Siemens Visicon Polaris Integration Specifications v7

Product Integration Specifications
Siemens Visicon Polaris Singulator Systems
Product Integration Specifications
Siemens Postal, Parcel & Airport Logistics

Document No.: 62.0017.000-00.ITG
Date: July 1, 2016
Revision: 7
© by Siemens AG 2016, all rights reserved
This document is protected by copyrights. The customer may only use and/or copy it for
the purpose of the above mentioned project. Dissemination to third parties, in whole or in
parts, is only allowed with the prior written approval by Siemens Postal, Parcel & Airport
Logistics LLC. In case no contract is awarded to Siemens, this offer and all copies of it
shall be returned to Siemens Postal, Parcel & Airport Logistics LLC.
All trademarks and registered trademarks are the property of the respective owners. The
use of registered names, trade names, description of goods etc. in this document, even if
not specially identified as such, does not imply that such names may be regarded as free
in the sense of legislation pertaining to registered trademarks and the protection of
trademarks and may therefore be used by anyone.
Postal address Siemens Postal, Parcel & Airport Logistics LLC

Logistics and Airport Solutions
2700 Esters Boulevard, Suite 200B
DFW Airport, TX 75261
Contact: Mr. David Hawkins

Tel.: (972) 947-7503
Cell: (817) 713-3294
Fax: (817) 856-4812
david. hawkins@Siemens.com
Visicon Polaris Singulator Systems Product Integration Specifications
Summary of Changes
REV DESCRIPTION DATE
1 INITIAL RELEASE 6/1/2015
2 UPDATED POWER CONNECTION DRAWING AND EDITED SECTIONS 2 AND 3 6/19/2015
3 UPDATED HEIGHT ADJUSTMENT LIMITS 6/29/15
ADDED NOTES FOR UPSTREAM AND HSLA GAPPER SPEED. ADDED 5 BELT GAPPER
4 11/20/15
AND SBS ELIMINATOR INTERFACE DRAWING
ADDED CONTROL REQUIREMENTS FOR UPSTREAM CONVEYORS AND NETWORK
5 01/15/16
DIAGRAM
CLARIFIED DESCRIPTION OF CONVEYOR UNDER POLARIS CONTROL AND ADDED
6 DESCRIPTION OF UPSTREAM FLOW CONTROL. ADDED MORE POWER DROP IN- 2/11/16
FORMATION INCLUDING SCCR FOR EACH PANEL. ADDED ACRONYM LIST.
ADDED POLARIS ASSEMBLY DRAWING, PATCH PANEL LAYOUT, SENSOR MOUNTING
AND CONFIGURATION DETAIL, AND ESTOP CIRCUIT DIAGRAM. UPDATED UPSTREAM
7 BELT CONFIGURATION, TAG LIST, POWER DISTRIBUTION DRAWING, AND POINT 7/01/2016
LOAD DRAWING. POLARIS SINGLE PANEL UPDATED AND MOVED 3 PANEL OPTION
TO APPENDIX.
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Table of Contents
Table of Figures .................................................................................................................................... 2
List of Tables......................................................................................................................................... 3
1. Executive Summary ................................................................................................................. 4
2. Siemens Visicon Polaris Singulator System Description ..................................................... 5
2.1. Siemens Visicon Singulator ........................................................................................................ 5
2.2. Offset Merge Conveyor Assembly .............................................................................................. 6
2.3. Carton Aligner Conveyor Assembly............................................................................................ 7
2.4. Side-by-Side Eliminator and Roller Bed Assembly ..................................................................... 7
2.5. Gapper Conveyor Assembly ...................................................................................................... 8
2.6. Visicon Main System Control Cabinet ........................................................................................ 8
3. Scope of Supply ..................................................................................................................... 10
3.1. Manufacturer’s Scope of Supply .............................................................................................. 10
3.2. Installer Scope of Supply.......................................................................................................... 11
3.3. Integrator Scope of Supply ....................................................................................................... 12
4. Commissioning, Break-In Period and Acceptance.............................................................. 22
4.1. Specification of Parcels for Commissioning and Acceptance ................................................... 23
5. Drawings - Standard Visicon/Polaris Assembly Drawing ................................................... 24
6. Acronym List .......................................................................................................................... 32
7. EXCLUSIONS (Not Included in the Manufacturer’s scope of supply)................................ 33
Appendix A – Tag List ......................................................................................................................... 34
Appendix B – Polaris 3 Panel Option .................................................................................................. 51
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Table of Figures
Figure 1: Polaris Network Diagram ..................................................................................................... 14
Figure 2: Polaris PN 62.0017.950-00 Patch Panel Layout .................................................................. 15
Figure 3: Density Sensor to VFD Interface Diagram ........................................................................... 17
Figure 4: Upstream Belt Density Detection Zones .............................................................................. 18
Figure 5: Upstream Peak Belt Density Example ................................................................................. 19
Figure 6: Daisy Chain Emergency Stop Example with Tiered E-STOP Control .................................. 20
Figure 7: Polaris Conveyor Manifest Diagram..................................................................................... 34
Figure 8: Multi-Panel Configuration Network Diagram ........................................................................ 51
Figure 9: Polaris PN 62.0017.910-00 Patch Panel Layout .................................................................. 52
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List of Tables
Table 1: Polaris PLC to Building Interlock Tag List ............................................................................. 35
Table 2: Building to Polaris PLC Interlock Tag List ............................................................................. 45
Table 3: Polaris PLC to Upstream Peer PLC Interlock Tag List .......................................................... 47
Table 4: Downstream Peer PLC to Polaris PLC Interlock Tag List ..................................................... 49
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1. Executive Summary
Siemens Postal, Parcel & Airport Logistics LLC (Siemens) is pleased to supply the Visicon
Polaris Singulator System for high-speed singulation of parcels.
The supplied components that comprise the Visicon Polaris Singulator System are described
in Section 2 of this Integration Specification.
Traditional singulation systems employ large arrays of roller conveyors, chutes and recircula-
tion lines, all of which take up valuable floor space and increase the ambient noise levels.
Siemens has developed advanced technology to handle throughput intelligently and quietly in
a 70 foot x 10 foot floor space. The Siemens Visicon Polaris Singulator is designed to contin-
uously process incoming bulk flow of parcels and deliver them in single file, accurately
gapped, directly onto take away conveyors for scanning and sortation.
The Visicon Polaris Singulator subsystem utilizes a real time camera vision system, computer
monitoring, and a matrix of independently controlled belt modules to singulate, align, and gap
parcels for sortation. The Visicon Polaris Singulator tracks and controls the conveying speed
and orientation of each individual item.
Most importantly the Siemens Visicon Polaris requires NO manual operator.
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2. Siemens Visicon Polaris Singulator System Description

Until now, current singulation solutions implied large systems of roller conveyors, chutes and
recirculation lines – all of which take up valuable floor space, increase noise and are self-
limiting with regard to scalability. To cope with this problem, Siemens has developed an ad-
vanced singulation technology. Siemens new flagship Visicon Polaris optimizes parcel
singulation in a single pass. Using less floor space of conventional systems, it handles up to
8,250 parcels per hour. Depending on parcel size the Visicon may exceed this rate of parcels
per hour.
The singulator processes incoming bulk streams of parcels in a continuous flow without inter-
nal recirculation, and delivers them single-file, directly onto take-away conveyors for scanning
and sortation.
2.1. Siemens Visicon Singulator
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Vision System
Visicon utilizes highly sophisticated image processing and a special multi-belt conveyor bed to
singulate, align and gap parcels for sortation. The vision system detects measures and tracks
the real-time position and orientation of parcels. Working in a closed loop with the singulator
controls, the Visicon tracks and controls the conveying speed and orientation of each individual
item. The Gapper unit creates both lateral and longitudinal gaps between adjacent parcels.
Singulator Bed
The singulator bed consists of a series of variable-speed belt actuators, each controlled by a
servomotor. The actuators move independently allowing each parcel to be manipulated in or-
der to optimize speed and orientation for singulation. The servomotors accelerate and deceler-
ate each belt so as to pull parcels away from the incoming flow in a sequence determined by
the main control algorithm and monitored by the vision system. Parcels can be aligned length-
wise or crosswise in order to optimize gaps and to move the parcels through the downstream
system more smoothly. Gaps are produced between the parcels at a nominal output speed, so
that all sides of the parcels can be scanned in sorter applications.
2.2. Offset Merge Conveyor Assembly
The items exiting the Visicon one at

a time are merged into a single file
stream on a 10 foot long section of
herringbone roller conveyor. This
device is directly connected to the
output of the Visicon. The Offset
Merge receives randomly oriented
and singulated parcels from an up-
stream conveyor, and merges these
parcels, in a single file fashion, for
discharge onto a carton aligner con-
veyor.
Offset, dual skewed live roller beds are used to transport and merge the parcels. The skewed
live rollers are powered by a pressure belt assembly mounted underneath the roller bed. De-
pendent on site layout and side-by-Side Eliminator discharge direction, left and right hand ver-
sions are available. The right hand version will have the shorter rollers on the right side and
the left version will have the shorter roller on the left side in the parcel flow direction.
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2.3. Carton Aligner Conveyor Assembly
The Carton Aligner receives the

single file stream of parcels from the
herringbone roller conveyor and
edge-aligns these parcels discharge
onto the Side by Side Eliminator
module.
A skewed live roller bed is used to

transport and edge-align the par-
cels. The carton aligner includes an
independently powered vertical belt
assembly along the alignment side
of the conveyor to eliminate the dragging friction of the parcel as it is being edge-aligned to
minimize skewing of the aligned parcels. Left and right hand versions are available based on
the side-by-side discharge direction. The right hand version will align the parcels to the right in
the direction of the parcel flow for a left discharge of side-by-side and vice versa for the left
hand version.
2.4. Side-by-Side Eliminator and Roller Bed Assembly
The Side-by-Side Eliminator receives

the singulated, edge aligned parcel
stream from the Carton Aligner and
transports these parcels single file
along two 4 foot long by 18 inch wide
belted conveyors in tandem for dis-
charge into the 5-belt Gapper.
Two 4 foot wide by 47 inch long roller

sections shall be positioned next to
the 18 inch wide belted conveyors
and oriented such that their direction
of travel is perpendicular to the path of the 18 inch wide belted conveyors. These roller sec-
tions are height adjustable (individually) so that they can be tuned to pull away any parcels
greater than 36 inches wide and will pull away one of any pair of side-by-side parcels with a
combined width of greater than 18 inches.
Each of the two 4 foot long belted conveyors and the two roller sections are independently
powered.
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All rollers in the roller section are driven by pressure belt assemblies beneath the rollers. The
gray rollers shown in the images represent urethane-sleeved or coated rollers on the second
and seventh roller sets closest to the belt conveyors. At the discharge of the Side-By-Side
Eliminator Roller Section, an Integrator can place a chute or conveyor depending on the site
plan.
2.5. Gapper Conveyor Assembly
The Gapper Conveyor Assembly is

comprised of a series of five, 4-foot long
conveyor beds. The individual belt
speeds are independently controlled by
a gapping algorithm running on a Pro-
grammable Logic Controller (PLC). The
Gapper provides the required accurate
spacing needed to ensure maximum
efficiency of the sortation subsystem.
Each belt is driven either by an AC mo-

tor with a Variable Frequency Drive
(VFD). All belts are independent with belt speeds that normally range from 0 FPM to 650 FPM.
A typical application is a 5 belt configuration to feed a sorter. The Gapper Conveyor Assembly
can be used with a singulator equipped with dynamic flow to eliminate the need for automatic
pressure conveyors. The carton rates for the Gapper Conveyor Assembly are highly variable
depending on the applications’ gapping table and parcel mix.
2.6. Visicon Main System Control Cabinet
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The Visicon Main System Control (MSC) Cabinet contains the

controls, computer system, and VFDs for the Visicon itself. There
are a about a dozen I/O signals that make up the standard
Visicon MSC interface to the overall Polaris system, plus hard-
wired safety and reset loops.
The Visicon MSC computer also features a removable solid state

drive (SSD) that contains both the operating system and the
Visicon application software. A backup SSD can be prepared
following installation and commissioning. This backup SSD can
quickly replace the SSD in the computer in the event of operating
system or application software corruption, or an SSD hardware
failure.
Enhanced Visicon Server Backup
The current Visicon computer is a Windows based system running on a server-class computer.
The computer is a high-reliability, high-availability model that is rated with a high MTBF of
thousands of hours. Computer failures, while rare, are possible. To mitigate this potential, the
Standard Polaris System is sold with Duplicate Server Configuration. Duplicate Server Con-
figuration consists of both a Primary and Stand-by computers mounted physically in each
Visicon MSC. The computers will be called A and B. Each computer will be simultaneously
connected to the various sub-systems on the Visicon, but only one computer at a time would
be turned on. The other computer would be shut down.
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3. Scope of Supply
3.1. Manufacturer’s Scope of Supply
Scope of delivery is a complete Visicon Polaris Singulator Systems consisting of:
1. Upstream Bulk Flow Control Software for minimum of 3 and up to 5 Conveyor Modules
as standard configuration. Additional conveyor belts and upstream belt configurations
can be controlled by Polaris if requested through a change order.
2. Siemens Visicon Singulator, PN AX32.1871.007-00, including:
 Gapper - Transition Belt Module

 Alignment Matrix Module
 Gap Correction Matrix Module
 Vision System Superstructure
 Main System Control Cabinet
3. Offset Merge Conveyor Assembly, PN 62.0017.445-00
4. Carton Aligner Conveyor Assembly, PN 62.0017.645-00
5. Side-by-Side Eliminator and Roller Bed Assembly, PN 62.0017.805-00
6. Gapper Conveyor Assembly, PN 62.0017.820-00
7. Polaris Motor Control Panel (MCP), PN 62.0017.950-00
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3.2. Installer Scope of Supply
Installer will be responsible for the following scope of supply:
1. Mechanically set the manufacturer supplied equipment per the integrator’s site layout
drawing.
2. Interconnect both mechanically and electrically all connections between the

manufacturer supplied equipment.
3. Configure all equipment settings per manufacturer’s instructions.
4. Guarantee the functionality of the Visicon Polaris system once installed.
Installer specification details are covered on separate document and are not included here.
3.2.1. Sample Installation Schedule
This sample Installation Schedule is provided as an example of possible installer activities on site
for the benefit of integration scheduling.
Week 1 – Mechanical Install (Saturday – Friday)

1. Set the Visicon Main System Control Cabinet and Polaris Control Panel into place so
Integrator has drop location to supply power.
2. Set the Visicon modules
3. Install the Vision System Superstructure
4. Install the Polaris modules
a. Offset Merge Conveyor
b. Carton Aligner Conveyor
c. Side-by-Side Eliminator and Roller Bed Assembly
d. Gapper Conveyor Assembly
Week 2 – Electrical Install (Saturday – Friday)

1. Install electrical conduit throughout Visicon/Polaris modules
2. Run electrical cables from Visicon Main System Control Cabinet to Polaris Control
Panel
3. Run electrical cables from Visicon Main Control Cabinet to Visicon Power Cabinets
(Master Distribution Cabinet, Slave Distribution Cabinet, and Transformer Cabinet).
4. Run electrical cables from Polaris Control Panel to Polaris modules
5. Power up control cabinets and modules
6. Install software, Configure Matrix Motors, Calibrate Camera
7. Perform functional test
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Week 3 - Commissioning / Break-In-Period / Acceptance Evaluation (Saturday – Friday)

1. Commissioning
2. Break-In-Period
3. Acceptance Evaluation
3.3. Integrator Scope of Supply
The intent of this section is to identify the integrator’s scope of supply from the perspective of
manufacturer and installer. Other scope of supply such as customer requirement and building
code are not considered in this document. It is expected that all mechanical and electrical
interface going out of Visicon/Polaris System to the building and the rest of the conveyor
system are the responsibility of the Integrator. All controls programming and communications
outside of the Visicon/Polaris System are responsibility of the Integrator with the exception of
the control of the required upstream conveyors
3.3.1. Scope of Supply for Visicon/Polaris
1. Layout Visicon/Polaris system within the building per the customer requirement and
supply installer with System layout drawing. Drawings with the mechanical dimensions
of the Visicon/Polaris system and floor loading for left hand and right hand versions are
included in Section 5 of this document. The remote panels must be located within 50
feet of wire length from the modules.
2. Perform all site prep work and ensure the Visicon Polaris system is properly supported.
3. Receive and unload Visicon/Polaris upon delivery. Note any visible shipping damage
on the Bill of Lading.
4. Stage and/or place the Visicon/Polaris on the mezzanine.
5. Equip the required conveyors upstream to the Visicon Polaris with new VFD’s, and
Ethernet/IP field bus controls connectivity as detailed in Section 0.
6. Perform upgrades to the upstream bulk flow train (including any refurbishment such as
new belting, rollers, bearings, drive belts, etc.) and fully commission and test the
upstream train prior to the planned start of Visicon Polaris Singulator System
commissioning and testing.
7. Tie in the Side-by-Side eliminator discharge to the recirculation line.
8. Connect building power to Visicon/Polaris cabinets and panels as described in Section

3.3.4 and drawing 62.0017.000-00MB of Section 5.
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7. Connect Polaris MCP to site’s building network and to upstream transport conveyors.
Figure 2 defines the patch panel ports for the integrator to follow. Figure 1 displays the
Polaris system network diagram. Please refer to Appendix A for a network diagram for
multi-panel configurations of Polaris.
8. Interface the site’s operations control PLC to the Polaris. The Polaris system logic
controller is an Allen Bradley ControlLogix PLC, Model Number 1756-L71. An interlock
tag list is provided in Appendix A with a description of each tag’s function. It is not
required to read/write to every tag. The integrator is responsible for interfacing only to
the tags that the customer needs to read or write to. The integrator shall resolve any
compatibility issues between Polaris Subsystem PLC and the Plant PLC external to the
Polaris system.
9. Interface the site’s HMI to the Polaris PLC. A list of interlock tags is provided in
Appendix A including relevant system statistics with which the site may wish to monitor
on a building HMI.
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Public Network
Plant HMI
Building
Polaris
(SITE DESIGNATED IP)
SLOT 1
SLOT 2
SLOT 3
Polaris ControlLogix
PanelView Plus Chassis
Graphics Terminal
(192.168.1.X)
(192.168.2.X)
Local Unmanaged
Switch
VFDs
MCP
Upstream
VFDs
Visicon PC
Peer-to-
Peer
Figure 1: Polaris Network Diagram
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INTRA‐PANEL
FIELD
POLARIS
PP1 (PATCH PANEL)
Polaris ControlLogix Chassis
IP: SITE DESIGNATED
TO BLDG TO BLDG NETWORK
PP1.1 PP1.1R
IP: 192.168.1.1
IP: 192.168.2.1
NETWORK (REDUNDANT)
SLOT 3
SLOT 1
SLOT 2
TO PEER
TO PEER PP1.2 PP1.2R (REDUNDANT)
TO VISICON
TO VISICON PP1.3 PP1.3R (REDUNDANT)
GDU TO BLDG
GDU TO BLDG
NETWORK PP1.4R PP1.4R NETWORK
(REDUNDANT)
PP2.1 PP1.1
Figure 2: Polaris PN 62.0017.950-00 Patch Panel Layout
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3.3.2. Integrator Conveyor Interfaces
3.3.2.1. Incoming Conveyors controlled by Polaris
In order to achieve the required overall performance, the Visicon Polaris MUST have Flow
Control over a minimum of 3 straight segments of bulk flow conveyors directly upstream of the
Visicon Polaris. These conveyers must be no less than 10 feet long and should be no longer
than 20 feet. The drives for each upstream bulk flow conveyor must be individually VFD
controlled. All VFDs in a given bulk flow conveyor train must be connected to communicate via
an Ethernet/IP connection with PLC located in the Visicon Polaris MCP. This PLC will control
stop, start, jam detection, jam recovery, bulk flow density, E-stop (via Safe-Torque-Off), and
fault monitoring / reporting for the entire bulk flow conveyor train.
All hardware, cable harness, and plumbing shall be provided and installed by the integrator.
The Installer will not perform the Visicon Singulation Subsystem commissioning and test until
all this is in place and 100% functional.
 Width: Maximum of 61.5 in
 Length: Minimum of 10 ft. and recommended maximum of 20 ft. Conveyors longer than
20 ft, if used, may require the photo eye to be relocated and custom tuning to be per-
formed by a controls engineer which may result in additional installation and commis-
sioning charges.
 Belt Type:
o BB X BB or FS X FS.
o High friction belting is not allowed.
 Height of the conveyor (Top of Belt):
o 30 inches minimum to 34 inches maximum adjustment (this is the Top of Belt ad-
justment range of the Visicon Polaris subsystem modules).
o The top of belt for the last 3 conveyors under Polaris control must have level trans-
fers with no waterfall or cascade. Conveyor transfer gap should be kept to a mini-
mum and UHMW transfer plate shall be provided.
 Input speed nominal:
o Motors to be capable of operating with a VFD (inverter duty) in the range of 20 Hz to

60 Hz. Conveyor speed at 60 Hz should be approximately 255 fpm.
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o Each conveyor has its own control and is affected by the downstream speed. The
Visicon is the pacing machine. All belts are “calibrated” based upon the conveyor
speed at 60 Hz as verified by a tachometer.
o Each of the collector belts as well as all of the feed belts range from zero to 250 fpm.
 Flow Control:
o Each upstream VFD must be a SEW MOVITRAC LTP-B VFD equipped with
EtherNet/IP option card LT FE33A.
SEW MOVITRAC LTP‐B TERMINAL BLOCK
2 3 4 6
SICK SICK
DS35-B15521 DS35-B15521
Sensor #2 Sensor #1 BLK BLK WHT WHT
Figure 3: Density Sensor to VFD Interface Diagram

o Each upstream conveyor under Polaris control is to be fitted with two sensors for
density measurement using the specified parts and satisfying the following require-
ments
 SICK DS35-B15521 Part # 1057654, Qty 2.
 SICK DOL-1205-G10M cable Part # 6010544, Qty 2.
 SICK BEF-WN-DX35 mounting bracket Part # 2069592, Qty 2.
 Density sensors are to be mounted facing slightly offset towards each other and
10 inches away from the centerline of the end-of-belt pulley and 0.75 inches
above the conveyor’s carrying surface.
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 Sensors shall be mounted 1 to 1.5 inches away from the side wall of the convey-
or.
 Threshold levels for each sensor will be dependent on the width of the conveyor
and be appropriately set by a technician.
 Seven distance sensing zones, equally spaced dependent on the belt width, will
be set as depicted in Figure 4.
o Any deviations will need to be submitted to Siemens for review and may require a
change order to customize Polaris configuration.
Conveyor Width
Minimum 1
Atleast 1"
spacing
inch Gap
DS1 DS1 DS1 DS1 DS2 DS2 DS2 DS2
Q1 far Q2 far Q1 near Q2 near Q2 near Q1 near Q2 far Q1 far
DS1 DS2
Figure 4: Upstream Belt Density Detection Zones
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3.3.2.2. Upstream Flow Management
1. Flow management of conveyors upstream of Polaris control is the responsibility of the

integrator.
2. In standard configuration any recirculation lines must merge prior to the conveyors un-
der Polaris control.
To achieve peak singulation throughput, the belt upstream of the Visicon must be densely
populated across the width of the belt with parcels averaging less than or equal to 20 inches in
length (longest side) and separation between parcels greater than 1 inch as shown in the ex-
ample photographs below.
Figure 5: Upstream Peak Belt Density Example
 The conveyor just upstream of the ones under Polaris control shall not exceed the mo-
mentary speed of the first Polaris controlled conveyor’s when the photo eye at the dis-
charge end of the upstream belt is blocked (i.e. avoid crushing any parcels on the Po-
laris controlled conveyor).
 The upstream bulk flow conveyor must be capable of supplying 8,250 parcels per hour
(PPH) of average parcel length of 20 inches or less at the transition point between plant
controlled and Polaris controlled conveyors (250 fpm input speed).
3.3.2.3. Outgoing Conveyor
 Width:
o The discharge width of Siemens 5-belt Gapper, the final component in the Polaris
Singulator Subsystem, is 43 inches.
 Height of the conveyor (top of belt):
o 30 inches minimum to 34 inches maximum adjustment (this is the Top of Belt ad-
justment range of the Visicon Polaris subsystem modules).
 Speed nominal with no High Speed Label Applicator (HSLA): 540 fpm fixed. Fixed
speed is a requirement.
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 Speed nominal with HSLA: 450 fpm fixed. Fixed speed is a requirement.
3.3.3. Emergency Stop Circuit
The Visicon Polaris emergency stop control circuit provides flexibility during integration. Refer
to Siemens drawing number 62.0017.950-00.GZ for detailed contact and terminal connection
information regarding Polaris emergency stop circuit. NOTE: For multi-panel Polaris configura-
tions please refer to 62.0017.910-00.GZ for emergency stop terminal data.
The safety relay circuit located in the Polaris MCP will provide:
 One free set of relay contacts for connection into the emergency stop circuit of the up-
stream conveyors under Visicon Polaris control. The diagram below illustrates one ap-
proach with which the system’s emergency stop control circuit may be configured.
Polaris MCP Polaris Upstream 1 Polaris Upstream 2
STO STO …
MAIN MAIN U1 U1 U2 U2
ESCR ESCR ESCR ESCR ESCR ESCR
+24V +24V …
COM COM
Upstream VFD #1 Upstream VFD #2
Figure 6: Daisy Chain Emergency Stop Example with Tiered E-STOP Control
 One free set of relay contacts for upstream panel emergency stopping. Optionally, the
upstream panel could be daisy chained off of the end of the last VFD stop circuit as
seen in Figure 6.
 The integrator is responsible for signalling the Polaris PLC via Ethernet/IP that a VFD
upstream has been emergency stopped. The integrator is also responsible for updating
the appropriate interlock tags in the PLC in the event that a conveyor is e-stopped.
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3.3.4. Primary Power Drops
Primary power drops must be provided to the installed locations of the Polaris Subsystem
cabinets by the integrator including supply of all connecting cables and conduits. Refer to Sec-
tion 5 for power drop layout drawings and other pertinent information.
 Visicon MSC (904 cabinet) requires a 480VAC, 3PH 50A service. It has a Short Circuit
Current Rating (SCCR) of 10 kA.
 Polaris MCP (950 cabinet) requires a 480VAC, 3PH, 60A service. It has a SCCR of 35
kA.
- For information on the power requirements for a multiple panel configuration of the
Polaris system, please refer to 0
 In addition, power to the motors and drives for the upstream conveyors controlled by
Polaris must be provided by the integrator.
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4. Commissioning, Break-In Period and Acceptance

Bulk parcel flow from the primary sorter divert collector conveyors are transported to the
Visicon Polaris Singulator Subsystem via a series of bulk flow conveyors and power turns.
The Visicon Polaris subsystem will singulate, gap, and discharge parcels to a downstream
conveyor for transport to the scanning and sortation subsystem.
Following the installation of each Visicon Polaris Singulator System the Siemens Service
Technician and/or Engineers on site will perform the following:
 Systems Commissioning – to evaluate and confirm all Polaris system components are
operational.
 One (1) Week Break-In Period – following Commissioning, Siemens will remain on-site
to support the initial hand-over to operations and to observe the systems performance.
Small adjustments may be introduced that could take the system off-line for a period of
time. The measured off-line time will be added to the calendar week if necessary (col-
lectively, the “Break-In Period”).
 Acceptance Evaluation – during the Break-In Period, Customer Operations will desig-
nate an Acceptance Evaluation time to run and measure for acceptance.
The Visicon Polaris Singulation Systems Installation and Commissioning Acceptance Form will
guide the technician and Customer PE through the checklist process.
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4.1. Specification of Parcels for Commissioning and Acceptance
AUTOMATION DEPLOYMENT GUIDELINES
FOR PACKAGE CLASSIFICATION AND DEVELOPMENT OF TEST PACKAGES
Regular Package (a.k.a. Conveyable Packages)
 Carton boxes; sometimes wrapped in plastic or duct tapes; possible rounded or dented
corners, bottom surface flat, concave or convex.
 Recycle Nylon Container (RNC) bags will be transported loose on belts that are 50% full
or greater.
 Styrofoam boxes; sometimes wrapped in plastic or duct tape; possible rounded or dent-
ed corners, bottom surface flat, concave or convex.
 Large Totes with bar code; large totes 27x27x9 loads may move inside the tote when
sorted, possible rounded or dented corners, bottom surface flat, concave or convex;
containing i.e. RNC, tote-able irregulars.
 The packages are of a stable nature (L>W and W>H). The parcel specification is noted
in the table below.
For all capacity calculations and performance related metrics, an average parcel length
is assumed to be 20”
Shape and conditions: Various physical attributes may impact the Visicon’s performance
such as (but not limited to) items with sharp-edged objects protruding, improper packaging;
loose film or straps. Such issues may cause jams.
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5. Drawings - Standard Visicon/Polaris Assembly Drawing
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Drawings - Standard Visicon/Polaris Assembly (Right Hand)
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Drawings - Standard Visicon/Polaris Assembly (Left Hand)
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Drawings - Standard Visicon/Polaris Point Load (Right Hand)
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Drawings - Standard Visicon/Polaris Point Load (Left Hand)
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Drawings - Power Distribution Plan
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Drawings – 5 Belt Gapper Interface
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Drawings – Side by Side Eliminator Interface
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6. Acronym List
Acronym Definition
HSLA High Speed Label Applicator
MCP Motor Control Panel
MSC Main System Control
PLC Programmable Logic Controller
RNC Recycle Nylon Container
SCCR Short Circuit Current Rating
SSD Solid State Drive
STO Safe Torque Off
VFD Variable Frequency Drive
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7. EXCLUSIONS (Not Included in the Manufacturer’s scope of sup-

ply)
1) Component fabrication drawings
2) Installation Drawings - Siemens will provide System drawings and Installation Specifica-
tions
3) Unloading of Visicon Polaris Singulator at jobsite.
4) Project Management
5) Electrical Installation
6) Mechanical installation
7) Field Supervision
8) Training
9) Spare Parts – beyond the Spares Kits provided or directly purchased from Supplier
10) Field Electrical Cables or Wire ways
11) Engineering services other than those required for the supply of equipment
12) Field electrical devices (photoeyes, disconnect switches etc.)
13) Main Electrical Feeds
14) Freight from DFW to Installation Site
15) Duties, taxes or permits
16) Shop set up and Testing
17) Programming support or use of Siemens test loop for Integrator testing
18) Factory Acceptance Testing
19) Support grid or support steel
20) Safety netting
21) Special guarding beyond standard supplied
22) Professional Engineering stamping
23) Siemens has not included any additional support steel for Singulators other than stand-
ard support legs for Singulation Subsystem top of belt elevation of 30 to 34 inches
above mounting surface. Other heights are possible, with additional engineering and
material cost.
24) Additional Stand By assistance if necessary will be available on T & M basis.
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Appendix A – Tag List
Tag List Reference

Polaris to Building Interlocks Table 1
Building to Polaris Interlocks Table 2
Polaris to Upstream Peer Interlocks Table 3
Downstream Peer to Polaris Interlocks Table 4
T‐3
T‐6 T‐5 T‐1
G‐5 G‐4 G‐3 G‐2 G‐1
T‐7
T‐4 Visicon Singulator …
T‐2
… U‐3 U‐2 U‐1
Figure 7: Polaris Conveyor Manifest Diagram
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Table 1: Polaris PLC to Building Interlock Tag List

LENGTH: DINT[64]
TAG NAME DATA TYPE DESCRIPTION
INTL_PLRS_TO_BLDG[0].0 BOOL POLARIS HEARTBEAT
INTL_PLRS_TO_BLDG[0].1 BOOL POLARIS PLC RUN MODE
INTL_PLRS_TO_BLDG[0].3 BOOL POLARIS AREA STARTED
INTL_PLRS_TO_BLDG[0].4 BOOL POLARIS AREA RUNNING
INTL_PLRS_TO_BLDG[0].5 BOOL POLARIS AREA STOPPED
INTL_PLRS_TO_BLDG[0].6 BOOL POLARIS AREA ALL FAULTS CLEAR
INTL_PLRS_TO_BLDG[0].7 BOOL POLARIS AREA MAINTENANCE MODE ACTIVE
INTL_PLRS_TO_BLDG[0].8 BOOL SPARE
INTL_PLRS_TO_BLDG[0].10 BOOL POLARIS START PB
INTL_PLRS_TO_BLDG[0].11 BOOL POLARIS STOP PB
INTL_PLRS_TO_BLDG[0].15 BOOL VISICON IS ON
INTL_PLRS_TO_BLDG[0].16 BOOL VISICON IS RUNNING
INTL_PLRS_TO_BLDG[0].17 BOOL VISICON HAS FAULT
INTL_PLRS_TO_BLDG[0].31 BOOL RUN SORTER ONLY
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INTL_PLRS_TO_BLDG[1].0 BOOL T‐1 FLOW STOP
INTL_PLRS_TO_BLDG[1].1 BOOL T‐1 RUNNING
INTL_PLRS_TO_BLDG[1].2 BOOL T‐1 NO MOTOR FAULT
INTL_PLRS_TO_BLDG[1].3 BOOL T‐1 NO JAM FAULT
INTL_PLRS_TO_BLDG[1].4 BOOL T‐1 NO FAULT
INTL_PLRS_TO_BLDG[1].5 BOOL T‐1 MTR DISC OFF IN MCP
INTL_PLRS_TO_BLDG[1].6 BOOL T‐1 COMMANDED TO RUN BUT IS NOT RUNNING
INTL_PLRS_TO_BLDG[1].7 BOOL T‐1 RUNNING BUT NOT COMMANDED TO RUN
INTL_PLRS_TO_BLDG[1].8 BOOL T‐1 VFD/MOTOR FAULT
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INTL_PLRS_TO_BLDG[3].10 BOOL G‐1 FLOW STOP
INTL_PLRS_TO_BLDG[3].11 BOOL G‐1 RUNNING
INTL_PLRS_TO_BLDG[3].12 BOOL G‐1 NO MOTOR FAULT
INTL_PLRS_TO_BLDG[3].13 BOOL G‐1 NO JAM FAULT
INTL_PLRS_TO_BLDG[3].14 BOOL G‐1 NO FAULT
INTL_PLRS_TO_BLDG[3].15 BOOL G‐1 MTR DISC OFF IN MCP
INTL_PLRS_TO_BLDG[3].16 BOOL G‐1 COMMANDED TO RUN BUT IS NOT RUNNING
INTL_PLRS_TO_BLDG[3].17 BOOL G‐1 RUNNING BUT NOT COMMANDED TO RUN
INTL_PLRS_TO_BLDG[3].18 BOOL G‐1 VFD/MOTOR FAULT
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INTL_PLRS_TO_BLDG[5].0 BOOL U‐1 NO FAULT
INTL_PLRS_TO_BLDG[5].1 BOOL U‐1 RUNNING
INTL_PLRS_TO_BLDG[5].2 BOOL U‐1 PE JAM
INTL_PLRS_TO_BLDG[5].3 BOOL U‐1 CONV IN AUTO
INTL_PLRS_TO_BLDG[5].4 BOOL U‐1 MTR DISC OFF
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INTL_PLRS_TO_BLDG[7] DINT SPARE
INTL_PLRS_TO_BLDG[8] DINT Panel disconnect pulled count
INTL_PLRS_TO_BLDG[9] DINT Average gap at system exit
INTL_PLRS_TO_BLDG[10] DINT Max parcels per hour recorded at system exit
INTL_PLRS_TO_BLDG[11] DINT Parcels per hour at system exit
INTL_PLRS_TO_BLDG[12] DINT Parcels per hour at entrance to the system
INTL_PLRS_TO_BLDG[13] DINT Total jam count
INTL_PLRS_TO_BLDG[14] DINT Total system time idle
INTL_PLRS_TO_BLDG[15] DINT Total flow stop count
INTL_PLRS_TO_BLDG[16] DINT Total system time running
INTL_PLRS_TO_BLDG[17] DINT Total VFD faults
INTL_PLRS_TO_BLDG[18] DINT Reported fault code from G‐1 VFD
INTL_PLRS_TO_BLDG[23] DINT Reported fault code from T‐1 VFD
INTL_PLRS_TO_BLDG[30] DINT Reported fault code from U‐1 VFD
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INTL_PLRS_TO_BLDG[40].0 BOOL Visicon heartbeat
INTL_PLRS_TO_BLDG[40].1 BOOL Visicon has fault
INTL_PLRS_TO_BLDG[40].2 BOOL Visicon running
INTL_PLRS_TO_BLDG[40].3 BOOL Visicon is on
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INTL_PLRS_TO_BLDG[41] DINT Visicon major fault code
INTL_PLRS_TO_BLDG[42] DINT Visicon matrix column 1 faulted
INTL_PLRS_TO_BLDG[49] DINT Visicon photoeye jammed
INTL_PLRS_TO_BLDG[50] DINT Visicon pre‐gap faulted
INTL_PLRS_TO_BLDG[51] DINT Visicon pre‐gap speed (ft/min)
INTL_PLRS_TO_BLDG[52] DINT Visicon throughput (parcels/hr)
INTL_PLRS_TO_BLDG[53] DINT Visicon transition belt faulted
INTL_PLRS_TO_BLDG[54] DINT Visicon camera faulted
INTL_PLRS_TO_BLDG[55] DINT Visicon average length (mm)
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Table 2: Building to Polaris PLC Interlock Tag List

LENGTH: DINT[8]
INTL_BLDG_TO_PLRS[0].0 BOOL BUILDING HEARTBEAT
INTL_BLDG_TO_PLRS[0].1 BOOL SPARE
INTL_BLDG_TO_PLRS[0].2 BOOL START POLARIS AREA
INTL_BLDG_TO_PLRS[0].3 BOOL STOP POLARIS AREA
INTL_BLDG_TO_PLRS[0].4 BOOL RESET POLARIS AREA
INTL_BLDG_TO_PLRS[0].5 BOOL RESET POLARIS STATISTICS
INTL_BLDG_TO_PLRS[0].8 BOOL UPSTREAM IS RUNNING
INTL_BLDG_TO_PLRS[0].9 BOOL DOWNSTREAM IS RUNNING
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INTL_BLDG_TO_PLRS[1] DINT SPARE
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Table 3: Polaris PLC to Upstream Peer PLC Interlock Tag List

LENGTH: DINT[8]
INTL_PLRS_TO_USTRM[0].0 BOOL Polaris heartbeat
INTL_PLRS_TO_USTRM[0].1 BOOL Polaris area running
INTL_PLRS_TO_USTRM[0].2 BOOL SPARE
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INTL_PLRS_TO_USTRM[1] DINT Polaris input speed value in ft/min
INTL_PLRS_TO_USTRM[2] DINT SPARE
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Table 4: Downstream Peer PLC to Polaris PLC Interlock Tag List

LENGTH: DINT[8]
INTL_DSTRM_TO_PLRS[0].0 BOOL Downstream heartbeat
INTL_DSTRM_TO_PLRS[0].1 BOOL Downstream is running
INTL_DSTRM_TO_PLRS[0].2 BOOL SPARE
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INTL_DSTRM_TO_PLRS[1] DINT SPARE
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Appendix B – Polaris 3 Panel Option

This Appendix contains information about additional, non-standard configurations of Polaris
that are not discussed in detail above. The Optional 3 panels can be used in lieu of the sin-
gle Polaris Motor Control Panel in situation where the Takeaway and 5 Belt Gapper Modules
are separated.
Public Network
Plant HMI
Building
Polaris
(SITE DESIGNATED IP)
SLOT 1
SLOT 2
SLOT 3
Polaris ControlLogix
PanelView Plus Chassis
Graphics Terminal
(192.168.1.X) (192.168.2.X)
Local Unmanaged
Switch
Logic Panel
Peer-to-
Upstream Peer
VFDs
Visicon PC
VFDs
VFDs
Gapper Panel Takeaway Panel
Figure 8: Multi-Panel Configuration Network Diagram
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POLARIS
PP1 (PATCH PANEL)
TO VISICON TO VISICON PATCH
PATCH PANEL PP1.1 PP1.1R PANEL (REDUNDANT)
TO TAKEAWAY TO TAKEAWAY PATCH
TO GAPPER TO GAPPER PATCH
PP1.4R PP1.4R
POLARIS
PP2 (PATCH PANEL)
TO BLDG TO BLDG NETWORK
NETWORK PP2.1 PP2.1R (REDUNDANT)
TO PEER
TO PEER PP2.2 PP2.2R (REDUNDANT)
GDU TO BLDG GDU TO BLDG
NETWORK PP2.3 PP2.3R NETWORK
PP2.4R PP2.4R
Figure 9: Polaris PN 62.0017.910-00 Patch Panel Layout
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Appendix B.1 Scope of Supply (Multi-Panel Configuration)

For a multiple panel configuration installation of Polaris, the manufacturer shall provide
all the necessary components as listed in Section 3.1 as well as additional components.
Scope of delivery is a complete Visicon Polaris Singulator Systems consisting of the
components listed below:
1. Polaris Logic Panel, PN 62.0017.910-00 (replaces PN 62.0017.950-00)
2. Takeaway Panel, PN 62.0017.930-00
3. Gapper Panel, PN 62.0017.920-00
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Appendix B.2 Power Drops/Requirements (Multi-Panel Configuration)

Primary power drops must be provided to the installed locations of the Polaris Subsystem
cabinets by the integrator including supply of all connecting cables and conduits:
 Visicon MSC (904 cabinet) requires a 480VAC, 3PH 50A service. It has a short-
circuit current rating (SCCR) of 10 kA
 Polaris Logic Panel (910 cabinet) requires a 120VAC, 6A clean power service.
 Polaris Takeaway Panel (920 cabinet) requires a 480VAC, 3PH, 31A service. It
has a SCCR of 35 kA
 Polaris Gapper Panel (930 cabinet) requires a 480VAC, 3PH, 23A service. It has a
SCCR of 35 kA
 In addition, power to the motors and drives for the upstream conveyors controlled
by Polaris must be provided by the integrator.
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Siemens Visicon Polaris Integration Specifications v7

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Product Integration Specifications

Siemens Visicon Polaris Singulator Systems

Product Integration Specifications

Siemens Postal, Parcel & Airport Logistics

Postal address Siemens Postal, Parcel & Airport Logistics LLC

Contact: Mr. David Hawkins

Most importantly the Siemens Visicon Polaris requires NO manual operator.

2. Siemens Visicon Polaris Singulator System Description

2.1. Siemens Visicon Singulator

2.2. Offset Merge Conveyor Assembly

The items exiting the Visicon one at

2.3. Carton Aligner Conveyor Assembly

The Carton Aligner receives the

A skewed live roller bed is used to

2.4. Side-by-Side Eliminator and Roller Bed Assembly

The Side-by-Side Eliminator receives

Two 4 foot wide by 47 inch long roller

2.5. Gapper Conveyor Assembly

The Gapper Conveyor Assembly is

Each belt is driven either by an AC mo-

2.6. Visicon Main System Control Cabinet

The Visicon Main System Control (MSC) Cabinet contains the

The Visicon MSC computer also features a removable solid state

Enhanced Visicon Server Backup

2. Siemens Visicon Singulator, PN AX32.1871.007-00, including:

 Gapper - Transition Belt Module

3. Offset Merge Conveyor Assembly, PN 62.0017.445-00

4. Carton Aligner Conveyor Assembly, PN 62.0017.645-00

5. Side-by-Side Eliminator and Roller Bed Assembly, PN 62.0017.805-00

6. Gapper Conveyor Assembly, PN 62.0017.820-00

7. Polaris Motor Control Panel (MCP), PN 62.0017.950-00

3.2. Installer Scope of Supply

Installer will be responsible for the following scope of supply:

2. Interconnect both mechanically and electrically all connections between the

3. Configure all equipment settings per manufacturer’s instructions.

4. Guarantee the functionality of the Visicon Polaris system once installed.

3.2.1. Sample Installation Schedule

Week 1 – Mechanical Install (Saturday – Friday)

Week 2 – Electrical Install (Saturday – Friday)

Week 3 - Commissioning / Break-In-Period / Acceptance Evaluation (Saturday – Friday)

3.3. Integrator Scope of Supply

3.3.1. Scope of Supply for Visicon/Polaris

4. Stage and/or place the Visicon/Polaris on the mezzanine.

7. Tie in the Side-by-Side eliminator discharge to the recirculation line.

8. Connect building power to Visicon/Polaris cabinets and panels as described in Section

(SITE DESIGNATED IP)

Figure 1: Polaris Network Diagram

Figure 2: Polaris PN 62.0017.950-00 Patch Panel Layout

3.3.2. Integrator Conveyor Interfaces

3.3.2.1. Incoming Conveyors controlled by Polaris

 Width: Maximum of 61.5 in

o High friction belting is not allowed.

 Height of the conveyor (Top of Belt):

 Input speed nominal:

o Motors to be capable of operating with a VFD (inverter duty) in the range of 20 Hz to

Sensor #2 Sensor #1 BLK BLK WHT WHT

Figure 3: Density Sensor to VFD Interface Diagram

 SICK DS35-B15521 Part # 1057654, Qty 2.

 SICK DOL-1205-G10M cable Part # 6010544, Qty 2.

 SICK BEF-WN-DX35 mounting bracket Part # 2069592, Qty 2.

Figure 4: Upstream Belt Density Detection Zones

3.3.2.2. Upstream Flow Management

1. Flow management of conveyors upstream of Polaris control is the responsibility of the

Figure 5: Upstream Peak Belt Density Example