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 E 2007 Nordson Corporation

For CE Declaration, refer to the LogiCommr 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: 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.

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.

Table of Contents i

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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 LogiCommR 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

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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 1 in Figure 4.

SIf 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

b

1

X

a

b

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

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Nordson BC5100 User manual

Nordson BC5100 User manual

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