BC5100 Bar Code Scanner

Transcription

1 BC5100 Bar Code Scanner Customer Product Manual Issued 8/07 NORDSON CORPORATION DULUTH, GEORGIA USA

2 For CE Declaration, refer to the LogiComm control 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: Address all correspondence to: Nordson Corporation Attn: Customer Service Lakefield Drive Duluth, GA Notice This is a Nordson Corporation publication which is protected by copyright. Original copyright date 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. Trademarks 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, FoamMix, HDLV, Heli-flow, Helix, Horizon, Hot Shot, icontrol, iflow, isocoil, Isocore, Iso-Flo, itrax, Kinetix, Little Squirt, LogiComm, Magnastatic, March, Maverick, MEG, Meltex, Microcoat, Micromark, MicroSet, Millennium, Mini Squirt, Mountaingate, MultiScan, Nordson, OptiMix, Package of Values, Pattern View, PermaFlo, Plasmod, Porous Coat, PowderGrid, Powderware, Printplus, Prism, ProBlue, Prodigy, Pro-Flo, ProLink, Pro-Meter, Pro-Stream, RBX, Rhino, Saturn, Scoreguard, Seal Sentry, Select Charge, Select Coat, Select Cure, Slautterback, Smart-Coat, Solder Plus, Spectrum, Speed-Coat, SureBead, Sure Clean, Sure Coat, Sure-Max, Tracking Plus, TRAK, Trends, Tribomatic, TrueBlue, Ultra, Ultrasaver, UpTime, Vantage, Veritec, VersaBlue, Versa-Coat, Versa-Screen, Versa-Spray, Walcom, Watermark, and When you expect more. are registered trademarks of Nordson Corporation. Accubar, Advanced Plasma Systems, AeroDeck, AeroWash, AltaBlue, AquaCure, ATS, Auto-Flo, AutoScan, Best Choice, Blue Series, Bravura, Check Mate, ClassicBlue, Classic IX, Controlled Fiberization, Control Weave, CPX, CScan, Cyclo-Kinetic, DispensLink, Dry Cure, DuraBraid, DuraCoat, DuraDrum, DuraPail, Easy Clean, EasyOn, EasyPW, Eclipse, E-Nordson, Equi=Bead, FillEasy, Fill Sentry, Fluxplus, G Net, G Site,, idry, ion, Iso-Flex, itrend, Lacquer Cure, Lean Cell, Maxima, MicroFin, MicroMax, Mikros, MiniBlue, MiniEdge, Minimeter, Multifil, Myritex, OptiStroke, Partnership+Plus, PatternJet, PatternPro, PCI, Pinnacle, Powder Pilot, Powercure, Precise Coat, Primarc, Process Sentry, Pulse Spray, Quad Cure, Ready Coat, Royal Blue, Select Series, Sensomatic, Shaftshield, SheetAire, Smart, SolidBlue, Spectral, Spectronic, SpeedKing, Spray Works, Summit, Sure Brand, SureMix, SureSeal, Sure Wrap, Swirl Coat, Tempus, Trade Plus, ThruWave, Ultrasmart, Universal, ValveMate, VersaDrum, VersaPail, Vista, Web Cure, and 2 Rings (Design) are trademarks of Nordson Corporation. Designations and trademarks stated in this document may be brands that, when used by third parties for their own purposes, could lead to violation of the owners rights Nordson Corporation All rights reserved

3 Table of Contents i Table of Contents Safety Qualified Personnel Intended Use Safety Alert Symbols Regulations and Approvals Personal Safety Fire Safety Action in the Event of a Malfunction Equipment Disposal System Overview System Components Scanner Trigger System Capabilities Applications Installation Check the Parts Inventory Select a Scanner Location Select a Trigger Location Mount the Equipment Connect the BC5100 Components to the LogiComm Control System Trigger Setup Adjust Cut-off Distance System Startup Check List System Setup BC5100 Screens BC5100 Screen Components Inspection Parameter Screen Components Properties Screen Components Nordson Corporation

4 ii Table of Contents Operation Scanner Indicators Start the System Change Products Maintenance Clean the Scanner Windows Troubleshooting Troubleshooting Table Check Trigger Operation Optimum Read Ranges for Different Bar Code Sizes Repair Replacing a Scanner Parts Bar Code Scanner Parts Trigger (Photocell) Accessories Appendix A: Technical Data Specifications A-1 Scanner A-1 Scanner Dimensions A-3 Trigger A-3 Bar Code Symbologies A Nordson Corporation

5 BC5100 Bar Code Scanner 1 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: using incompatible materials making unauthorized modifications removing or bypassing safety guards or interlocks using incompatible or damaged parts using unapproved auxiliary equipment operating equipment in excess of maximum ratings 2007 Nordson Corporation

6 2 BC5100 Bar Code Scanner 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. Do not operate or service equipment unless you are qualified. Do 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. Keep 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. Relieve (bleed off) hydraulic and pneumatic pressure before adjusting or servicing pressurized systems or components. Disconnect, lock out, and tag switches before servicing electrical equipment Nordson Corporation

7 BC5100 Bar Code Scanner 3 If 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. Obtain 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. To 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. Shut down all equipment immediately if you notice static sparking or arcing. Do not restart the equipment until the cause has been identified and corrected. Do not smoke, weld, grind, or use open flames where flammable materials are being used or stored. Provide adequate ventilation to prevent dangerous concentrations of volatile materials or vapors. Refer to local codes or your material MSDS for guidance. Do not disconnect live electrical circuits while working with flammable materials. Shut off power at a disconnect switch first to prevent sparking. Know where emergency stop buttons, shut off valves, and fire extinguishers are located. Clean, maintain, test, and repair equipment according to the instructions in your equipment documentation. Use 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: Disconnect and lock out electrical power. Close pneumatic shutoff valves and relieve pressure. Identify 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 Nordson Corporation

8 4 BC5100 Bar Code Scanner 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 LogiComm control 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 2007 Nordson Corporation

9 BC5100 Bar Code Scanner 5 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: Scanner Trigger LogiComm control system (control module and touch-screen panel) 2007 Nordson Corporation

10 6 BC5100 Bar Code Scanner 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: Match bar code Mismatch bar code No 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 Nordson Corporation

11 BC5100 Bar Code Scanner 7 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 Figure 3 LA 650 trigger 1. LED indicators 2. Cut-off point adjustment screw 3. Receiver elements 4. Emitter 2007 Nordson Corporation

12 8 BC5100 Bar Code Scanner 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. Application Verify bar codes on high-speed production lines. Verify bar codes on both constant speed and variable speed lines. Verify bar codes in either ladder or picket-fence orientation of the bar code. Verify different bar codes with the same scanner. Stop the parent machine upon bad code detection. Eject or mark products with detective bar codes. Applications Explanation 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. The system is not affected by changes in the line speed. 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. The system can read any of the following codes: Code 39 Code 128 UPC/EAN Codabar Code 93 Pharmacode (from 2 16 bars) Bobst Code (from 2 16 bars) Interleaved 2 of 5 Whenever a bad code is detected, the LogiComm control system can be programmed to issue a machine stop. 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 Nordson Corporation

13 BC5100 Bar Code Scanner 9 Installation Check the Parts Inventory 1. Verify shipment of the following components: one scanner and a scanner interconnect cable one trigger and a trigger cable LogiComm control system with the master control module with bead verification capability mounting 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 Location Factor Best opportunity for scanning bar code Sufficient space for mounting Avoiding interference from glue assist lines Reduction of reflected light Protection of cables Protection from dust and moisture 1. Consider the following recommendations and requirements in choosing a location for the scanner. Recommendation or Requirement Select a location where the code is fully visible to the scanner. On carton folder glue machines, the best opportunity is often just prior to or after the glue flap pre-break section. Consider 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. Refer to Technical Data, Appendix A for scanner dimensions. Locate scanner so that no glue assist lines pass through the scan line. 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. Protect the connecting cable from any moving machine parts and passing products. Choose a location that meets IP54 requirements Nordson Corporation

14 10 BC5100 Bar Code Scanner Select a Scanner Location (contd) 2. Position the scanner so that the bar code label will pass through the scan line. If a picket-fence orientation is used, align the scan line so that half of each bar is above the line and half below, see 1 in Figure 4. If a ladder orientation is used, align the scan line so that the code is centered on the scan line, see 2 in Figure 4. a a X b b X X 1 X Figure 4 Correct label alignment 2 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 2007 Nordson Corporation

15 BC5100 Bar Code Scanner Set the distance from the scanner window to the surface of the product. For Pharmacode and Bobst code, set the distance at 127 mm (5 in.). For 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 mm (4 6 in.). 127 mm (5.0 in.) 1 Figure 5 Distance from scanner to product surface 1. Product surface 2007 Nordson Corporation

16 12 BC5100 Bar Code Scanner 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: Pitching 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 Skewing the scanner approximately 10 degrees from the vertical in either direction) as shown in Method B in Figure Figure 6 Method A Two ways to avoid reflected light Method B 1. Product surface 2. Approximately 10 from line parallel to product surface 3. Approximately 10 from line perpendicular to product surface 2007 Nordson Corporation

17 BC5100 Bar Code Scanner 13 Select a Trigger Location 1. Consider the following recommendations and requirements in choosing a location for the trigger: Location Factor Sensing speed Sensing range Interference with scanner operation Protection of cables Protection from dust and water Recommendation or Requirement Position the trigger lens so that it can sense the substrate at a line speed higher than 900 m/min (2953 ft/min). Position the trigger lens so that it can sense from mm ( in.). Make sure that the light from the trigger does not shine (or is not reflected) into the scanner. Select a location that protects cables from any moving machine parts and passing products. 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 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 Nordson Corporation

18 14 BC5100 Bar Code Scanner Select a Trigger Location (contd) 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 Nordson Corporation

19 BC5100 Bar Code Scanner 15 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 Figure 9 Mounting the trigger and the scanner 1. Trigger 2. Scanner 3. Folding carton 4. Flap guide 2007 Nordson Corporation

20 16 BC5100 Bar Code Scanner 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 2007 Nordson Corporation

21 BC5100 Bar Code Scanner 17 Use the following instructions to connect the scanner and trigger to the control module. 1. Connect one end of the scanner interconnect cable to the 15-pin scanner connector. Connect the other end of the cable to the Smart Sensor connector (high density D-SUB, 15-pin connector) on the control module s verification I/O bank. 2. Connect the trigger cable to the TRIGGER connector on the control module s verification I/O bank. If necessary, use one of the trigger extension cables to make the connection. 3. Connect the encoder cable to the ENCODER connector on the control module s master I/O bank. 4. Connect the machine stop output cable from the machine stop output relay box to the SYSTEM I/O input on the master I/O bank. 5. Connect the LogiComm control system components according to the instructions in the LogiComm Control System manual and the Touch-screen Panel Installation for Basic and Expanded Systems instruction sheet Nordson Corporation

22 18 BC5100 Bar Code Scanner Trigger Setup The LA 650 trigger is shipped with a default cut-off distance setting of 50 mm (1.96 in.). This gives optimal sensing performance at a sensing distance of about 30 mm (1.18 in.). The cut-off distance is adjustable from mm ( in.). Objects lying beyond the cut-off distance are ignored, even if they are highly reflective. However, it is recommended to have a dark background or, even better, free space beyond the substrate, especially when processing transparent plastics Figure 11 LA 650 trigger setup 1. Receiver elements 2. Lens 3. Object 4. Cut-off distance 5. Background 6. Sensing range 7. Emitted light beam Adjust Cut-off Distance 1. Use a small screwdriver in the adjustment screw. See Figure 3 for the cut-off point adjustment screw location. 2. Turn right to increase or left to decrease the cut-off distance. 3. Adjust the cut-off distance until the threshold is reached and the yellow light indicator changes state. NOTE: For optimal sensing performance, the direction of travel of the substrate should always follow the axis from the receiver elements towards the light emitter, see Figure 12 for the recommended direction of travel. Figure 12 Recommended substrate travel 2007 Nordson Corporation

23 BC5100 Bar Code Scanner 19 System Startup Check List Before setting up the system, make sure of the following: The trigger and the scanner are connected to the control module. The touch-screen panel is turned on. The control module is turned on Nordson Corporation

24 20 BC5100 Bar Code Scanner System Setup Follow the sequence of screens on the touch-screen panel to set the BC5100 and the LogiComm control system for operation. Figure 13 Sequence of screens to enter the BC5100 screens 2007 Nordson Corporation

25 BC5100 Bar Code Scanner 21 BC5100 Screens When you select BC5100 as a sensor type in the Smart Sensor Select screen (Setup Page 3 of 4), sensor number 6 on the Main Menu will change in appearance. Figure 14 Sensor #6 on the Main Menu 2007 Nordson Corporation

26 22 BC5100 Bar Code Scanner BC5100 Screens (contd) Press the sensor number 6 button on the Main Menu, and the following screen appears: Figure 15 BC5100 screen 2007 Nordson Corporation

27 BC5100 Bar Code Scanner 23 BC5100 Screen Components The following table explains the functionality of each component in the BC5100 menu screen. This button/component Active/Inactive button Trigger button Learn Code button Inspection Parameters button Clear Code Error button Properties button Reset Counter button No Match counter reading Match counter reading No Read counter reading Current code Match code Does this Activates or deactivates bead verification for that specific sensor. Selects a trigger for use with the sensor. Obtains a good code from the next bar code, and this code is considered good for the products in the production line. Allows the user to set parameters for the BC5100 sensor. Refer to Inspection Parameters. Resets the screen displaying the mismatched code, and proceeds to the next code. Allows the user to set smart sensor properties. Refer to Properties. Resets the counter reading to zero. Displays the number of products whose bar codes do not match the learn code. Displays the number of products whose bar codes match the learn code. Displays the number of products whose bar codes could not be read. Indicates that the code responds to the following conditions: Match Mismatch No read Indicates the reference bar code that the system has been taught Nordson Corporation

28 24 BC5100 Bar Code Scanner Inspection Parameter Screen Components Press the Inspection Parameters button on the BC5100 menu screen, and the following screen appears: Figure 16 Inspection Parameter screen The following table explains the functionality of each component in the BC5100 Inspection Parameter screen. This button/component Pharmacode Enabled/Disabled Machine Action On No Match On No Read Does this Enables or disables pharmacode. Allows the user to program the system response by setting the following parameters: On No Match On No Read Enables or disables (Yes or No) the ejector to reject a product. Sets the reject parameter to Yes or No. NOTE: Under Smart Sensor Machine Stop After 1 Defect, the Machine Stop output activates a product with a bad bar code by setting the following conditions: On No Match: Yes or No On No Read: Yes or No 2007 Nordson Corporation

29 BC5100 Bar Code Scanner 25 Properties Screen Components Press the Properties button on the BC5100 menu screen, and the following screen appears: Figure 17 Properties screen The following table explains the functionality of each component in the Properties screen. This button/component Trigger Settings Sensor Beep Control Software Versions Does this Select from any of the following trigger setting options: Light On Dark On NOTE: Light On activates the trigger at the leading edge of the product. The leading edge is the edge or face of the product that the trigger senses first on the production line. This setting is also used as the starting point for the delay measurement. Dark On activates the trigger at the trailing edge of the product. The trailing edge is the product edge that causes the trigger to stop sensing the product as the product passes by the trigger. Allows the user to program the sensor beep control from any of the following options: Beep Off Beep On Good Read Beep On No Read Provides the software versions and application version of the scanner Nordson Corporation

30 26 BC5100 Bar Code Scanner Operation Prior to routine operation, make sure that the system learns a good bar code. The system uses this bar code to check each product it reads. When the leading edge (or some other selected edge) of a product activates the trigger, the read cycle begins. The sensor repeatedly reads the target area on the product, looking for a bar code that matches the good code the system was taught. If a match is found, the Match counter will display a numeric value on the BC5100 menu screen. When the No Match or No Read counters display a numeric value, it indicates the any of the following conditions: the code is either missing or significantly out of registration the code cannot be reliably read the code does not match the reference code taught to the system. Scanner Indicators Figure 18 Scanner indicators Item Indicator Function of Key or Light 1 POWER light (red) Turns on when power is applied to the scanner. 2 Read rate lights Not used. 3 Status light Not used. 4 GOOD CODE light Turns on with each readable code. Beeper (not shown) Beeps with each bar code that is successfully read. However, a code that can be successfully read can still be a bad code if it does not match the reference code that was taught to the system Nordson Corporation

31 BC5100 Bar Code Scanner 27 Start the System 1. Make sure that the LogiComm control system is powered on. 2. Start the production line and run it at jog speed. 3. Stop the line when the entire bar code is within the scan line. 4. Start the production line. 5. Press Learn Code on the BC5100 menu screen. 6. Verify that the code is the correct bar code before teaching it to the system. 7. Press Teach Active Sensors on the Main Menu screen. 8. In the BC5100 menu screen, observe the data in the following counters: Match No Match Defects No Read NOTE: If the Match counter has zero defects, go to step 9. If the No Match Defects counter displays zero (0), repeat the Learn Code procedure, making sure that the code used to teach the system is good (and properly designed) and that the product is stationary during the teach process. 9. Increase the line speed to normal operating speed. Allow the line speed to stabilize and ensure that the feed system is stable. NOTE: Examine the displayed bar code image. Make sure that at least one product is sensed after the learn product before a new bar code image is displayed. If the displayed image is very dark, the distance from the sensor to the product needs to be adjusted. Adjust the distance until the image is legible Nordson Corporation

32 28 BC5100 Bar Code Scanner Change Products Use the following table as a checklist of possible tasks or procedures to perform whenever there is a change in the production process, whether it is a product changeover or some minor change. Task or Procedure Change the sensor location Change the sensor angle to the product surface Do a trial run Find the removal point for defective products Teach tracking distances Teach the system a good bar code When to Perform When the product size or shape changes or the bar code size or location changes, ensure that the distance from the sensor window to the code is about 15 mm (0.59 in.). When the reflectivity changes enough to affect the performance of the sensor. When the sensor location has changed or when the bar code has been changed in any way. Anytime the product size or shape changes or when the normal operating speed has been changed. Anytime the distance between the trigger and the pre-eject sensor changes. If the product size or shape changes, change the position of the pre-eject sensor to achieve smooth ejection or marking in the correct place. Whenever there is any change in the production process, product design, or bar code. A new reference code must be taught each time the system is powered up Nordson Corporation

33 BC5100 Bar Code Scanner 29 Maintenance WARNING: Allow only qualified personnel to perform the following tasks. Follow the safety instructions in this document and all other related documentation. Clean the Scanner Windows As part of routine operation, periodically clean the scanner windows as described in the following procedure. The buildup of dust, dirt, or film on either window can alter the performance of the scanner. The frequency that cleaning is required may vary, depending on the operating environment in which the scanner is used. At the minimum, clean the window once a week. 1. Turn off the control module power. WARNING: Never look directly into the laser light source or point the beam at other people. Looking at the source of the laser beam can cause serious injury to the eyes. 2. Clean the scanner windows with a clean, dry Q-tip or cotton cloth. 3. Turn on the control module power Nordson Corporation

34 30 BC5100 Bar Code Scanner Troubleshooting WARNING: Allow only personnel with appropriate training and experience to operate or service the equipment. The use of untrained or inexperienced personnel to operate or service the equipment can result in injury, including death, to themselves and others, and damage to the equipment. WARNING: If this equipment is used with other Nordson equipment, refer to the manuals provided with that equipment for instructions and applicable precautions. Failure to observe this warning may result in personal injury or death. Troubleshooting Table Problem Possible Cause Corrective Action Good code not taught. 1. System detects bad codes when codes are good Incorrect code taught. Scanner knocked out of position. Scanner impaired by reflection. Bar code printing is out of registration or the product is skewed. Scanner lens dirty or blocked. Carton flutter is causing bar code movement. Teach a good code. This must be done each time the system is turned on. Verify that the system was taught the correct code and that no bar-like printing near the actual code can be read by the scanner as a good code. Check the position of the scanner. Adjust the scanner position. Refer to Select a Scanner Location. Verify that the code position has not shifted relative to the scanner. Clean or remove obstruction. Refer to Clean the Scanner. Stabilize the carton so that the distance from the scanner to the bar code remains the same during the read cycle and from one product to the next. Continued Nordson Corporation

35 BC5100 Bar Code Scanner 31 Problem Possible Cause Corrective Action 1. System detects bad codes when codes are good, contd. 2. System starts reporting errors at higher line speeds The distance of scanner to product not within read range. Trigger activating read cycle at the wrong time. Trigger activated more than once per product (double-triggering). System reporting bad codes at higher line speeds. Wrong colors on bar code print. The bar code is not properly designed. Poor trigger location. Product not stable at high line speeds. Distance of scanner to product not within read range. Line speed too fast. Bar code not properly designed. Correct scanner range. Refer to Figure 19 to find the optimum distance. Verify that the trigger activates the read cycle as the bar code enters the read range. Refer to Select a Trigger Location. Determine whether a cutout or some printing is causing a second read cycle to occur during each product. If this is the case, relocate the trigger. Refer to System Starts Reporting Errors at Higher Line Speeds, problem 2, given next. Print the code in black against a white background. Orange, yellow, or red codes cannot be read at all. Alternatives to a black code are dark gray, dark blue, or dark green. Alternatives to a white background are a muted beige, yellow, or red. Check the bar code design. Refer to Select a Trigger Location. Stabilize the product so that the distance from the scanner to the bar code remains the same during the read cycle and from one product to the next. Correct scanner range. Refer to Figure 19 to find the optimum distance. Refer to Check for a Sufficient Number of Scans. Check the bar code design. Continued Nordson Corporation

36 32 BC5100 Bar Code Scanner Troubleshooting Table (contd) Problem Possible Cause Corrective Action 3. System fails to detect The trigger is out of position. Check the alignment of the trigger bad bar codes and adjust. 4. System not rejecting or marking products with defective codes 5. System rejecting or marking the wrong products Trigger cable is loose or disconnected at the LogiComm control module. Improper trigger sensitivity. Trigger lens dirty or blocked. Trigger or trigger cable defective. Scanner not receiving power. System is detecting bad codes but not rejecting or marking these products. Reject not enabled. Reject signal not reaching control module. Problem in the LogiComm control system. BC5100 trigger knocked out of position. The procedure for teaching the tracking distances was not correctly performed. Problem in the LogiComm control system. Plug the cable back into the appropriate connector. Refer to Trigger Setup. Clean or remove obstruction. Replace. Check the power light on the scanner. If it is off, first check the continuity of the connecting cables (the scanner cable and the interconnect cable). If these are good, replace the scanner. Verify settings. Enable the reject function at the touch-screen panel. Enable the reject function by pressing the Reject Control button on the touch-screen panel. Configure the Reject Control settings. Check that the pre-eject trigger and encoder are working. Refer to the LogiComm Control System manual or the embedded Help in the touch-screen panel to troubleshoot. The trigger must be returned to its original position or the new tracking distance must be taught to the system. Clear the machine of all products and cover the scanner window when you teach tracking. Refer to the LogiComm Control System manual or the embedded Help in the touch-screen panel to troubleshoot. Continued Nordson Corporation

37 BC5100 Bar Code Scanner 33 Problem Possible Cause Corrective Action Machine stop not enabled. 6. Machine stop function not working 7. Machine cannot be restarted after a stop Problem in the LogiComm control system. The machine-stop contacts in the LogiComm control system need to be reset. Enable the machine stop function by pressing the Machine Control Settings button on the touch-screen panel. Configure the machine stop settings. Refer to the LogiComm Control System manual or the embedded Help in the touch-screen panel to troubleshoot. Enable the machine stop function by pressing the Machine Control Settings button on the touch-screen panel. Check Trigger Operation 1. Slow down the production line until you can observe the yellow TRIGGER LED on the control module turn on and off with each passing product. 2. Verify that the LED turns on when the trigger detects the product s leading edge (or some other selected edge) and turns off when it detects the trailing edge (or some other selected edge). If the light fails to turn on or if it turns on and off more than once, refer to Trigger Setup under Installation Nordson Corporation

38 34 BC5100 Bar Code Scanner Optimum Read Ranges for Different Bar Code Sizes inches 0 0 millimeters : a b 2: a b c d millimeters inches Figure 19 Optimum bar code size read range 1. Narrow bar width: High density 5 mil (0.127 mm) 7.5 mil (0.191 mm) 2. Narrow bar width: Low density 7.5 mil (0.191 mm) 10 mil (0.254 mm) 15 mil (0.381 mm) 20 mil (0.508 mm) 2007 Nordson Corporation

39 BC5100 Bar Code Scanner 35 Repair WARNING: Allow only personnel with appropriate training and experience to operate or service the equipment. The use of untrained or inexperienced personnel to operate or service the equipment can result in injury, including death, to themselves and others, and damage to the equipment. WARNING: If this equipment is used with other Nordson equipment, refer to the manuals provided with that equipment for instructions and applicable precautions. Failure to observe this warning may result in personal injury or death. Replacing a Scanner CAUTION: Failure to observe may result in equipment failure. WARNING: Do not open the scanner housing when power is applied to the scanner. Opening the scanner could expose you or others to eye injury from the laser light. With the housing open, the laser light intensity can reach a power of 7 mw. WARNING: Never look directly into the laser light source or point the beam at other people. Looking at the source of the laser beam can cause serious injury to the eyes. 1. Make sure that the LogiComm control system is turned off. 2. Wait five seconds for the power supply voltage to bleed off. 3. Disconnect the scanner interconnect cable from the cordset on the scanner. 4. Remove the scanner from its mounting and replace it with a new one. 5. Attach the cordset of the new scanner to the interconnect cable. 6. Turn on the LogiComm control system Nordson Corporation

40 36 BC5100 Bar Code Scanner Parts To order parts, call the Nordson Customer Service Center or your local Nordson representative. Use this five-column parts list, and the accompanying illustration, to describe and locate parts correctly. BC5100 Bar Code Scanner Parts Part Description SCANNER HEAD, BAR CODE, W/ LABEL, BC CABLASSY, 15POS, HI-DENSTY, DSUB, 15FT, SHLD CABLASSY, 15POS, HI-DENSTY, DSUB, 25FT, SHLD BRACKET ASSY, TOP MOUNT, LA5100 Trigger (Photocell) Part Description PHOTOCELL, LA650, NPN/PNP BRACKET, FOR LA650 PHOTOEYE CABLE, EXT, PHOTOCELL, STR. 5M, LOGICOMM Accessories Part Description CABLEASSY, 15PIN D SUB TO WIRES, 5 METERS CABLEASSY, DSUB, 15POS, M/F, 15FT ADAPTER, MACHINE STOP RELAY, LOGICOMM LIGHT TOWER, LED, 4LIGHT W/SIREN, LOGICOMM CABLEASSY, M/F, 7PIN DIN, LOGICOMM EJECTOR, ROTARY, 230 VAC 3PH, CCW (OP SIDE) EJECTOR, ROTARY, 400/480 VAC 3PH, CCW (OPSIDE) EJECTOR, ROTARY, 230 VAC 3PH, CW (DRV SIDE) EJECTOR, ROTARY, 400/480 VAC 3PH, CW (DRVSIDE) 2007 Nordson Corporation

41 Technical Data A-1 Appendix A Technical Data Specifications NOTE: For most bar code designs, the picket-fence orientation allows higher line speeds because more scans can be completed during the scan cycle. Scanner Item Specification Line speed Up to 207 m/min (680 ft/min) Scan rate 2000 scans/second Maximum resolution mm (7.5 mil or in.) Minimum quiet zone Pharmacode/Bobst code: 7 mm All other codes: 5 times the width of the narrowest bar Number of bars Pharmacode/Bobst code: from 2 to 16 bars All other codes: specification does not apply Recommended range Pharmacode/Bobst code: fixed at 127 mm (5.0 in.) All other codes: mm ( in.) Bar code orientation Ladder or picket fence Readable symbologies Code 39 Code 128 UPC/EAN Codabar Code 93 Pharmacode Bobst code Interleaved 2 of 5 Continued Nordson Corporation

42 A-2 Technical Data Scanner (contd) Orientation Item Maximum line speed Scan rate Maximum resolution Skew angle Pitch angle Distance to substrate Minimum quiet zone Sensor mounting Operating temperature Required warm up time Enclosure rating IP 54 Dimensions LogiComm connector Light source Emissions Safety class Ladder or picket fence Specification 425 m/min (1400 ft/min) in picket fence orientation 150 m/min (500 ft/min) in ladder 25 mm (0.98 in.) bar height 2000 per second mm (0.01 in.) 40 degrees maximum 50 degrees maximum Pharmacode/Bobst code: 127 mm (5.0 in.) fixed All other codes: 100 to 200 mm (3.94 to 7.87 in.) minimum distance required Pharmacode/Bobst code: 7 mm (0.28 in.) All other codes: 5 times the width of the narrowest bar Matte Surface: 90 to surface for matte or non-glossy surface Glossy surface/reflective surface: 10 off from line parallel to product surface (pitching) 10 from line perpendicular to product surface (skewing) 0 60 C ( F) 15 minutes minimum x x mm (2.28 x 3.0 x 1.63 in.). Also see figure A-1. Smart verification sensor (15 pin D-Sub) Semiconductor visible laser diode (650 nm nominal) radiated: CISPR22 EN55022: 1994 Class A conducted: CISPR22 EN055022: 1994 Class A CDRH Class II 2007 Nordson Corporation

43 Technical Data A-3 Scanner Dimensions mm (2.28 in.) mm (3.0 in.) mm (1.63 in.) Figure A-1 Dimensions Trigger Item Sensing Speed Sensing Range Sensing Beam Indicators Connections Operating condition temperature Specification More than 900 m/min (2953 ft/min) line speed mm ( in.) Visible red laser Two LED indicators indicate the following conditions: Green steady: Power on Green flashing: Output overload Yellow steady: Substrate sensed Yellow flashing: Marginal excess gain. Readjust the trigger by moving it closer to the substrate. 5-Pin, 180 connector plug, NPN and PNP outputs. 10 C +50 C ( F) Relative humidity: 90% (at 50 C, non-condensing) 2007 Nordson Corporation

44 A-4 Technical Data Bar Code Symbologies 2007 Nordson Corporation

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