AXICON CHECKRITE 5 BARCODE VALIDATOR

Transcription

1 AXICON CHECKRITE 5 BARCODE VALIDATOR DOCUMENTATION BOOKLET Copyright 2014 Axicon Auto ID Ltd

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3 CONTENTS Page INTRODUCTION 4 Verification and Validation an explanation 5 START UP GUIDE Product Overview 7 What s in the box 8 Optional extras 8 OVERVIEW and Operation of the system 9 Setting up for a production run 10 During the Production Run 11 INSTALLING the System 13 Appendix and laser certification 20 QUICK-START GUIDE 21 Axicon Software License Agreement 22 Disclaimer 24 AXICON WARRANTY Warranty 25 Service Record

4 Thank you for purchasing an Axicon Checkrite 5 Barcode Validation System. This short guide will enable you to get started with your Axicon Validator quickly and easily. Please read and follow the instructions carefully in order to get the best from your barcode validator

5 IMPORTANT INFORMATION 1. Verification and Validation Your guide to Quality Control 1.1 There is a significant difference between barcode verification and barcode validation and it is important to understand the difference. 1.2 The only valid method of assessing barcode quality to the correct standards is to use an ISO/ANSI grade verifier. (A niche area in which Axicon is the world-leader) An ISO/ANSI verifier takes about 20,000 measurements of the barcode and analyses the print quality in order to provide the use with an overall print quality grade. This is the method that all major retailers throughout the world (as well as many other industries) use in order to measure the barcode quality and to assess whether or not it meets the correct standards - and indeed this is the only valid test of print quality. 1.3 Because of the amount of data that needs to be accurately collected and analysed it is simply not possible to achieve this with an on-line system at production line speeds and so the standards then specify that an "appropriate statistical sample" of each and every batch should be made. And it is then up to the user to determine what is an "appropriate statistical sample", and the assessment should be based upon the potential variability of the print quality during the production run. This can be affected by such factors as the substrate type, print method, choice of inks etc etc. 1.4 This sampling inevitably means that a few barcodes in the batch will be measured to the correct standards BUT it also means that if this is the - 5 -

6 only test being performed then only a very limited number of products are actually being tested other products may have an unreadable barcode, no barcode at all, or (worse still) the wrong barcode! 1.5 This is where the use of a "validator" comes in - it does not replace the use of a verifier but instead supplements it. If the verifier is there to ensure that an "appropriate statistical sample" of all products are measured to the correct standard then the validation will provide an additional (not replacement) check to ensure that every single product has a barcode on it and that all of those barcode were scannable with the scanner used (and that all barcodes decoded as the same number). 1.6 Because the validator does not measure quality in the same way as a barcode verifier it is simply not possible to calibrate this against a verifier - the two instruments work in entirely different ways. 1.7 The purpose of an on-line Validator is to improve the Process Control Program by supplementing the off-line ISO/ANSI verifier - it means that rather than just a small sample of codes being measured as would be the case using a verifier, that level of checking can now be supplemented by ensuring that every product has a scannable barcode (i.e. was capable of being read by this scanner)

7 2. Axicon Checkrite 5 Barcode Validator Product Overview 2.1 The Axicon Checkrite 5 Barcode Validator is a mid-performance validator it uses the intelligence that is built into the scanner to decode a barcode and to check whether this is the same decoded number as previously read. It can also check whether a successful read was made during a predetermined time span. 2.2 If there is a product with an unreadable or a mis-matched barcode then the validator can be set to illuminate a light display on the front panel - it also has a spare relay contact available to the user than can be used to, for example, activate an ejection arm, or trigger the production line to stop. 2.3 The speed and efficiency with which the Checkrite 5 can detect and read the barcode is, of course, directly linked to the print quality of the barcode as well as the scanning distance; we would therefore recommend the use of an ISO/ANSI grade verifier as part of the set-up of the Checkrite 5 to achieve optimum performance

8 3. WHAT S IN THE BOX? Please ensure that the following items are present upon receipt. Axicon Checkrite 5 Validator control box Barcode scanner Sensor By default the standard Checkrite 5 system is supplied with a broken beam sensor and reflector as this gives the most reliable performance in the widest range of applications. (Axicon also offer both short-range and long-range reflective sensors as alternatives.) Wallet containing Documentation Booklet (includes Start Up Guide) OPTIONAL EXTRAS Axicon also offer the following optional extras to be used in conjunction with the system:- - Mounting Arm - Mounting brackets - Mounting cradle - 8 -

9 4. OVERVIEW AND OPERATION OF THE SYSTEM The hub of the system comprises a PLC based control unit with relay to which a laser bar code reader is attached. The purpose of the system is to check that the barcodes on the products are readable and are the correct code. Before the production run starts it is necessary to train the scanner to recognize the correct decoded number. This is done by using a Show-&-Go method to record the correct decoded number into the memory of the scanner. The barcode on each product seen will then be compared to this and action taken if it differs from it

10 4.1 SETTING-UP FOR A PRODUCTION RUN Immediately prior to a run the system should be set to train mode. This is done by turning the key-switch on the control box momentarily to the left and holding it there whilst moving the required barcode past the scanner and then allowing it to return to the central position. This will cause the barcode to be loaded into the scanner Master Label memory. It will remain in the memory even after power-off. CENTRE: Normal operating position Key removable LEFT: Hold key against spring in Learn position whilst scanner is scanning the barcode. Amber light will illuminate to indicate that a learn process is taking place. This is then used as the Master Label. Key is retained Key switch RIGHT: Reset System OVERIDE if left in this position Key removable

11 4.2 DURING THE PRODUCTION RUN As a bar coded item passes the sensor it breaks the reflected beam which causes the scanner to be automatically triggered and the laser is switched on for the pre-configured timeout period If a new trigger is received (item passing the sensor) before the timeout has expired the previous read-cycle will end immediately and a new cycle started The output from the scanner is then fed into the PLC in the control box which interprets them and illuminates the lamps appropriately: A. If the code is successfully decoded and is the same as the Master Label, the Green Lamp will illuminate. GOOD READ. B. If the code does not read because it is unreadable, misapplied or not present, the Amber Lamp will illuminate. NO READ. 5 consecutive No Reads (default setting) will cause a machine stop with both Amber and Red Lamps illuminated. (Note: The number of consecutive no-reads before both amber and red beacons are illuminated can be modified in the PLC settings and this should ideally be done at the time of manufacture) C. If the code is not the same as the Master Label the Red Lamp will illuminate. MISMATCH. The machine stop will operate* *Machine Stop :- There is an extra relay output available for connection to a line stop input. This is a volt-free relay contact (which can carry a 24VDC or VAC signal) and is configured with both normally-closed and normally-open contacts on the connector

12 At the end of a Good Read or a No Read cycle the relevant lamp will remain illuminated until the next trigger. This means that the result of the previous cycle is always visible. A new trigger switches the lamps off and a new cycle begins. 5 consecutive No Reads (No Read counter) will cause a machine stop with both Amber and Red lamps illuminated and latched. A Good Read or a manual Reset from the key-switch will reset the No Read counter. The Master Label is always remembered for power-down and will not need to be reloaded at the start of every batch. Once the machine Stop has operated it can only be reset by turning the front panel switch to the right. The switch can be left in this position and the key removed. Under this condition the system is disabled so this must be at the discretion of an authorised operator. It is strongly suggested that they key is not left in the unit during production runs

13 5.0 INSTALLING THE SYSTEM WARNING The Checkrite 5 Validator requires a mains voltage power supply ( v) with the consequent risk of injury. The Validator should only be installed by suitably qualified personnel. After installation the key to the front door should be removed and retained in a safe place away from the validator. (Operators should not need to open the front door for any reason whatsoever). Neither Axicon Auto ID Ltd nor the vendor of the validator can accept any liability arising from the incorrect installation or operation of this equipment

14 The following description assumes that the control unit is suitably mounted and the stop signal is connected to the machine stop input Mounting the scanner Positioning the scanner:- Guidance Recommendations as to the optimum distance from the scanner to the barcode:- Code Media/Print Magnification % Scan Distance (mm) EAN13 Thermal label 150% 100% 100mm EAN13 Litho on white 100% 100% 100mm GS1 128 Thermal label 60% 100% 220mm ITF14 Thermal label 60% 100% 220mm ITF14 Ink-jet 75% 75% 220mm ITF14 ITF14 ITF14 ITF14 Flexo on white board 100% 100% 220mm Flexo brown code on white board 100% 75% 220mm Thermal label on green 80% 70% 200mm Thermal label on pink 80% 100% 200mm ITF14 Thermal label 80% 100% 200mm ITF14 ITF14 Flexo on brown board 65% 90% 200mm Flexo on brown board 100% 95% 220mm (These are based upon tests performed by Axicon and may need to be adjusted for other substrates or codes

15 5.1.2 Mounting the Scanner IMPORTANT:- When mounting the scanner to a bracket screws of M4 x 6mm should be used. If screws are used which are too long these may damage the scanner. Mount the scanner at an angle of approximately 10 between the laser beam and the barcode. This is recommended to avoid specular reflections from the surface of the code. Note:- if this is not done then the read rate of the barcode will be significantly reduced. Tilt angle of approx 10 to avoid specular reflections from surface of barcode Scanner PRODUCT (moving into or away from this page) Range to suit code type and size (see above) Troubleshooting:- If, having mounted the scanner at the recommended distance and tilt angle the barcode read-rate is poor, we would recommend that samples of the barcode be checked off line by an ISO/ANSI verifier to assess print quality as the most likely cause of the problem is a badly printed barcode. Corrective action should then be applied as necessary. Tests have shown that poor quality barcodes significantly reduce the read rate of a scanner and also make it mush more sensitive to having the correct scanner/barcode distance

16 5.2 Mounting the Control Box Preferred option: The user may purchase the optional Mounting cradle in which case they would fit the cradle to the wall/machine and then drop the validator into the cradle, connect it up and it is ready to go. Alternative option:- The control box may be mounted direct to the wall/machine without the use of a cradle, using the mounting positions as shown in the diagram below. (Please note that this would involve opening up the validator in order to mount the control box.) Care must be taken by the installer to ensure that no components inside the validator are damaged during this fitting process, also that ingress of dust etc is avoided. 4 off x 10mm mounting holes on a 200 x 150mm rectangle Mounting hole dimension of Control Box Rear View

17 5.3 Installing the trigger sensor/setting time-out period The trigger sensor must be mounted such that it should start the scanning process just before the bar code moves in front of the scanner and after the previous barcode has cleared the scanning path. As standard the Checkrite 5 is supplied with a broken beam sensor comprising the sensor which is positioned at one side of the production line and the reflector at the other. When the reflective beam is broken then the read-cycle begins. The scanner will have a pre-set time-out period. The time-out period must be sufficiently long to ensure that the barcode has completely moved past the scanner before it expires (and automatically switches off). The amount of time required depends upon the line speed, position of the barcode on the box etc. Sensor Reflector PRODUCT Direction of travel Bar Code Sensor Scanner Axicon also offer both short range and long range sensors for special applications, however the broken beam-sensor is supplied as standard since this gives consistently the best performance and is the most reliable

18 5.4. Machine Stop output The connector panel on the underside of the Checkrite 5 looks like this:- You will see the Machine Stop connector at the left hand side. The connector contacts are shown here:- This allows the user to select the appropriate contacts to meet either a normally open or normally closed requirement 5.5 Maintenance Once installed the scanner window should be cleaned of any dirt. Please note that the recommended method is to apply a small quantity of commercial glass cleaner to a soft lint-free cloth and wipe the window with this. Do not soak the scanner with liquid cleaner and do not rub excessively as either will adversely affect the operation of the system and could permanently damage the scanner. The window should be kept clean for best performance and this should form part of a regular maintenance routine

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20 6.0 Checkrite 5 - Lamp Status:- Green only. Last cycle was a GOOD READ Amber only. Last cycle was a NO READ Red only. Last cycle was a MISMATCH Amber and Red. Last cycle was a fifth consecutive NOREAD

21 7.0 APPENDIX a. Laser Safety :- The Checkrite 5 barcode validator is supplied as standard with a Datalogic scanner. Please see the scanner manufacturer s datasheet for their laser safety declaration and certification

22 8.0 Checkrite 5 - Quick Start Guide 1. On power-up turn Key 45º to right ( RESET ) to clear all indicators then return to centre for operation. 2. Load new product or packaging onto the line 3. Turn Key 45º to left ( LEARN ). HOLD in this position whilst scanning the required master barcode the amber lamp will be illuminated to indicate a successful learn. The user should then allow the key to spring back. The key should be removed at this time to prevent the code being overwritten. 4. Start the line 5. Green lamp = Good, Amber = NoRead (5 in a row will stop the line with Amber & Red on). Red (only) = Mismatch (Stops the line immediately). 6. Red and Amber lamps on = 5 consecutive no-reads which has triggered a line-stop 7. After a Line Stop remove all incorrect packaging, turn Key 45º to right ( RESET ) and return to centre; it s now ready to start again. 7.a) NOTE: System will remember the Master Code on Power-off there is no need to re-enter it. Last Code GOOD Last Cycle NOREAD Last Code WRONG CODE (RESET Switch to restart) 5 Consecutive No Reads (RESET Switch to restart) Note - The Key can be removed while in RESET position this provides a System Override which can be useful where a pack design does not include a barcode

23 AXICON SOFTWARE LICENCE AGREEMENT This software is Copyright Axicon Auto ID Limited Some models within the Checkrite range utilise embedded Axicon software. Where this is the case use of the Software within the system is subject to the Axicon Software Licence terms set forth below. Using the Software indicates your acceptance of these Licence terms. If you do not accept these Licence terms within 14 days, you may return the entire unused product for a full refund. AXICON SOFTWARE LICENCE TERMS - LICENCE GRANT Axicon grants you a Licence to use any number of copies of the Software, but only for Use in conjunction with the Axicon hardware product that accompanied the Software. "Use" means storing, loading, installing, executing or displaying the Software. You may not modify the Software or disable any licensing or control features of the Software. OWNERSHIP The Software is owned and copyrighted by Axicon Auto ID Limited. Your Licence confers no title or ownership in the Software and is not a sale of rights in the Software. COPIES You may only make copies of the Software for archival purposes or when copying is an essential step in the authorised use of the Software. You must reproduce all copyright notices in the original Software on all copies

24 You may not copy the Software onto a bulletin board or similar publicly accessible system. NO DISASSEMBLY OR DECRYPTION You may not disassemble or decompile the software without prior written consent from Axicon. TRANSFER Your Licence will automatically terminate upon any transfer of the Software. Upon transfer, you must deliver the Software, including any copies and related documentation, to the transferee. The transferee must accept these Licence Terms as a condition of the transfer. TERMINATION Axicon may terminate your Licence upon notice of failure to comply with any of these Licence Terms. Upon termination, you must immediately destroy the Software, together with all copies, adaptations and merged portions in any form. EXPORT REQUIREMENTS You may not export or re-export the Software in contravention of any applicable laws or regulations. This agreement should be construed in accordance with the laws of England

25 DISCLAIMER In the following the expression "Validator" means the validator hardware and the associated software. We have taken care to ensure that this validator is free from defects. However since we have no control over the circumstances in which you might use the validator, you must satisfy yourself that the performance of the validator is suitable for your needs. Neither Axicon Auto ID Limited nor the vendor of this Validator can accept any liability for any loss or damage (consequential or otherwise) which may be caused by use of this validator. If the validator or any part of it is defective in any way, or in some other way does not meet your expectations, the liability of Axicon Auto ID Limited is limited to the cost of the product. You should bear this limitation in mind if you use this validator in any situations where the acceptance or rejection of shipments of goods or your reputation may depend upon the quality of a barcode. Under no circumstances is this validator licensed or authorised for use in any situation whatsoever where the health or safety of humans or animals might be put at risk

26 AXICON WARRANTY WARRANTY ON ALL PRODUCTS The Axicon Checkrite 5 Validator is sold with a one year parts and labour warranty against manufacturing defects. This is a Return to Bench warranty with shipping costs in one direction being borne by the customer/distributor. The Checkrite 5 contains no user-serviceable parts and should not be opened except by suitably qualified personnel. Axicon reserves the right to charge an inspection fee for any equipment returned under warranty for which no fault is found. Please contact Axicon to obtain an RMA number before returning any equipment. This number must be quoted on all documentation. Axicon cannot accept responsibility for equipment returned without a RMA number. If a Checkrite 5 validator has been damaged through incorrect installation or operation then Axicon reserve the right to charge an inspection and quotation fee

27 To arrange for your validator to be factory serviced. 1. Contact the Axicon Auto ID Ltd on Telephone: +44 (0) Fax +44 (0) We will provide you with a RMA number (Return to Manufacturer Authority) for your authorisation. 3. Please fill in all details requested on the RMA form enclosed with this letter, including the RMA number. 4. Return the validator (including all cables), the completed RMA form, purchase order, your payment details and this documentation booklet to our Service Department at Axicon Auto ID Ltd, Church Road, Weston on the Green, Bicester, Oxfordshire OX25 3QP. Axicon Auto ID Ltd cannot take responsibility for units returned in sub-standard packaging. 5. Axicon Auto ID Ltd will normally complete the service and return your validator within 7-10 days from the date received. OTHER FAULTS OR DAMAGE If, during the service /re-calibration of your equipment other faults or damage are found additional costs may be applicable. We will automatically send you details of the necessary repair and an estimate of cost. EQUIPMENT RENTAL SCHEME Axicon Auto ID Ltd also offers an equipment rental scheme for customers who require replacement equipment for the duration of the service Please contact us for further details

28 HOW TO CONTACT AXICON Axicon Auto ID Ltd Church Road, Weston on the Green, Oxfordshire OX25 3QP, UK Tel.: +44 (0) Fax: +44 (0) Fax VCAS/Repairs: +44 (0) info@axicon.com VCAS/Repairs: vcas@axicon.com Technical Support: Website: support@axicon.com For service and support in the Americas please log on to for contact details Due to Axicon s continuing product improvement programs, specifications and features herein are subject to change without notice. All trademarks are acknowledged as belonging to their respective companies. YOUR AXICON DISTRIBUTOR

29 VCAS SERVICE RECORD Validator Model Serial Number Date Service Undertaken Name & Signature Axicon Auto ID Limited Company Registration Number: VAT Registration Number: GB Checkrite 5 Documentation Booklet Version 5 Jan 2014.