Checkpoint Systems WRTZ1500 RFID UHF Reader User Manual Users manual

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Box Tunnel Read Station
User’s Manual
Revision 02
CKP P/N 10071147
Checkpoint Systems, Inc.
Checkpoint Systems International GmbH
Ersheimer Str. 69
69434 Hirschhorn
(06272)928-0
Box Tunnel Read Station User’s Manual
Copyright © 2016 by Checkpoint Systems, Inc. All Rights Reserved.
Checkpoint® is a registered trademark of Checkpoint Systems, Inc.
Published by:
Checkpoint Systems International GmbH.
Ersheimer Str. 69
69434 Hirschhorn
Germany
Part Number: 10071147
Revision: 02
Last Modified: October 17, 2016
Trademarks
Checkpoint is a registered trademark of Checkpoint Systems, Inc.
Other product and company names herein may be trademarks of their respective owners.
“Microsoft, Windows, and Windows NT are registered trademarks of Microsoft Corporation in
United States and/or other countries.”
Other products © or ® their respective manufacturers or copyright holders.
Copyright and Warranty Information
The information in this guide is subject to change without notice.
Because of the changing nature of this product information presented, Checkpoint Systems,
Inc. is not liable for any omissions, misstatements, or other errors of information.
The information presented in the User’s Manual may not be copied, used or disclosed to
others for the purpose of procurement or manufacturing without the written permission of
Checkpoint Systems, Inc. This guide and the products discussed in this guide are the
exclusive property of Checkpoint Systems Inc. Copyright laws of the United States protects
all information and products.
© Checkpoint 2016. All rights reserved.
Doc. PN 10071147 | Revision 02
Box Tunnel Read Station User’s Manual
Page 2 of 16
Table of Contents
1 REVISION CONTROL .............................................................................................4
1.1 Revision History...............................................................................................4
2 SAFETY INFORMATION .........................................................................................5
2.1 Basic Safety Information ..................................................................................5
2.2 Cautions For Doors and Powered Devices ......................................................6
3 INTRODUCTION .....................................................................................................7
3.1 System Design 3D View ..................................................................................7
3.2 Versions Overview ...........................................................................................8
3.3 Installation Requirements ................................................................................8
3.4 Box Tunnel Read Station Hardware Overview .................................................9
3.4.1
3.4.2
Main Hardware................................................................................................................. 9
Light Stack (Signal Tower) .............................................................................................. 11
3.5 Start Up Sequence ........................................................................................ 11
3.6 Normal Operation ..........................................................................................12
3.6.1
3.6.2
3.6.3
3.6.4
3.6.5
RFID Start Sensor .......................................................................................................... 12
RFID Stop Sensor .......................................................................................................... 12
Fixed Antenna ................................................................................................................ 12
External Interfaces ......................................................................................................... 12
Relay Functions ............................................................................................................. 12
4 TECHNICAL DATA .................................................................................................14
4.1 Mechanical Data ............................................................................................14
4.2 Electrical Data ...............................................................................................14
4.3 Environment Specification .............................................................................14
4.4 Schematics and Diagrams .............................................................................14
4.5 Cable Entry Module Handling Instruction .......................................................15
4.6 Declaration of Conformity ..............................................................................16
© Checkpoint 2016. All rights reserved.
Doc. PN 10071147 | Revision 02
Box Tunnel Read Station User’s Manual
Page 3 of 16
1 Revision Control
1.1 Revision History
Content changes to this document from its previous version to the current level are indicated
by Microsoft Word track changes bars (|) in the left margin of the document unless a
complete rewrite is indicated. Accept all tracked changes to the current document before
updating it. This procedure highlights the new changes made to the document by the author
thus facilitating efficient review of the document.
Revision #
Revision Date
Change Description and Explanation
Created/Changed By
00
20.01.2016
CR2633K
Heiko Doering
01
20.06.2016
CR2633N
Heiko Doering
02
12.10.2016
CR2633P
Heiko Doering
© Checkpoint 2016. All rights reserved.
Doc. PN 10071147 | Revision 02
Box Tunnel Read Station User’s Manual
Page 4 of 16
2 Safety information
2.1 Basic Safety Information
• All trained Field Service Technicians, installers and operators must read this
document before using the Box Tunnel Read Station for the first time. This
document explains the intended mode of operation. Please keep this document for
later reference.
• The Box Tunnel Read Station is used for contact less reading of RFID (Radio
Frequency Identification) Tags. Use only in the manner described.
• Never use the Box Tunnel Read Station in areas where there is a danger of explosion.
• Follow all safety warnings (see Page 6 below) on the equipment. Depending on
your role and responsibility for installation, maintenance or normal use of the
product, please acknowledge the safety precautions described in the Installation
Manual (CKP P/N 10085388) and/or your local Maintenance Manual(s).
• All safety notices in this manual are identified with a Caution symbol shown at left.
Caution indicates the possibility of system equipment failure, whereas a Warning
symbol (below left) indicates danger of bodily harm or other serious injury or
even death.
• It is essential to comply with the electrical, mechanical and environmental
specifications given in the Technical Data section.
• Users (Operators) are NOT permitted to make any changes or modifications to the
hardware, electronics or wiring. Checkpoint-certified technicians are permitted to
make electrical changes to non-radio circuitry (e.g., custom wiring for site
integration).
• Users are not permitted to make any mechanical modifications, and it will void all
guarantee claims if changes are made.
• Dispose of the Box Tunnel Read Station properly after taking out of service. Never
put this product into the normal household waste.
© Checkpoint 2016. All rights reserved.
Doc. PN 10071147 | Revision 02
Box Tunnel Read Station User’s Manual
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2.2 Cautions For Doors and Powered Devices
The Box Tunnel doors are removable, but this should not be done unless necessary. Never
bypass the switches.
Warning: The safety precautions described below must be observed at all times.
Please observe the Pinch Point and Live Voltage warnings on the system (see table below).
Sign
Safety Precaution
Control Box is under Live Voltage
Before opening the Control Box disconnect mains;
to service the electronics, fully remove the electrical
plug from the AC Mains socket.
Even when the Mains Control Switch is in the OFF
position or the fuse F1 is off, parts of the device can
be under live voltage.
“Pinch Point”
Keep hands/fingers clear of openings and when
applying or removing the enclosure doors.
Where these labels are applied, there is a potential
for squeezing or physical harm.
At the entrance and exit opening of the tunnel,
there is a high risk to get squeezed between a box
on the conveyor and the housing entrance.
Never put a hand or other body parts inside the
openings of the tunnel, except to service. When
servicing the device(s), the system must be turned
off completely as described above.
© Checkpoint 2016. All rights reserved.
Doc. PN 10071147 | Revision 02
Box Tunnel Read Station User’s Manual
Page 6 of 16
3 Introduction
3.1 System Design 3D View
Box 500 enclosure with parts hidden to reveal components inside the tunnel enclosure.
Component Name
Control Box
Light Stack
RFID Start Sensor / Beam Switch control signal
RFID Stop Sensor
Antenna 1 (Top)
Antenna 4 (Left)
Antenna 3 (Bottom, fixed pattern antenna)
Antenna 2 (Right)
© Checkpoint 2016. All rights reserved.
Doc. PN 10071147 | Revision 02
Box Tunnel Read Station User’s Manual
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3.2 Versions Overview
CKP P/N
Omnify
Description
Region
Detailed description
10093429
*BOX TUNNEL
READ 500 ETSI
ETSI
RFID Read tunnel, sometimes called
“Assignation Station V2.”
This size tunnel supports boxes (shipping
containers) up to 600mm in height and
conveyor widths up to 500mm. The physical
enclosure has an entrance/exit opening that is
650mm in height.
See table below for English measure
conversions from metric standard (SI).
10040615 *BOX TUNNEL
READ 800 ETSI
ETSI
Tunnel for 800mm conveyor width, 500mm
box height, 550mm opening height.
10054589 *BOX TUNNEL
READ 500 FCC
FCC
FCC region performance; Tunnel for 500mm
conveyor width, 600mm box height, 650mm
opening height.
10073543 *BOX TUNNEL
READ 800 FCC
FCC
FCC region performance; Tunnel for 800mm
conveyor width, 500mm box height, 550mm
opening height.
Metric (SI)
*English,
Imperial Units
400mm
15.75in
500mm
19.69in
550mm
21.65in
600mm
23.62in
650mm
25.59in
800mm
31.50in
*Rounded to the nearest 1/100th of an inch.
3.3 Installation Requirements
Installation must be done by a Checkpoint Field Service technician trained for the
installation of this hardware.
Between 1 and 4 Ethernet/LAN Ports must be provided by the customer near the
house installation position. The customer LAN port(s) should be no more than 5m away
from the control box. Refer to Section 4.2 Electrical Data for AC mains requirements.
If there is a need to replace or add cables into the control box, refer to Section 5.4
Cable Entry Module Handling Instruction for the description of the SKINTOP CUBE
cable entry module.
© Checkpoint 2016. All rights reserved.
Doc. PN 10071147 | Revision 02
Box Tunnel Read Station User’s Manual
Page 8 of 16
3.4 Box Tunnel Read Station Hardware Overview
The Box Tunnel Read Station is a large enclosure with main components listed below:
•
•
•
•
UHF RFID Reader (WRTZ-1500 with housing)
fixed beam antenna
beam switch antennas
“Standard” Light Barrier (Beam Break) Sensors
There are several other important components such as the I/O Board for DC
Applications, and secondary Sensors and a Barcode Scanning device, and their host
electronics, involved with the solution. The following components are also standard:
•
•
•
•
Control box
Light stack
(4) Lever action Switches to detect open doors
Shielding chambers (i.e. the walls)
3.4.1 Main Hardware
All antennas and electronics are mounted inside shielding to reduce RF spill to other
stations. There is no need to disassemble the conveyor at the installation. The enclosure
is designed to be built up around the conveyor.
Detection of the RFID tags/labels and the process for starting and stopping the RFID
Reader’s inventory (EPC read) are discussed later on this document.
Users do not typically have access to the control box electronics (5).
If advanced user maintenance or troubleshooting is expected, additional documentation
will be provided.
Note: Box 500 with two doors opened to show the internal components.
© Checkpoint 2016. All rights reserved.
Doc. PN 10071147 | Revision 02
Box Tunnel Read Station User’s Manual
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#
Name and Manufacturer
Antenna, Beam switch, Checkpoint (P/N varies by region)
Beam Sensors (2 inside enclosure), Leuze HRT-46B/66-S12
Light Stack, Werma 69750055
Door switches, Honeywell 9432580
Control Box, assembled by Checkpoint or an external manufacturer
Antenna, Kathrein (P/N varies by region)
Name and Manufacturer
Fuse, D4A, Schneider C60HD104 - 25698
Safety Relays, Zander Aachen SR3C
10
11
12
Time Relays, Finder 82.01.0.240.0000
Relays, Finder 38.62.0.024.0060
RFID Reader, WRTZ-1500, Checkpoint 10034075
PCB, I/O Board for DC Applications, Checkpoint 10089472
13
14
15
16
17
18
19
PCB, RF Circulator board, Checkpoint 10056858
Cable, Antenna Coax, 4,7m, for Beam switch Antenna, Checkpoint 9432018
Cable, Antenna Coax, 2,5m, for Kathrein Antenna
PSU,12V DC for Reader, XP Power, 7421850
PSU, 24V DC, (P/N and Manufacturer will vary by region)
Startup Button
AC Mains Control Switch (power switch)
Discuss your requirements for spare parts with your Local Checkpoint Representative.
Parts may be pre-ordered to have on site as spares.
© Checkpoint 2016. All rights reserved.
Doc. PN 10071147 | Revision 02
Box Tunnel Read Station User’s Manual
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3.4.2 Light Stack (Signal Tower)
The light stack has three colors as indicators for the current status of the system.
Signal
Continuous on (or flashing)
Off
Red
Error/ Conveyor stopped
Normal operating mode
Amber
Reader’s RF transmit is on;
several other optional meanings
RF off
Green
System Health Status OK
Possibly no power/ wiring or
relay issue
All on
All LEDs are illuminated during startup
All off
Power is off
Note: LED states are configurable.
Combinations of the colors are expected (e.g. red and green LEDs both on at the same
time). For your unique application, Checkpoint FS/Engineering will provide documents
that indicate what each color means for your use case/control wiring.
3.5 Start Up Sequence
To start using the Box Station, the Operator must turn the Mains Control Switch to the
ON position. Immediately after, the 24V PSU and the safety relay (B4) are powered.
There is a Push Button Startup switch on the front of the Control Box. The start button
will be green (LED is illuminated), and this indicates that the system is ready to be
turned ON. The Operator must press the switch to initiate the start up.
Immediately after, the RFID Reader and additional relay components in the circuit are
powered. After approximately one minute (60 seconds), the system will be operation
(RFID Reader is booted up and the Light Stack changes color to Green or goes off,
depending on the configuration).
As an Optional feature, the system can be programmed to send a “Ready” signal to the
conveyor PLC to start the conveyor.
To turn Power OFF:
Turn the Mains Control Switch to the OFF position.
© Checkpoint 2016. All rights reserved.
Doc. PN 10071147 | Revision 02
Box Tunnel Read Station User’s Manual
Page 11 of 16
3.6 Normal Operation
The Box Station will detect EPCs which are previously encoded to the RFID tags/labels
which pass through it in lots (sometimes called “Bundles”). The “EPC-LOT” streaming data
is processed by an external system, either a Server (OAT Edge Box) or even cloud
services. The system can only accurately distinguish the EPC belonging to one shipping
container from another if it is properly tuned and there is adequate distance between
boxes. The minimum distance between boxes is a function of the speed of the conveyor.
Refer to the Marketing Sell Sheets and/or Installation Manual for more details.
3.6.1 RFID Start Sensor
The start sensor is positioned nearer to the tunnel entrance than the stop sensor. The
sensor’s rising edge signal is triggered by the leading edge of the box. The sensor’s
secondary signal is also triggered, and remains held in a low state while the box is
present. The Beam Switch function is driven without interaction with the RFID Reader.
When the antennas are “switched” this means the sensor detects a container/box in front
of it. The RFID Start Signal (Sensor 1 input) is routed to GPI2, and the reader turns on
Inventory when the signal arrives.
3.6.2 RFID Stop Sensor
The stop sensor only uses the primary output (only 1 connector attached to this cable,
while the start sensor has 2 connectors from it, accordingly). Its role is to tell the RFID
Reader to stop Inventory. The container/box in motion passes the sensor, which causes
the falling edge signal, which is what the I/O Board and RFID Reader are programmed to
look for. When the box passes, RFID reads stop.
3.6.3 Fixed Antenna
The RFID UHF Pattern is directional, with the polar pattern aimed toward the tunnel exit.
This antenna only transmits, like the others, between events of RFID Start and RFID Stop
trigger signals.
3.6.4 External Interfaces
The RFID Reader’s ETHERNET port will typically be connected to a LAN port for
customer network access (or else an “unmanaged switch”) where a local network can be
set up for the devices involved with the total solution to exchange communications. There
is a standard TCP/IP port reserved for incoming messages (OFS signaling to Wirama).
PuTTY can be used to see the outbound (EPC-LOT) streaming data or to check integrity
of the incoming messages.
There is also a cable reserved for hard-wired signaling to an external conveyor relay for
emergency Stop/Start of the conveyor based on reader events (see X3 Interface section
below).
3.6.5 Relay Functions
S1 is the Mains Control Switch (Power ON/OFF). S2 is the Start button with LED.
S3 to S6 are the Door switches. They are in series with the Safety Relay which can power
down the 12V Power Supply, causing the RFID Reader to shut off; meanwhile, the relay
triggers the appropriate Light Stack LED to indicate processing has halted.
When S1 is ON, the 24V PSU and the Safety Relay B4 are powered.
After momentary actuation of the Start button (S2 Switch) the reader PSU gets power and
K3 receives power.
When time relay K3 starts, K3-15/18 contacts are opened for one minute (60 seconds) .
During this time the reader boot up and set its outputs in a defined condition. The K315/18 will close after the defined time (one minute).
© Checkpoint 2016. All rights reserved.
Doc. PN 10071147 | Revision 02
Box Tunnel Read Station User’s Manual
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The output to the PLC (Programmable logic controller) is then controlled by the reader.
This is the normal operating mode.
3.6.5.1 Input/Outputs and Door Switch shutdown
When GPO4 of the reader changes its state to turn on the red light from the signal tower,
the relay K2 will open the contacts K2-21/22. With (optional) wiring, the open contact
(normally closed circuit, now open) is the signal to the conveyor PLC telling it to stop the
conveyor.
When a network failure appears the reader will change the state of all Outputs. All 3
indicators from the signal tower off and K1-21/22- open the switch contact to the conveyor
PLC-information to stop the conveyor.
Opening a door will activate the safety relay B4.
The contact B4-13/14 will open and the reader PSU gets switched off.
The contact B4-23/24 will open and give a stop signal the conveyor PLC.
The contact B4-41/42 will close and P1 illuminate the Start switch S2 then.
The safety relay will remain in this state until all doors are closed again and the Start
button gets actuated to reset the safety relay.
3.6.5.2 X3 Interface function:
The interface X3 is a preassembled connector. Available from pins 3 and 1, the normally
closed circuit indicates normal operation. If a network failure, one of the 4 doors gets
opened or a power failure appears the contact between these pins gets an open state.
© Checkpoint 2016. All rights reserved.
Doc. PN 10071147 | Revision 02
Box Tunnel Read Station User’s Manual
Page 13 of 16
4 Technical Data
4.1 Mechanical Data
System Version
Length/
mm
Width/
mm
Height/mm*
Weight/kg
packed
Box 500 versions
2500
1350
1740- 1950 mm
350
Box 800 versions
2500
1600
1740- 1950 mm
400
Note: *height excludes the light stack (add 770mm for height to top of standard light stack).
4.2 Electrical Data
Input Voltage: 100-240 V~; 50/60 Hz; 0,5-0,25A, internal Fuse D4A
At the house installation position must be a mains socket with a fuse of C10A or higher. A
second AC outlet may be required for power connection of (optional) peripheral devices.
4.3 Environment Specification
Operating Temperature
5-45 °C
Storage Temperature
-20 to 65°C
Relative Humidity
5% to 95% non-condensing
4.4 Schematics and Diagrams
The Box Tunnel circuit diagram and wiring diagram of the control box/system components
will be distributed to the responsible Technicians at your site.
© Checkpoint 2016. All rights reserved.
Doc. PN 10071147 | Revision 02
Box Tunnel Read Station User’s Manual
Page 14 of 16
4.5 Cable Entry Module Handling Instruction
SKINTOP CUBE cable entry module
Removing a sealing module:
1. lift the clamping bracket with a screw driver
2. fold away the clamping brackets
3. remove the sealing module out of the
opened clamping brackets
Prepare and inserting of a new cable:
1. select the sealing module according the
cable diameter
2. fit the sealing module parts to the cable
3. insert the sealing module into the frame
4. lock the clamping bracket
Caution: After all changes to the SKINTOP CUBE module ensure that all cables and sealing modules are
properly inserted into the frame. All clamping brackets must be closed.
© Checkpoint 2016. All rights reserved.
Doc. PN 10071147 | Revision 02
Box Tunnel Read Station User’s Manual
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4.6 Declaration of Conformity
© Checkpoint 2016. All rights reserved.
Doc. PN 10071147 | Revision 02
Box Tunnel Read Station User’s Manual
Page 16 of 16

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