Accu-Sort RFR-02 Reference guide

Accu-Sort®Systems, inc.
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Revised:
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RFR-02 READER TEST PROCEDURE
______________________________________________________________________________
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©Accu-Sort Systems, inc.
Note: You shall refer to ERP to determine the Rev. of assembly.
1.0 PURPOSE
This document provides instructions for testing assembly #1000052365 (12 VDC Power) and
1000053245 (10-30 VDC Power)
2.0 SCOPE
This document applies to any of the above items that have the potential of being shipped to a
customer in order to fulfill a sample request or a normal sale. It shall be used by ASI production
when being assembled, set-up or tested at ASI. At the discretion of the appropriate ASI personnel, it
can also be used by outside vendors.
3.0 RESPONSIBILITY
Primary: Production
Support: Manufacturing Engineering
4.0 REFERENCES
GU-ERP-019 Guide to Quality Module Data Entry
SF-QAF-006 Parts Return Reject Repair Tag
SP-QAF-005 Control of Nonconforming Product
WI-QAF-015 In-Process Inspection
1000052365 RFR-02 (12VDC Powered) Assembly BOM
1000053245 RFR-02 (10-30VDC Powered) assembly BOM
5.0 DEFINITIONS
6.0 REQUIREMENTS
Tools Required
RFID Spectrum Analyzer
Universal Counter
3/16” Nut Driver
Variable Power Supply
Philips Screwdriver
Flat Screwdriver
RFA-02 ASI Antenna 5” x 7”
Test Leads (“Jumper Cables”)

Accu-Sort®Systems, inc.
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Issued: 07/06/05
Revised:
TP-ENM-704
Rev. A
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©Accu-Sort Systems, inc.
BNC – BNC Test Cable
Test Laptop or PC (Win32)
Tools Required (cont.)
RFR-02 Power Supply w/AC Cord
ISO 15693 RFID Tag
RFID Tag 7” Test Stand
Input Test Wiring Harness
Output Test Wiring Harness
Serial Cable (9pin Male – 9pin Female) w/Pins 2, 3, and 5 Straight
B&B Electronics Model #485PTBR RS232-RS422 Converter
7.0 PROCEDURE
7.1 Remove the lid from the RFR-02.
7.2 Check external and internal hardware tightness and cable installation (make sure the wiring
harnesses are correctly aligned on their headers, off a pin, etc.).
7.3 Remove the metal cover from the RF section of the board with a flat screw driver.
7.4 Inspect. Visually inspect component soldering quality, particularly the inductor area.
7.5 Install shield over RF section, ensure that all fingers alternate around cover and are gripping
tight.
7.6 Plug in serial cable (RS232) from COM1 of Test PC to the “SETUP” port on the RFR-02.
7.7 On the Test PC, run the program “rfr02setup.exe”.
7.8 Plug in AC power to the RFR-02 reader.
7.9 In the rfr02setup program, go to “Update Firmware”.

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Revised:
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©Accu-Sort Systems, inc.
7.9.1 Go to “Choose File”. The above screen capture shows an example of what happens
after you choose a file. Location of file may vary on from shown.
7.9.2 Select “R02STD05.HEX”, or current released version of firmware.
7.9.3 Click on “Download”; turn on power after a one second delay. (The network LED
(RED) should be flashing which indicates serial activity). Also, when the RFR-02
is being flashed, the progress bar to the right of the “Download” button will
progress from left to right. When the process is complete, you will notice that the
Valid LED and the Network LED on the RFR-02 will flash three times
simultaneously.
7.9.4 Click “OK”.
7.9.5 Close program.
7.10 The BNC connector cable shouldn’t be plugged into any device. Short the inner conductor
to the outside ground of the cable to discharge any electrical build-up.
7.11 Plug the BNC connector cable into the input of the spectrum analyzer. Make sure the
Spectrum Analyzer has been powered-on for at least 1 hour prior to testing. Now we will set
up the Spectrum Analyzer for testing.

Accu-Sort®Systems, inc.
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Revised:
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©Accu-Sort Systems, inc.

Accu-Sort®Systems, inc.
511 School House Road
Telford, PA 18969 U.S.A.
1-800-BAR-CODE
1-(215)-723-0981
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Revised:
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Rev. A
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©Accu-Sort Systems, inc.
7.12 Setting Amplitude On the Spectrum Analyzer (see above picture):
7.12.1 Press “Amplitude”.
7.12.2 Press “2”,”5”.
7.12.3 Press +dbm (top softkey in the “DATA” section of the Spectrum Analyzer).
Reference Level is now set.
7.13 Setting Frequency (13.56MHz) On the Spectrum Analyzer:
7.13.1 Press “FREQUENCY”.
7.13.2 Press “1”,”3”,”.”,”5”,”6” then “MHz” (softkey in the “DATA” section). Center
Frequency is now set.
MHz
+dBm
Trace Button
Clear Write A (when
Trace is previously
pressed)
Max Hold A
(when Trace
is previously
p
ressed
)
kHz

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Revised:
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7.14 Setting Span (500 KHz) On the Spectrum Analyzer:
7.14.1 Press “SPAN”.
7.14.2 Press “5”,”0”,”0” then “KHz”. Span is now set.
7.15 Plug the BNC cable to antenna input #1.
7.16 Verify that the amplitude is +22 dBm. (tolerance ±1.5 dB)
7.17 Press “TRACE”.
7.18 Press the soft key (to the immediate right of the display on the Spectrum Analyzer) “MAX
HOLD A”. This freezes the amplitude.
7.19 Press “PEEK SEARCH”.
7.20 Record the amplitude value.
7.21 Press CLEAR WRITE A. (Top soft key)
7.22 Change the frequency to 27.12 MHz. (This is the 2nd harmonic)
7.23 View the 2nd harmonic amplitude. Refer to step 7.13 for setting frequency.
7.23.1 Press “MAX HOLD A”, and then “PEAK SEARCH”.
7.23.2 Record the 2nd harmonic amplitude. (Always on the negative dBm as small as
possible)
7.23.3 Inspect. Verify that the level is less than -30dBm.
7.24 Press “TRACE”.
7.25 Press the soft key “CLEAR WRITE A”. (This turns off max hold)

Accu-Sort®Systems, inc.
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1-800-BAR-CODE
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Revised:
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7.26 Measure the frequency.
7.26.1 Plug the BNC connector into the universal counter on port “CHA 100 MHz”.
7.26.2 Frequency light must be lit.
7.26.3 Make sure channel A is lit and the gate is at 1 µsec.
7.26.4 Record the frequency. The frequency should be 13.56MHz ± 500Hz.
7.27 Plug the BNC connector back into the input port on the Spectrum Analyzer.

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7.28 Checking Antenna 2 Port.
7.28.1 If “Antenna LED” is lit on the RFR-02, antenna 1 is selected.
7.28.2 Connect the BNC cable to antenna 2 on the RFR-02.
7.29 Go into Procomm.
7.29.1 Set/verify baud rate is 19.2 k and to the correct COM port on the Test PC. (The
RFR-02 always defaults to setup port after we flash the RFR-02)
7.29.2 After flash is complete, type “setup” in lower case letters. (The firmware version
will be displayed) Also note that whenever you reboot the RFR-02, you will see an
ACK (♠or 0x06) transmitted from the RFR-02 about 3 seconds from power-on.
Commands will only be accepted after this is displayed.

Accu-Sort®Systems, inc.
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Revised:
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©Accu-Sort Systems, inc.
7.29.3 Press “?”; Press Enter. (This will show all the parameters of the reader)
Baud SettingComm Por
t

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©Accu-Sort Systems, inc.
Note: All commands must be in CAPS.
7.29.4 Type “ANTENNA3” (press enter) to switch to dual antenna mode. An accepted
command returns a STX and ACK ((☻) 0x02 and (♠) 0x06, respectively). An
INvalid command yields a STX and NAK ((☻) 0x02 and 0x15, respectively). You
can see from the above example that I have both presented.
7.29.5 Type “SAVE”; press enter. (Saves information)
7.29.6 Type “EXIT”; press enter. (Exits out of setup mode)

Accu-Sort®Systems, inc.
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7.30 Type “R299” to get to 2nd antenna. (Note: Antenna status LED should be off)
7.31 Repeat steps 7.17 to 7.25 for antenna 2 measurements.
7.32 Take voltage measurement on pin 1 of U2 from chassis ground. (Result should be
+11.30VDC to +11.40VDC)
7.33 Turn antenna 1 back on by typing “R199”.
7.34 Read Rate Test.
7.34.1 Unplug the RFR-02’s cable from the spectrum analyzer and plug it into the test
RFA-02 antenna.
Result of invalid command
Result of valid command

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7.34.2 Remove cable from antenna 2 and plug into antenna 1 of the RFR-02.
7.34.3 Use the 7” spacer and reference tag. Reference the picture below.
7.34.4 Center the spacer on the antenna; ensure that long axis of test tag is parallel with the
long axis of the antenna.
7.34.5 Type “R199” on the PC five times.
7.34.6 Inspect. Verify that you are always reading 100/100. Note sometimes a 99/100
reading will show up this is acceptable as long as it happens no more than 1 time out
of the five.
7.34.7 Record read rate %.
7.34.8 Change cable to antenna 2 on the RFR-02.
7.34.9 Repeat for antenna 2 by typing “R299” five times.
7.34.10 Record read rate %.

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7.35 Testing Input 1 and 2 Triggers.
7.36 Go to setup mode by typing “setup”.
7.37 Type “ANTENNA1”; press enter. (For trigger switching)
7.38 Type “TRIGGER13”; press enter. Type “TRIGGER 23”; press enter. Type “SAVE”; press
enter. Type “EXIT”; press enter.
7.39 Output port test setup. Verify the following.

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7.39.1 On the variable power supply, the cable from the fixed voltage section (+6VDC)
should be connected to the output port on the reader.
7.39.2 LED Output 2 – yellow wire to anode LED, cathode of LED to negative side of +6V
output (variable voltage output section).
7.39.3 LED Output 1 – blue wire to anode LED, cathode of LED to negative side of +6V
output (variable voltage output section).
7.39.4 Meter is set on +25V reference with voltage set at 5VDC using reference knob to
adjust.
7.39.5 +6V output is set to 5VDC using voltage adjust knob on +6VDC side of power
supply. To check level push Meter button to +6V read bottom scale of voltage
display.
7.40 Plug the test cable trigger input into trigger #2.
Pin 1

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7.41 Measure the voltage between pins 2 and 4 of the test header, voltage should fall between
11.30 and 11.40 VDC.
7.42 Short pin 4 to pin 1 (tapping) on test header using the orange jumper wire cable, this tests
the non-isolated input (+5VDC). For every tap you should again get 20000 on the Procomm
display and the blue LED on the lid should flash as well.
7.43 To test the output of the RFR-02, when you get a valid read, the bottom LED (LED Output
1) will light on the Variable Power Supply. When you get an invalid read, the top LED
(LED Output 2) will light on the Variable Power Supply. Please see image below for
reference.
No Tag
LED
Valid
Read
LED

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7.44 Remove tag and repeat step 7.42, Procomm should display 2NO TAG and the LED
connected between the yellow wire and the power supply should light. Note the blue LED
on the lid should not light.
7.45 Connect Blue jumper wire between common of power supply and pin 5 of the test header.
7.46 Connect Yellow wire to +25V of power supply and tap pin 3 of test header, for every tap
you should again get 20000 on the Procomm display and the blue LED on the lid should
flash. This test evaluates the Isolated input of RFR-02’s Input 2.
7.47 If steps 7.42 through 7.46 pass, the RFR-02’s Input 2 and the Outputs are deemed
functional. Record as passed.
7.48 Move the BNC cable from antenna 2 to antenna 1 and move test connector from input 2 to
input 1 on the RFR-02.
7.49 Repeat steps 7.42 through 7.47 with the only difference being that Procomm will show
10000 with a tag in the field and 1NO TAG when the tag is removed from the antenna field.
7.50 To Test RS232 + RS422 Network Port.

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7.50.1 Type “setup”.
7.50.2 Type “DEFAULT” to default all parameters.
7.50.3 Type “COMM1” for RS232 network.
7.50.4 Type “SAVE” then “EXIT”.
7.51 Power off RFR-02.
7.52 Remove serial cable from setup port.
7.53 Remove test cables from Input 1 and Output connectors.
7.54 Plug in straight through RS232 cable (Pin 2, 3, and 5 only). to the RFR02’s Network port

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7.55 Power RFR-02 on.
7.56 Type “R99” on Procomm after the RFR-02 powers on. Remember, wait for the ACK (♠)
before inputting any commands to the RFR-02. Procomm should display VALID READS:
100/100. This checks the communication for the RS232 section of the Network port.
Record as passed.
7.57 Type “setup”, then “COMM2”, then “SAVE”, then “EXIT”.
7.58 Turn off the RFR-02.
7.59 Remove serial cable from Network port and connect it to the RS233 to RS485 converter
(B&B Electronics Model #485PTBR). See wiring diagram below.
Wait for ACK!

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7.60 Plug the cable connected to the RS422 side of the converter to the RFR-02’s network port.
7.61 Power on RFR-02.
7.62 Type “R99” a few times. Procomm should display VALID READS: 100/100, this checks
the communication for the RS422 section of the Network port. Record as passed.

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7.63 Type “setup”, DEFAULT, SAVE, EXIT. This sets the RFR-02’s parameters back to the
default values.
7.64 Power down RFR-02.
7.65 Disconnect all cables from RFR-02.
7.66 Attach Lid to RFR-02 making sure that the metal gasket is properly seated around the
perimeter of the RFR-02 and no internal cables are being pinched. P3 & P2 cables must be
separated for consistency.
7.67 Transfer RFR-02 to burn-in rack, connect power supply to RFR-02, and connect BNC cable
from reader antenna 1 to RFA-02 test antenna. Connect serial cable to setup port of RFR-
02.
7.68 Power on RFR-02 and ensure that the Network and Antenna LED blink 3 times. Type
“R99” to make sure that Procomm displays VALID READS: 100/100.
7.69 To exercise the continuous read during burn-in Type “R050063”. Screen should be
continuously being updated with the following data on next page. (Note: Data may vary
with tag used):