SICK RFCS-HP User manual

OPERATING INSTRUCTIONS
RFCS-HP
Track and trace system

Described product
RFCS-HP
Manufacturer
SICK AG
Erwin-Sick-Str. 1
79183 Waldkirch
Germany
Legal information
This work is protected by copyright. Any rights derived from the copyright shall be
reserved for SICK AG. Reproduction of this document or parts of this document is
only permissible within the limits of the legal determination of Copyright Law. Any modi‐
fication, abridgment or translation of this document is prohibited without the express
written permission of SICK AG.
The trademarks stated in this document are the property of their respective owner.
© SICK AG. All rights reserved.
Original document
This document is an original document of SICK AG.
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Contents
1 About this document........................................................................ 4
1.1 Information on the operating instructions.............................................. 4
1.2 Target group.............................................................................................. 4
1.3 Further information................................................................................... 4
1.4 Related applicable documents................................................................ 4
1.5 Symbols and document conventions...................................................... 4
2 Safety information............................................................................ 6
2.1 Basic safety notes..................................................................................... 6
2.2 Intended use............................................................................................. 6
2.3 Improper use............................................................................................. 7
2.4 Qualification of personnel........................................................................ 7
3 Product description........................................................................... 8
3.1 Scope of delivery....................................................................................... 8
3.2 System components................................................................................. 8
3.3 System setup............................................................................................ 9
3.4 Functionality.............................................................................................. 11
4 Maintenance...................................................................................... 13
4.1 Maintenance............................................................................................. 13
4.2 Maintenance............................................................................................. 13
4.2.1 Visual inspection of the photoelectric retro-reflective sen‐
sor............................................................................................. 13
4.2.2 Visual inspection of measuring wheel encoder..................... 13
4.2.3 Visual inspection of the cables............................................... 14
4.3 Replacing components............................................................................. 14
5 Troubleshooting................................................................................. 15
5.1 Important information.............................................................................. 15
5.2 Fault indications of the components....................................................... 15
5.3 Troubleshooting the controller................................................................. 15
5.4 Faults during operation............................................................................ 16
5.5 Detailed fault analysis.............................................................................. 16
5.6 Status log.................................................................................................. 16
6 Decommissioning............................................................................. 17
7 Technical data.................................................................................... 18
7.1 RFID system data sheet........................................................................... 18
7.2 Modules data sheet.................................................................................. 18
7.3 Antenna data sheet.................................................................................. 18
CONTENTS
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1 About this document
1.1 Information on the operating instructions
Read these operating instructions carefully before starting any work in order to familiar‐
ize yourself with the product and its functions.
The operating instructions are an integral part of the product and should remain acces‐
sible to the personnel at all times. When handing this product over to a third party,
include these operating instructions.
These operating instructions are not intended for project planning, installation or com‐
missioning of the product. Those tasks are carried out by SICK Service.
1.2 Target group
This document is intended for persons who operate and maintain the product.
1.3 Further information
The product page with further information can be found at sick.com.
The following information is available depending on the product:
•This document in all available language versions
•Data sheets
•Other publications
•CAD files and dimensional drawings
•Certificates (e.g., declaration of conformity)
•Software
•Accessories
1.4 Related applicable documents
Related applicable documents from SICK
Document Title Part number Source
Operating
instructions
Track and Trace Controller 8025454 www.sick.com/8025454
Operating
instructions
WLA16 Photoelectric sen‐
sors
8020348 www.sick.com/8020348
Operating
instructions
DFV60 Measuring wheel
encoder
8013709 www.sick.com/8013709
Related applicable documents from other manufacturers
Document Title Source
Operating
instructions
Impinj R700 www.impinj.com
1.5 Symbols and document conventions
Warnings and other notes
DANGER
Indicates a situation presenting imminent danger, which will lead to death or serious
injuries if not prevented.
1 ABOUT THIS DOCUMENT
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WARNING
Indicates a situation presenting possible danger, which may lead to death or serious
injuries if not prevented.
CAUTION
Indicates a situation presenting possible danger, which may lead to moderate or minor
injuries if not prevented.
NOTICE
Indicates a situation presenting possible danger, which may lead to property damage if
not prevented.
NOTE
Highlights useful tips and recommendations as well as information for efficient and
trouble-free operation.
Instructions to action
►The arrow denotes instructions to action.
1. The sequence of instructions is numbered.
2. Follow the order in which the numbered instructions are given.
✓The tick denotes the results of an action.
ABOUT THIS DOCUMENT 1
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2 Safety information
2.1 Basic safety notes
WARNING
Health hazard as a result of high-frequency electromagnetic radiation!
The RFID read/write device is used for the automatic, stationary identification of wire‐
less-based ISO/IEC18000-6C/EPCglobal UHF C1G2 compatible RFID data cards and
their management. Observe the operating instructions!
For regulatory-compliant operation, the max. permissible transmitting power must be
adhered to; refer to the operating instructions for the required configuration settings!
When operating the device, the human exposure regulations in accordance with
EN50364 must be observed.
The device must have a minimum distance of 30cm between the source of radiation
and your body in order to limit the exposure of the human body to electromagnetic
radiation.
NOTICE
Observe the following to ensure the RFID system is used safely and as intended.
•The notes in these operating instructions must be complied with.
•The national and international legal specifications apply to the installation and use
of the product, to the commissioning of said device, and to recurring technical
inspections, in particular:
– The accident prevention regulations and work safety regulations.
– Any other relevant safety regulations
•The manufacturer and user of the product are responsible for coordinating and
complying with all applicable safety specifications and regulations in cooperation
with the relevant authorities.
•Through checks must be carried out by qualified safety personnel or specially
authorized and instructed personnel and must be documented such that they can
be replicated and traced at any time.
•These operating instructions must be made available to the operator of the prod‐
uct. The product operator must be instructed by qualified safety personnel and
must read the operating instructions.
NOTICE
Operation site
The system is intended solely for use in industrial environments and as a stationary
system. Radio interference may arise when used in residential areas.
2.2 Intended use
RFCS-HP is an RFID system for identifying objects positioned close to one another on a
conveying line. The UHF transponders (known as "RFID tags") are reliably detected and
assigned to the objects. The RFID system can be used for objects with just one tag as
well as for identifying tags in a group.
The RFID system may only be used for the purpose described above.
The product must be mounted and commissioned by SICK Service. After that, the
product may only be used by competent personnel.
2 SAFETY INFORMATION
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Operation is allowed in an industrial environment, in warehouses or in a manufacturing
environment. Acceptable applications include the acquisition of master data in ERP
systems, the comparison of incoming goods against advice notes, and the inspection of
outgoing goods.
NOTE
The antenna and reader types are dependent on the country in which the system is
operated. They are subject to national standards and regulations.
The product must only be used within the limits of the prescribed and specified techni‐
cal specifications and operating conditions at all times.
Incorrect use, improper modification or manipulation of the product will invalidate any
warranty from SICK; in addition, any responsibility and liability of SICK for damage and
secondary damage caused by this is excluded.
2.3 Improper use
Impermissible ambient conditions
•Outdoor areas
•Explosion-hazardous area
2.4 Qualification of personnel
Any work on the product may only be carried out by personnel qualified and authorized
to do so.
Qualified personnel are able to perform tasks assigned to them and can independently
recognize and avoid any potential hazards. This requires, for example:
•technical training
•experience
•knowledge of the applicable regulations and standards
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3 Product description
3.1 Scope of delivery
NOTICE
►After delivery, inspect the product for transport damage and report any such
damage immediately.
►Check that the delivery includes all components listed on the delivery note.
3.2 System components
The RFID system comprises the following devices:
2
1
5
3
4
Figure 1: System components
No. Component Explanation
1Impinj R700 RFID reader The RFID reader is the read unit for RFID detection.
Using up to four antennas, it processes all current
transponders in the carrier frequency range of 860 ...
960MHz.
The frequency depends on the standards and regula‐
tions of the country where the product is being used.
2Controller
Control cabinet
The controller is the central control unit of the RFID
system. It evaluates the read results of the RFID reader
and assigns the identified tags to objects.
The controller receives the accurately determined posi‐
tions for the purpose of tag assignment via the inte‐
grated photoelectric retro-reflective sensor and the
measuring wheel encoder.
The controller is mounted in the control cabinet. The
central voltage supply is also housed in the control cabi‐
net.
3Reader modules with
antennas
The RFID antennas integrated in the reader modules
detect RFID transponders inside the RFID system.
Depending on the version, up to four antennas are used.
4Photoelectric retro-reflec‐
tive sensor
Information is included in the operating instructions for
the components.
5Measuring wheel encoder Information is included in the operating instructions for
the components.
3 PRODUCT DESCRIPTION
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3.3 System setup
The RFID system consists of modules that can be freely combined, thereby enabling the
product to be adapted to the relevant on-site conditions. As a result, the RFID system
can respond flexibly to the different widths and heights of conveying systems, as well as
to the different positions of tags on the objects passing through it.
The modules of the RFID system are self-supporting. They are assembled using mount‐
ing brackets – no additional frame is necessary.
2
1 4
3
Figure 2: System setup
1Reader modules with integrated antenna
2Structural modules
3Mounting bracket for assembling the modules
4Mounting rails and mounting bracket for suspending the RFID system on the conveyor
system
Reader modules
5
4
3
2
1
Figure 3: Reader modules
1Integrated antenna of the reader modules
2Integrated absorber panels of the reader modules (covered on the inside by a plastic
panel)
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3Recesses for connecting the antenna downlead
4Recesses for mounting the antenna
5Cable duct on the outside of the stainless steel tray
The number and position of the reader modules in the RFID system are based on the
expected detection location of the tags in the RFID system. A reader module can also
be attached to the underside of the conveying system in order to achieve an optimum
read result. An RFID system can be equipped with a maximum of four reader modules.
Figure 4: Conveying system with reader module on the underside
NOTE
When using antennas located underneath the belt, the area between the antenna and
the conveyor belt must be free of metal.
Structural modules
1
2
Figure 5: Structural modules
1Structural module
2Cable duct
Structural modules serve only to implement the individual RFID system; no antennas
can be mounted in them. The structural modules are made from stainless steel and
come with a cable duct on the outside. The structural modules are also equipped with
absorber panels. Large and small structural modules are available (see "Modules data
sheet", page 18).
3 PRODUCT DESCRIPTION
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Mounting bracket
1
2
Figure 6: Mounting bracket
1Mounting bracket
2Female threads on the side edges of the modules
The individual modules are connected to one another using mounting brackets. Varia‐
ble bracket sizes of 30°, 45°, 90° or 180° allow the product to be customized for the
specific user application. Female threads on the side edges of the modules ensure that
the mounting brackets can be screwed on quickly.
3.4 Functionality
As soon as the object passes the photoelectric retro-reflective sensor on the belt, the
RFID read/write unit in the RFID system is activated. The tags contained in the object
are detected by the antennas of the reader modules and read by the RFID reader. The
beam path of the photoelectric retro-reflective sensor is interrupted, which also enables
the time when the object enters the RFID system to be identified.
The measuring wheel encoder uses incremental signals to provide the exact position of
the object on the belt once it has passed the photoelectric retro-reflective sensor.
The information provided by all the components of the RFID system converges in the
controller. An algorithm, which has proven its worth in the field over many years,
calculates the unique assignment of every read tag to the associated object.
The read results are evaluated in the controller and forwarded via the host interface to
a higher-level system such as an ERP system. The user defines the time at which data is
output.
Processing several objects simultaneously
The RFID system ensures that tags and objects are uniquely assigned even if several
objects are in the tunnel at the same time.
This means that objects can travel through the RFID system with short distances
between them. The distance to be observed between the objects is dependent on the
number of tags that must be processed per object.
NOTE
The algorithm works with both RFID tags and bar codes. Therefore, either of these
technologies, or even a combination of the two, can be used with the RFID system.
PRODUCT DESCRIPTION 3
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Operation
After installation and configuration, the system continues running without any further
handling and provides the required data.
All user-specific parameters are saved on a microSD card in the controller.
3 PRODUCT DESCRIPTION
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4 Maintenance
4.1 Maintenance
The following maintenance work must be carried out at the specified time intervals:
Table 1: Maintenance intervals
Device Maintenance task Inter‐
val*
Version
RFID reader Clean the cooling fins of the housing 2x/year Trained person‐
nel
Photoelectric retro-
reflective sensor
•Clean the light emission window and
reflector
•Visually inspect the photoelectric retro-
reflective sensor and reflector for rota‐
tion that may have occurred as a result
of touching or the like
4x/year Trained person‐
nel
Measuring wheel
encoder
•Visually inspect the measuring wheel
encoder for signs of wear on the meas‐
uring wheel
•Check the contact of the measuring
wheel with the conveyor belt
4x/year Trained person‐
nel
General Visually inspect the electrical cabling and
wiring for damage
1x/year Specialist
Check the general tunnel reading per‐
formance
1x/year Specialist
*The intervals depend on the ambient conditions and degree of contamination. In addition, the intervals
must be defined according to how important they are for the user process.
4.2 Maintenance
4.2.1 Visual inspection of the photoelectric retro-reflective sensor
Photoelectric retro-reflective sensors are maintenance-free. It is recommended to carry
out the following tasks at regular intervals:
►Clean the outer optical surfaces.
►Check the screw fittings and plug connections.
►Check that the photoelectric retro-reflective sensor and reflector are correctly
aligned.
4.2.2 Visual inspection of measuring wheel encoder
►Check that the measuring wheel has sufficient contact with the belt.
►Visually inspect the measuring wheel encoder.
Figure 7: Visual inspection of measuring wheel encoder
►Check the level of wear on the measuring wheel. If it is so badly worn that contact
with the belt is impaired, the entire measuring wheel encoder must be replaced.
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4.2.3 Visual inspection of the cables
►Check the electrical installation regularly.
►Make sure that all cable connections are secure.
WARNING
Loose connections or scorched cables
►Rectify defects such as loose connections or scorched cables immediately.
WARNING
Damaged cable insulation
If the insulation on the connecting cables is damaged, there is a risk of fatal electrocu‐
tion.
4.3 Replacing components
Faulty or damaged components must be dismantled and replaced with new or repaired
components. All user-specific parameters are saved on a microSD card in the controller.
Therefore, components can be easily replaced without involving a qualified technician.
NOTE
Repairs to the tunnel components may only be performed by qualified and authorized
service personnel from SICK.
WARNING
Disconnect the power to the plant
►Make sure the voltage supply for the entire system is disconnected while the
device is being replaced.
4 MAINTENANCE
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5 Troubleshooting
5.1 Important information
WARNING
Danger in the event of malfunction
Cease operation if the cause of the malfunction has not been clearly identified!
►If errors cannot be clearly identified and not safely eliminated, shut down the
system.
NOTE
If an error cannot be resolved with the help of the information provided in this section,
contact your local SICK subsidiary.
5.2 Fault indications of the components
NOTE
Information is included in the operating instructions for the components.
5.3 Troubleshooting the controller
►Check that all controller interfaces are connected correctly.
Checking the triggering
The 1 LED must light up in the X4TRIGGER block.
LED does not light up
Possible cause of fault Troubleshooting
Beam path is permanently interrupted by an
object
►Eliminate the permanent interruption by the
object.
Photoelectric retro-reflective sensor is not
aligned with the reflector
►Readjust the photoelectric retro-reflective
sensor and align it with the reflector.
Signal ground not activated ►Set the S1 signal ground switch to GND.
Wire is not correctly attached in the terminal
block.
►Check that the wires in the X4 terminal
block are attached correctly.
•Brown wire to 7 24V
•Blue wire to 8 GNDISO
•Black wire to 1 IN1+
Incorrectly set sensitivity ►Readjust the receiver unit of the photoelec‐
tric retro-reflective sensor.
Photoelectric retro-reflective sensor is defec‐
tive
►Replace the device.
Checking the measuring wheel encoder
When the measuring wheel is turned, LEDs 5 and 6 in the X5INCREMENT terminal block
must flash alternately.
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LEDs are not flashing
Possible cause of fault Troubleshooting
There is no/insufficient contact between the
measuring wheel and the conveyor belt
►Make sure that there is good contact
between the measuring wheel and the con‐
veyor belt on-site.
►If the measuring wheel shows signs of
wear, replace it.
Signal ground not activated ►Set the S2 signal ground switch to GND.
Wire is not correctly attached in the terminal
block.
►Check that the wires in the X5 terminal
block are attached correctly.
•Brown wire to 7 24V
•Blue wire to 8 GNDISO
•White wire to 1 IN5+
•Black wire to 3 IN6+
Encoder is defective ►Replace the device.
5.4 Faults during operation
NOTE
Before replacing a device, a detailed fault analysis must be performed using SOPAS.
5.5 Detailed fault analysis
The controller outputs faults in different ways. Fault output is staggered, allowing for an
increasingly detailed level of analysis:
•Communication errors can occur when transmitting telegrams to the controller.
The controller then returns a fault code.
•For faults that occur during reading, fault codes are written to a status log.
5.6 Status log
•The status log is retained even after switching the device off and on again.
•The system distinguishes between four types of faults:
– Information
– Warning
– Error
– Critical fault
The system saves only the last five entries for each fault type.
NOTE
Contact SICK Support for a more detailed analysis of the fault situation.
5 TROUBLESHOOTING
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6 Decommissioning
NOTICE
Disposal of batteries, electrical and electronic devices
►In accordance with international directives and regulations, batteries, accumula‐
tors, and electrical or electronic devices must not be disposed of with household
waste.
►The owner is obligated to dispose of the devices at the end of their service life via
the appropriate public disposal points.
►This icon on the product, packaging, or in this document indicates that a product
is covered by these provisions:
NOTICE
The applicable local and statutory environmental regulations and guidelines for the
disposal of industrial and electrical waste must be observed.
The following assemblies may contain substances that need to be disposed of sepa‐
rately:
•Electronics: capacitors, accumulators, batteries.
•Displays: Liquid in the LC displays.
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7 Technical data
7.1 RFID system data sheet
Table 2: RFID system data sheet
Features Value
Label/tag type EPC Global Gen2 Class1
Minimum conveying width 300mm
Conveyor speed Up to 3 m/s
Maximum number of tags per object Dependent on the object length in the direc‐
tion of transport, materials, density of tags,
etc.
Supply voltage 100 V … 264 V AC; 50 … 60 Hz
Power consumption of entire system Typically 50 W
Enclosure rating / protection class IP54
Ambient operating temperature Information is included in the operating
instructions of the controller.
Storage temperature
Interfaces
7.2 Modules data sheet
Table 3: RFID system modules
Features Structural module Reader module
Dimensions (mm) 1,200 × 500 × 80
1,200 × 250 × 80
1,200 × 500 × 80
Weight (kg) Approx. 15
Approx. 9
Approx. 17
Integrated antenna No Yes
Integrated absorber panels Yes Yes
7.3 Antenna data sheet
Table 4: Antenna data sheet
Features ETSI FCC
Frequency 865 ... 870MHz 902 ... 928MHz
Gain 12dBic 11dBic
3dB aperture angle H 30°
V 62°
H 30°
V 63°
Impedance 50Ω
Polarization Right circular
Connector N jack (female), back
Housing Aluminum, polycarbonate
Enclosure rating / protection
class
IP 54
Weight 2.8kg
Dimensions [W × H × D] (mm) 650 × 320 × 32 630 × 320 × 40
7 TECHNICAL DATA
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TECHNICAL DATA 7
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Detailed addresses and further locations at www.sick.com
Australia
Phone [phone]
1800 33 48 02 – tollfree
E-Mail [email protected]
Austria
Phone [phone]
E-Mail [email protected]
Belgium/Luxembourg
Phone [phone]
E-Mail [e-mail]
Brazil
Phone [phone]
E-Mail [e-mail]
Canada
Phone [phone]
E-Mail [email protected]
Czech Republic
Phone [phone]
E-Mail [email protected]
Chile
Phone [phone]
E-Mail [email protected]
China
Phone [phone]
E-Mail info[email protected]
Denmark
Phone [phone]
E-Mail [email protected]
Finland
Phone [phone]
E-Mail [email protected]
France
Phone [phone]
E-Mail [e-mail]
Germany
Phone [phone]
E-Mail [e-mail]
Greece
Phone [phone]
E-Mail [email protected]
Hong Kong
Phone [phone]
E-Mail [email protected]
Hungary
Phone [phone]
E-Mail ertek[email protected]
India
Phone [phone]
E-Mail [e-mail]
Israel
Phone [phone]
E-Mail [e-mail]
Italy
Phone [phone]
E-Mail [e-mail]
Japan
Phone [phone]
E-Mail [email protected]
Malaysia
Phone [phone]
E-Mail enquiry[email protected]
Mexico
Phone [phone]
E-Mail mex[email protected]
Netherlands
Phone [phone]
E-Mail [e-mail]
New Zealand
Phone [phone]
0800 222 278 – tollfree
E-Mail [email protected]z
Norway
Phone [phone]
E-Mail [email protected]
Poland
Phone [phone]
E-Mail [e-mail]
Romania
Phone [phone]
E-Mail [email protected]
Singapore
Phone [phone]
E-Mail [email protected]
Slovakia
Phone [phone]
E-Mail [e-mail]
Slovenia
Phone [phone]
E-Mail [email protected]
South Africa
Phone [phone]
E-Mail [e-mail]
South Korea
Phone [phone]
E-Mail infok[email protected]
Spain
Phone [phone]
E-Mail [e-mail]
Sweden
Phone [phone]
E-Mail [e-mail]
Switzerland
Phone [phone]
E-Mail [email protected]
Taiwan
Phone [phone]
E-Mail [email protected]
Thailand
Phone [phone]
E-Mail [e-mail]
Turkey
Phone [phone]
E-Mail [e-mail]
United Arab Emirates
Phone [phone]
E-Mail [email protected]
United Kingdom
Phone [phone]
E-Mail [e-mail]
USA
Phone [phone]
E-Mail [e-mail]
Vietnam
Phone [phone]
E-Mail [email protected]
SICK AG|Waldkirch|Germany|www.sick.com
8028460/2023-08-08/en