FASTENAL 922194627V10 FAST Bin System User Manual

FASTENAL 922194627V10 FAST Bin System

Trademark Information

Fastenal is a registered trademark of Fastenal Company. FAST Bin is a service mark of Fastenal Company. All other trade names mentioned in this manual are the trademarks or registered trademarks of their respective holders.

Support Information

These units are manufactured, owned, installed, maintained, and operated by: Fastenal Company 2001 Theurer Blvd Winona, Minnesota 55987 USA
Support (toll-free): +1 866-829-1564

CAUTION: Qualified Fastenal support staff is required to install and maintain the FAST Bin℠ system. Unauthorized installation, changes, or maintenance by non-Fastenal personnel can result in the system not working as intended and could void the user’s authority to operate the equipment. Please contact Fastenal at the toll-free number listed above if you need assistance or have questions regarding the FAST Bin system.

System Description

This document describes the Fastenal® FAST Bin℠ system, which enables remote monitoring of inventory by means of sensing and communication technologies to report the state of the inventory to a central Fastenal server.

The FAST Bin system consists of five devices that are used to create two different types of installations: Infrared (IR) Bins and Radio Frequency Identification (RFID) Bins. The devices include IR Bins, RFID Bins, Controllers, Readers, and Repeaters. The IR system uses IR Bins, Controller(s), and Repeater(s) to communicate information, while
the RFID system uses RFID Bins, Controller(s), and a Reader.

Each device uses one or more communication technologies to transfer the information, as shown below:

FAST Bin Communication

• Ethernet: A standard technology used to connect digital devices on a network using a wired connection
• Long Range Radio (LoRa): A protocol that provides low power, wide area communication between remote sensors & gateways connected to the network
• Cellular: A network technology that enables mobile device communication via cells and transceivers
• Bluetooth Low Energy (BLE): A power-conserving variant of Bluetooth technology, which provides short-range wireless interconnection of digital devices

System Operation

The FAST Bin system automates the current manual method of checking inventory that is stored in Fastenal standard Bin systems as shown below:

Standard Fastenal Bin Systems The following subsections describe how each of the FAST Bin devices work. Infrared (IR) Bins The IR Bins consist of a standard Bin plus two printed circuit boards (PCBs) that sit opposite each other inside the Bin;

The PCBs are protected by a plastic insert as shown below:

Infrared (IR) Bin

• There is an array of LED IR emitters on one PCB and corresponding IR sensors on the opposite PCB.
• Obstruction of an IR beam equates to the presence of inventory at that point inside the bin.
• The obstructed or unobstructed state, as detected by the sensors, is transmitted to the Controller by means of Bluetooth Low Energy (BLE), and the data for each Bin is then transmitted to the Fastenal Server via the Internet.
• Multiple IR Bins communicate via BLE directly with a single Controller. If distance or obstructions are an issue, a Repeater can be used. In this case, the IR Bins communicate via BLE with the Repeater, which in turn communicates via Long Range Radio (LoRa) with the Controller.

CAUTION: Use only the battery provided. There may be a risk of explosion if a wrong type of battery is used for the unit. The battery cannot be subjected to high or low extreme temperature and low air pressure at high altitude during use, storage or transportation. Disposal of battery into fire or a hot oven, or mechanically crushing or cutting or the battery can result in an explosion. Leaving the battery in an extremely high temperature surrounding environment can result in an explosion or the leakage of flammable liquid of gas. Battery subjected to extremely low air pressure may result in an explosion or the leakage of flammable liquid or gas. Dispose of used battery according to the instructions of local regulations or laws.

Radio Frequency Identification (RFID) Bins

• RFID Bins are standard Bins with RFID tags applied (as shown below). When a Bin has been emptied of its contents, it is manually placed in the replenishment area of the RFID enclosure.
• The Reader, which is located in the enclosure’s subfloor, registers the presence of the RFID tag on the Bin. The Reader then transmits the tag ID to the Controller via LoRa, and the data is then transmitted to the Fastenal Server via the Internet.

Bin with Radio Frequency Identification (RFID) tag

Reader

The Reader reads Bins with RFID tags and sends the information to the Controller via a LoRa connection. See the Radio Frequency Identification (RFID) Bins section for more information on the location of the Reader.

Controller

The Controller is a communication hub for the overall FAST Bin system and uses several different data streams to communicate with the other FAST Bin devices.

Repeater The Repeater is used when it is necessary to increase the range of the BLE transmitters. BLE messages are received by the BLE Module. The Repeater then relays the message delivered to the Controller using LoRa communications.

Indicator Lights

The following sections define the indicator lights located on each device. For the controller, repeater, and RFID repeater a blink of all green LEDs in a pattern indicates that the device is being updated.

Controller

·         Off: No IR Bins are being actively monitored

LoRa| Green| ·         Solid: At least one Repeater or RFID Reader is being actively monitored.

·         Off: No Repeater or RFID Reader is being monitored.

Internet

| Red| ·         Solid: There is no network connection to the controller via Ethernet or Cellular radio.
Yellow| ·         Solid: Ethernet port has a local network connection, but there is no connection to the Internet.
Green| ·         Solid: Either the Ethernet port or an installed cellular radio adapter has a good internet connection.

Repeater

·         Off: No IR Bins are being actively monitored

LoRa| Green| ·         Solid: LorA Link to a Controller has been established.

·         Off: No LoRa link to a Controller has been established.

Power| Green| ·         Solid: Powered on but locked up

·         Heartbeat: Powered on and running

·         Off: No power

Reader

·         Off: No LoRa link to a controller has been established.

·         Heartbeat: Powered on and running

·         Off: No power

New Tag| Green| ·         Solid: A new tag has been read at 25 times

·         Off: No new tags within the last five seconds

Device Labels [Controller and Reader] The following images define the labels for the Controller, Repeater, and Reader.

Controller Label

The label for the Controller is shown below; this label is located on the bottom of the device:

Reader Label The label for the Reader is shown in figure below:

Reader Label The label is located on the RFID enclosure as shown with the red circle in Figure 11:

Installation Instructions

The following instructions define how to install the FAST Bin devices. Qualified Fastenal support staff are required to install the FAST Bin system. The Controller, Repeater, and Reader devices are powered on when plugged in (i.e., there is no on/Off switch on the devices).

It is recommended that the Readers/RFID Bins, Repeaters, and/or racks of IR Bins be installed before choosing the Controller location. This will allow optimal placement of the Controller based on the range requirements of the other devices. See Physical Placement Guidelines in Appendix A for more information on placing the devices. The following table summarizes the maximum distances between each device.

IR Bins

1. Remove the battery insulation pull tab.
2. Ensure that the placement of the Bin is within 50 feet (15.2 meters) of the nearest Controller or Repeater.

RFID Enclosure

1. Assemble the RFID enclosure per assembly instructions provided with the enclosure.
2. Place the enclosure on top of the Bin rack and plug in the power cable.
   • The best practice is to place the enclosure on particle board, on top of the racking/shelf.
3. Ensure that the enclosure placement is within 500 feet (152.4 meters) of the nearest Controller.
4. Ensure that the communications diagnostic light on the front of the enclosure is lit up showing a connected state.

Repeater

1. Install the Repeater using the guidelines in Appendix A.
2. Ensure the Repeater is within 500 feet (152.4 meters) of the Controller.
3. Plug in the power cable to a standard wall power outlet.
4. Ensure that the LEDs are showing that the device is in a connected state.

Controller

1. Configure the device:
   • If the site uses DHCP Ethernet, then no special network setup isrequired.
   • If the site requires use of a static IP address, contact Fastenal support to configure the network settings.
2. Plug in the power cable to a standard wall power outlet.
3. Ensure that the controller has a network connection and is plugged in via the network connection LED indicator.
4. Ensure that no Reader or Repeater is more than 500 feet (152.4 meters) from the Controller and that the LEDs are showing that all devices are in a connected state.

Technical Specifications

Controller

Regulatory Numbers – Basic Controller| FCC ID: 2APK7-922194626V10

IC ID: 23979-922194626V10

---|---
Regulatory Numbers – Controller with cellular data interface| FCC ID: 2APK7-922194622V10

IC ID: 23979-922194622V10

Dimensions| 5.556” W x 4.862” L x 2.0” H

(14.11 cm W x 12.35 cm L x 5.08 cm H)

Weight| 0.71 lbs. (0.322 kg)
Power| 5.0 VDC +/-10%, 1.2A max input
Operating Temperature| 60.8° to 89.6° F (16° to 32° C)
Operating Humidity| 20% to 80%
External Ports & Connections| Ethernet, Power
Supported Protocols & Regulatory Identification Numbers| LoRa: 903-914.2 MHz (12500 bps max) FCC ID: T9JRN2903

IC ID: 6514A-RN2903

BLE:     FCC ID: XPYBMD360 IC ID: 8595A-BMD360

Supported Antennas| ·         LoRa: Flat Patch RF Antenna (Yageo ANTX100P001BWPEN3)

·         BLE: Integrated trace antenna in BLE module

·         4G LTE (with optional cellular module installed):

Taoglas, Ltd. TG.30.8113

Reader

Regulatory Identifications Numbers| FCC ID: 2APK7-992194627V10

IC ID: 23979-992194627V10

---|---
Dimensions of RFID enclosure (in which Reader is housed)| 48” W x 18” H x 24” H

(121.92 cm W x 45.72 cm L x 60.96 cm H)

Power| 5.0 VDC+/-10%, 0.4 A max input
Operating Temperature| 60.8° to 89.6° F (16° to 32° C)
Operating Humidity| 20% to 80%
External Ports & Connections| Power
Supported Protocols & Regulatory Identification Numbers| LoRa: 903-914.2 MHz (12500 bps max) FCC ID: T9JRN2903

IC ID: 6514A-RN2903

Supported Antennas| LoRa: Flat Patch RF Antenna (Yageo ANTX100P001BWPEN3)

RFID: Two (2) Patch Antennas (Abracon ARRG-0004)

Device Labels [Repeater] Repeater Label The label for the Repeater is shown; the label is located on the bottom of the device.

Repeater

Regulatory Identifications Numbers| FCC ID: 2APK7-9705080V1-0

IC ID: 23979-9705080V10

---|---
Dimensions| 3.839” W x 3.352” L x 1.5” H

(9.75 cm W x 8.51 cm L x 3.81 cm H)

Weight| 0.33 lbs.
Power| 5.0 VDC+/-10%, 0.4 A max input
Operating Temperature| 60.8° to 89.6° F (16° to 32° C)
Operating Humidity| 20% to 80%
External Ports & Connections| Power
Supported Protocols & Regulatory Identification Numbers| LoRa: 903-914.2 MHz (12500 bps max) FCC ID: T9JRN2903

IC ID: 6514A-RN2903

BLE:

FCC ID: XPYBMD360 IC ID: 8595A-BMD360

Supported Antennas| LoRa: Flat Patch RF Antenna (Yageo ANTX100P001BWPEN3)

BLE: Integrated trace antenna in BLE module

Device Labels [IR Bins] IR Bin Labels The labels for the IR220 and IR230 bins are shown below; the labels are located on the side of the bins.

IR 220 Bin

Regulatory Identifications Numbers| FCC ID: 2APK7-92219462110

IC ID: 23979-92219462110

---|---
Dimensions| 4.25” W x 7.5” L x 3” H

(10.80 cm W x 19.1 cm L x 7.62 cm H)

Weight| 0.4 lbs.
Power| 3.0 VDC, CR2032 battery
Operating Temperature| 60.8° to 89.6° F (16° to 32° C)
Operating Humidity| 20% to 80%
External Ports & Connections| None
Supported Protocols & Regulatory Identification Numbers| None
Supported Antennas| BLE: PCB meandering inverted F

IR220 IR 230 Bin  Regulatory Id

Regulatory Identifications Numbers| FCC ID: 2APK7-92219462510

IC ID: 23979-92219462510

---|---
Dimensions| 5.5” W x 11.0” L x 5” H

(13.97 cm W x 27.94 cm L x 12.7 cm H)

Weight| 1.2 lbs.
Power| 3.0 VDC, CR2032 battery
Operating Temperature| 60.8° to 89.6° F (16° to 32° C)
Operating Humidity| 20% to 80%
External Ports & Connections| None
Supported Protocols & Regulatory Identification Numbers| None
Supported Antennas| BLE: PCB meandering inverted F

IR230

Compliance Information

The following compliance information applies to the IR Bins, Controller, Reader, and Repeater devices.

FCC Compliance Statement

This device complies with Part 15 of the FCC Rules. Operation is subject to two conditions:

1. This device may not cause harmful interference, and
2. This device must accept any interference that may be received or that may cause undesired operation.

Changes or modifications not expressly approved by the party responsible for compliance could void the user’s authority to operate the equipment.
FCC Statement

This equipment has been tested and found to comply with the limits for a Class A digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment. This equipment generates, uses, and can radiate radio frequency energy and, if not installed and used in accordance with the user manual, may cause harmful interference to radio communications. Operation of this equipment in a residential area is likely to cause harmful interference in which case the user will be required to correct the interference at his own expense.

Canadian (IC) Statement of Compliance This device complies with RSS-247 of the Industry Canada rules. Operation is subject to two conditions.

1.  This device may not cause harmful interference, and
2. This device must accept any interference that may be received or that may cause undesired operation.

ISED Compliance Statement This device contains license-exempt transmitter(s)/receiver(s) that comply with Innovation, Science and Economic Development Canada’s license-exempt RSS(s). Operation is subject to the following two conditions

1. This device may not cause interference.
2. This device must accept any interference, including interference that may cause undesired operation of the device.

Appendix A: Physical Placement Guidelines

Controller Placement Placing the Controller in an optimal location ensures that the Controller will have a much better signal with far less interference. It may be necessary in large facilities to install multiple controllers. The following guidelines can be used to help place the Controller in an optimal location.

NOTE: The Controller and Repeater are designed to sit on a shelf or other surface to allow for access to the regulatory information on the device label (which is located on the bottom of each device).

1. Centralize the Controller: Make sure you place the Controller in the middle of all the devices (i.e., Readers and Repeaters) that are being used. The signal strength from the Controller is somewhat based on the distance. A central position can allow even distribution to all devices.
2. Controller Placement: Try to place the Controller as high as possible in the room, so the signal gets dispersed throughout the facility.
3. Minimize the Number and Angle of Walls: Keep the number of walls and ceilings between the Controller and the Reader/Repeater devices to a minimum. Always imagine a direct line of sight between the Controller and Reader/Repeater devices. Position devices so that the signal will travel straight through a wall or ceiling (instead of at an angle) for better reception.
4. Wall Building Materials: Consider the type of building material through which the signal must travel. Drywall or open doorways are good choices. Materials and objects such as walls with insulation, glass, brick, concrete, steel, metal, water, or mirrors can degrade signal strength. Also, do not place the Controller inside a cabinet or a storage area/space.
5. Avoid Other Wireless Devices: Place appliances, such as cordless telephones, microwaves, Wi-Fi routers, and televisions, as far away as possible from the Controller (at least 3 to 6 feet (1 to 2 meters)). This will significantly reduce any interference that these appliances may cause.

Repeater and RFID Enclosure/Reader Physical Placement

1. IR Bin Placement:
   • Envision each IR bin as being at the center of a large circle with a 25-foot radius. At least one Repeater or Controller should be within the edge of that circle.
   • It is important that no IR Bin be more than 25 feet (7.62 meters) from a Controller or repeater. Then install each Repeater within this distance from all bins it must support using the same guidelines as defined for the Controller Placement.
2. RFID Bin Placement: Placing the RFID enclosure/Reader is constrained only by the requirement that it cannot be more than 500 feet (152.4 meters) from the Controller.

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