Balluff HF-0405-XXX-01 Passive RFID Reader/Writer User Manual Part I

BALLUFF inc Passive RFID Reader/Writer Users Manual Part I

Contents

Users Manual Part I

HF-0405 RFID Controller
Passive High Frequency Radio Frequency Identification Controller
Operator’s Guide
How to Install, Configure and Operate
Escort Memory Systems’ HF-0405
RFID Controllers
HF-0405 RFID Controller Models:
• HF-0405-232-01
• HF-0405-422-01
• HF-0405-485-01
HF-0405-232/422/485-01 – Radio Frequency Identification Controller – Operator’s Guide.
Part No: 17-1303 Rev 1.A
3
Escort Memory Systems Warranty
Escort Memory Systems warrants that all products of its own manufacturing conform to Escort
Memory Systems’ specifications and are free from defects in material and workmanship when
used under normal operating conditions and within the service conditions for which they were
furnished. The obligation of Escort Memory Systems hereunder shall expire one (1) year after
delivery, unless otherwise specified, and is limited to repairing, or at its option, replacing
without charge, any such product which in Escort Memory Systems’ sole opinion proves to be
defective within the scope of this Warranty. In the event Escort Memory Systems is not able to
repair or replace defective products or components within a reasonable time after receipt
thereof, Buyers shall be credited for their value at the original purchase price. Escort Memory
Systems must be notified in writing of the defect or nonconformity within the warranty period
and the affected product returned to Escort Memory Systems factory or to an authorized
service center within thirty (30) days after discovery of such defect or nonconformity.
Shipment shall not be made without prior authorization by Escort Memory Systems.
This is Escort Memory Systems' sole warranty with respect to the products delivered
hereunder. No statement, representation, agreement or understanding oral or written, made
by an agent, distributor, representative, or employee of Escort Memory Systems which is not
contained in this warranty, will be binding upon Escort Memory Systems, unless made in
writing and executed by an authorized Escort Memory Systems employee.
Escort Memory Systems makes no other warranty of any kind what so ever, expressed or
implied, and all implied warranties of merchantability and fitness for a particular use which
exceed the aforementioned obligation are here by disclaimed by Escort Memory Systems and
excluded from this agreement. Under no circumstances shall Escort Memory Systems be
liable to Buyer, in contract or in tort, for any special, indirect, incidental, or consequential
damages, expenses, losses or delay however caused. Equipment or parts which have been
subject to abuse, misuse, accident, alteration, neglect, unauthorized repair or installation are
not covered by warranty. Escort Memory Systems shall make the final determination as to the
existence and cause of any alleged defect. No liability is assumed for expendable items such
as lamps and fuses. No warranty is made with respect to equipment or products produced to
Buyer's specification except as specifically stated in writing by Escort Memory Systems in the
contract for such custom equipment. This warranty is the only warranty made by Escort
Memory Systems with respect to the goods delivered hereunder, and may be modified or
amended only by a written instrument signed by a duly authorized officer of Escort Memory
Systems and accepted by the Buyer.
Extended warranties of up to four years are available for purchase for most Escort Memory
Systems products. Contact Escort Memory Systems or your distributor for more information.
Escort Memory Systems reserves the right to make modifications or improvements without
prior notification. Escort Memory Systems shall not be liable for technical or editorial errors or
omissions contained herein, nor for incidental or consequential damages resulting from the
use of this material. Product names mentioned herein are for identification purposes only and
may be trademarks and or registered trademarks of their respective companies.
Escort Memory Systems™ and the Escort Memory Systems logo are registered trademarks of
Escort Memory Systems, a Datalogic Group Company.
Copyright © 2004-2005 Escort Memory Systems ALL RIGHTS RESERVED
Table Of Contents
5
Table of Contents
TABLE OF CONTENTS.............................................................................................5
CHAPTER 1 ● GETTING STARTED ........................................................................9
Introduction ...................................................................................................................... 9
Our Background........................................................................................................................... 9
The HF-0405 RFID Controller .....................................................................................................9
HF-0405 Features ........................................................................................................... 10
FCC and CE Compliance Notice ............................................................................................... 11
About this Guide ............................................................................................................ 11
About this Guide ............................................................................................................ 12
HEX Notation ............................................................................................................................. 12
Who Should Read this Guide? .................................................................................................. 12
How this Guide is Organized .....................................................................................................13
Unpacking and Inspecting the HF-0405 .......................................................................14
Contents of the HF-0405 Package ............................................................................................ 15
User Supplied Components....................................................................................................... 15
Product and Document Versions.................................................................................. 16
Controller Model Number and Hardware Version ..................................................................... 16
Operator’s Guide Document Revision Number ......................................................................... 16
Updating the HF-0405 Firmware ................................................................................... 17
Downloading the Latest Updates............................................................................................... 17
RFID Demonstration Utility ........................................................................................................ 17
Customer Applications..................................................................................................18
RFID Strategy & Case Studies .................................................................................................. 18
CHAPTER 2 ● HARDWARE DESCRIPTION .........................................................21
Dimensions and Diagrams ............................................................................................ 21
Installation and Mounting Guidelines .......................................................................... 22
RFID Installation Checklist......................................................................................................... 22
Know Your Application Requirements ....................................................................................... 22
Antenna Environment ................................................................................................................ 23
Mounting the HF-0405............................................................................................................... 24
Words of Caution ....................................................................................................................... 24
RFID Tags .......................................................................................................................25
Overview.................................................................................................................................... 25
Tag Embodiments...................................................................................................................... 27
Tag Memory............................................................................................................................... 28
Tag Memory Map....................................................................................................................... 29
Memory Optimization................................................................................................................. 29
ISO 1443A/B.............................................................................................................................. 31
ISO 15693.................................................................................................................................. 31
ISO 18000-3.1 ........................................................................................................................... 31
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6
CHAPTER 3 ● POWER & COMMUNICATION CONFIGURATION........................32
Power Requirements...................................................................................................... 32
Warning about “Hotplugging”.....................................................................................................32
Serial Interface Options.................................................................................................33
HF-0405 Model Numbers and Supported Serial Interface Protocols ........................................ 33
RS232 Interface Connection ..................................................................................................... 34
RS422 Interface Connection ..................................................................................................... 34
RS485 Interface Connection ..................................................................................................... 34
Making Connections ...................................................................................................... 35
Connecting the HF-0405 to the Host ......................................................................................... 35
COM Port Configuration ................................................................................................ 35
COM Port Parameter Options ................................................................................................... 35
Pinouts ............................................................................................................................ 36
HF-0405-232/422 Pinouts .........................................................................................................36
HF-0405-485 Pinouts................................................................................................................. 36
HF-0405-485 Pinouts................................................................................................................. 37
The Configuration Tag ................................................................................................... 38
Configuration Tag Overview ......................................................................................................38
Configuration Tag Memory Map ................................................................................................ 38
Using the Configuration ............................................................................................................. 38
CHAPTER 4 ● LED STATUS .................................................................................39
Normal LED Operation Functions................................................................................. 39
LED Descriptions ........................................................................................................... 40
HF-0405-232 LED Status ..........................................................................................................41
HF-0405-422 LED Status ..........................................................................................................41
HF-0405-485 LED Status ..........................................................................................................42
Special LED Operation Functions ............................................................................................. 44
Error Conditions......................................................................................................................... 46
CHAPTER 5 ● COMMUNICATION PROTOCOLS .................................................47
Communication Overview ............................................................................................. 47
ABx Command Protocols .............................................................................................. 47
ABx Command Structures ......................................................................................................... 48
ABx Response Structures.......................................................................................................... 48
ABx Command Parameters....................................................................................................... 49
ABx Fast Command Protocol .................................................................................................... 51
ABx ASCII Command Protocol.................................................................................................. 53
ABx Standard Command Protocol............................................................................................. 58
CHAPTER 6 ● RFID COMMANDS .........................................................................60
RFID Command Table .................................................................................................... 60
Command 04 ◘ (0x04): Tag Fill................................................................................................. 61
Table Of Contents
7
Command 05 ◘ (0x05): Read Data ........................................................................................... 64
Command 06 ◘ (0x06): Write Data............................................................................................ 67
Command 07 ◘ (0x07): Read Tag ID (SN)................................................................................ 70
Command 08 ◘ (0x08): Tag Search .......................................................................................... 73
Command 0D ◘ (0x0D): Start/Stop Continuous Read .............................................................. 76
Command 0A ◘ (0x0A): Set RS232/422 Baud Rate ................................................................. 82
Command 36 ◘ (0x36): Send Controller Configuration ............................................................. 84
Command 37 ◘ (0x37): Read Controller Configuration............................................................. 86
Command 38 ◘ (0x38): Read Controller SN ............................................................................. 88
Command A1 ◘ (0xA1): Reset Controller.................................................................................. 90
CHAPTER 7 ● ABX ERROR CODES.....................................................................91
ABx Error Code Table .................................................................................................... 91
ABx Fast Error Response Structure............................................................................. 92
ABx ASCII Error Response Structure........................................................................... 93
ABx Standard Error Response Structure..................................................................... 94
CHAPTER 8 ● TROUBLESHOOTING....................................................................95
HF-0405 Troubleshooting Table.................................................................................... 95
Contact Technical Support............................................................................................ 95
APPENDIX A ● SPECIFICATIONS .........................................................................96
HF-0405 Data Sheet........................................................................................................96
Technical Specifications ............................................................................................... 97
APPENDIX B ● MODELS AND ACCESSORIES ....................................................98
HF-0405-232-01 ............................................................................................................... 98
HF-0405-422-01 ............................................................................................................... 98
HF-0405-485-01 ............................................................................................................... 98
HF-0405 Compatible Accessories ............................................................................................. 99
APPENDIX C ● ASCII CHART ..............................................................................100
APPENDIX D ● RFID TERMINOLOGY & DEFINITIONS ......................................101
INDEX……………………………………………………………………………………..107
Table Of Contents
8
www.ems-rfid.com
Chapter 1: Getting Started
9
Chapter 1 ● Getting Started
This chapter contains an introduction to Escort Memory Systems and includes
general information relating to the HF-0405 RFID Controller and common uses for
RFID technology.
Introduction
Welcome to the HF-0405 Series RFID Controller Operator’s Guide. This guide will
assist you in the installation, configuration and operation of Escort Memory Systems’
HF-0405 Series RFID Controllers.
The HF-0405 Series is a complete line of passive high frequency read/write Radio-
Frequency Identification solutions. They are designed to be compact, reliable and
rugged, and though they measure only 56mm x 40mm, the HF-0405 RFID
Controllers are highly integrated with everything you will need to start benefiting from
RFID technology.
Our Background
Since 1985, Escort Memory
Systems has been an industry
leader in providing Radio
Frequency Identification (RFID)
devices and has built a solid
reputation by consistently
delivering an extended selection
of quality, durable industrial RFID
systems.
Today, Escort Memory Systems
continues to deliver a complete
line of high performance,
industrial RFID equipment,
including the HF-0405 Series RFID Controller.
The HF-0405 RFID Controller
Escort Memory Systems' HF-0405 Series RFID
Controllers are the latest in our line of passive RFID
controllers that utilize the Radio Frequency (RF) field
from the controller’s integrated antenna to power RFID
enabled tags. By being able to receive power from the
RFID controller, the tag, itself, does not need a battery
and is said to be “passive”.
Passive tags must enter the antenna’s electromagnetic
field to establish a radio link which allows for the transfer
of information through inductive coupling. The HF-
0405 uses the internationally recognized ISM frequency
Chapter 1: Getting Started
10
of 13.56 MHZ to power the tag and then modulates side-band frequencies to
communicate.
The HF-0405 system provides cost effective RFID data collection and
control solutions to shop floor, item-level tracking, and material
handling applications.
The entire RFID system works by attaching a tag (or
transponder) to a product or its carrier which acts as an
electronic identifier, portable job sheet, or real-time tracking
database. Tags are identified, read and written to by issuing
specific commands to the HF-0405 RFID Controller from the
Host.
Tags can be read and/or written to (which is sometimes referred
to as “interrogating the tag”) through any nonconductive, non-metallic
material, while moving or standing still, in or out of the direct line of sight.
The HF-0405 series RFID Controller is compatible with all LRP and HMS Series tags
from Escort Memory Systems. The HF-0405 can also
communicate with ISO 14443 and ISO 15693 tags
from other manufacturers.
Escort Memory Systems uses error checking routines
that ensure that the RFID controller receives tag data
correctly even in environments with heavy RF
interference. LED indicators on the RFID controller
provide continuous real-time feedback on the status of
the unit. (See Chapter 5, for more information
regarding LED status).
HF-0405 Features
• Supports for multiple high performance RF, ABx, air and serial
communications protocols.
• 13.56 megahertz RFID Controller with integrated antenna.
• Compact size (approximately 4cm X 5.5cm).
• Flash memory for software updates.
• Auto configurable / Software programmable
• Eight LED status indicator lights.
• Reads/Writes ISO 14443A/B and ISO 15693 compatible RFID tags
• Reads/Writes existing LRP and HMS Series tags from Escort Memory
Systems
• 90% backward compatible with Escort Memory Systems HMS827, HMS828,
LRP75 RFID Controllers
• FCC/CE/ARIB T-82 Agency compliance certified
Chapter 1: Getting Started
11
FCC and CE Compliance Notice
FCC Part 15.105
This equipment has been tested and found to comply with the limits for a Class B
digital device, pursuant to part 15 of the FCC Rules. These limits are designed to
provide reasonable protection against harmful interference in a residential installation.
This equipment generates, uses and can radiate radio frequency energy and, if not
installed and used in accordance with the instructions, may cause harmful
interference to radio communications. However, there is no guarantee that
interference will not occur in a particular installation. If this equipment does cause
harmful interference to radio or television reception, which can be determined by
turning the equipment off and on, the user is encouraged to try to correct the
interference by one or more of the following measures:
• Reorient or relocate the receiving antenna.
• Increase the separation between the equipment and receiver.
• Connect the equipment into an outlet on a circuit different from that to which
the receiver is connected.
• Consult the dealer or an experienced radio/TV technician for help.
FCC Part 15.21
Users are cautioned that changes or modifications to the unit not expressly approved
by Escort Memory Systems may void the user's authority to operate the equipment.
This device complies with Part 15 of the FCC Rules. Operation is subject to the
following two conditions: (1) This device may not cause harmful interference, and (2)
this device must accept any interference that may cause undesired operation.”
This product complies with CFR Title 21 Part 15.225, EN-300-330, EN-300-683,
TELEC, EN 60950, IEC 68-2-1, IEC 68-2-6, IEC 68-2-27, IEC 68-2-28.
Chapter 1: Getting Started
12
About this Guide
This document provides guidelines and instructions on how to install and operate the
HF-0405 Series RFID Controllers. Also included are descriptions of the RFID
command set with instructions describing how to issue commands to the HF-0405
Series RFID Controllers.
Occasionally throughout this guide, we refer to the HF-0405 RFID Controller as the
HF-0405, the HF-0405 Controller or just simply the RFID controller.
HEX Notation
In this guide, numbers expressed in Hexadecimal notation are prefaced with “0x”. For
example, the number of fingers on a typical person is expressed as "10" in decimal or
as "0x0A" in hexadecimal. See Appendix C for a chart containing Hex values, ASCII
characters and their corresponding decimal integers.
Who Should Read this Guide?
This guide should be read by those who will be installing, configuring and operating
the HF-0405 RFID Controller. This may include the following people:
• Hardware Installers
• System Integrators
• Project Managers
• IT Personnel
• System and Database Administrators
• Software Application Engineers
• Service and Maintenance Engineers
We have
attempted to
make this guide
as simple and
straightforward
as possible.
Where ever
possible, we will
attempt to
explain and
demystify RFID
for you.
Chapter 1: Getting Started
13
How this Guide is Organized
• The opening chapter in this guide describes the basic features and functionality
of the HF-0405 RFID Controller. You will also find customer case studies and
background information necessary for understanding RFID.
Chapter 1 ● Getting Started
• Chapters 2-4 discuss the configuration of your RFID environment and provide
information relating to the actual functionality, installation and setup of the HF-
0405 and the configuration of your RFID environment.
Chapter 2 ● Hardware Description
Chapter 3 ● Power & Communication Configuration
Chapter 4 ● LED Status
• Chapter 5 talks about communication protocols and ABx command protocols.
Chapter 5 ● Communication Protocols
• Chapter 6 contains a detailed listing of the RFID commands supported by the
HF-0405.
Chapter 6 ● RFID Commands
• Chapter 7 will help you recognize and interpret ABx and RFID error codes.
Chapter 7 ● ABx Error Codes
• If you are having problems or need Technical Support see Ch. 8.
Chapter 8 ● Troubleshooting
• Lastly, you will want to familiarize your self with the back of this document. There
you will find several Appendix sections designed to provide additional technical
assistance and reference information.
Appendix A ● Specifications
Appendix B ● Models and Accessories
Appendix C ● ASCII Chart
Appendix D ● RFID Terminology & Definitions
Chapter 1: Getting Started
14
Unpacking and Inspecting the HF-0405
Unpack the HF-0405 hardware and accessories. Retain the original shipping carton
and packing material in case any items need to be returned. Inspect each item
carefully for evidence of damage. If an item appears to be damaged, notify your
distributor immediately.
Chapter 1: Getting Started
15
Contents of the HF-0405 Package
The HF-0405 Series RFID Controller product package
contains the following components:
• HF-04050 Series RFID Controller
• Mounting Bracket
• 2 screws (M4-20 PPH SS 18-8\302)
• 2 nuts (M4 SS 18-8\302)
• HF-0405 Series Configuration Tag
Mounting Bracket
Each HF-0405 Controller ships with an L-shaped
polycarbonate mounting bracket and the necessary
hardware required to mount the controller to the mounting bracket.
Configuration Tag
Each HF-0405 RFID Controller is shipped with a unique configuration tag. The
configuration tag contains manufacturing data regarding the controller and can be
used to restore the controller’s factory defaults in the event that serial
communications become programmed to an unknown state. For the HF-0405-485
model, the configuration tag can be used to manually set the Subnet16™ node
address.
The configuration tag is a 112-byte ISO15693 compliant RFID tag that has had most
of its memory addresses locked at the factory to prevent important data from being
overwritten. However, for testing and demonstration purposes, certain addresses of
the configuration tag have not been locked and can be written to.
We recommend storing the configuration tag in a safe location in case the need
arises to use it. Refer to Chapter 3 for more information regarding the use of the
configuration tag.
User Supplied Components
The User Must Supply the Following Components:
• Host computer or Programmable Logic Controller (PLC) with an RS232,
RS422 or TCP/IP serial interface connection
• DC Power Source supplying 10~30 Voltage DC, with an Operating Range of
180mA and a Surge Current of 250mA.
Escort Memory Systems approved RS232, RS422 or RS485 compatible
serial communications cable (See Appendix B, for cables and accessories)
Also, have plenty of HF-0405 Series compliant Passive Read/Write Tags available for
testing and system integration.
Plan to have the
user supplied
items tested and
running prior to
the installation
of your HF-0405
RFID Controller.
Chapter 1: Getting Started
16
Product and Document Versions
Controller Model Number and Hardware Version
There are three versions of the HF-0405 RFID Controller, each designed to support
specific serial interface requirements. The model number and supported serial
interface connections are listed below:
The HF-0405-232-01 supports RS232 Serial Interface.
The HF-0405-422-01 supports RS422 Serial Interface.
The HF-0405-485-01 supports RS485 Serial Interface.
RS232 will support cable lengths up to 15m for point-to-point Host/Controller
connections.
RS422 will support cable lengths up to 50m for point-to-point Host/Controller
connections (provided adequate gauge cabling is used for power and signals).
RS485 supports Subnet16™ Multidrop bus architecture and protocol, allowing for up
to 16 connection nodes on one bus connected through a Subnet16 Gateway.
For more information on model numbers, parts and accessories for all HF-0405
Series RFID Controllers see Appendix B: Models & Accessories.
Operator’s Guide Document Revision Number
This is the original publication of Escort Memory Systems’ HF-0405 Series RFID
Controller – Operator’s Guide. It coincides with the initial release of the HF-0405
Series Controllers.
Document No. 17-1303 Revision 1.A
HF-0405-232/422/485 - High Frequency Passive Radio Frequency Identification
Controller – Operator’s Guide.
Chapter 1: Getting Started
17
Updating the HF-0405 Firmware
Downloading the Latest Updates
The operating system for the HF-0405 is stored in flash memory in the form of
firmware on an EEPROM chip. Occasionally, Escort Memory Systems will release
firmware updates (and its revised documentation) for the HF-0405. To ensure that
your RFID system is up to date, and to benefit from improvements to the latest
firmware code, we recommend that you download and install any future updates.
HF-0405 RFID Controller Updates
Firmware and Documentation updates are located at the following Web address:
http://www.ems-rfid.com/hf-series.html
For instructions on how to install a firmware update, please see our online help
documentation located at the above mentioned Web address.
RFID Demonstration Utility
Also available at http://www.ems-rfid.com/hf-series.html is our Windows based RFID
demonstration utility. This utility can be used to demonstrate how RF commands are issued,
how to update the firmware and how modify the configuration of the HF-0405.
Chapter 1: Getting Started
18
Customer Applications
With over 20 years of RFID success in automation of automotive, electronics,
material handling and food processing industries, Escort Memory Systems has built a
global reputation by providing complete supply chain solutions that track products
during initial manufacturing all the way through the warehousing, distribution and
logistics product flows.
High data transfer rates and versatility of use with different tag types and packaging,
make the HF-0405 Series RFID Controllers unique to the market. With an IP67
rating, the rugged and durable HF-0405 Series Controllers are suited for applications
in Automotive, Electronics, Meat Processing, Pharmaceuticals and Packaging
industries.
RFID Strategy & Case Studies
RFID Strategy is a term given to describe the manner or rationale in which a
company utilizes RFID communications to achieve quality, accountability, profit
and/or other business goals.
Strategies for RFID Implementation
• Read-Only Strategy
• Pass/Fail Strategy
• Standard Read/Write Strategy
• Mixed Read Only / Read/Write Strategy
• Your Own Unique Strategy
RFID Application Case Studies
The following case studies are taken from real-world RFID applications our
customers have put to good use.
In one proven configuration, a company applies disposable RFID labels to their
products during manufacturing and then tracks them, via RFID, throughout the entire
distribution channel. From manufacturing through retail and out to customers, the
complete supply chain history is stored directly within the product. In essence, this
method of using RFID labels creates "smart products"
that can communicate with their surrounding
environment.
RFID Helps Get Your Motor Running
An ingenious example of using RFID to create an
electronic manifest belongs to an automobile maker
that was looking for ways to improve and streamline their
engine manufacturing procedures.
Initially, an RFID tag containing routing and build
instructions is attached to an engine carrier. As the engine
and carrier approach each production station, the tag is read by
Chapter 1: Getting Started
19
an RFID controller which first determines whether or not the engine should be at the
given station. If affirmative, the build information is read from the tag and transferred
back to the Host. The Host then instructs automated equipment such as computer
numerically controlled (CNC) mills, nut-runners and inspection equipment, to carry
out the build instructions for that production station.
After each operation is performed, important quality data and/or production results
are written to the tag before the engine carrier is sent to the next station. This allows
their workers to later investigate any quality issues quickly across varying lots.
Should an operation fail or is found to be unsuccessful, a failure code is written to the
tag. Then, as the engine carrier reaches the next production station, the failure code
is read from the tag and the engine is rerouted to a rework station. At the rework
station, the tag is once again read to determine where the failure occurred, why it
occurred and how the engine must be repaired. After successfully reworking the
engine, the successful code is written to the tag and the carrier can be transferred
back into the production line.
Furthermore, because time stamp and production station ID numbers are tracked
with each engine carrier, and are later stored in a master database, all engines built
at a given production station or within a specific time span can be easily identified.
Providing a means of locating only those parts that have common manufacturing
traits, this can be extremely useful should a quality concern arise and a recall is
required. RFID tracking has helped this company minimize the number of engines
affected in quality concern bulletins.
Also, because specific build instructions were initially written to the tag, the same
production line can be used to produce multiple engine models, eliminating the need
for dedicated production lines.
In the electronics industry, companies are taking the electronic manifests a step
further, by using RFID to enable production line operations to continue even if the
Host fails or goes off-line. With specific build instructions pre-written, the tag can
communicate directly with a local RFID controller at a given station, all build
instructions related to that station, are able to continue uninterrupted.
RFID Labels Make Television Sets “Smart”
During production, a large television set
manufacturer affixes RFID labels to the
inside housing of each television. After
utilizing RFID labels for tracking purposes
(as explained above), the labels accompany
the new "smart TV sets" into the warehouse.
In the warehouse, the labels are used for
locating a specific model and for routing
different models to their intended storage
locations.
Moreover, with the ability of RFID controllers
to communicate with multiple labels within
the same antenna field, all “smart TVs” can
be read or written to as they exit the
warehouse, regardless of whether the
televisions are stacked on pallets or
Chapter 1: Getting Started
20
transported individually. This process enables the company to write destination
information to the tag and to record shipping invoices, providing the trigger for
automated electronic billing.
Upon reaching the distribution center, the "smart TVs" are read upon entering the
building, providing instant receipt for inventory systems and automatic payment for
suppliers.
The "smart TVs" are then
distributed and tracked into their
retail outlets where the label is
used for anti-theft and real-time
inventory management. Finally,
when the television is
purchased and leaves the store,
customer and product
information is written to the
RFID label.
Should the customer ever return
the television to a service center,
the TV’s complete record can
be instantly accessed on a
computer (even before the
customer has reached the
service counter).
How’s that for bringing
service to a new level?
Chapter 2: Hardware Description
21
Chapter 2 ● Hardware Description
This chapter contains descriptions and diagrams of the HF-0405 hardware and
explains your options for choosing compatible RFID tags.
Dimensions and Diagrams
The images below contain the dimensions of the HF-0405 RFID
Controller.
Chapter 2: Hardware Description
22
Installation and Mounting Guidelines
RFID Installation Checklist
• Know your Application Requirements (see below).
• Know the benefits you expect to achieve.
• Select experienced integrators (contact Escort Memory Systems for a list of
knowledgeable integrators).
• Develop a list of environmental concerns: metal, monitor emissions, temperature.
• If a new approach is being taken to applying RFID, run a pilot test of the
proposed solution.
• Acquire and test all user supplied components (see Chapter 1).
• Train in-house personnel, regardless of position or data capture experience.
• Use only Escort Memory Systems approved cables and connectors (see
Appendix B for a list of recommended cables and accessories).
Know Your Application Requirements
• Application Line Speeds: (how fast do your product lines, conveyor belts travel?)
• Number of Read Stations: (how many RFID controllers will you need?)
• Connectivity: (Will the HF-0405 connect to a PC, PLC or Bus?)
• Mounting Surfaces: (where will the HF-0405 be mounted?)
• Temperatures: (Is the mounting area near sources of extreme heat?)
• Tag Memory and Memory Maps: (How much tag memory space will your
application require and have you developed a map outlining where your data will
be stored?)
• Read Only vs. Read/Write: (will your application read tags, write to tags, or
both?)
• Read/Write Range: (what is the projected distance between the proposed
mounting location and the tag path?)
• Disposable vs. Reusable Tags: (Will tags be reused, or will they be written off,
disposed or destroyed?)
• Target Tag Pricing and Volume: (How many tags will you regularly use and what
is the level of quality of the tag your application should have?)
• Requirements for Maintenance and Support: (who will maintain, backup and
support your entire RFID system?).
Chapter 2: Hardware Description
23
Antenna Environment
The antenna that is used to communicate with RFID tags is integrated within the
housing module of the HF-0405 RFID Controller. Electromagnetic interference (EMI)
and the presence of metal near the reading field of the antenna can affect the
communication range of the RFID controller. The maximum distance from tag and
antenna should not be greater than 10cm.
Antenna Range
Antenna to Tag Range
Need Actual
Data &
Images
Chapter 2: Hardware Description
24
Mounting the HF-0405
1. Select a suitable location for the HF-0405 where it will
be isolated from electromagnetic radiation.
2. Securely attach the HF-0405 to the L-Mounting
Bracket using the hardware provided. The HF-0405
has two mounting holes in the enclosure which will
accept the included screws. Recessed Hex patterns in
the enclosure eliminate the need for locking washers
on the nuts. Do not use thread locking compounds on
the screws or nuts.
Torque specification for screws: .7 Nm or equivalent 6 Lbs
/ inch. This goes for the controller screws as well as for the
mounting of the bracket.
3. Fasten the other end of the Mounting Bracket to the
work area you have selected. The controller may be
mounted horizontally or vertically but should be
mounted in such a manner that the LED indicators can
easily be seen during operation. Stay well within the
RF field of the controller for the tags you plan to use.
4. Maintain at least 20 centimeters minimum spacing between adjacent HF-0405
units (other RF devices operating on the same frequency may require greater
distances of separation).
Words of Caution
Avoid mounting the HF-0405 to metal or near sources of EMI and electrical noise. Do
not route cables near other unshielded cables or wiring carrying high voltage or high
current. Only cross cables at perpendicular intersections and avoid routing cables
near motors and solenoids. Because electrical noise from other sources can be
conducted through metal, a polycarbonate mounting bracket is provided to isolate the
HF-0405 from this potential cause of problems.
The 0405 Controller contains ESD sensitive components. Always observe ESD-
sensitive procedures when mounting the controller. Mounting the controller
improperly can damage the unit and may void the HF-0405’s warranty.
The HF-0405 is designed to withstand 8kV of direct electro-static discharge (ESD)
and 15kV of air gap discharge. However, it is not uncommon for some conveyor
applications to generate considerably higher ESD levels. Use adequate ESD
prevention measures to dissipate potential high voltages.
Chapter 2: Hardware Description
25
RFID Tags
Overview
RFID Tags, also referred to as transponders, smart labels, or inlays come in a variety
of sizes, memory capacities, frequencies, temperature ranges, read ranges and
embodiments. The HF-series controllers are capable of reading all of Escort Memory
Systems’ HMS and LRP series tags as well as tags made by many other
manufacturers. It is important to know that not all 13.56MHz tags are compatible and
even tags that are compliant to the ISO15693 or ISO1443 standards may not be
compatible with RFID controllers compliant to the same standards. This is because
these standards leave many features open to the discretion of the RFID equipment
manufacturers to implement or define. When using any tag other than those supplied
by Escort Memory Systems ensure compatibility of those tags with your RFID system
provider.
As of this publication, tags that contain the following RFID ICs are compatible with
the HF-0405-series controller.
HMS Series:
• Philips Mifare Classic, 1k-byte* + 32-bit ID (ISO 14443A)
• Philips Mifare Classic, 4k-byte** + 32-bit ID (ISO 14443A)
*Mifare 1k-byte is the total EEPROM memory in the IC. Of this
memory, 736-bytes are available for user data.
**Mifare 4k-byte is total EEPROM memory in the IC. Of this memory,
3,440-bytes are available for user data.
Chapter 2: Hardware Description
26
LRP Series:
• Philips ICODE 1, 48-byte + 64-bit ID
• Philips ICODE SLi, 112-byte + 64-bit ID (ISO 15693)
• Texas Instruments Tag-it, 32-byte + 64-bit ID (ISO 15693)
• Infineon My-D Vicinity, 1k-byte + 64-bit ID (ISO 15693)
The tags listed above are all are passive devices, meaning that they require no
internal batteries. These tags are read/write tags except for their unique ID number
(serial number) which is read only. There are no serviceable or repairable parts
inside a tag; however, most tags are rated for over 100,000 write cycles and 10-years
of data retention. The write cycle life specification of 100,000 times is actually a
conservative number as test results of over one million write cycles have been
recorded.
Many factors can affect the performance between the controller’s antenna and the
tag’s antenna. These include; the tag integrated circuit (IC), the antenna coil design,
the antenna conductor material, the antenna coil substrate, the bonding method
between the tag IC and the antenna coil, and the embodiment material.
Additionally, the mounting environment of the tag and controller can hinder
performance due to other materials affecting the tuning of either antenna. Escort
Memory Systems has spent extra effort to produce the best quality tags that obtain
optimum performance with our RFID controllers. In most cases, optimal conductivity
will be obtained when mounting the tag and controller antennas in locations free from
the influence of metals and EMI devices.
It is also important to select tags and controllers which have optimum inductive
coupling characteristics. Typically, the larger the tag’s antenna and the controller’s
antenna, the better the range performance achieved. However, mismatched antenna
sizes will have negative performance effects. Consider that the power and
communication between the tag and the controller is made through inductive
coupling between two coils as in a transformer. With a large antenna coil on the
controller side (primary winding) and a small antenna coil on the tag (secondary
Chapter 2: Hardware Description
27
winding) poor inductive coupling will occur. Additionally, the flux density of the
magnetic field may not be dense enough for the lines of flux to couple with a small
tag’s coil resulting in read nulls (dead spots) within the RF field. Alternately, a small
antenna coil on the controller side and a large antenna coil on the tag will also
produce poor results.
Given the variety of influences that may affect read and write performance, it is
important to choose the controller and tags with these concerns in mind and it is
always recommended to test the system on a small scale before implementing a
large scale installation. Be sure to review the tag datasheets to ensure proper
selection and the best combination of tags for your application.
Tag Embodiments
RFID Labels and inlays or inlets are
the lowest cost solution and are
typically used in an open
system in which the tag
leaves the facility on the
product or is destroyed
at the end of the
process.
The process of
creating the antenna
coil pattern is critical.
Typically, lower cost
processes such as printing,
produce the lowest quality
antenna. Low quality antennas go into
low quality tags that exhibit poor conductivity or
cracking when flexed.
An inlay is a substrate (polyester, Mylar etc.) with a printed,
screened or etched antenna coil. Sometimes the coil can even be
a wire that is laid down onto the substrate and is bonded to it with heat.
Typically the RFID IC is attached by means of flip-chip technology and the electrical
connections are made by means of conductive epoxies.
Wire wound coils tend to produce the most
efficient RF conductors and survive flexing
well but are often more expensive because
they take longer to produce. Labels or
Inlays with etched copper antenna coils
tend to be the most reliable low cost
solution, providing consistent low
resistance coils and flexible inlays.
However, because etching is a subtractive
process, much of the copper is etched
away during the fabrication process
resulting in higher prices due to the cost of
the metals being discarded.
Inlays can be applied to sticker-backed
paper to create label tags which is usually
Chapter 2: Hardware Description
28
done in large volumes on roll to roll production equipment. Inlays can also be used in
laminated cards such as smart credit cards, providing a low cost tag with some
protection from impact damage.
As RFID grows, there are many developments being made in the area of mass
production, low cost, quality antenna coils. One area of promise is the process of
electroplating printed or screened coils with copper to improve conductivity.
PCB Tags produced by Escort Memory Systems are designed for encasement inside
totes, pallets, or products that will offer the protection normally afforded by an
injection molded enclosure. These tags are
made from etched copper PCB materials
(e.g. FR-4) that are die bonded, by means
of high quality wire bonding, to ensure
reliable electrical connections that are
superior to flip-chip assembly methods.
The RFID IC is then encapsulated in epoxy
to protect it and the electrical connections.
Molded tags also utilize Printed Circuit
Board technology and are the most rugged
and reliable of the tags offered by Escort
Memory Systems. These tags are
designed for closed loop applications
where the tag is reused so the additional cost of the tag can be amortized over the
life of the production line. Typically these tags will be mounted to a pallet or carrier
that transports the product through the production process. Other applications for
these tags include, but are not limited to: embedding the tag into concrete floors for
location identification by forklifts and Automatically Guided Vehicles (AGVs), shelf
identification for storage and retrieval systems, and tool identification.
Escort Memory Systems offers a wide variety of molded tags that have been developed
over the years for real world applications. High temperature tags using patented
processes and specialized materials allow tags to survive elevated temperatures, such
as those required for automotive paint and plating applications.
Tag Memory
Tag memory varies in capacity and organization. The memory is organized in blocks
of bytes which vary from RFID IC manufacturer to manufacturer. Even when
compliant to ISO15693, the bytes and memory addressing can differ from one
manufacturer to another. Most commonly the bytes are organized in blocks of 4 or 8
bytes depending on the RFID IC. All of the bytes may not be available for data as
some bytes may be used for security and access conditions. For more information
about a specific RFID tag’s memory allocation, please refer to the IC manufacturers’
website for product data sheets.
Escort Memory Systems has taken great care to simplify the addressing of tag
memory. Mapping logical addresses to physical addresses is handled by the HF-
0405 Controller’s operating system. All a user needs to know is the starting address
at which data should begin and the number of bytes to be written or read. However,
extra attention should be paid to the memory block structure when memory lock
commands are used. When data is locked, it can never be changed. All data within
the block of addresses specified will be locked. Caution should be exercised when
using memory lock commands as it cannot be unlocked, even by Escort Memory
Chapter 2: Hardware Description
29
Systems.
Tag memory addressing begins at Address 0, therefore the highest addressable
memory location is one less than the total number of bytes in the tag (address count
does not start at one). Each address is one byte (8-bits) and a byte is the smallest
unit addressable. For example, writing 8-bytes of data beginning at address 0 will fill
addresses 0 to 7 with 64-bits of data in all.
Tag memory size is often specified by the number of bits, as this produces a larger
number (8x) and inflates product specifications. Escort Memory Systems however,
prefers to specify tag size in terms of bytes, as it is typically what our customers are
really interested in knowing and more closely reflects how the data is stored and
retrieved from a tag.
Tag Memory Map
For any application, the use of the tag memory should be well thought out. It is
advisable to allow more memory space than is initially required, as inevitably a need
will arise to store more data. A memory map is simply a definition of what data will be
stored at what locations on the tag for the application. For example:
Example of a Tag Memory Map
Address 00 -15: Product Serial Number
Address 16 - 47: Model Number
Address 48 - 63: Date of Manufacture
Address 64 - 71: Lot Number
Address 72 - 87: Factory ID
Address 88 - 111: Reserved for future use
Memory Optimization
In the example above, a 112-byte tag is used. This may not seem like much data
storage space when one considers that this would only allow for a short paragraph of
alpha-numeric characters. But employing a sophisticated memory map utilizing all
896-bits in this tag would provide much more usable data space in the tag.
It should first be understood that data is always stored in tag memory in a binary form
of 1’s and 0’s. The standard method of notating binary data is to use the hexadecimal
numbering system. Otherwise it would be far too confusing looking at a screen full of
1’s and 0’s.
Below is an example of how hexadecimal notation simplifies the expression of
decimal and binary numbers. This example shows the decimal value 52,882, its
binary equivalent and its 2-byte Hex integer:
Decimal Binary Hexadecimal
52,882 1100111010010010 CE92
Chapter 2: Hardware Description
30
When the character “D” is typed on the keyboard, for instance, the ASCII code
representing the capital “D” is stored to the tag, which, in this case, would be the
hexadecimal value 0x44. So in the example above, instead of using 5-bytes of data
to store the ASCII bytes representing characters 5, 2, 8, 8, and 2 (ASCII bytes: 0x35
0x32 0x38 0x38 0x32) simply writing the two bytes 0xCE and 0x92 serves the same
purpose while using 60% less memory space on the tag. (Refer to Appendix C in this
document for the ASCII table).
Additionally, if a database program with look up values is used in the RFID
application, the logic level of the individual bits in the tag can be used to maximize
tag memory.
The following example shows how a single byte of data can be used to track an
automobile at eight production stations. The binary value one (“1” ) in this example
represents a required operation and the value zero (“0”) represents an operation that
is not required.
Chapter 2: Hardware Description
31
ISO 1443A/B
RFID ICs designed to support ISO 14443A and/or 14443B were originally intended
for use in “smart cards.” Today, for example, smart cards are being used to facilitate
financial transactions in banking, passport, bus and ski lift ticketing applications. For
this reason there are many security authentication measures taken within the “air
protocol” between the RFID controller and the tag.
Escort Memory Systems was the first RFID company to adopt ISO 14443 Standards
into its’ RFID ICs which were initially designed for industrial automation applications.
Because the typical RFID application does not require security levels that of which
monetary applications necessitate, certain security features have not been
implemented in the HF-0405 Controllers. It is important to understand the security
requirements of your application before assuming the HF-0405 is suitable.
Tags that have built-in security features require the exchange and authentication of
software “keys”. To authenticate communication and permit the transfer of data to
and from the tag, the RFID controller and tag must use the same security keys.
This authentication ritual is carried out with every command from the RFID controller
and on every block of tag data. The HF-0405’s operating system (HFOS) manages
security transparently to the user. The HF-0405 not only supports Escort Memory
Systems’ security keys, it supports the default transport keys supplied by many other
IC manufacturers.
ISO 15693
The ISO 15693 Standard was established after the RFID industry identified that the
lack of standards was preventing the market from growing to a greater potential. At
the time, Philips Semiconductor and Texas Instruments were the two major chip
manufacturers producing RFID ICs for the ISM frequency of 13.56MHz. Yet each
used their own unique protocol and modulation algorithm. Through ISO 15693, Texas
Instruments’ Tag-it and Philips Semiconductors’ ICODE product lines were
standardize on mutually compatible standards.
After standardizing to ISO 15693, the door opened for other silicon manufacturers to
enter the RFID business, many of which have contributed to this and other ISO
Standard definitions.
This healthy competition has spawned rapid growth in the industry and has led to the
development of other standards, such as ISO 18000 for EPC applications.
ISO 18000-3.1
The ISO 18000 standard has not been implemented in the HF-series controller at the
time this guide was published. It is, however, a planned product enhancement for
future release which will provide support for EPC and UID tag applications.
Some ISO
14443 tags
made by other
manufacturers
might not be
readable by HF-
0405 controllers.
Likewise, an
Escort Memory
Systems ISO
14443
compatible tag
may not
communicate
properly with a
controller from a
different
manufacturer.
Test your
proposed RFID
tags thoroughly
to ensure
complete
compatibility.

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