Accubar Bar Code Verifier

Transcription

1 Accubar Bar Code Verifier Customer Product Manual Issued 2/10 NORDSON CORPORATION DULUTH, GEORGIA USA

2 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 February 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, AquaGuard, Asymtek, Automove, Autotech, Baitgun, Blue Box, CanWorks, Century, CF, Clean Coat, CleanSleeve, CleanSpray, Control Coat, Coolwave, Cross-Cut, Cyclo-Kinetic, Dispensejet, DispenseMate, DuraBlue, Durafiber, Durasystem, Easy Coat, Easymove Plus, Econo-Coat, EFD, ETI, Excel 2000, FlexiCoat, Flexi-Spray, Flex-O-Coat, Flow Sentry, Fluidmove, FoamMelt, FoamMix, Heli-flow, Helix, Horizon, Hot Shot, Isocoil, Isocore, Iso-Flo, JR, KB30, Kinetix, Little Squirt, Magnastatic, March, MEG, Meltex, Microcoat, Micromark, MicroSet, Millennium, Mini Squirt, Moist-Cure, Mountaingate, MultiScan, Nordson, OmniScan, OptiMix, Package of Values, PatternView, PermaFlo, Plasmod, PluraFoam, Porous Coat, PowderGrid, Powderware, Prism, ProBlue, Pro-Flo, ProLink, Pro-Meter, Pro-Stream, RBX, Rhino, Saturn, SC5, S. design stylized, Seal Sentry, Select Charge, Select Coat, Select Cure, Slautterback, Smart-Coat, Solder Plus, Spectrum, Speed-Coat, Spraymelt, Spray Squirt, Super Squirt, Sure Coat, Tela-Therm, Tracking Plus, Trends, Tribomatic, Ultrasaver, UniScan, UpTime, Veritec, VersaBlue, Versa-Coat, Versa-Screen, Versa-Spray, Walcom, Watermark, and When you expect more. are registered trademarks of Nordson Corporation. AeroDeck, AeroWash, Apogee, ATS, Auto-Flo, AutoScan, BetterBook, CanNeck, Chameleon, Check Mate, ColorMax, Controlled Fiberization, Control Weave, CPX, Dry Cure, Dura-Coat, DuraPail, Dura-Screen, Easy Clean, Eclipse, EcoDry, e.dot, E-Nordson, Equi=Bead, ESP, e Stylized, Fillmaster, Fill Sentry, Gluie, HDLV, icontrol, iflow, Ink-Dot, ion, Iso-Flex, itrend, itrax, KVLP, Lacquer Cure, Maxima, MicroFin, MicroMax, Minimeter, Multifil, OptiStroke, Origin, PatternPro, PluraMix, Powder Pilot, Powercure, Primarc, Printplus, Process Sentry, Pulse Spray, PurTech, Ready Coat, Royal Blue, Scoreguard, Select Series, Sensomatic, Shaftshield, SheetAire, Spectral, Spectronic, Speedking, Spray Works, Summit, SureBead, Sure Brand, Sure Clean, Sure-Max, Swirl Coat, Tempus, ThruWave, Trade Plus, Trak, TrueBlue, Ultra, Ultrasmart, Universal, Vantage, Viper, 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. All rights reserved

3 Table of Contents i Table of Contents Description System Components Scanner Console Trigger Other Components System Capabilities Applications Features Installation Check the Parts Inventory Select a Scanner Location Select a Trigger Location Select a Console Location Mount the Equipment Connect All Cables Setup Adjust the Trigger Standard Trigger Adjustment Fiber-optics Trigger Adjustment Trial Run Find the Removal Point for Defective Products Teach the Tracking Distance Operation Accubar Console Controls and Indicators Scanner Indicators Start the System Restart the System After a Machine Stop Change Products Clean the Scanner Windows Troubleshooting System Wiring Diagram Troubleshooting Table Check for a Sufficient Number of Scans Formula for Picket-Fence Label Orientation Formula for Ladder Label Orientation Check Trigger Operation Repair Replacing the Line Fuse Replacing the Machine Stop Relay Replacing a Scanner

4 ii Table of Contents Parts Using the Illustrated Parts List Major Components Bracket Components Cables Recommended Spare Parts Technical Data Specifications System Control Console Scanner Trigger Equipment Dimensions Control Console Scanner Bar Code Selection A-1 Selecting a Symbology That Accubar Can Verify A-2 Meeting External Requirements or Standards A-2 Encoding the Information A-4 Encoding Variable-Length Data A-4 Minimizing the Code Space Requirement A-5 Maximizing Verification Security A-6 Selecting a Symbology that is Easy to Print A-7 Bar Code Design A-8 Deciding on the Print Size for the Code A-8 Providing a Sufficient Quiet Zone A-8 Choosing the Code Orientation A-9 Selecting the Color and Contrast for the Code A-9 Printing Considerations A-9 Ensuring a High Quality Substrate A-9 Achieving the Required Print Quality A-10

5 Accubar Bar Code Verifier 1 Accubar Bar Code Verifier Description The Accubar Bar Code Verifier monitors bar code accuracy in high speed packaging and converting operations. Accubar detects unreadable, missing and incorrect codes. Accubar uses a laser diode scanner capable of 2000 scans per second that can monitor any of eight bar code symbologies at line speeds up to 425 mpm (1400 fpm). It indicates the status of each product with a good code or bad code indicator. Each time it finds a defective code, it turns on two outputs. One output can be used to stop the parent machine or its feed section. The other output is used for linking the Accubar system to a Nordson G-NET verification system. When the Accubar system is used with a G-NET system, products with defective bar codes are automatically tracked and either ejected from the line or marked for removal. G-Site Interface (not part of system) Bad-Code Output Cable Console Machine-stop Cable Scanner Trigger A Figure 1 Key Components of the Accubar Bar Code Verifier

6 2 Accubar Bar Code Verifier System Components The Accubar system has three major components: laser scanner control console trigger (photo eye) The system includes the hardware and cables used to mount and connect these components. 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. If a sufficient number of good reads is obtained, the scanner sends a good-read signal to the Accubar console. The scanner recognizes eight different bar code symbologies and reads codes in either the ladder or the picket-fence orientation. Scanner Bar Code Scan Line Figure 2 LA5100 Scanner

7 Accubar Bar Code Verifier 3 Console The console provides the controls and indicators required to operate the Accubar system. It also contains a power supply, output relays, and a microprocessor. The microprocessor controls the automatic teach function and stores the reference code. The system detects a bad code: when the print quality of the code is so defective that the code is unreadable when the code is in the wrong position or altogether missing when the wrong code (one other than the reference code) is detected. Console Operator Panel Figure 3 Accubar Console

8 4 Accubar Bar Code Verifier Trigger A diffuse-mode photo eye is used as a trigger to begin and end the scan cycle. The trigger signals the system to begin the scan cycle when it senses the leading edge (or some other selected edge) of the product. Scanning continues until the trailing edge (or some other selected edge) of the product is sensed. Two types of photo eyes are available for the trigger. The standard trigger provides a small spot diameter and has a response time of 300 microseconds. The optional fiber-optics photo eye can be used when mounting space is limited or when a faster response is required. The fiber-optics trigger can be set for either a 50 or a 500 microsecond response time. Fiber-Optics Zone Trigger Standard Zone Trigger Figure 4 Standard and Fiber-Optics Triggers Other Components The Accubar system also includes cables to connect the major components including two output cables, one for stopping the machine and one for sending a bad-code output signal to a Nordson G-NET verification system. A variety of mounting components is available.

9 System Capabilities Accubar Bar Code Verifier 5 This section explains the key applications of the Accubar system and some of its major features. The key industries in which the system is used include folded carton manufacturing, case sealing, and container filling. Applications 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. Check die-cut or print registration. Stop the parent machine upon bad code detection. Eject or mark products with detective bar codes. Explanation The scanner operates at 2000 scans per second at line speeds as high as 425 mpm (1400 fpm) for codes in the picket-fence orientation. The system is not affected by changes in line speed. The system can read bar codes in either the picket-fence or the ladder orientation. However, for most bar code designs, 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). The system can read any of the following codes: UPC/EAN Code 39 Interleaved 2 of 5 Code 93 Code 128 Codabar Pharmacode (from 3 16 bars) Bobst Code (from 3 16 bars) The system can be used to monitor bar code movement in the direction perpendicular to the scan line when picket-fence orientation is used. For example, if a bar code is 6 mm (0.25 in.) high and the scan line is centered so that 3 mm (0.13 in.) of each bar is above the scan line and 3 mm is below, the system will generate a fault anytime the code position shifts more than 3 mm (0.13 in.) in either direction that is perpendicular to the scan line. At this point the scanner can no longer read the code because it has moved outside the scan line. Whenever a bad code is detected, the system activates an output that can be used to stop a machine or its feed section. Whenever a bad code is detected, the system activates an output that can be used to send a signal to a G-NET detection system. When the G-NET system receives a signal from the Accubar system, it automatically tracks the product and either ejects it or marks it for removal.

10 6 Accubar Bar Code Verifier Features Feature Automatic teaching Enable/disable alarm key Quick-disconnect cables Easy-to-use central control panel Use of international symbols on panel Description The system captures the next good bar code and uses it as the reference code. The alarm function can be quickly enabled or disabled by pressing a single key. Electrical installation can be quickly completed by plugging in the quick-disconnect cables. Troubleshooting is facilitated. Operation requires the use of only three keys and six indicators. The system turns on either a GOOD CODE or a BAD CODE indicator for each product that is scanned. Non-English speaking personnel can quickly understand how to operate the system. Installation Check the Parts Inventory 1. Verify shipment of the following components: one Accubar console one LA5100 scanner and a scanner interconnect cable one trigger (photo eye) and a trigger cable mounting hardware for the major components (optional) one machine-stop cable one fault-output cable two power cables (one 115 VAC and one 230 VAC cable). 2. Inspect the equipment for any damage that may have occurred during shipping. Report any problems to a Nordson representative.

11 Accubar Bar Code Verifier 7 Select a Scanner Location 1. Consider the following recommendations and requirements in choosing a location for the scanner. 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 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. With a G-NET system, consider a location soon after the feed section so the feeding of products can be stopped quickly when defective bar codes are detected on the line. Refer to Technical Data 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 photo eye. 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. 2. Position the scanner so the bar code label will pass through the scan line. If a picket-fence orientation of the code is used, align the scan line so that half of each bar is above the line and half below. If a ladder orientation of the code is used, align the scan line so that the code is centered on the scan line. Direction of Line Travel Direction of Line Travel X Scan Line Scan Line X X Picket-Fence Orientation of Bar Code X Figure 5 Correct Label Alignment for Picket-Fence and Ladder Oriented Labels Ladder Orientation of Bar Code

12 8 Accubar Bar Code Verifier Select a Scanner Location (contd) 3. Set the distance from the scanner window to the surface of the product. For Pharmacode and Bobst code, the distance should be fixed at 127 mm (5 in.). For all other codes, set the distance at 127 mm (5.0 in.), but ensure that the mounting bracket allows the distance to be adjusted from mm (4 6 in.). 127 mm (5.0 in.) Figure 6 Product Surface Distance from Scanner to Product Surface If the bar code is in the picket-fence orientation, ensure that the scanner is positioned correctly in relation to the direction of product flow. Figure 7 shows the correct position of a scanner that is mounted above or below the product surface. NOTE: If a bar code in the picket-fence orientation does not approach the scanner on the side where the cable connects to the scanner, the scanner will not operate properly. If the bar code is in the ladder orientation, the direction of product flow does not matter. Product Flow Back of Scanner Product Flow Scanning from Above Product Scanning from Below Product Figure 7 Scanner Position for Picket-Fence Bar Codes A

13 Accubar Bar Code Verifier 9 5. See Figure 8. 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 slightly by either: a. Pitching the scanner approximately 10 degrees from the horizontal (in either direction) as shown. Avoid angles from 3 5 degrees, which can cause increased reflection. b. Skewing the scanner approximately 10 degrees from the vertical in either direction) as shown. Method A Method B Product Surface Approximately 10 from Line Parallel to Product Surface Approximately 10 from Line Perpendi to Product Surface Figure 8 Two Ways to Avoid Reflected Light

14 10 Accubar Bar Code Verifier Select a Trigger Location 1. Consider the following recommendations and requirements in choosing a location for the trigger: Location Factor Distance of lens from product surface Interference with scanner operation Avoiding stress on fiber-optic cable Protection of cables Protection from dust and water Recommendation or Requirement (standard trigger) Position the trigger lens mm ( in.) from the product surface. (fiber-optic trigger) Position the trigger lens mm ( in.) from the product surface. Make sure that the light from the trigger does not shine (or is not reflected) into the scanner. Avoid excessive bending of the fiber-optic lens cable. The inside bend radius should not be less than one inch. 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 9 and 10. Outside Limit of Read Range Position of Bar Code Where Successful Reads Start Occurring Scan Line Edge of Product That Activates Trigger Carton or Other Product Optimum Location for Trigger Direction of Line Travel Figure Optimum Location of Trigger for Picket-Fence Oriented Bar Codes For bar codes with picket-fence orientation, successful reads start when the entire code (including quiet zones) is within the scan line.

15 Accubar Bar Code Verifier 11 Scan Line Outside Limit of Read Range Position of Bar Code Where Successful Reads Start Occurring Edge of Product That Activates Trigger Optimum Location for Trigger Carton or Other Product Figure 10 Direction of Line Travel Optimum Location of Trigger for Ladder Oriented Bar Codes For bar codes with ladder orientation, successful reads start when the leading edge of the code first crosses the scan line. Select a Console Location Location Factor Ease of operation Sufficient cable lengths Protection of console from damage Protection from dust and water Sufficient space for mounting Recommendation or Requirement Locate at eye level for optimum viewing. Locate where all the connecting cables are long enough to reach from the external components (the scanner and the trigger) to the console. Verify also that the power cable is long enough to reach a power outlet and, if the system is used with a G-NET detection system, verify that the output cable will reach the G-SITE network interface. Protect the console from personnel moving about and from moving equipment or other objects. Select a location that meets IP54 requirements. Refer to Technical Data for console dimensions.

16 12 Accubar Bar Code Verifier Mount the Equipment 1. Mount the scanner in the selected location using either the bracket components that were ordered with the Accubar system (see Figure 11) or brackets that you supply. 2. Mount the trigger in the selected location. For the fiber-optics trigger, connect the fiber-optics cable to the trigger housing using the instructions that were shipped with the trigger. Trigger Scanner Folding Carton Figure 11 Mounting the Trigger and the Scanner

17 Accubar Bar Code Verifier 13 CAUTION: Failure to observe may result in equipment damage. 3. Mount the Accubar console in the selected location. Use either the mounting pole and two clamps and two 1 / 4-20 screws that were ordered with the Accubar system or brackets that you supply. Mounting Pole Accubar Console Access Hole for Set Screw Mounting Surface Mounting Clamp Figure 12 Mounting of Accubar Console with Nordson Brackets

18 14 Accubar Bar Code Verifier Connect All Cables 1. Connect one end of the scanner interconnect cable to the 15-pin scanner connector. Connect the other end of the cable to the connector labeled LASER on the back on the Accubar console. ACCUBAR CONSOLE MACHINE STOP PARENT MACHINE LASER SCANNER SYSTEM TRIGGER 115/230 VAC 50/60 HZ BAD CODE OUTPUT LASER PHOTOEYE POWER G-NET SYSTEM G-SITE INTERFACE FORCE 1 SENSOR A Figure 13 Accubar System Wiring Diagram 2. Connect the trigger cable to the connector labeled PHOTOEYE on the back of the console. If necessary, use one of the trigger extension cables to make the connection. 3. Connect either the fault output cable or the machine stop output cable, or both, depending on the application. See the following table for applicable instructions. Objective Operate the Accubar system as a standalone system that stops the machine when products with faulty bar codes are detected. Operate the Accubar system as part of the G-NET system, which ejects or marks products with defective bar codes. Operate the Accubar system as part of the G-NET system and have the systems work together such that the Accubar system detects a product with a defective bar code and stops the feed section of the machine, and the G-NET system ejects the product. Procedure 1. Connect one end of the machine stop cable to the connector labeled MACHINE STOP on the back of the Accubar console. 2. Connect the wires at the other end of the cable to the machine so that it will stop when the machine-stop contacts open. See Figure Connect one end of the fault cable to the connector labeled BAD CODE OUTPUT on the back of the Accubar console. 2. Connect the other end of the cable to the connector labeled FORCE 1 SENSOR on the G-SITE network interface. 1. Connect the machine stop cable as instructed in the top box of this table, but in step 2, connect the wires so they will stop the feed section of the machine instead of machine itself. 2. Connect the fault cable as instructed in the middle box of this table.

19 Accubar Bar Code Verifier 15 Î Î Black (common) White Red (normally closed) Figure 14 Shield Machine Stop Cable Wiring B 3. Select either the 115 VAC or the cable 230 VAC power cables shipped with the Accubar console. Connect one end of the cable to the connector labeled POWER on the back of the Accubar console. Plug the other end of the cable into a 115 VAC or 230 VAC power source (50/60 Hertz). 4. Where possible, tie cables together using wire ties and ensure that all cables are embedded in conduits or raceways along the machine. Make sure that cables are protected from any moving or rotating parts of the machine or from moving products. 5. Label all cables using appropriate names or numbers.

20 16 Accubar Bar Code Verifier Setup Adjust the Trigger Standard Trigger Adjustment 1. Remove the cover from the back of the trigger housing. 2. Select an operating setting: light-operate mode for light-colored or reflective products. dark-operate mode for dark-colored or non-reflective products. Sensitivity Adjustment Screw Alignment/Output Indicator Light/Dark Mode Selector Figure 15 Controls and Indicators on Standard Trigger 3. Set the light/dark mode switch Light-on operation: Turn the mode selector switch fully clockwise. Dark-on operation: Turn the mode selector switch fully counter-clockwise. 4. Stop the production line, place the product on the line opposite the trigger and verify that the red output light is flashing rapidly. If not, adjust the distance of the lens from the product surface until the light is flashing rapidly, keeping within the recommended distance of mm ( in.) 5. Turn the sensitivity adjustment screw until the red output light is turning on and off at the fastest rate: clockwise to increase sensitivity. counter-clockwise to decrease sensitivity. 6. Run the line at jog speed. Verify that the red output light turns on with the leading edge of the product (or some other edge used to activate the trigger) and off with the trailing edge of the product (or some other edge used to deactivate the trigger). 7. Run the line at normal operating speed and verify that the trigger is working correctly. 8. Replace the cover on the back of the trigger housing.

21 Accubar Bar Code Verifier 17 Fiber-optics Trigger Adjustment 1. Decide whether to use the 50 μs (0.05 ms) mode or the 500 μs (0.5 ms) mode. For most applications, the 50 μs mode is best. Signal Strength Display Response Time Selector Output Indicator Power-on Indicator Sensitivity Adjustment Screw Figure 16 Controls and Indicators on Fiber-optics Trigger Check the current setting of the response time selector switch. Turn the switch to the desired setting. 3. Run the production line at normal operating speed. 4. Turn the sensitivity adjustment screw until the yellow output light is turning on and off with each product: clockwise to increase sensitivity. counter-clockwise to decrease sensitivity.

22 18 Accubar Bar Code Verifier Trial Run Use this procedure to check system operation and fine-tune it for the best performance. 1. If the ALARM ENABLE light is on, press ALARM ENABLE. The light turns off, indicating that the machine-stop and fault outputs are disabled. 2. Rotate the trigger to a position where it will not be activated by products. 3. Start the production line and run it at jog speed. 4. Stop the line when the entire bar code is within the scan line. NOTE: The teach procedure can be performed at normal operating speed, but it is not as reliable as teaching the code while it is stationary with the read cycle manually activated. When the line is running, the system can interpret printing on the product or even parts of the machine as a good code. If this happens, the Accubar system will not be able to detect bad codes. 5. Press TEACH. 6. Place a hand in front of the trigger and keep it there. Make sure that the yellow PHOTO SENSOR light on the Accubar console is on. 7. Remove the hand to end the scan cycle. The yellow PHOTO SENSOR light turns off and the system captures the bar code (if it is a readable code) and stores it in the system s memory. It uses this bar code as the reference code for checking all other codes. 8. Replace the trigger in its original position, being careful that the trigger-to-product distance is set the same as before. 9. Increase the line speed to about one half the normal operating speed. 10. Observe the green GOOD CODE and red BAD CODE lights on the Accubar console. If the green GOOD CODE light is always on or on except for a few BAD CODE lights, go to the next step of this procedure. If the BAD CODE light is always on, repeat the teach procedure, making sure that the code used to teach the system is a good one (and properly designed) and that the product is stationary during the teach process. If the GOOD CODE light turns on some, but the rate of BAD CODE indications is too high, try one or more of the adjustments in the following table to fine-tune the system s performance.

23 Accubar Bar Code Verifier 19 Adjustment Prevent light from reflecting back into the scanner. Increase the scan time. Adjust the distance of the scanner window from the product surface (unless the bar code is a Pharmacode or a Bobst code). Examine the code design. Instructions Eliminate any unnecessary light (sunlight, ambient lighting, task lighting) in the scanner area. In addition, place the scanner at an angle to the product surface (about 10 degrees) as instructed in the procedure Select a Scanner Location. Locate the trigger so that the bar code receives the maximum number of scans possible for this line speed. Refer to Select a Trigger Location. Move the scanner window closer or further from the product surface within the recommended range of mm ( in.). Use Figure 17 to find the optimum distance. NOTE: For Pharmacode or Bobst code, the distance should be fixed at 127 mm (5.0 in.). Determine whether the bar code is properly designed. Refer to the appendix of this manual for the principles of good code design. 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. 11. Increase the speed to normal operating speed and verify that the system is still detecting good codes when the bar codes are good. If the system starts reporting bad codes at the higher line speed, either reduce the line speed or try one or more of the adjustments in the table for the previous step. 12. Press ENABLE ALARM and challenge the system with some products with known bad codes to see if they are detected. If the system successfully detects the defective codes, you have completed this procedure. If the system fails to detect the defective codes, refer to Troubleshooting.

24 20 Accubar Bar Code Verifier Trial Run (contd) inches 0 0 millimeters Narrow Bar Width: High Density 5 mil (0.127 mm) 7.5 mil (0.191 mm) 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) millimeters inches Figure 17 Optimum Read Ranges for Different Bar Code Sizes

25 Accubar Bar Code Verifier 21 Find the Removal Point for Defective Products Use this procedure to find where the product with the defective bar code stops when the machine stops, or, in some cases, where the first defective product stops when the system finds a series of defective bar codes. Once this location has been identified and marked on the parent machine, products can be quickly found and removed with defective bar codes when the machine stops. 1. Create several defective products by marking over the bar code with a black marking pen. 2. Run the line at normal operating speed. 3. Feed one of the defective products into the machine. 4. When the machine stops, locate the marked product. 5. Place a piece of tape or make some other mark on the machine at the center point on the defective product. NOTE: Verify results by repeating the test. Press ALARM RESET, start the machine, and place another product with a blackened code on the line. If the line is running at the same speed as before, the product should stop in the same location. NOTE: If the operating speed of the machine is changed for any reason, the defective product will come to a stop in a different location. Change the position of the mark when changing line speeds. Repeat this procedure every time product with a different size or shape is used. Teach the Tracking Distance If the Accubar system is linked to a G-NET system, teach the tracking distance for product ejection or marking. Refer to the G-NET system manual and follow the procedure Teach the Tracking Distances for the System. Cover the scanner window prior to performing the procedure and remove the cover after completing the procedure. Also, when instructed to press the TEACH key, press the TEACH key on the G-NET console, not the Accubar console.

26 22 Accubar Bar Code Verifier Operation Prior to routine operation, teach the system a good bar code. The system uses this bar code to check each product it scans. When the leading edge (or some other selected edge) of a product activates the trigger, the read cycle begins. The scanner repeatedly scans 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 system turns on the GOOD CODE light. It turns on the BAD CODE light when a code is either missing or significantly out of registration, cannot be reliably read, or does not match the reference code taught to the system. The system also turns on two outputs each time a defective code is detected. One output can be used to stop the production machine or the machine s feed section. The other output can be linked to a Nordson G-NET verification system. When the Accubar system is used with a G-NET system, products with defective bar codes are automatically tracked and either ejected from the line or marked for removal. Accubar Console Controls and Indicators Figure 18 Accubar Console Controls and Indicators

27 Accubar Bar Code Verifier 23 Item Control/Indicator Function of Key or Light 1 Power switch Used to turn the system on or off. 2 POWER light (red) Turns on when power is applied to system. 3 ENABLE ALARM light (green) Turns on when the alarm is enabled. 4 ENABLE ALARM key Used to enable or disable the alarm. 5 ALARM RESET light (red) Turns on when alarm contacts have been tripped and must be reset. 6 ALARM RESET key Used to reset the alarm contacts. 7 BAD CODE light (red) Turns on each time a bad code is detected. 8 GOOD CODE light (green) Turns on each time a good code is detected. 9 TEACH key Used to capture the next readable bar code, which becomes the reference code. 10 PHOTO SENSOR light (yellow) Turns on when the read cycle is activated (by the leading edge or some other edge) and turns off when the read cycle is deactivated (by the trailing edge or some other edge). Scanner Indicators Figure 19 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.

28 24 Accubar Bar Code Verifier Start the System Use this procedure to start the system after it has been turned off. NOTE: Upon returning the system to operation after an interruption or break in the production run if the system did not turn off, skip the first nine steps of this procedure. Perform step 10, and, if the alarm is off, step Place the power switch on the Accubar console in the on position. 2. Rotate the trigger to a position where it will not be activated by products. 3. Start the production line and run it at jog speed. 4. Stop the line when the entire bar code is within the scan line. NOTE: The teach procedure can be done at normal operating speed, but this method is not as reliable as teaching the code while it is stationary and the read cycle is manually activated. When the line is running, the system can interpret printing on the product or even parts of the machine as a good code. If this happens, the Accubar system will not be able to detect bad codes. 5. Verify that the code is the correct bar code before teaching it to the system. 6. Press TEACH. 7. Place a hand in front of the trigger and keep it there. Make sure that the yellow PHOTO SENSOR light on the Accubar console is on. 8. Remove the hand to end the scan cycle. The yellow PHOTO SENSOR light turns off and the system captures the bar code (if it is a readable code) and stores it in the system s memory. It uses this bar code as the reference code for checking all other codes. 9. Replace the trigger in its original position, being careful that the trigger-to-product distance is set the same as before. 10. Increase the line speed to normal operating speed. Allow the line speed to stabilize and ensure that the feed system is stable. 11. Press ENABLE ALARM. The alarm and machine stop outputs are enabled and the light on the key turns on.

29 Accubar Bar Code Verifier 25 Restart the System After a Machine Stop Use this procedure to resume operation when a defective product causes a machine stop (or a stop of the feed section). 1. Locate the defective product (or products) and try to determine the type of bar code error that caused the machine stop. Take any corrective action that may be needed. NOTE: If the system is installed to stop the parent machine (and not just the feed section of the machine), the defective product will be located at the point you marked on the line in the procedure Find the Removal Point for Defective Products. 2. Press ALARM RESET. The light on the key turns off. 3. Start the machine (or the feed section of the machine). 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 trigger location. Adjust the trigger sensitivity. Change the scanner location. Change the scanner 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 size or shape (or color) of the product changes, when the location or size of the bar code changes, or when the position of the scanner changes. Anytime the trigger location is changed or adjusted or when there is a change on the surface of the product (printing or type of material used). When the product size or shape changes or the bar code size or location changes. If the code is a Pharmacode or Bobst code, ensure that the distance from the scanner window to the code is always 127 mm (5.0 in.). For all other codes, the recommended range is mm ( in.). When the reflectivity changes enough to affect the performance of the scanner. When the trigger location or scanner 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 Accubar 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.

30 26 Accubar Bar Code Verifier 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. Place the power switch on the console in the off position. 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. Place the power switch on the console in the on position. 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 or Veritec 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. System Wiring Diagram ACCUBAR CONSOLE MACHINE STOP PARENT MACHINE LASER SCANNER SYSTEM TRIGGER 115/230 VAC 50/60 HZ BAD CODE OUTPUT LASER PHOTOEYE POWER G-NET SYSTEM G-SITE INTERFACE FORCE 1 SENSOR Figure 20 System Wiring Diagram A

31 Accubar Bar Code Verifier 27 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. 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. 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. Correct scanner range. Refer to Figure 21 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. 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.

32 28 Accubar Bar Code Verifier Problem 2. System Starts Reporting Errors at Higher Line Speeds 3. System Fails to Detect Bad Bar Codes 4. System Not Rejecting or Marking Products With Defective Codes 5. System Rejecting or Marking the Wrong Products Possible Cause 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. The zone trigger out of position. Trigger cable is loose or disconnected at the G-SITE or trigger connector. 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. Alarm not enabled. Alarm signal not reaching G-NET system. Problem in the G-NET system. Accubar trigger knocked out of position. Corrective Action 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 21 to find the optimum distance. Refer to Check for a Sufficient Number of Scans. Check the bar code design. Check the alignment of the trigger and adjust. Refer to the G-NET product manual. Plug the cable back into the appropriate connector. Refer to Adjust the Trigger. 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, alarm enable and that the reject function is enabled at the G-NET console. Check the ENABLE ALARM key. Check for secure linking cable connections at the back of the Accubar console (BAD CODE OUTPUT) and at the G-SITE interface (force 1 sensor). If the cable is damaged, replace it. If the light on the REJECT ON/OFF key is off, press the key. If it is on, refer to the troubleshooting section in the G-NET manual for other troubleshooting advice. The trigger must be returned to its original position or the new tracking distance must be taught to the system. Refer to the G-NET manual for instructions on how to teach tracking.

33 Accubar Bar Code Verifier 29 Problem 6. Machine Stop Function Not Working 7. Machine Cannot Be Restarted After a Stop Possible Cause The procedure for teaching the tracking distances was not correctly performed. Problem in the G-NET system. Alarm not enabled. The machine is not receiving the machine stop signal. Problem in the G-NET system. The machine-stop contacts in the Accubar system need to be reset. The machine-stop contacts in the G-NET system need to be reset. Corrective Action Clear the machine of all products and cover the scanner window when you teach tracking. Refer to the G-NET manual for the correct procedure. Refer to the troubleshooting section of the G-NET manual1 Check the ENABLE ALARM key. Check for secure cable connections at the back of the Accubar console (labeled MACHINE STOP) and at the machine. If the cable is frayed or severed, replace it. If the cable is good, replace the machines-stop relay. Refer to Replacing the Machine Stop Relay in the repair section of this manual. Check the G-NET console. Check the Accubar console. If the Accubar system is part of a G-NET verification system, check the G-NET console. If the light on the alarm reset key is on, push the key. The light turns off and the machine can be restarted.

34 30 Accubar Bar Code Verifier Troubleshooting Table (contd) inches 0 0 millimeters Narrow Bar Width: High Density 5 mil (0.127 mm) 7.5 mil (0.191 mm) 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) millimeters inches Figure 21 Optimum Read Ranges for Different Bar Code Sizes Check for a Sufficient Number of Scans Use the formulas for either picket-fence orientation or ladder orientation to ensure that each bar code receives a minimum of 12 complete scans. The formulas can also be used to find the maximum possible line speed to achieve the minimum number of complete scans or to find the optimum length of scan line for a given line speed for picket-fence oriented labels. NOTE: If you are unable to achieve the desired line speed, contact your Nordson representative.

35 Accubar Bar Code Verifier 31 Formula for Picket-Fence Label Orientation No. of Complete Scans = Scan Width Label Width Scan Rate 3 Line Speed where the scan width is the width of the scan line and the label length is the length of the label, including quiet zones. Example: If the label is 25 mm wide, the scan line is 100 mm wide, and the line speed is 400 mpm, the number of complete scans would be calculated 400 m min 1000 mm m as follows: 6666 mm sec 60 sec min No. of Scans = 100 mm 25 mm 2000 scan sec 3 x 2000 scan/sec mm sec = = 19 complete scans Formula for Ladder Label Orientation No. of Complete Scans = Label Height Scan Rate 3 60 sec min Example: If the label is 25 mm high and the line speed is 400 mpm, the number of complete scans would be calculated as follows: Line Speed = No. of Scans = 400 m min 1000 mm m 60 sec min 6666 mm sec 25 mm 2000 scans sec mm sec = 4 complete scans (an insufficient number of scans, requiring a drop in line speed) Check Trigger Operation 1. Slow down the production line until you can observe the yellow PHOTO SENSOR light on the Accubar console turn on and off with each passing product. 2. Verify that the light 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 Adjust the Trigger.

36 32 Accubar Bar Code Verifier 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 or Veritec 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 the Line Fuse 1. Place the power switch on the Accubar console in the off position. 2. Unplug the main power cable from the back of the console. 3. See Figure 22. Slide the fuse holder out (toward you) by inserting a small screwdriver in the tab on top of the holder. Figure 22 Insert a Screwdriver in the Fuse Holder Tab