55
7.4 Electrical connection via connection unit MA 8-01 / MA 8-02 ............................................ 56
7.4.1 PWR IN HOST/RS485 connector – voltage supply/RS 485 ........................................................ 56
7.4.2 SW IN/OUT socket – switching input and switching output......................................................... 57
7.4.3 BCL/BPS socket – connecting the BPS 8 to the MA 8-01/MA 8-02 ............................................ 59
7.4.4 Termination of the RS 485 interface............................................................................................ 60
8 Configuration / device parameters................................................................................. 61
8.1 RS 232/RS 485 interface ................................................................................................... 61
8.1.1 General information ..................................................................................................................... 61
8.2 BPS Configuration Tool software....................................................................................... 62
8.2.1 Installation of the BPS Configuration Tool software .................................................................... 62
8.2.2 Brief manual for the BPS Configuration Tool............................................................................... 63
8.2.3 Setting the parameters ................................................................................................................ 67
8.3 Service operating mode ..................................................................................................... 68
8.3.1 Activate service interface............................................................................................................. 68
8.3.2 Connecting the service interface ................................................................................................. 68
8.3.3 Overview of commands and parameters.....................................................................................69
8.4 Overview of the parameter structure.................................................................................. 70
8.5 Detailed description of the tabs.......................................................................................... 71
8.5.1 Control ......................................................................................................................................... 72
8.5.2 Position detection ........................................................................................................................ 73
8.5.3 Communication............................................................................................................................ 78
8.5.4 Switching input............................................................................................................................. 80
8.5.5 Switching output .......................................................................................................................... 82

Leuze electronic BPS 8 3
Table of contents
9 Protocols for position value output ............................................................................... 84
9.1 Binary protocol 1 – BPS 8 SM 10x-01 / BPS 8 SM 10x-05 ................................................ 84
9.1.1 Data format .................................................................................................................................. 84
9.1.2 Request telegram to the BPS 8 SM 10x-01 / BPS 8 SM 10x-05 ................................................. 84
9.1.3 BPS 8 SM 10x-01 / BPS 8 SM 10x-05 response telegram.......................................................... 86
9.2 Binary protocol 2 – BPS 8 SM 10x-02 ............................................................................... 91
9.2.1 Data format .................................................................................................................................. 91
9.2.2 Request telegram to the BPS 8 SM 10x-02.................................................................................91
9.2.3 BPS 8 SM 10x-02 response telegram ......................................................................................... 93
9.3 Binary protocol 3 – BPS 8 SM 10x-03 ............................................................................... 98
9.3.1 Data format .................................................................................................................................. 98
9.3.2 Request telegram to the BPS 8 SM 10x-03.................................................................................98
9.3.3 BPS 8 SM 10x-03 response telegram ....................................................................................... 100
9.4 Binary protocol 4 – BPS 8 SM 10x-04 ............................................................................. 102
9.4.1 Data format ................................................................................................................................ 102
9.4.2 Request telegram to the BPS 8 SM 10x-04............................................................................... 102
9.4.3 BPS 8 SM 10x-04 response telegram ....................................................................................... 105
9.4.4 Binary protocol 4 request sequences ........................................................................................ 107
9.5 Binary protocol 6 – BPS 8 SM 10x-10 ............................................................................. 109
9.5.1 Data format ................................................................................................................................ 109
9.5.2 Request telegram to the BPS 8 SM 10x-10............................................................................... 109
9.5.3 BPS 8 SM 10x-10 response telegram ....................................................................................... 111
10 Diagnostics and troubleshooting ................................................................................. 113
10.1 Operating indicators of the LEDs ..................................................................................... 113
10.2 General causes of errors ................................................................................................. 113
10.3 Error on the interface ....................................................................................................... 114
11 Maintenance ................................................................................................................... 115
11.1 Cleaning........................................................................................................................... 115
11.2 Repairs, servicing ............................................................................................................ 115
11.3 Disassembling, packing, disposing .................................................................................. 115
12 Type overview and accessories ................................................................................... 116
12.1 Type overview: BPS 8...................................................................................................... 116
12.2 Type overview: Bar code tape ......................................................................................... 116
12.3 Accessories – Modular connection unit ........................................................................... 117
12.4 Accessories – Fieldbus gateway...................................................................................... 117
12.5 Accessories – Cables ...................................................................................................... 117
12.6 Accessories – Mounting device ....................................................................................... 118
12.7 Accessories - Configuration software .............................................................................. 118
13 Appendix......................................................................................................................... 119
13.1 EC Declaration of Conformity .......................................................................................... 119

About this document
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1 About this document
1.1 Used symbols and signal words
Table 1.1: Warning symbols and signal words
Table 1.2: Other symbols
Symbol indicating dangers to persons
Symbol indicating dangers from harmful laser radiation
NOTE Signal word for property damage
Indicates dangers that may result in property damage if the measures
for danger avoidance are not followed.
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.
BCB Bar code tape (general)
BCB8 Bar code tape (BCB type with 30 mm grid)
BPS Bar code Positioning System
BT Mounting device
CDRH Center for Devices and Radiological Health
CFR Code of Federal Regulations
DGUV Deutsche Gesetzliche Unfallversicherung (statutory German accident
insurance association)
EMC Electromagnetic compatibility
EN European standard
FE Functional earth
IEC International Electrotechnical Commission

About this document
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Table 1.3: Terms and abbreviations
IO or I/O Input/Output
IP International Protection
LED Light Emitting Diode
MA Modular connection unit
MVS Type of control bar code
NEC National Electric Code
PE Protective Earth
PWR Power – Supply voltage
UL Underwriters Laboratories
UV Ultraviolet light

Safety
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2Safety
The bar code positioning systems of the BPS 8 series and the MA 8… modular connection
unit have been developed, produced and tested subject to the applicable safety standards.
They correspond to the state of the art.
2.1 Intended use
The bar code positioning system of the BPS 8 series is an optical measuring system which
uses visible red laser light to determine the position of the BPS relative to a permanently
mounted bar code tape.
The optional connector and interface unit MA 8… is intended for the easy connection of bar
code positioning systems of type BPS 8.
Areas of application
The BPS 8 bar code positioning systems are designed for the following areas of application:
• Crane bridges and trolleys
• High-bay storage devices
• Side-tracking skates
• Telpher lines
•Elevators
NOTE
Declaration of Conformity
A copy of all declarations of conformity available for the product can be found in the
appendix of this handbook (see chapter 13.1 "EC Declaration of Conformity" on
Page 119).
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.
Only operate the device in accordance with its intended use.
Leuze electronic GmbH + Co. KG is not liable for damages caused by improper use.
Read these operating instructions before commissioning the device. Knowledge of
this document is required in order to use the equipment for its intended purpose.
NOTE
Comply with conditions and regulations!
Observe the locally applicable legal regulations and the rules of the employer's liability
insurance association.

Safety
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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:
• in rooms with explosive atmospheres
• as stand-alone safety component in accordance with the machinery directive 1
• for medical 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.
CAUTION
UL applications!
For UL applications, use is only permitted in Class 2 circuits in accordance with the NEC
(National Electric Code).
1. Use as safety-related component within the safety function is possible, if the component combination is designed
correspondingly by the machine manufacturer.
NOTE
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
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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 elec-
trical systems and independently detect possible dangers.
In Germany, certified electricians must fulfill the requirements of DGUV Provision 3 (e.g.
electrician foreman). In other countries, there are respective regulations that must be
observed.
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
ATTENTION, LASER RADIATION – LASER CLASS 2
Never look directly into the beam!
The device satisfies the requirements of IEC 60825-1:2007 (EN 60825-1:2007) safety
regulations for a product of laser class 2 as well as the U.S. 21 CFR 1040.10 regulations
with deviations corresponding to "Laser Notice No. 50" from June 24, 2007.
Never look directly into the laser beam or in the direction of reflected 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 reflec-
tive 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.
Observe the applicable statutory and local laser protection regulations.
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.

Safety
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Figure 2.1: Laser apertures, laser warning signs
NOTE
Affix laser information and warning signs!
Laser warning and laser information signs are affixed to the device (see Figure 2.1):
In addition, self-adhesive laser warning and information signs (stick-on labels) are supplied
in several languages (see Figure 2.2).
Affix the laser information sheet to the device in the language appropriate for the place
of use.
When using the device in the U.S.A., 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.
ALaser aperture
BLaser warning sign
A
A
B
B

Safety
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Figure 2.2: 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:
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GB7247.1-2012
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1,7 mW
<420 μs
655 nm
1,7 mW
<420 μs
655 nm
1.7 mW
<420 μs
655 nm
1,7 mW
<420 μs
655 nm
1,7 mW
<420 μs
655 nm
1,7 mW
<420 μs
655 nm
1.7 mW
<420 μs
655 nm
1.7 mW
<420 μs
655 nm
50038277-03

Technical data of BPS 8
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3 Technical data of BPS 8
3.1 General specifications BPS 8
Optical data
Light source Laser diode
Beam deflection Via rotating polygon wheel
Reading distance See reading field (Figure 3.3 and Figure 3.4 on Page 15)
Optical window Glass
Laser class 2 acc. to IEC 60825-1:2007
Wavelength 655nm
Max. output power (peak) 1.7mW
Impulse duration < 420 µs
Measurement data
Reproducible accuracy ±0.15 … ±1mm depending on device version
Response time 26.6ms (configurable)
Output time 3.3ms
Basis for contouring error cal-
culation
13.3ms
Working range BPS 8 SM 102: 80 … 140mm
BPS 8 SM 100: 60 … 120mm
Max. traverse rate 4 m/s
Electrical data
Operating voltage 1) BPS 8: 4.9 … 5.4VDC
With MA 8…: 10 … 30VDC
Power consumption BPS 8: 1.5W
With MA 8…: max. 2W
Interface type RS 232 directly or in combination with MA 8.1,
RS 485 in combination with MA 8-01/MA 8-02
Service interface RS 232 directly on the BPS 8,
RS 232 via MA 8.1,
RS 485 via MA 8-01/MA 8-02,
with default data format:
9.6 kBit/s, 8 data bits, no parity, 1 stop bit
Switching input /
switching output
1 switching input, 1 switching output, each is programma-
ble,only in combination with MA 8…
Green LED Device ready (power on)
Mechanical data
Degree of protection IP 67
Weight 70g
Dimensions (H x W x D) 48 x 40.3 x 15mm (BPS 8 SM 102…),
61 x 51 x 17.4mm (BPS 8 SM 100…)
Housing Diecast zinc

Technical data of BPS 8
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Table 3.1: General specifications
Environmental data
Operating temperature range 0 °C … -40 °C
Storage temperature range -20 °C … -60 °C
Air humidity Max. 90% rel. humidity, non-condensing
Vibration IEC 60068-2-6, test Fc
Shock/continuous shock IEC 60068-2-27, test Ea
Electromagnetic compatibility EN 61000-6-2:2005+AC:2005,
EN 61000-6-3:2007+A1:2011+AC:2012
Conformity CE, CDRH
Certifications 1) 2) UL 60950-1, CSA C22.2 No.60950-1
Bar code tape
Max. length (measurement
length)
10,000 m 3)
Ambient temperature -40 °C … -120 °C
Mech. properties Scratch and wipe resistant, UV resistant,
moisture resistant, partly chemical resistant
1) For UL applications: use is permitted exclusively in Class 2 circuits according to NEC
2) These sensors shall be used with UL Listed Cable assemblies rated 30V, 0.5A min, in the
field installation, or equivalent (categories: CYJV/CYJV7 or PVVA/PVVA7)
3) Depends on the transmission protocol and on the configured resolution.

Technical data of BPS 8
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3.2 Dimensioned drawings
BPS 8 SM 102… with front beam exit
Figure 3.1: BPS 8 SM 102… dimensioned drawing
ATurning connector, turnable 90°
BIndicator diodes (B1: status LED, B2: decode LED)
CScanning beam, divergence max. 5mm at 150 mm reading distance
DOptical axis
Thread depth:
3mm
Thread depth:
3mm

Technical data of BPS 8
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BPS 8 SM 100… with lateral beam exit
Figure 3.2: BPS 8 SM 100-01 dimensioned drawing
ATurning connector, turnable 90°
BIndicator LEDs (B1: status LED, B2: decode LED)
CScanning beam, divergence max. 5mm at 150 mm reading distance
DOptical axis
Thread depth:
3mm
Thread depth:
3mm

Technical data of BPS 8
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3.3 Reading field curves
BPS 8 SM 102 with front beam exit
Figure 3.3: Reading field curve BPS 8 SM 102 with front beam exit
BPS 8 SM 100 with lateral beam exit
Figure 3.4: Reading field curve BPS 8 SM 100 with lateral beam exit
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
0 102030405060708090 100 110 120 130 140 150 160 170
Reading distance [mm]
Reading field width [mm]
Working range
BPS 8 SM 102
-70
-60
-50
-40
-30
-20
-10
0
10
20
30
40
50
60
70
0 102030405060 70 80 90 100 110 120 130 140 150 160 170
Reading distance [mm]
Reading field width [mm]
Working range
BPS 8 SM 100

MA 8… / MA 2xxi connection units
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4 MA 8… / MA 2xxi connection units
Various connection units are available for convenient electrical connection:
•MA 8.1 RS 232 interface Operating voltage 10 … 30VDC
•MA 8-01 RS 485 interface Operating voltage 10 … 30VDC
•MA 8-02 RS 485 interface Operating voltage 10 … 30VDC
•MA 2xxi Different fieldbus systems Operating voltage 18 … 30VDC
MA 8-01 and MA 8-02 differ in the resistor network for the termination of the RS 485 inter-
face:
•MA 8-01 390/ 220/ 390
•MA 8-02 47k/ 150/ 47k
You can find connection and interconnection cables of varying lengths in Chapter 12.5
"Accessories – Cables" on page 117.

MA 8… / MA 2xxi connection units
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4.1 MA 8.1 connection unit
The MA 8.1 modular connection unit is an optional accessory for the connection of a BPS 8
to a DC voltage supply of 10 to 30 V DC. If offers the following advantages over the instal-
lation of the BPS 8 as a stand-alone device:
• M12 socket for switching input and switching output
• M12 connector for RS 232 interface and voltage supply 24VDC
• M12 socket for connection of the BPS 8
Figure 4.1: Dimensioned drawing and pin assignment of the MA 8.1 connection unit
A
B
C
AM12 socket, 5-pin, A-coded
BM12 connector, 5-pin, A-coded
CFE connection
all dimensions in mm

MA 8… / MA 2xxi connection units
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4.2 MA 8-01 / MA 8-02 connection unit
The modular connection unit is an optional accessory when connecting a BPS 8 to an
RS 485 interface. The RS 485 interface, the switching input and the switching output are all
connected to the MA 8-01/MA 8-02. It also supplies voltage to the BPS 8. The MA 8-01/
MA 8-02 connection unit offers the following advantages over the installation of the BPS 8
as a stand-alone device:
• M12 socket for switching input and switching output
• M12 connector for RS 485 interface and voltage supply 24VDC
• M12 socket for connection of the BPS 8
Figure 4.2: Dimensioned drawing and pin assignment of the MA 8-01/MA 8-02 connection
A
B
C
AM12 socket, 5-pin, A-coded
BM12 connector, 5-pin, A-coded
CFE connection
all dimensions in mm

MA 8… / MA 2xxi connection units
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unit