AXICON

CHECKRITE 5

BARCODE VALIDATOR

DOCUMENTATION BOOKLET

www.axicon.com

© Copyright 2014 Axicon Auto ID Ltd

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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 28

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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.

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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

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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).

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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 pre-

determined 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.

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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

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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.

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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.

Key switch

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

CENTRE: Normal operating position Key removable

RIGHT: Reset System OVERIDE if left in this position Key removable

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4.2 DURING THE PRODUCTION RUN

4.2.1 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.

4.2.2 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.

4.2.3 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 110-240VAC signal) and is configured with both normally-closed

and normally-open contacts on the connector.

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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.

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5.0 INSTALLING THE SYSTEM

WARNING

The Checkrite 5 Validator requires a mains voltage power supply

(100 – 240v) 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.

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The following description assumes that the control unit is suitably

mounted and the stop signal is connected to the machine stop input.

5.1. Mounting the scanner.

5.1.1. 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 Flexo on white board 100% 100% 220mm ITF14 Flexo brown code on white board 100% 75% 220mm ITF14 Thermal label on green 80% 70% 200mm ITF14 Thermal label on pink 80% 100% 200mm ITF14 Thermal label 80% 100% 200mm ITF14 Flexo on brown board 65% 90% 200mm ITF14 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.

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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.

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.

PRODUCT (moving into or away from

this page)

Scanner

Tilt angle of approx 10 to avoid specular reflections from surface of barcode

Range to suit code type and size (see 5.1.1 above)

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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.

Mounting hole dimension of Control Box – Rear View

4 off x 10mm mounting holes on a 200 x 150mm rectangle

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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.

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.

PRODUCT Direction of travel

Scanner

Bar Code Sensor

Sensor Reflector

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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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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

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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.

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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) 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.

5 Consecutive No Reads (RESET Switch to restart)

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AXICON SOFTWARE LICENCE AGREEMENT This software is Copyright © 1995-2014 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.

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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.

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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

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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.

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To arrange for your validator to be factory serviced.

1. Contact the Axicon Auto ID Ltd on Telephone: +44 (0) 1869 351155 Fax +44 (0) 1869 352404 Email: vcas@axicon.com

2. 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.

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HOW TO CONTACT AXICON

Axicon Auto ID Ltd

Church Road, Weston on the Green, Oxfordshire OX25 3QP, UK

Tel.: +44 (0) 1869 35 11 55

Fax: +44 (0) 1869 35 1 205

Fax VCAS/Repairs: +44 (0) 1869 35 24 04

Email : info@axicon.com

Email VCAS/Repairs: vcas@axicon.com

Technical Support: support@axicon.com

Website: www.axicon.com

For service and support in the Americas please log on to www.axicon.com 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

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VCAS SERVICE RECORD

Validator Model

Serial Number

Date Service Undertaken Name &

Signature

Ax i con Auto ID L im i ted

Company Registration Number: 2003365 VAT Registration Number: GB 578651102

Checkrite 5 Documentation Booklet Version 5– Jan 2014.