ZZ0815 - RFID system IFM - Free user manual and instructions

USER MANUAL ZZ0815 IFM

Instructions for set-up

RF-identification system

ZZ0814

ZZ0815

ZZ0816

ZZ0817

Incoming/outgoing goods

Contents

1 Preliminary note 3

1.1 Symbols used 3
1.2 Warnings.... 3
1.3 Legal and copyright information 3

2 Safety instructions.... 4

2.1 Safety instructions for loading/unloading 4

3 Intended use.... 5
4 Items supplied.... 6
5 Function 8

5.1 Load control 9
5.2 Logging....9
5.3 Loading Unloading 10

6 Installation.... 11

6.1 Installing set ZZ0814.... 11
6.2 Installing set ZZ0816.... 12
6.3 Installing sets next to each other with divider grid 13

7 Electrical connection.... 14

7.1 Connecting the ZZ0814 15
7.2 Connecting the ZZ0815 15
7.3 Connecting the ZZ0816 16
7.4 Connecting the ZZ0817.... 16
7.5 ZZ1124 pin assignment.... 17
7.6 DTE830 pin assignment 18
7.7 Wiring AL1326 20
7.8 AL3050 pin assignment.... 22
7.9 O3D354 pin assignment 23

8 Set-up 24

8.1 DTE830....24
8.2 O3D354 24

8.2.1 Connecting ifm Vision Assistant 24
8.2.2 Creating an application 24

8.3 ZZ1124 25
8.3.1 Data exchange between ZZ1124 and higher-level system 25

8.3.1.1 File exchange with result file 27
8.3.1.2 File exchange without result file 28

8.3.2 Structure of the feedback file.... 28
8.3.2.1 Examples 29

8.3.3 Structure of the results file.... 29
8.3.3.1 Examples 30

8.3.4 Retrieving the feedback file via SSH 31

8.3.5 MQTT 32

8.4 DV2510.... 34

9 Maintenance, repair and disposal 36
10 Approvals/standards 37
Glossary 38

1 Preliminary note

You will find instructions, technical data, approvals and further information using the QR code on the unit / packaging or at www.ifm.com.

1.1 Symbols used

√ Requirement
Instructions
Reaction, result

[...] Designation of keys, buttons or indications

→ Cross-reference

Important note

Non-compliance may result in malfunction or interference.

Information

Supplementary note

1.2 Warnings

Warnings indicate the possibility of personal injury and damage to property. This enables safe product handling. Warnings are graded as follows:

WARNING

Warning of serious personal injury

▷ If the warning is not observed, fatal and serious injuries are possible.

CAUTION

Warning of minor to moderate personal injury

▷ If the warning is not observed, minor to moderate injuries are possible.

ATTENTION

Warning of damage to property

▷ If the warning is not observed, damage to property is possible.

1.3 Legal and copyright information

© All rights reserved by ifm electronic gmbh. No part of these instructions may be reproduced and used without the consent of ifm electronic gmbh.

All product names, pictures, companies or other brands used are the property of the respective rights owners.

2 Safety instructions

- The unit described is a subcomponent for integration into a system.

• The system architect is responsible for the safety of the system.

• The system architect undertakes to perform a risk assessment and to create documentation in accordance with legal and normative requirements to be provided to the operator and user of the system. This documentation must contain all necessary information and safety instructions for the operator, the user and, if applicable, for any service personnel authorised by the architect of the system.

• Read this document before setting up the product and keep it during the entire service life.

• The product must be suitable for the corresponding applications and environmental conditions without any restrictions.
• Only use the product for its intended purpose (→ Intended use).
• If the operating instructions or the technical data are not adhered to, personal injury and/or damage to property may occur.
• The manufacturer assumes no liability or warranty for any consequences caused by tampering with the product or incorrect use by the operator.
• Installation, electrical connection, set-up, operation and maintenance of the product must be carried out by qualified personnel authorised by the machine operator.
• Protect units and cables against damage.

2.1 Safety instructions for loading/unloading

WARNING

Severe injuries and bruises

▷ The ZZ081x set does not replace the proper loading and unloading of goods.
▷ Goods that are not loaded and unloaded properly can fall and injure people in the vicinity.
▶ Load and unload incoming and outgoing goods properly and safely.

3 Intended use

The ZZ081x set is a system to detect incoming and outgoing goods in outdoor and indoor areas. The incoming and outgoing goods are equipped with ID tags and are recorded by RFID read/write heads.

Data such as the loading direction and the time stamp are recorded via the ID tags.

If the gate function Load control is activated, the data is provided and the system waits for a response from the ERP system.

If the gate function Logging is activated, the data is provided as a feedback file. The feedback file is retrieved from an ERP system or MQTT broker. The ERP system or the MQTT broker must be provided by the operator.

The ERP system saves successful unloading and loading in a result file. The result file is sent to the edge
Controller. The edge
Controller analyses the unloading and loading of goods via the results file. The result can then be signalled via the connected signal light and the buzzer.

Clients connected to the MQTT broker can retrieve and process the data.

The set ZZ081x includes all devices and cables necessary for operation. The ID tags are not included.

The devices are pre-programmed. The O3
Dxxx device must be set up for the application using the ifm Vision Assistant software. The ZZ081x set can then be put into operation after assembly and electrical connection.

4 Items supplied

The ZZ081x sets are divided into gates and detection of the loading direction.

• Master gate: ZZ0814, ZZ0816
• Extension gate: ZZ0815, ZZ0817

Up to 9 extension gates can be operated on one master gate.

The loading direction of the goods is detected differently by the sets:

• Detection via O3D 3D sensor: ZZ0814, ZZ0815
• Detection via 2x light barrier: ZZ0816, ZZ0817

The device is supplied without installation and connection accessories.

Available accessories: www.ifm.com.

The optimum function is not ensured when using components from other manufacturers.

Scope of delivery ZZ0814, ZZ0815 (detect loading direction via O3D 3D sensor)

Article	ZZ0814 master gate	ZZ0815 extension gate	Description
ZZ1124	1	0	edge Controller with gate soft-ware
E70450	1	0	Connection cable for ZZ1124
DTE830	1	1	RFID evaluation unit UHF
ANT860	4	4	RFID antenna UHF
E80332	4	1	Connection cable
AL3050	1	1	Ethernet switch (M12)
AL1326	1	1	IO-Link master with Ether Net/IP interface
O3D354	1	1	3D sensor
DV2510	1	1	5-segment light tower
EVC108	1	1	Connection cable
DN4032	1	1	Switched-mode power supply 24 V DC
EVC003	4	4	Connection cable with socket
E12166	1	1	Connection cable with socket for O3D
EVC928	1	0	Ethernet connection cable with RJ45 plug
EVC907	1	1	Ethernet connection cable, 5 m
EVC908	3	3	Ethernet connection cable, 10 m
E80412	1	1	Adapter cable for DTE830

Scope of delivery ZZ0816, ZZ0817 (detect loading direction via 2x light barrier)

Article	ZZ0816 master gate	ZZ0817 extension gate	Description
ZZ1124	1	0	edge Controller with gate soft-ware
E70450	1	0	Connection cable for ZZ1124
DTE830	1	1	RFID evaluation unit UHF
ANT860	4	4	RFID antenna UHF
E80332	4	1	Connection cable
AL3050	1	1	Ethernet switch (M12)
AL1326	1	1	IO-Link master with Ether Net/IP interface
OGP700	2	2	Laser retro-reflective sensor
E20722	2	2	Reflector for retro-reflective laser sensor
DV2510	1	1	5-segment light tower
EVC108	3	3	Connection cable
DN4032	1	1	Switched-mode power supply 24 V DC
EVC003	4	4	Connection cable with socket
EVC928	1	0	Ethernet connection cable with RJ45 plug
EVC907	1	1	Ethernet connection cable, 5 m
EVC908	3	3	Ethernet connection cable, 10 m
E80412	1	1	Adapter cable for DTE830

5 Function

The ZZ081x set is a system to detect incoming and outgoing goods in outdoor and indoor areas. The incoming and outgoing goods are equipped with ID tags and are recorded by RFID read/write heads.

The ID tags must be designed for the UHF band (ISO 18000-6C EPC Class1 Gen2).

The UHF devices included in the ZZ081x set are connected to the edge
Controller via TCP/IP. The data is processed in the edge
Controller.

Contents of set ZZ0814:

O3D354 3D sensor

edge
Controller ZZ1124

RFID evaluation unit DTE830

RFID antenna ANT860

Ethernet switch AL3050

AL1122 IO-Link master

Signal light DV2510

Contents of set ZZ0816:

Retro-reflective laser sensor OGP700

edge
Controller ZZ1124

RFID evaluation unit DTE830

RFID antennas ANT860

Ethernet switch AL3050

AL1122 IO-Link master

Signal light DV2510

Functions

The ZZ0814 and ZZ0816 sets have the following functions:

• TCP/IP communication with up to 10 DTE830 UHF evaluation units (1x Master Gate and 9x Extension Gate)
• Set ZZ0814: Detection of the loading direction of the goods via O3D354 3D sensor
• Set ZZ0816: Detect the loading direction of the goods via the OGP700 retro-reflective laser sensor
• Creating a feedback file via the edge
  Controller
• Reading a result file via the edge
  Controller
  • Show status on the display of the edge
  Controller and the light tower / buzzer
• Simple user interface for evaluation unit configuration
• Gate function [Load control:] Providing the data and waiting for a response from the ERP system (→ Load control ☐ 9)
• Gate function [Logging]: Providing the data as a feedback file (→ Logging ☐ 9)
• Gate function [Loading Unloading]: Behaviour of the gate when detecting movements (→ Loading Unloading ☐ 10)

Functions not included

The following functions must be provided by the client:

- A program that collects the feedback file from the edge
Controller ZZ1124, sends it to the ERP system and then deletes it from the edge
Controller

• Evaluation in the ERP system
- Creation of a results file by the ERP system with pass/fail information
• A program for transferring the results file from the ERP system to the edge
Controller ZZ1124
• Mounting accessories for the devices

5.1 Load control

With activated gate function [Load control]:

• The data is provided.
- The system waits for a response from the higher-level ERP system. The response is sent as a result file from the connector program.

▶ Use the [File exchange] transfer method for the [Load control] gate function.

The [File exchange] transfer method requires a file exchange system.

The file exchange system is provided by the operator. The file exchange system retrieves the feedback file and forwards it to the higher-level ERP system. The feedback file contains the data from the last reading in JSON data format.

The higher-level ERP system compares the feedback file with the delivery note. The result of the comparison is written to the ERP results file. The ERP results file is sent back to the edge
Controller for evaluation. The edge
Controller uses the ERP results file to analyse the loading and unloading of goods.

5.2 Logging

If the gate function [Logging] is activated:

- The data from the readings is provided as a feedback file. As soon as >10 feedback files are available in the file system, the oldest one will be overwritten (ring buffer). Separate feedback files are provided for each gate.

- The system waits not for a response from the higher-level system.

▶ For the gate function [Logging], use the transmission method [File exchange] or [MQTT].

The [MQTT] transmission method requires a connected MQTT broker.

The MQTT broker is provided by the operator. The data read from the RFID incoming and outgoing goods recording system is sent from the edge
Controller to the MQTT broker. Clients connected to the MQTT broker then retrieve the data and process it further.

5.3 Loading Unloading

The [Loading Unloading] function sets the behaviour of the gate when movements are detected. Available settings:

[Loading]: Book goods when moving towards the lorry.	[Unloading]: Book goods when moving from the direction of the lorry.	[Loading + Unloading]: Book goods when moving from and to the lorry.

1: ID tag
2: Detection of direction
3: Antenna array

Loading

With the setting [Loading], goods are booked when moving towards the lorry. A movement in the opposite direction can be booked manually.

Depending on the orientation of the ID tag and in the case of a lorry trailer with fixed side walls (e.g. box body construction), the goods can be booked out automatically.

▶ Select the [Loading] setting for loading.
▶ Only allow goods to be booked out via manual confirmation.
▶ With direction detection via 3D sensor or laser reflex light barrier, only activate the antenna field when loading.

Unloading

With the setting [Unloading], goods are booked for a movement from the direction of the lorry. A movement in the opposite direction can be booked manually.

Depending on the orientation of the ID tag and in the case of a lorry trailer with fixed side walls (e.g. box body construction), the goods can book themselves in automatically.

▶ Select the [Unloading] setting for unloading.
▶ Only allow goods to be booked in via manual confirmation.
▶ With direction detection via 3D sensor or retro-reflective laser sensor, only activate the antenna array when unloading.

Loading + Unloading

With the setting [Loading + Unloading], goods are booked when moving from and to the lorry.

6 Installation

6.1 Installing set ZZ0814

The ZZ0814 set detects the loading direction via the O3D354 3D sensor.

1: edge
Controller ZZ1124
2: Direction detection with O3D354 3D sensor
3: Signal light DV2510
4: Upper RFID antennas ANT860
5: Lower RFID antennas ANT860
6: Distance between loading area and UHF gate
7: Distance between load and UHF gate

Fig. 1: Installed set ZZ0814

Install the devices in the set:

▶ Install the two lower ANT860 RFID antennas at a height of approx. 1 m (5).

▶ Install the upper two ANT860 RFID antennas at a height of approx. 2 m (4).

▷ A distance of at least 1 metre must be maintained between the loading area and the RFID antennas (6).

▷ A distance of at least 2.5 metres must be maintained between the load in the warehouse and the RFID antennas (7). If goods fitted with ID tags are stored too close to the RFID antennas, this can lead to errors being detected.

▶ Mount the DV2510 signal light so that it is clearly visible above the door (3).

▶ Mount the 3D sensor O3D354 in the centre above the door (2).

▷ The 3D sensor must be installed at a height of at least 2.50 metres. The exact height and position depends on the required detection range (ROI).

Mounted height of the O3D354	Detection zone
2.50 m	2.75 x 2.00 m
3.00 m	3.30 x 2.40 m
3.50 m	3.85 x 2.80 m
4.00 m	4.40 x 3.20 m

▶ Install the edge
Controller ZZ1124 near the door (1).
▷ The set is installed.

6.2 Installing set ZZ0816

The ZZ0816 set detects the loading direction via the 2 OGP700 light barriers.

Fig. 2: Installed set ZZ0816

1: edge
Controller ZZ1124
2: Signal light DV2510
3: Upper RFID antennas ANT860
4: Lower RFID antennas ANT860
5: Direction detection with 2x OGP700 retro-reflective laser sensor
6: Distance between loading area and UHF gate
7: 2x reflector for retro-reflective laser sensor E20722
8: Distance between load and UHF gate

Install the devices in the set:

▶ Install the two lower ANT860 RFID antennas at a height of approx. 1 m (4).
▶ Install the upper two ANT860 RFID antennas at a height of approx. 2 m (3).

▷ A distance of at least 1 metre must be maintained between the loading area and the RFID antennas (6).
▷ A distance of at least 2.5 metres must be maintained between the load in the warehouse and the RFID antennas (8). If goods fitted with ID tags are stored too close to the RFID antennas, this can lead to errors being detected.

▶ Mount the DV2510 signal light so that it is clearly visible above the door (2).

▶ Install the OGP700 retro-reflective laser sensors (5) and the E20722 reflectors (7) at a height of approx. 0.5 m.

▷ Maintain a distance of 0.3 m between the light barriers.

▶ Install the edge
Controller ZZ1124 near the door (1).
▷ The set is installed.

6.3 Installing sets next to each other with divider grid

Several sets can be installed next to each other by installing dividers between the sets. The divider grids prevent interference between the sets.

1: Set
2: Divider grid

Fig. 3: Sets mounted side by side with divider grid (bird's eye view)

Goods stored in the vicinity of the set can cause malfunctions.

▶ Do not store any goods within a radius of 2 metres.

The distances mentioned are rough guidelines and depend on the local installation situation and the settings used for the devices.

Install divider grids between the sets

Divider grids reduce the necessary distance between the sets.

Fit the divider grid between the sets:

▶ Keep a distance of 1 metre between the sets.
▶ Install a partition grid with minimum dimensions of 2.5 m x 2.0 m (height x width) between the sets.

Installing sets without divider grids

Without a divider grid between the sets, the distance required to avoid interference is greater.

Installing sets next to each other without divider grid:

▶ Keep a distance of 4 metres between the sets.

7 Electrical connection

The device must be connected by a qualified electrician.

Device of protection class III (PC III).

The electrical supply must only be made via PELV/SELV circuits.

▶ Disconnect power before connecting the device.

ATTENTION

The IP rating indicated in the data sheet is only reached if the M12 connectors are firmly screwed. Loosely screwed M12 connectors can damage the unit.

▶ Screw the M12 connector to the device applying 1 to 1.5 Nm.
▶ Cover unused device connections with protective covers.

Fig. 4: Connected devices

1: 24 V DV power supply (blue lines)
3: Ethernet (green lines)
5: Connection to the customer network (red line)

2: IO-Link (orange lines)
4: Coaxial connection (black lines)

Connect external PLC

Ports X01 and X02 of the AL1326 are used as standard for the OGP700 retro-reflective laser sensors. Alternatively, the ports can be used as digital inputs for an external PLC.

Further information on the digital inputs can be found in the AL1326 operating instructions: documentation.ifm.com

7.1 Connecting the ZZ0814

The Master Gate ZZ0814 detects the loading direction via the 3D sensor O3D354.

▶ Connect the devices as shown in the table.

Starting the connection (device connection)	Connection via cable	Destination of the connection (device connection)
ZZ1124 - ETH0	EVC908	AL3050 - P1
ZZ1124 – ETH 1	EVC928	Customer network
ZZ1124 - Supply	E70450 and EVC003	DN4032 (24 V DC 5 A)
AL3050 - Supply	EVC003	DN4032 (24 V DC 5 A)
DTE830 - PWR	EVC003	DN4032 (24 V DC 5 A)
DTE830 - ETH	EVC907 and E80412	AL3050 - P2
DTE830 – AP 1	E80332	ANT860 (antenna 1)
DTE830 – AP 2	E80332	ANT860 (antenna 2)
DTE830 – AP 3	E80332	ANT860 (antenna 3)
DTE830 – AP 4	E80332	ANT860 (antenna 4)
AL1326 - PWR	EVC003	DN4032 (24 V DC 5 A)
AL1326 – ETH0	EVC908	AL3050 - P3
AL1326 – P3	EVC108	DV2510
O3D - PWR	E12166	DN4032 (24 V DC 5 A)
O3D – ETH	EVC908	AL3050 - P4

7.2 Connecting the ZZ0815

The Extension Gate ZZ0815 is an extension for the master gate ZZ0814.

▶ Connect the devices as shown in the table.

Starting the connection (device connection)	Connection via cable	Destination of the connection (device connection)
AL3050 – X31	EVC003	DN4032 (24 V DC 5 A)
AL3050 - P1	EVC908	ZZ0814 - free port of the AL3050
DTE830 - PWR	EVC003	DN4032 (24 V DC 5 A)
DTE830 - ETH	EVC907 and E80412	AL3050 - P2
DTE830 – AP 1	E80332	ANT860 (antenna 1)
DTE830 – AP 2	E80332	ANT860 (antenna 2)
DTE830 – AP 3	E80332	ANT860 (antenna 3)
DTE830 – AP 4	E80332	ANT860 (antenna 4)
AL1326 - PWR	EVC003	DN4032 (24 V DC 5 A)
AL1326 – ETH0	EVC908	AL3050 - P3
AL1326 – P3	EVC108	DV2510
O3D - PWR	E12166	DN4032 (24 V DC 5 A)
O3D – ETH	EVC908	AL3050 - P4

7.3 Connecting the ZZ0816

The master gate ZZ0816 detects the loading direction via the OGP700 light barriers.

▶ Connect the devices as shown in the table.

Starting the connection (device connection)	Connection via cable	Destination of the connection (device connection)
ZZ1124 - ETH0	EVC908	AL3050 - P1
ZZ1124 – ETH 1	EVC928	Customer network
ZZ1124 - Supply	E70450 and EVC003	DN4032 (24 V DC 5 A)
AL3050 - Supply	EVC003	DN4032 (24 V DC 5 A)
DTE830 - PWR	EVC003	DN4032 (24 V DC 5 A)
DTE830 - ETH	EVC907 and E80412	AL3050 - P2
DTE830 – AP 1	E80332	ANT860 (antenna 1)
DTE830 – AP 2	E80332	ANT860 (antenna 2)
DTE830 – AP 3	E80332	ANT860 (antenna 3)
DTE830 – AP 4	E80332	ANT860 (antenna 4)
AL1326 - PWR	EVC003	DN4032 (24 V DC 5 A)
AL1326 – ETH0	EVC908	AL3050 - P3
AL1326 – P3	EVC108	DV2510
AL1326 – P1	EVC108	OGP700
AL1326 – P2	EVC108	OGP700

7.4 Connecting the ZZ0817

The extension gate ZZ0817 is an extension for the master gate ZZ0816.

▶ Connect the devices as shown in the table.

Starting the connection (device connection)	Connection via cable	Destination of the connection (device connection)
AL3050 – X31	EVC003	DN4032 (24 V DC 5 A)
AL3050 - P1	EVC908	ZZ0816 - free port of the AL3050
DTE830 - PWR	EVC003	DN4032 (24 V DC 5 A)
DTE830 - ETH	EVC907 and E80412	AL3050 - P2
DTE830 – AP 1	E80332	ANT860 (antenna 1)
DTE830 – AP 2	E80332	ANT860 (antenna 2)
DTE830 – AP 3	E80332	ANT860 (antenna 3)
DTE830 – AP 4	E80332	ANT860 (antenna 4)
AL1326 - PWR	EVC003	DN4032 (24 V DC 5 A)
AL1326 – ETH0	EVC908	AL3050 - P3
AL1326 – P3	EVC108	DV2510
AL1326 – P1	EVC108	OGP700
AL1326 – P2	EVC108	OGP700

7.5 ZZ1124 pin assignment

Fig. 5: ZZ1124 rear

1: Voltage supply
3: USB 1
5: Ethernet 1

2: USB 0
4: Ethernet 0

Voltage supply

Pin assignment	Pin	Assignment
	114	L+
	119	L+
	120	GND
	121	L+

Ethernet

Pin assignment	Pin	Assignment
	1	TxD+
	2	RxD+
	3	TxD-
	4	RxD-

7.6 DTE830 pin assignment

Fig. 6: DTE830 rear

1: Antenna 4, R-TNC 50 Ω
3: Antenna 2, R-TNC 50 Ω
5: GPIO, M12 socket, 12 poles, A-coded
7: Ethernet with PoE Plus (Power over Ethernet), M12 socket, 8 poles, X-coded

2: Antenna 3, R-TNC 50 Ω
4: Antenna 1, R-TNC 50 Ω
6: voltage supply, M12 connector, 4 poles, A-coded

GPIO

Pin assignment	Pin	Assignment
	1	OUT CMN
	2	OUTPUT 1
	3	INPUT 3
	4	INPUT CMN
	5	INPUT 1
	6	GND
	7	UB
	8	OUTPUT 4
	9	OUTPUT 3
	10	OUTPUT 2
	11	INPUT 2
	12	INPUT 4

Voltage supply

Pin assignment		Pin	Assignment
		1	+24 V DC
		2	GND
		3	GND
		4	+24 V DC

Ethernet

Pin assignment	Pin	Assignment
	1	TX+ / PoE+1
	2	TX- / PoE+1
	3	TX+ / PoE+2
	4	TX- / PoE+2
	5	PoE+1
	6	PoE+1
	7	PoE+2
	8	PoE+2

7.7 Wiring AL1326

Fig. 7: AL1326 front side

IN / OUT X21, X22, X23

Pin assignment	Pin	Assignment
1 25 4 3	1	TX+
	2	RX+
	3	TX-
	4	RX-
	5	Not used

Voltage supply X31

Pin assignment	Pin	Assignment
	1	+24 V DC
	2	Not used
	3	GND
	4	Not used

IO-Link port Class A X01.. X08

Pin assignment	Pin	Assignment
	1	Sensor supply (US) L+
	2	Digital input
	3	Sensor supply (US) L-
	4	C/Q IO-Link
	5	Not used

Gate contact switch

Port X04 of the AL1326 is reserved for a gate contact switch:

• If the gate is open, ID tags are detected by the UHF gate.
- If the gate is closed, the UHF gate is in sleep mode and does not detect any ID tags.

Switch the UHF gate to sleep mode:

▶ Apply a high signal to the digital input of port X04.

Connect external PLC

Ports X01 and X02 of the AL1326 are used as standard for the OGP700 retro-reflective laser sensors. Alternatively, the ports can be used as digital inputs for an external PLC.

Further information on the digital inputs can be found in the AL1326 operating instructions: documentation.ifm.com

7.8 AL3050 pin assignment

Fig. 8: AL3050 front side

1: Voltage supply X31
2: Ethernet X01
3: Ethernet X02
4: Ethernet X03
5: Ethernet X04
6: Ethernet X05
7: Ethernet X06

Voltage supply X31

Pin assignment	Pin	Assignment
	1	+24 V DC (US)
	2	Not used
	3	GND (US)
	4	Not used

Ethernet X01.. X06

Pin assignment	Pin	Assignment
	1	TX+
	2	RX+
	3	TX-
	4	RX-
	5	Not used

7.9 O3D354 pin assignment

Fig. 9: O3D354 rear

1: Ethernet
2: Power supply and switching inputs/outputs

Ethernet

Pin assignment	Pin	Assignment
	1	TX+
	2	RX+
	3	TX-
	4	RX-

Power supply and switching inputs/outputs

Pin assignment	Pin	Assignment
	1	U+
	2	Trigger input
	3	GND
	4	Switching output 1 (digital or analogue)
	5	Switching output 3 / ready
	6	Switching output 2 (digital)
	7	Switching input 1
	8	Switching input 2

8 Set-up

Before set-up, the units are to be mounted ( → Installation ☐ 11) and electrically connected ( → Electrical connection ☐ 14).

8.1 DTE830

The DTE830 is set using the UHF gate solution software. The software is used to set the DTE830 as a gate. In addition, the operating direction, the RFID reader and the RFID antennas are set.

The software is pre-installed on the edge
Controller ZZ1124. The software manual is available in the download area of the DTE830: documentation.ifm.com

Activating multiple gates

The gates must be activated one after the other:

▶ First activate the master gate and then the extension gates.

Simultaneous activation of the power supply to several gates causes connection problems

▷ If the power supplies of the gates are activated at the same time, the gates log on to the master gate with the same IP address. This causes the gates to be assigned incorrectly.

▶ Activate the power supplies of the gates one after the other.

Gate 1 is preset as the master gate.

8.2 O3D354

The O3D354 is set up with the ifm Vision Assistant software. The software, the software manual and the operating instructions are available in the download area of the O3D354: documentation.ifm.com

8.2.1 Connecting ifm Vision Assistant

▶ Connect the O3D354 to the ifm Vision Assistant software:

▶ Connect the O3D354 to the of the voltage supply and to the PC via Ethernet.

▷ See operating instructions, chapter "Electrical connection".

The following functions are described in detail in the software manual.

▶ Start the ifm Vision Assistant software.

▶ Select the [Find sensor] button.

▷ The [Find device] function searches for the O3D354 in the network and establishes a connection. The O3D354 is automatically assigned an IP address.

▶ Select the [Save] button:

8.2.2 Creating an application

Two applications must be created on the O3D354 using the ifm Vision Assistant software.

Direction detection and trigger application

Create the "Direction detection and trigger" application:

▶ Add a new application in the [Application] area.

▶ Select the [User defined mode] wizard for the new application.
▶ In the [Image settings] area, set the image of the O3D354 according to the installation situation.
▶ In the [Models] section, create a new [Level] model.

▷ Select the [Level model] [Underfilling].

▷ Select the [Measurement task] [ Maximum].

▶ For direction detection, create 2 [Search zones] (ROI) in front of the gate.

Fig. 10: View from top: 2 search zones (ROI) in front of the gate

▷ The search zone ROI 0 is orientated towards the stored goods in the warehouse.
▷ The ROI 1 search zone is aligned to the lorry.

▶ In the [Models] section, [measure] and [teach] the [Reference level].
▷ The area of the search zones must be free of objects when teaching the reference level.
▶ In the [Models] section, set the [switching thresholds] to the minimum object height.
▶ Automatically create a logic configuration in the [Logic] area.
▶ Check the behaviour of the switching thresholds in the [Overall test] area.
▶ Save the application.
▶ In the [Application] area, rename the application to "Direction detection and trigger".
▷ The application is created and tested.

Direction detection application and PAUSE mode trigger

Create the "Direction detection and PAUSE mode trigger" application:

▶ In the [Application] area, duplicate the "Direction detection and trigger" application.
▶ Edit the duplicated application.
▶ In the [Image settings] area, set the [Trigger] to [Process interface].
▶ Save the application.
▶ In the [Application] area, rename the application to "Direction detection and trigger PAUSE mode".
▷ The application is created.

8.3 ZZ1124

The UHF gate solution software is pre-installed on the edge
Controller ZZ1124. The software starts immediately after setting up the edge
Controller.

The software is described in the software manual. The software manual is available in the download area of the ZZ1124: documentation.ifm.com

8.3.1 Data exchange between ZZ1124 and higher-level system

Data is exchanged between the edge
Controller ZZ1124 and a higher-level system (ERP, MES, DCS) via feedback and result files. To do this, the UHF gate is set to the [Load control] or [Logging] function. A transfer method is then set for the function.

Load control

If the UHF gate is set to [Load control]:

• The data is provided.
- The system waits for a response from the higher-level ERP system. The response is sent as a result file from the connector program.

▶ Use the [File exchange] transfer method for the [Load control] gate function.

The [File exchange] transfer method provides a JSON file that contains the data read from the RFID goods receipt and goods registration system. The JSON file can be processed further.

Logging

If the UHF gate is set to [Logging]:

• The data from the readings is provided as a feedback file. As soon as >10 feedback files are available in the file system, the oldest one will be overwritten (ring buffer). Separate feedback files are provided for each gate.
• The system waits not for a response from the higher-level system.

▶ For the gate function [Logging], use the transmission method [File exchange] or [MQTT].

The [File exchange] transfer method provides a JSON file that contains the data read from the RFID goods receipt and goods registration system. The JSON file can be processed further.

The [MQTT] transmission method provides the data read from the RFID goods receipt and goods registration system to an MQTT broker. Clients connected to the MQTT broker can then retrieve and process the data.

8.3.1.1 File exchange with result file

If the gate function [Load control] and the transmission method [File exchange] are set, a result file is provided.

Fig. 11: Data exchange with results file

8.3.1.2 File exchange without result file

If the gate function [Logging] and the transfer method [File exchange] are set, no result file is provided.

Fig. 12: Data exchange without result file

8.3.2 Structure of the feedback file

The feedback file generated by the ZZ1124 is saved in the JSON file format. The feedback file contains all the important information required by the higher-level system. The feedback file must be fetched from the file system of the ZZ1124 by the higher-level system and deleted.
The feedback file has the following structure:

ID	Gate ID	Direction	EPC	TID	USER	ISO8601 (Time)
1	490503	IN	E2801114200087CB7700 2222	/	/	03/15/202113:14:30
2	490503	OUT	E2801114200087AA7700 4265	/	/	03/15/202113:14:30
3	490402	IN	E2801114200087AA7788 4265	/	/	03/15/202113:14:30

Id

Unique ID of the data record.

Gate ID

Unique ID (numerical value) of the gate. The gate ID is set in the gate configuration.

Direction

Loading direction (Direction
Type, Enum):

"θ": Incoming

"1": Outgoing

EPC

Electronic Product Code. Data on the ID tag assigned to a good.

TID

The transponder ID is a globally unique identification number of the ID tag.

The TID is currently not supported (as of 11/2021).

USER

The USER memory area is a memory area on the ID tag for application-specific data.

The USER memory area is currently not supported (as of 11/2021).

ISO8601 (Time)

Time stamp according to ISO 8601.

8.3.2.1 Examples

The following examples show data records from feedback files.

Example 1

[{"eventID":1,"gateID":490503,"direction":"IN","EPC":"E2801114200087CB77002222","TID":"E21F202100000000000000B","user":"","timestamp":"2021-03-15T13:14:30+0100"},
{"eventID":2,"gateID":490503,"direction":"IN","EPC":"E2801114200087CB77002223","TID":"E21F202100000000000C79F","user":"","timestamp":"2021-03-15T13:14:30+0100"},
{"eventID":3,"gateID":490503,"direction":"IN","EPC":"E2801114200087CB77002224","TID":"E21F20210000000000C714","user":"","timestamp":"2021-03-15T13:14:30+0100"},
{"eventID":4,"gateID":490503,"direction":"IN","EPC":"E2801114200087CB77002225","TID":"E21F2021000000000C723","user":"","timestamp":"2021-03-15T13:14:30+0100"}]} 

Example 2

[{"eventID":5,"gateID":490502,"direction":"OUT","EPC":"E2801114200087CB77001234E21F2021000000000002AD5F","TID":"","user":"","timestamp":"2021-03-15T13:14:30+0100 

Example 3

[{"eventID":6,"gateID":490512,"direction":"OUT","EPC":"E2801114200087CB77009876","TID":"E21F2021000000000001767B","user":"","timestamp":"2021-03-15T13:14:30+0100"}] 

8.3.3 Structure of the results file

The higher-level system compares the feedback file with the stored delivery note. The higher-level system then sends its feedback back to the edge
Controller via a results file in JSON file format. The edge
Controller analyses the loading and unloading of goods via the results file.

The results file has the following structure:

ID	Gate ID	direction	EPC	TID	USER	ISO8601 (time)	Result
1	490503	IN	E2801114200 087CB7700 2222	/	/	03/15/2021 13:14:30	OK
2	490503	OUT	E2801114200 087AA7700 4265	/	/	03/15/2021 13:14:30	Nok
3	490402	IN	E2801114200 087AA7788 4265	/	/	03/15/2021 13:14:30	ok

Id

Unique ID of the data record.

Gate ID

Unique ID (numerical value) of the gate. The gate ID is set in the gate configuration.

Direction

Loading direction (Enum):

"θ": Incoming

"1": Outgoing

EPC

Electronic Product Code. Data on the ID tag assigned to a good.

TID

The transponder ID is a globally unique identification number of the ID tag.

The TID is currently not supported (as of 11/2021).

USER

The USER memory area is a memory area on the ID tag for application-specific data.

The USER memory area is currently not supported (as of 11/2021).

ISO8601 (Time)

Time stamp according to ISO 8601.

Result

Displays the result of the evaluation with the higher-level system.

Result (UHFGateResults, Enum):

"OK 2: The item is in line with the plan."

"NOK": The item does not match the plan.

"ERROR": The item is incorrect or not in the system.

" COMPLETE": The delivery note was loaded completely without errors.

8.3.3.1 Examples

The following examples show data records from result files.

Example 1

[{"eventID":1,"gateID":490503,"direction":"IN","EPC":"E2801114200087CB77002222","TID":"E21F202100000000000000B","user":"","timestamp":"2021-03-15T13:14:30+0100","result":"OK"},
{"eventID":2,"gateID":490503,"direction":"IN","EPC":"E2801114200087CB77002223","TID":"E21F202100000000000C79F","user":"","timestamp":"2021-03-15T13:14:30+0100","result":"OK"},
{"eventID":3,"gateID":490503,"direction":"IN","EPC":"E2801114200087CB77002224","TID":"E21F202100000000000C714","user":"","timestamp":"2021-03-15T13:14:30+0100","result":"OK"},
{"eventID":4,"gateID":490503,"direction":"IN","EPC":"E2801114200087CB77002225","TID":"E21F20210000000000C723","user":"","timestamp":"2021-03-15T13:14:30+0100","result":"COMPLETE"}] 

Example 2

[{"eventID":5,"gateID":490502,"direction":"OUT","EPC":"E2801114200087CB77001234E21F2021000000000002AD5F","TID":"","user":"","timestamp":"2021-03-15T13:14:30+0100","result":"COMPLETE"}] 

Example 3

[{"eventID":6,"gateID":490512,"direction":"OUT","EPC":"E2801114200087CB77009876","TID":"E21F2021000000000001767B","user":"","timestamp":"2021-03-15T13:14:30+0100","result":"ERROR"}] 

8.3.4 Retrieving the feedback file via SSH

The feedback file can be retrieved from the file system of the ZZ1124 via SSH. (→ Data exchange between ZZ1124 and higher-level system ☐ 25)

The following example shows how to retrieve the feedback file via SSH. The following settings are used for the example:

PORT: "22"

USER: "root"

PASSWD: "pdm3"

CODESYS_ROOT_PATH: "/home/cds-apps/JSONFiles/"

DATA_FILE: "./config/data.json"

Fig. 13: Sequence diagram of the SSH connection

Flow

1. The client tries to establish a connection to the ZZ1124 with q 2000 ms timeout.

2. The client reads and checks all new JSON files in the folder "/home/cds-apps/JSONFiles/" . The JSON files are then copied to a temporary folder.

3. The client compares and tags the registered ID tags from the host with the expected ID tags from the delivery note.

4. The client adds a ".result" suffix in the file name to the processed JSON files.

5. The client deletes all JSON files in the temporary folder.

8.3.5 MQTT

MQTT (Message Queueing Telemetry Transport) is an open network protocol for machine-to-machine (M2M) communication. It is used for communication with an ERP such as SAP. The transferred data is formatted in JSON. The data model and the interfaces follow the EPCIS standard (gs1.org).

Device	EPCIS Scanner
Protocol	MQTTS/TLS
MQTT broker host and port	e7ff829e-a915-4650-a8ca-08005c2dc356.us10.cp.iot.sap:8883
MQTT client ID	EPCISJSONMQTT
X.509 client certificate
Client secret key	a! VxkUngDxmd#J6fzT09?#tr3nu9A6rK7?mt
Publishing topic	messages/EPCISJSONMQTT
Example of "Publish payload"(Example is optimised for ifm data structure)	{ "EPCISBody":{ "Event List":[ { "Object Event":{ "event Time":"2020-11-03T20:35:31.116-06:00", "event TimeZoneOffset":"-06:00", "epcList":[ { "epc":"111234567000000204"möglich ist auch: urn:epc:id:sscc: 111234567000.000204 } ], "action":"IN",(direction) "read Point":"Dock1", "epcextension":[ { "EPC":"111234567000000204", "TID":"1", "USER":"ABC" } ] }} }}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}}
Subscribable topic for confir-mation	ack/EPCISJSONMQTT

8.4 DV2510

The signal light contains the following signalling elements:

1: LED segment 1

2: LED segment 2

3: LED segment 3

4: LED segment 4

5: LED segment 5

6: Buzzer

Fig. 14: Position of the display elements

Mode

The signalling light can be used in [Default Mode] or [Compatibility Mode].

Setting the mode is described in the ZZ1124 software manual: documentation.ifm.com

Default Mode

LED segment	Colour	State	Description
(1)	green	Operating status	The gate is active.
	Yellow	Pause	The gate was paused manually.
	red	Error	Error in the gate hardware, NTP, ERP etc. The gate has detected a goods transfer in the wrong direction.
(2)	BlackLED segment not lit	BlackLED segment not lit	The LED segment (2) is not used in [Default Mode] and is not lit.
(3), (4) and (5)	BlackLED segment not lit	Wait for trigger	Wait for trigger.
	blue	No ID tag	No ID tag detected,
	Yellow	Reading an ID tag	An ID tag is being read or a data transfer is active.
(3), (4) and (5)	green	Result OK	The result of the goods turnover is OK and agrees with ERP.
	red	Result not OK	The result of the goods turnover is not OK and does not match ERP.
	Purple	Goods handling completed	Goods handling is successfully completed and matches ERP.

Compatibility Mode

LED segment	LED behaviour	Colour	State	Condition ends when..
(1)	Permanently.	green	The gate is active and waiting.	... ID tags can be read.
	Permanently.	Yellow	An ID tag is being read or a data transfer is active.	... the reading of ID tags is finished.
	Permanently.	Red	The gate was paused manually.	... pausing is ended manually.
	Permanently.	Red	Error in the gate hardware, NTP, ERP etc. The gate has detected a goods transfer in the wrong direction.	... the error has been rectified.
(2)	Permanently.	Green	The result of the goods turnover is OK and agrees with ERP.	...new ID tags are read.
	Flashes	red	The result of the goods turnover is not OK and does not match ERP.	... the error has been rectified.
(444 / 3)	Flashes	blue	No ID tag detected or ID tag is defective.	... 15 s are over.
(4)	Permanently.	green	Goods handling is successfully completed and matches ERP.	... 2 minutes have passed or new ID tags are read.
	Permanent / flashing	Yellow	Goods handling is processed. The behaviour depends on the LED segment (2).	... the goods handling is completed.

9 Maintenance, repair and disposal

The unit is maintenance-free.

▶ Contact ifm in case of malfunction.
▶ Do not open the housing as the unit does not contain any components which can be maintained by the user. The unit must only be repaired by the manufacturer.
▶ Clean the device using a dry cloth.
▶ Dispose of the unit in accordance with the national environmental regulations.

10 Approvals/standards

For approvals and standards, the following information is available:

• Test standards and regulations: documentation.ifm.com
• EU declaration of conformity and approvals: documentation.ifm.com
• Notes relevant for approval: Package insert of the device and documentation.ifm.com

Glossary

ERP

ERP (Enterprise Resource Planning) refers to the planning, control and management of personnel, resources, capital, equipment, materials, information and communication technology, with the focus on an efficient operational value creation process and continuously optimised control of business and operational processes.

MQTT

MQTT (Message Queueing Telemetry Transport) is an open network protocol for machine-to-machine (M2M) communication. The protocol transmits telemetry data between devices in the form of messages. High delays and limited networks are not a problem. An MQTT server (broker) stores the data of the communication partners and can be used as a status database. This makes it possible to connect small, non-performant MQTT devices to an MQTT broker, with the devices collecting data or receiving commands. A complex situation picture is created on the MQTT broker. The situation picture can be analysed on the broker or by a powerful communication partner.

ROI

Region of Interest (ROI) is the area that is taken into account when evaluating the target reflections. Targets outside this area will not be taken into account. The area can be adjusted individually under the radar settings.