Nordson BC5100 User manual

NORDSON CORPORATION •DULUTH, GEORGIA •USA
www.nordson.com
BC5100 Bar Code Scanner
Customer Product Manual
Part 1076483A
Issued 8/07

Part 1076483A E2007 Nordson Corporation
All rights reserved
For CE Declaration, refer to the LogiCommrcontrol system manual.
Nordson Corporation welcomes requests for information, comments, and inquiries about its products. General information
about Nordson can be found on the Internet using the following address: http://www.nordson.com.
Address all correspondence to:
Nordson Corporation
Attn: Customer Service
11475 Lakefield Drive
Duluth, GA 30097
Notice
This is a Nordson Corporation publication which is protected by copyright. Original copyright date 2007.
No part of this document may be photocopied, reproduced, or translated to another language without the prior written
consent of Nordson Corporation. The information contained in this publication is subject to change without notice.
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AccuJet, AeroCharge, Apogee, AquaGuard, Asymtek, Automove, Baitgun, Blue Box, CanWorks, Century, CF, Clean Coat, CleanSleeve, CleanSpray,
ColorMax, Color-on-Demand, Control Coat, Coolwave, Cross-Cut, Dispensejet, DispenseMate, DuraBlue, Durafiber, Dura-Screen, Durasystem, Easy Coat,
Easymove Plus, Ecodry, Econo-Coat, e.dot, EFD, ESP, e stylized, ETI, Excel 2000, Fillmaster, FlexiCoat, Flex-O-Coat, Flow Sentry, Fluidmove, FoamMelt,
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could lead to violation of the owners’ rights.

Table of Contents i
Part 1076483A
E2007 Nordson Corporation
Table of Contents
Safety 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Qualified Personnel 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intended Use 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Alert Symbols 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regulations and Approvals 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Personal Safety 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fire Safety 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Action in the Event of a Malfunction 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equipment Disposal 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Overview 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Components 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scanner 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trigger 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Capabilities 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Applications 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check the Parts Inventory 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Select a Scanner Location 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Select a Trigger Location 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mount the Equipment 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Connect the BC5100 Components to the
LogiComm Control System 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trigger Setup 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjust Cut-off Distance 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Startup Check List 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Setup 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BC5100 Screens 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BC5100 Screen Components 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspection Parameter Screen Components 24. . . . . . . . . . . . . . . . . . . . . .
Properties Screen Components 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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Operation 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scanner Indicators 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start the System 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Change Products 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maintenance 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clean the Scanner Windows 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting Table 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Check Trigger Operation 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Optimum Read Ranges for Different Bar Code Sizes 34. . . . . . . . . . . . . . . .
Repair 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing a Scanner 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Parts 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bar Code Scanner Parts 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trigger (Photocell) 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Accessories 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix A: Technical Data
Specifications A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scanner A-1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scanner Dimensions A-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Trigger A-3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bar Code Symbologies A-4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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BC5100 Bar Code Scanner
Safety
Read this section before using the equipment. This section contains
recommendations and practices applicable to the safe installation,
operation, and maintenance (hereafter referred to as “use”) of the product
described in this document (hereafter referred to as “equipment”). Additional
safety information, in the form of task-specific safety alert messages,
appears as appropriate throughout this document.
WARNING: Failure to follow the safety messages, recommendations, and
hazard avoidance procedures provided in this document can result in
personal injury, including death, or damage to equipment or property.
Qualified Personnel
Equipment owners are responsible for making sure that Nordson equipment
is installed, operated, and serviced by qualified personnel. Qualified
personnel are those employees or contractors who are trained to safely
perform their assigned tasks. They are familiar with all relevant safety rules
and regulations and are physically capable of performing their assigned
tasks.
Intended Use
Use of Nordson equipment in ways other than those described in the
documentation supplied with the equipment may result in injury to persons
or damage to property.
Some examples of unintended use of equipment include:
Susing incompatible materials
Smaking unauthorized modifications
Sremoving or bypassing safety guards or interlocks
Susing incompatible or damaged parts
Susing unapproved auxiliary equipment
Soperating equipment in excess of maximum ratings

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Safety Alert Symbols
The following safety alert symbol and signal words are used throughout this
document to alert the reader to personal safety hazards or to identify
conditions that may result in damage to equipment or property. Comply with
all safety information that follows the signal word.
WARNING: Indicates a potentially hazardous situation that, if not avoided,
can result in serious personal injury, including death.
CAUTION: IIndicates a potentially hazardous situation that, if not avoided,
can result in minor or moderate personal injury.
CAUTION: (Used without the safety alert symbol) Indicates a potentially
hazardous situation that, if not avoided, can result in damage to equipment
or property.
Regulations and Approvals
Make sure all equipment is rated and approved for the environment in which
it is used. Any approvals obtained for Nordson equipment will be voided if
instructions for installation, operation, and service are not followed.
All phases of equipment installation must comply with all federal, state, and
local codes.
Personal Safety
To prevent injury follow these instructions.
SDo not operate or service equipment unless you are qualified.
SDo not operate equipment unless safety guards, doors, or covers are
intact and automatic interlocks are operating properly. Do not bypass or
disarm any safety devices.
SKeep clear of moving equipment. Before adjusting or servicing any
moving equipment, shut off the power supply and wait until the
equipment comes to a complete stop. Lock out power and secure the
equipment to prevent unexpected movement.
SRelieve (bleed off) hydraulic and pneumatic pressure before adjusting or
servicing pressurized systems or components. Disconnect, lock out, and
tag switches before servicing electrical equipment.

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SIf you receive even a slight electrical shock, shut down all electrical
equipment immediately. Do not restart the equipment until the problem
has been identified and corrected.
SObtain and read Material Safety Data Sheets (MSDS) for all materials
used. Follow the manufacturer’s instructions for safe handling and use
of materials, and use recommended personal protection devices.
STo prevent injury, be aware of less-obvious dangers in the workplace
that often cannot be completely eliminated, such as hot surfaces, sharp
edges, energized electrical circuits, and moving parts that cannot be
enclosed or otherwise guarded for practical reasons.
Fire Safety
To avoid a fire or explosion, follow these instructions.
SShut down all equipment immediately if you notice static sparking or
arcing. Do not restart the equipment until the cause has been identified
and corrected.
SDo not smoke, weld, grind, or use open flames where flammable
materials are being used or stored.
SProvide adequate ventilation to prevent dangerous concentrations of
volatile materials or vapors. Refer to local codes or your material MSDS
for guidance.
SDo not disconnect live electrical circuits while working with flammable
materials. Shut off power at a disconnect switch first to prevent sparking.
SKnow where emergency stop buttons, shut off valves, and fire
extinguishers are located.
SClean, maintain, test, and repair equipment according to the instructions
in your equipment documentation.
SUse only replacement parts that are designed for use with original
equipment. Contact your Nordson representative for parts information
and advice.
Action in the Event of a Malfunction
If a system or any equipment in a system malfunctions, shut off the system
immediately and perform the following steps:
SDisconnect and lock out electrical power. Close pneumatic shutoff
valves and relieve pressure.
SIdentify the reason for the malfunction and correct it before restarting the
equipment.
Equipment Disposal
Dispose off equipment and materials used in operation and servicing
according to local codes.

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System Overview
The BC5100 is a bar code scanner that monitors bar code accuracy in high
speed packaging and converting operations. The scanner detects
unreadable, missing, and incorrect codes.
This manual describes the connection, setup, and operation of the BC5100
system when used in conjunction with the LogiCommRcontrol system.
Figure 1 System overview
1. LogiComm control module
2. Touch-screen panel
3. Machine stop relay
4. Towards the ejector
5. BC5100 scanner
6. Trigger
7. Encoder

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The BC5100 system uses a laser diode scanner capable of 2000 scans per
second that can monitor any of the eight bar code symbologies at line
speeds up to 207 mpm (680 fpm).
When the BC5100 system is used with a LogiComm control system,
products with defective bar codes are automatically tracked and either
ejected from the production line or marked for removal. The LogiComm
control system may be programmed to stop the production line when a
defective code is detected.
The user interface for setting up and monitoring the BC5100 with the control
module is contained in the touch-screen panel.
NOTE: For specific details on installing and operating the LogiComm
control module and the touch-screen panel, refer to the appropriate
documentations.
System Components
The BC5100 system has three major components:
SScanner
STrigger
SLogiComm control system (control module and touch-screen panel)

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Scanner
When a bar code moves into the field of view of the scanner, the system’s
trigger starts the read cycle. The scanner repeatedly scans the bar code as
it moves through the visible laser beam, called the scan line. Depending on
the read at the end of a trigger cycle, the system sends out any of the
following three signals:
SMatch bar code
SMismatch bar code
SNo read output
Figure 2 Scanner
1. Scanner
2. Bar code
3. Scan line
NOTE: The scanner recognizes eight different bar code symbologies and
reads the codes in either ladder or picket-fence orientation. Refer to Bar
Code Symbologies given in Appendix A.

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Trigger
The BC5100 scanner uses the LA 650 trigger (photocell) to begin and end
the scan cycle. The LA 650 trigger uses a red laser beam to detect
substrates. The trigger signals the system to begin the scan cycle when it
senses the leading edge (or some other selected edge) of the product. The
scanning cycle continues until the trailing edge (or some other selected
edge) of the product is sensed.
1
2
3
4
Figure 3 LA 650 trigger
1. LED indicators
2. Cut-off point adjustment screw
3. Receiver elements
4. Emitter

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System Capabilities
This section explains the key applications of the BC5100 system. The key
industries in which the system is used include: folded carton manufacturing,
case sealing, and container filling.
Applications
Application Explanation
Verify bar codes on high-speed
production lines.
The scanner operates at 2000 scans per second at line speeds as
high as 207 m/min (680 ft/min) for codes in the picket-fence
orientation.
Verify bar codes on both constant
speed and variable speed lines. The system is not affected by changes in the line speed.
Verify bar codes in either ladder or
picket-fence orientation of the bar
code.
The system can read bar codes in either picket-fence or ladder
orientation. However, for most bar code designs, the picket-fence
orientation allows higher line speeds because more scans can be
completed during the scan cycle. For a 25 mm (1 in.) high bar code
in the ladder orientation, the maximum line speed is approximately
150 mpm (500 fpm). Refer to Figure 4.
Verify different bar codes with the
same scanner.
The system can read any of the following codes:
SCode 39
SCode 128
SUPC/EAN
SCodabar
SCode 93
SPharmacode (from 2 −16 bars)
SBobst Code (from 2 −16 bars)
SInterleaved 2 of 5
Stop the parent machine upon bad
code detection.
Whenever a bad code is detected, the LogiComm control system
can be programmed to issue a machine stop.
Eject or mark products with
detective bar codes.
Whenever a bad code is detected, the system activates an output
to the LogiComm control system. When the control module
receives a signal from the BC5100 system, it automatically tracks
the product and either ejects it or marks it for removal.

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Installation
Check the Parts Inventory
1. Verify shipment of the following components:
Sone scanner and a scanner interconnect cable
Sone trigger and a trigger cable
SLogiComm control system with the master control module with bead
verification capability
Smounting hardware for the major components
2. Inspect the equipment for any damage that may have occurred during
shipping. Report any problems to a Nordson representative.
Select a Scanner Location
1. Consider the following recommendations and requirements in choosing
a location for the scanner.
Location Factor Recommendation or Requirement
Best opportunity for scanning bar
code
SSelect a location where the code is fully visible to the
scanner.
SOn carton folder glue machines, the best opportunity is often
just prior to or after the glue flap pre-break section.
SConsider a location soon after the feed section so that the
feeding of products can be stopped quickly when defective
bar codes are detected on the line.
Sufficient space for mounting Refer to Technical Data, Appendix A for scanner dimensions.
Avoiding interference from glue
assist lines
Locate scanner so that no glue assist lines pass through the
scan line.
Reduction of reflected light Locate the scanner away from direct sunlight, bright ambient, or
task lighting, or light from other equipment, such as the system’s
trigger. Minimize the amount of direct or reflected light that can
enter the scanner.
Protection of cables Protect the connecting cable from any moving machine parts
and passing products.
Protection from dust and moisture Choose a location that meets IP54 requirements.

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Select a Scanner Location (contd)
2. Position the scanner so that the bar code label will pass through the
scan line.
SIf a picket-fence orientation is used, align the scan line so that half of
each bar is above the line and half below, see 1in Figure 4.
SIf a ladder orientation is used, align the scan line so that the code is
centered on the scan line, see 2in Figure 4.
a
b
1
X
X
a
b
X
X
2
Figure 4 Correct label alignment
1. Picket-fence orientation of the bar code
a. Direction of travel
b. Scan line
2. Ladder orientation of the bar code
a. Direction of travel
b. Scan line

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3. Set the distance from the scanner window to the surface of the product.
SFor Pharmacode and Bobst code, set the distance at 127 mm (5 in.).
SFor all other codes, set the distance also at 127 mm (5 in.). Make
sure that the mounting bracket allows the distance to be adjusted
from 102 −152 mm (4 −6 in.).
1
127 mm
(5.0 in.)
Figure 5 Distance from scanner to product surface
1. Product surface

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Select a Scanner Location (contd)
4. If the product surface is shiny or reflective so that light could be reflected
from the product surface back into the scanner, slightly tilt or skew the
scanner by following one of the methods given below:
SPitching the scanner approximately 10 degrees from the horizontal
(in either direction) as shown in Method A in Figure 6. Avoid angles
from 3 −5 degrees, which can cause increased reflection,
or
SSkewing the scanner approximately 10 degrees from the vertical
in either direction) as shown in Method B in Figure 6.
1
3
2
Method A Method B
Figure 6 Two ways to avoid reflected light
1. Product surface 2. Approximately 10_from line
parallel to product surface
3. Approximately 10_from line
perpendicular to product surface

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Select a Trigger Location
1. Consider the following recommendations and requirements in choosing
a location for the trigger:
Location Factor Recommendation or Requirement
Sensing speed Position the trigger lens so that it can sense the substrate
at a line speed higher than 900 m/min (2953 ft/min).
Sensing range Position the trigger lens so that it can sense from
2 −100 mm (0.08 −4 in.).
Interference with scanner operation Make sure that the light from the trigger does not shine (or
is not reflected) into the scanner.
Protection of cables Select a location that protects cables from any moving
machine parts and passing products.
Protection from dust and water Select a location that meets IP67 requirements.
2. Position the trigger so that the scan cycle is activated where successful
reads start occurring. See Figures 7 and 8.
1
6
5
4
2
3
7
Figure 7 Optimum location of trigger for picket-fence oriented bar codes
1. Outside limit of read range
2. Position of bar code where
successful reads start
3. Scan line
4. Carton or other product
5. Direction of line travel
6. Optimum location for trigger
7. Edge of product that activates
trigger
NOTE: For bar codes with picket-fence orientation, successful reads start
when the entire code (including quiet zones) is within the scan line.

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Select a Trigger Location (contd)
3
4
1
5
7
6
2
Figure 8 Optimum location of trigger for ladder oriented bar codes
1. Scan line
2. Outside limit of read range
3. Position of bar code where
successful reads start
4. Carton or other product
5. Direction of line travel
6. Optimum location for trigger
7. Edge of product that activates
trigger
NOTE: For bar codes with ladder orientation, successful reads start when
the leading edge of the code first crosses the scan line.

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Mount the Equipment
Equipment and production line configuration may dictate a variation in the
mounting options described in this section.
1. Mount the scanner in the selected location using either the bracket
components that were ordered with the BC5100 system or brackets that
you supply.
2. Mount the trigger in the selected location. For instructions on mounting
the trigger refer to the appropriate documentation.
1
2
3
4
Figure 9 Mounting the trigger and the scanner
1. Trigger
2. Scanner
3. Folding carton
4. Flap guide

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Connect the BC5100 Components to the LogiComm Control System
Figure 10 System overview
1. LogiComm control module
2. Touch-screen panel
3. Machine stop relay
4. Towards the ejector
5. BC5100 scanner
6. Trigger
7. Encoder