Hexagon Geosystems Services QC235A safeMINE 700018 User Manual Manual

Safemine Ltd safeMINE 700018 Manual

Manual

INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 1 of 56 March 2011 ® INSTALLATION AND MAINTENANCE GUIDE FOR SAFEMINE COLLISION AVOIDANCE SYSTEMS FIRMWARE VERSION 2.20 SMTOOL VERSION 1.30 MARCH 1ST, 2011 © 2009-2011 SAFEMINE LTD. SWITZERLAND
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 2 of 56 March 2011
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 3 of 56 March 2011 Section 1 – Hardware ...................................................................................................................... 6Safety ............................................................................................................................................... 7System .......................................................................................................................................... 7Installation ..................................................................................................................................... 7Introduction ..................................................................................................................................... 8Objective ....................................................................................................................................... 8Technology .................................................................................................................................... 8Implementation .............................................................................................................................. 8Limitations ..................................................................................................................................... 8Components .................................................................................................................................. 10Main units .................................................................................................................................... 10GPS ......................................................................................................................................... 10Radio Frequency (RF) communication .................................................................................... 10Low power behavior ................................................................................................................. 10Installing the Main Unit ................................................................................................................ 11Connector Details – Main Unit ................................................................................................. 12Specifications for QC230/235: ................................................................................................. 13GPS & RF Antenna ..................................................................................................................... 15Antenna Models ....................................................................................................................... 15Specifications for the GPS / RF Antenna .................................................................................... 15Remote Display unit .................................................................................................................... 17Connections – Remote Display ............................................................................................... 17Specification for Remote Display ............................................................................................. 17Connectors and Cabling .............................................................................................................. 19Antenna Cables ....................................................................................................................... 19Section 2 – Software and Programming ..................................................................................... 20Programs and Files ....................................................................................................................... 21Required Components ................................................................................................................ 21Firmware and the Configuration File ........................................................................................ 22Remote Management .................................................................................................................. 23File up- download over RF .......................................................................................................... 23SAFEmine Configuration Tool (discontinued) ............................................................................. 24Configuration file .......................................................................................................................... 25Sample configuration file ............................................................................................................. 25Site Specific Parameters ............................................................................................................. 26Radio Channel ......................................................................................................................... 26Channel Hopping ..................................................................................................................... 26Minimum required parameters .................................................................................................... 27Vehicle ID ................................................................................................................................ 27Vehicle Type ............................................................................................................................ 27Vehicle Dimensions ................................................................................................................. 28Antenna position ...................................................................................................................... 28Optional parameters .................................................................................................................... 28LED Notification Distances ...................................................................................................... 28
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 4 of 56 March 2011 Safety Length ........................................................................................................................... 29Vehicle data ............................................................................................................................. 29Buzzer volume ......................................................................................................................... 29User Interface Mask ................................................................................................................. 29Reducing nuisance alarms .......................................................................................................... 29Infobeep ...................................................................................................................................... 29Alarm Suppressions ................................................................................................................. 30Maximum exception speed ...................................................................................................... 32Optional Features ......................................................................................................................... 34Speeding Alert ......................................................................................................................... 34Rollover alert ............................................................................................................................ 34Voice output ................................................................................................................................ 34Data Recording ........................................................................................................................... 34Log interval .............................................................................................................................. 34Obstacles .................................................................................................................................... 35Areas ........................................................................................................................................... 36Stockpile Collision Avoidance ..................................................................................................... 36Special configurations ................................................................................................................. 37Test Station ................................................................................................................................. 37Examples ................................................................................................................................. 38Rotating Vehicles (Patent Pending) ............................................................................................ 39Minimum Turn Radius .............................................................................................................. 39Usage ...................................................................................................................................... 39Limitations ................................................................................................................................ 39Dual Zone vehicles ...................................................................................................................... 41Digital I/O ..................................................................................................................................... 41Visual Displays and Alarms ......................................................................................................... 41Alarm "Hysteresis" ....................................................................................................................... 42Inside detection ........................................................................................................................... 42Button press recording ................................................................................................................ 42Error codes .................................................................................................................................... 43Limitations ..................................................................................................................................... 44Section 3 – Installation and Maintenance ................................................................................... 45Installation ..................................................................................................................................... 46General Advice ............................................................................................................................ 46Recommended installation procedure ......................................................................................... 46Maintaining the System ................................................................................................................ 47DECLARATION OF CONFORMITY ............................................................................................... 47Appendix A: Recommended parts ............................................................................................. 48Appendix B: Additional Figures and Drawings .......................................................................... 49Antenna Cable ............................................................................................................................. 49Battery Cable ............................................................................................................................... 49Appendix C: Installation Checklist .............................................................................................. 50Appendix D: Maintenance Checklist ........................................................................................... 51
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 5 of 56 March 2011 Appendix E: Troubleshooting guide ........................................................................................... 52Main Unit Power .......................................................................................................................... 55Power Cable ............................................................................................................................ 55Fuse ......................................................................................................................................... 55Remote Display Connection ........................................................................................................ 55Antenna and Cable ...................................................................................................................... 56Connection ............................................................................................................................... 56Crimp Contacts ........................................................................................................................ 56
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 6 of 56 March 2011 Section 1 – Hardware
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 7 of 56 March 2011 Safety System Operating any type of vehicle inside a mine at any time of the day is an inherently dangerous activity which is associated with considerable risks for crew, passengers, third parties, pedestrians, other vehicles and any object in its vicinity. In order to make full and safe use of SAFEmine QC200 series products, it is absolutely essential to be fully aware of the risks, operating conditions, restrictions and limitations associated with their use, including to ensure a proper installation and to perform regular software updates. This includes familiarity with and strict adherence to the Operating Manual and the Installation Manual. Installation All work done to install the SAFEmine Collision Avoidance System shall be done in accordance with safe work standards and shall comply with the latest Health, Safety, and Reclamation Code for Mines in the local jurisdiction. A vehicle equipped with the SAFEmine System must be operated in the same safe manner as if the SAFEmine System was not installed. The system is not a substitute for normal safe driving procedures and may never be relied upon. The SAFEmine System will provide no warning for some hazards, such as vehicles, obstacles, and other objects not equipped with properly operating SAFEmine devices. SAFEmine products are intended as an additional tool in determining potential traffic threats, supporting an alert and conscientious driver. SAFEmine products are never to be used in any application where failure of the products could result in personal injury or material damage. Before using, the latest versions of the respective manuals are to be consulted for familiarization with product operation and limitations. SAFEMINE MAKES NO WARRANTIES WITH RESPECT TO THE PRODUCT. IN NO EVENT WILL SAFEMINE LTD. BE LIABLE FOR LOST USE, PROFITS, REVENUE, COST OF PROCUREMENT OF SUBSTITUTE GOODS, OR ANY DAMAGES. SAFEmine products may not be used in the USA and Canada unless the operator or customer has been authorized to do so in writing by SAFEmine Ltd. Customers agree to indemnify and hold harmless SAFEmine Ltd., its subsidiaries, and affiliates, and their respective successors and assigns, from and against all third party claims, loss, damage or expense, and any other liabilities whatsoever, which may be incurred by SAFEmine Ltd. with respect to any of the SAFEmine products. In addition, SAFEmine Ltd.'s current "General Terms and Conditions of Sale" apply.
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 8 of 56 March 2011 Introduction Objective The main task for SAFEmine QC200 series products is to support the operator, while he scans the space ahead and around the vehicle with his own eyes, cameras and other aids. SAFEmine products are simple to use and are designed not to distract the operator from operating the vehicle. Technology The SAFEmine system – based on technology widely used in aviation – consists of a main unit, an operator's interface (both output and input) and a dual antenna (one for GPS, one for radio communication). Depending on the product selected, the operator's interface is integrated into the main unit, or mounted as a separate display unit. The main unit contains all main sensors (GPS engine, radio transceiver, micro-controller, memory, data interfaces and a series of sensors), The operator interface provides both a directional display of nearby traffic and danger, the beeper/loudspeaker for acoustical warnings and one button for input. SAFEmine QC200 series products receive position and movement information from an internal high-sensitivity 50 channel GPS receiver with an external antenna. Additional sensors and logic further enhances the accuracy of position measurements. The predicted driving path of the vehicle in which a SAFEmine QC200 series product is installed, is calculated by the main unit and the obtained information is transmitted by radio, as a low power digital burst signal at frequent intervals. Provided they are within receiving range, these signals are received by other vehicles also equipped with SAFEmine QC200 series products. The incoming signal is compared with the driving path calculated and predicted for the second vehicle, taking into account configuration parameters like maximum acceleration or vehicle dimension. At the same time, SAFEmine QC200 series products optionally compare the predicted driving path with known static obstacle data, e.g. electric power lines. Implementation If a SAFEmine QC200 series product determines the risk of dangerous proximity to another vehicle or to an obstacle equipped with a SAFEmine QC200 series product, the unit gives the operator a warning of the greatest danger at that moment. This warning is given by a buzzing sound (beep) and bright light emitting diodes (LED). The display also gives indication of the threat level, plus the horizontal bearing to the threat. The operating range is very dependent upon the antenna installation in or outside the vehicle. The normal range is about 500m for line-of-sight operations, but up to 2 km may be achieved in individual cases. For their radio communication, SAFEmine QC200 series products use a proprietary patent- and copyright-protected protocol. Any non-licensed use, dissemination, copying, implementation or reverse engineering of the SAFEmine QC200 series radio communication protocol, their hardware and software or parts of it is forbidden by law and will be prosecuted. SAFEmine is a registered trademark and may not be used without license. Limitations SAFEmine is not designed for use  in deep or narrow open pit mines where availability of GPS satellites is not sufficient  in any other application than open pit mining  on vehicles with excessive vibration SAFEmine units are only to be used with other SAFEmine units, otherwise inconsistent function may occur. SAFEMINE Ltd. cannot assume any liability from correct or incorrect use of above
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 9 of 56 March 2011 specified products other than regular warranty according to SAFEmine Ltd. General Terms and Conditions.
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 10 of 56 March 2011 Components Main units The main unit houses the GPS receiver, radio transceiver, processor, interface logic and additional sensors. The housing is made of aluminum with plastics end-bezels. All connectors are on the back side of the unit. The Main Unit is produced in two versions: Model QC235, with an integrated operator display, as shown above, and the Model QC 230, which utilizes a separate remote display connected by means of the Remote Display Cable, part number QD221. GPS 50 channel GPS L1 receiver with SBAS (WAAS, EGNOS) capability, integrated RAIM (Receiver Autonomous Integrity Monitoring) and active multipath detection and elimination algorithms; GALILEO ready. Radio Frequency (RF) communication Less than 1 % Duty Cycle, Peak Pulse Power10 mW (ERP). License free ISM / SRD bands, software selectable depending on country of use Europe, Africa: 868.2 and 868.4 MHz, others Australia: 921MHz North America: around 951MHz South America: around 951MHz Asia: various Country of Origin: Switzerland, Harmonized System Customs Code 852610 Low power behavior If supply voltage is below 9.6V at startup, a ‘low supply power’ error is displayed and the device will not power up. If voltages below 9.6V are observed at any time during operation, the ‘Power’ LED will turn red and ‘Error Power’ is announced every 30 seconds on the voice output as long as there is sufficient voltage to do so. At voltages below 9V the operation of the SAFEmine unit is no longer guaranteed.
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 11 of 56 March 2011  Installing the Main Unit It must be assured that only one SAFEmine QC200 series product is operated per vehicle. The main unit must be secured in such a position that the operator has the front panel display with the LEDs in direct view, can hear the acoustic warning tone and can operate the control button. The front panel display may not be obstructed at any time. The main unit must not impede the operation of the vehicle (incl. emergency procedures) and in particular it must not reduce the operators field of view. The connectors at the back of the main unit must remain accessible to allow the upload of firmware and maintenance from a PC with an extension cable. Cables must not be bent or attached under stress. The installation must allow adequate space for cable connectors and antennae cables. The lower face of the main units’ aluminum housing includes two blind threads, so that the housing can easily be secured by two M4 screws. Forcing longer than 8 mm screws into the nuts may cause damage! The unit should be installed on a flat surface so that the housing is not subject to any mechanical stress. 3D Models (Solidworks) of the housing and all connectors are available on request. Care should be taken not to allow the devices to be exposed to liquids. Should the unit become humid, it must be thoroughly dried prior to use. Wet devices can sustain permanent damage. Sudden massive cooling should be avoided, as condensation may occur inside the unit. The main unit should be connected directly to battery power to ensure continued operation in case of vehicle stopping or breakdown. A 3A fuse should be installed near the vehicles battery on both power and ground. A sealable fuse holder is highly recommended. Furthermore the fuse should be secured with a cable tie to make any tampering obvious. If vehicle is equipped with a "breaker" the housing should not be connected to vehicle ground as otherwise a ground loop occurs. The housing is black to minimize glare and is specified for temperatures from -40°C to +85°C. It is recommended to attach the cables to the vehicle in a semi permanent way (e.g. cable ties), so they can easily be (re)moved for service and maintenance. 51mm 70mm Figure 3 Main unit bottom view
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 12 of 56 March 2011 Connector Details – Main Unit Power / Interface connector To vehicle or add-on modules Type M12 male, 8 contacts Pin function # of pins Pin type Pin # Cablecolor Ground 1 Power 2 brown Power (+9 to +28VDC) overvoltage and polarity protected 1 Power in 1 white Digital I/O (optional) use to control power down modes e.g. connect to ignition May also be used to switch a load (see below) (0-28V, 0.4A) 1 Input / Output 7 blue RS485 (optional) for GPS augmentation input, Modbus for IO modules Allows interfacing to a wide range of commercially available input / output modules, such as switches to control cameras on haul trucks 2 Input (RX) Output (TX) 5 6 gray pink CAN listener (optional) (typically J1939, ISO 11898) 2 IO H L 3 4 green yellow Audio (voice) out (optional) 1 Output 8 red Digital Output (pin 7):  "High Side Switch"  maximum continuous load current: 0.4A  may switch capacitive, inductive and resistive loads  On-state resistance: 350mOhm  short circuit protected  ESD protection: 5kV  Pulled up with 4.7kOhm Display / Update connector Data and power to remote display and other peripherals Type M8 female, 4 contacts Pin function # of pins Pin type Pin # Cablecolor Ground 1 Power 3 blue 12V out (sanitized) 1 Power 1 brown RS 232 (data to display and for updates) Firmware can be updated through this interface. 2 Input (RX) Output (TX) 2 4 white black Load Power (2, white) QC23x Load GND I/O (7, blue)
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 13 of 56 March 2011 GPS connector SMA female for 3.3V active GPS antenna Only antenna supplied by SAFEmine may be used. RF connector SMA female for 50 Ohm RF antenna Only antenna supplied by SAFEmine may be used. Specifications for QC230/235: Parameter Conditions1 Dimensions excl. connectors 81 x 30 x 98 mm3 overall 81 x 30 x 108 mm3 Weight without cables 210 g Power Supply nominal 12 - 28 VDC Power Supply Range min / max 9.5 / 31 VDC Power Consumption typical @12 V < 55 mA peak @12 V < 180 mA standby @12 V < 35 mA Processor ARM7, 32bit @ 60 MHz GPS 50 channel GPS L1, ISO/TS 16949 qualified, GALILEO ready Time to operation after power-up typical 50 s Time to operation from "hot" standby max 2 s Traffic alert range typical 500m Maximum number of moving units in range typical 50 Direction of Targets Updated typical 4 Hz Average Latency typical 250 ms Operating Conditions .2 Operating temperature -40°C to +85°C Storage temperature -40°C to +85°C Humidity 85%, non condensing 1 All specification are at an ambient temperature of 25°C. 2 Operation beyond the "Operating Conditions" is not recommended and exposure beyond the "Operating Conditions" may affect device reliability.
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 14 of 56 March 2011 Vibration IEC 68-2-6 10-500 Hz; 2 hours/axis; 5g Shock no function IEC 68-2-27 30g/11ms (halfsine); 3 Shock/axis Protection rating IEC 60529 IP54 Connectors Power M12, male, 8 contacts (IP67) GPS SMA Female, color coded RF SMA Female, color coded Remote Display M8, female, 4 contacts (IP67)
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 15 of 56 March 2011 GPS & RF Antenna The external combined GPS & RF antenna supplied with the main unit must be connected; the main unit will not operate without the antennas. Always verify that the antennas are connected to the correct inputs. The connectors are identical for both antenna types. Improper installation of the antenna and its cables is the prominent cause for malfunction. The antenna must be professionally installed by trained personnel only and only the antenna supplied with the equipment by SAFEmine may be used! Antenna Models - Through Hole Mount QF021 The screw mount antenna comes with 10/15cm of cable. The advantage of using short cables on the antenna and then connect and run extension cables is that in case of damage to either the antenna or the cables the defective part can be replaced separately. Furthermore testing of the cable and antenna independently is possible with an SWR meter (available through SAFEmine) To mount the antenna a hole must be drilled or punched into the surface. The diameter of the hole must be at least 19mm (3/4") the surface should also not be thicker than 12mm (1/2") In order to secure the antenna mounting it is necessary to have access to the underside of the hole. For optimal performance, it is recommended that the antennas be mounted on a horizontal metal surface. This will provide the best acquisition for GPS satellites and will also optimize the RF antenna element. To attach the antenna, first remove the nut. The attached gasket provides a sealant to prevent moisture from entering. Feed the cables through the hole, seat the antenna on the surface, and then reattach the nut. The nut should be tight in order to properly seal the gasket. Tighten the nut with a wrench. Finally, feed the cables to the receiver thru additional jumper cables. The inside of the mounting screw of this antenna is NOT sealed. If it is exposed to the outside additional sealing is required before installation. The mounting screw of this antenna must be isolated from the vehicle to avoid ground loops. Suitable insulating washers are available from SAFEmine. - Magnetic Mount QF024 The magnetic mount antenna comes with 3.5m of cables, both GPS & RF. Specifications for the GPS / RF Antenna Parameter Conditions QF012 QF024 Mounting type Through Hole Magnetic Weight 480g 620g
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 16 of 56 March 2011 Dimensions ø107 x 91 mm Power Supply from main unit Connector 2 * SMA Male Operating temperature -40°C to +85°C Storage temperature -40°C to +85°C Protection rating IP 67 Cable 2 * 20cm, coaxial 2 * 3.5m, coaxial  Installing the Antenna The antenna must be mounted on the highest point of the vehicle, with 360° unobstructed view of the sky and at least 50cm away from any other transmitting antenna. The antenna should not have any electrically conducting surfaces (e.g. metal, carbon fiber) above or immediately alongside. If the roof is made out of non metallic material, a ground plane of minimum 18cm diameter must be mounted underneath the antenna. Mounting brackets for various vehicles (Haul Trucks etc.) are available from your local SAFEmine distributor. On tracked vehicles, the antenna must be mounted as close as possible to the axis of rotation! Snow and ice buildup reduces the performance of the antenna and must be removed prior to operation.
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 17 of 56 March 2011 Remote Display unit The back side of the aluminum housing includes two blind threads, so that the housing can easily be secured by two M4 screws (no longer). Forcing longer than 8 mm screws into the nuts may cause damage! 3D Models (Solidworks) of the housing and all connectors are available on request. Alternatively the remote display can be fixed with 3M dual lock (see Appendix A: Recommended parts), This is ideal for installation, where the owner of the vehicle does not want to drill holes in his dashboard Mounting Holes Remote Cable Connector The Remote Display QD200 can also be used with the Main Unit with internal Display QC235. This configuration is not described in further detail here. Connections – Remote Display Data and power from main unit Connector type M8 male, 4 contacts Specification for Remote Display Parameter Conditions Dimensions excl. connectors 80 x 30 x 20 mm3overall 80 x 30 x 30 mm3Weight without cables 60 g Power Supply from Transceiver CG1-S Connector M8, male, 4 contacts (IP67) Operating temperature -40°C to +85°C Storage temperature -40°C to +85°C Vibration IEC 68-2-6 10-500 Hz; 2 hours/axis; 5g Shock IEC 68-2-27 30g/11ms (halfsine)3 Shock/axis; no function Protection rating IP54 Construction Anodized aluminum with plastic end-bezels, all connectors on the back side.
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 18 of 56 March 2011 Figure 1 Front view of remote display Each User Interface has  12 red / green LED in a circle, diameter 20mm  1 red / green status LED each for Mode / Reverse / Ready /Power / "Ready" / Mode  1 multifunctional button LED brightness is automatically controlled based on ambient light, with backlight for night operation. Buzzer with max. 85dB sound level (@10cm) volume can be automatically controlled based on ambient noise. Figure 2 Rear view of remote display
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 19 of 56 March 2011 Figure 6 Minimum bend radius of RF195coaxial cable for one-time (above) andrepeated bends (below). Connectors and Cabling Antenna Cables It is recommended to source coaxial low loss cables including connectors of proper length and high quality from a professional local supplier. Any work on radio RF cabling must be done professionally by trained personnel according to Safemine specifications. Manufacturing of coaxial cables to custom length on site requires specialist tools (strip and crimp tools, soldering iron, SWR meter) and know-how / experience and may result in reduced reliability. Contact SAFEmine if on site cable confectioning is necessary. Recommended maximum cable length between antenna and main unit: Coaxial cable type Max. length RF Max. length GPS RG174 DO NOT USE 5m HDF-195/CFD-195 LMR -195 5m 10m LMR 400 15m 15m Use of other coaxial cable types must be approved in writing by SAFEmine! The maximum acceptable attenuation rate for the RF cable is 3dB at 900MHz. The maximum acceptable attenuation rate for the GPS cable is 10dB. To calculate the attenuation rate, sum up the attenuation of all segments as specified by the cable manufacturer. Add 0.3dB for any connection. The minimum bend radius of the coaxial cables must be strictly observed! Typical minimum bend radius for RF195 type cables is 18mm (3/4 in.) on installation, 60mm (2 1/3 in.) for repeated bending. It is highly recommended to add a braided sleeve around the cables for further UV and abrasion protection. Wear and damage to the RF and GPS antenna cables is not covered under warranty. Connections in the antenna cable must be sealed over the whole assembly with heat shrink tubing (glue type). In addition, outside connections must be sealed with silicone tape to ensure a reliable, weatherproof operation. Never use ‘electrical tape’ or to weatherproof RF connections! No installation may have more than one (1) connection. No PVC tape (black ‘electrical tape’) may be used for sealing connectors! All antenna cables must be carefully tied to the vehicle. Loosely vibrating cable will fatigue and the central conductor will break over time! Make cables removable to prevent them from being cut when the vehicle is being serviced.
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 20 of 56 March 2011 Section 2 – Software and Programming
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 21 of 56 March 2011 Programs and Files Required Components For the installation of the Collision Avoidance System you will need the following hardware:  PC or Laptop running Windows 2000 or later.  M8 to USB Cable (QLxxx) or M8 to serial port cable (QL014) and RS232 to USB converter if PC has no serial port.  Power Supply or Battery (12 or 24 volts) and the following software:  SM Tool (SAFEmine Software Utility)  H-Term  Latest Firmware (v.2.24)  Configuration File (see configtemplate.ini)  USB Driver (for use with cables above that connect to USB port on computer) Note: All necessary programs and files referred to above can be obtained on-line through www.safe-mine.com/support/partners. Enter your user name and password and then select the corresponding directory. Contact info@safe-mine.com if you don’t have a username and password. Figure 1 SAFEmine support file repository
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 22 of 56 March 2011 Firmware and the Configuration File The QC230/235 is controlled by firmware, basically a small, embedded program that is stored permanently in read-only memory. The firmware reads a unique configuration file (refer to “Configuration file” for programming details) that is created and/or modified by the installer which customizes the behavior of the device for the particular vehicle on which it is installed. Both the firmware and configuration file need to be uploaded to the QC230/235 for the system to function properly. Firmware is periodically updated by SAFEmine software engineers. Many features and improvements are available by uploading the latest released version. As a helpful feature, the firmware version is display during start-up. Three green LEDs are lit sequentially for one second, according to the firmware revision (“2”, “0”, “0”), where “0” is 12 o’clock, and numbers increment clockwise.  Setting up the SM Tool File Utility - 1. If not already done, obtain and install a copy of SM Tools on your PC or Laptop. 2. Connect power (12 volts to 28 volts) to the SAFEmine QC230/235. 3. Connect either the QLxxx or QL014 to the M8 connector of the QC230/235, depending on the type of port you have available. 4. Click on the SM Tools icon and start the program. 5. The window as shown in Figure x below appears. 6. Choose the correct COM port at the lower left-hand corner.  Uploading Firmware 1. Choose the correct firmware file 2. Disconnect power from the unit 3. Press "Start Update" 4. Apply power. Four red status LED should stay lit after 5 seconds. If device powers up normally, retry, select different serial port. 5. Wait 45 seconds, or until the message box appears 6. Do not cut power until SAFEmine device has restarted completely (another 20 seconds)! 7. Watch for Errors on restart on the SAFEmine device display 8. In case you have a SAFEmine unit with remote display, you must check for Errors on the PC screen (not yet implemented) or by connecting the display after the update.  Uploading a configuration file 1. Browse using the button to the right […] and choose the desired configuration file. Please refer to page X for details on modifying a configuration file. 2. Click the [Upload] button. Figure 2 The first tab of SM Tool permits the uploading of a new version of firmware to the QC230/235.
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 23 of 56 March 2011 3. Wait 15 seconds, or until a message box appears. 4. Disconnect and reconnect power to the SAFEmine QC230/235. 5. Watch for Errors on startup on the SAFEmine QC230/235. 6. In the case where you are using a QC230 (the unit without an integrated display), check for errors by connecting the display after the update.  Converting a raw log file 1. Choose the file to convert. 2. Press the button corresponding to the type of desired output file 3. Find the converted file in the same directory as the original file. “Analyze” will analyze the recorded file and print the results into a text file. “Convert GE’ will convert the log file into a Google Earth compatible .kml format file. “Convert CSV” will convert the raw data into CSV (Comma Seperated Value) format for further analysis. Remote Management Most operations can be performed on nearby devices using the RF link. Note that the remote device has to be operational and GPS has been locked. File up- download over RF Certain maintenance operations can be performed over the air. Requirements:  PC with latest SM Tools installed, .NET > 3.0 recommended  Local device connected to PC and powered up. Preferably, the device also has GPS reception. This will add direction and distance information in the host selection dialogue.  Peer device with firmware >= 2.00 Figure 3 The File Transfer Tab permits up- and downloading of files to and from the unit Figure 4 The File Conversion Tab permits the conversion of raw log files to other formats
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 24 of 56 March 2011 In SM Tools select “Remote Connection”, “Enable”. The list of available peer devices will be populated automatically. Select a device, proceed as usual to download/upload files, and configuration file. Very carefully check that you are connected to the unit you want to program on! Limitations:  The peer device must have GPS reception; otherwise it will not show up in the list.  Transmit speed is about 1500 bytes per second in good conditions, but will degrade with increasing data traffic (i.e. other nearby vehicles). SAFEmine Configuration Tool (discontinued) Figure 5 Discontinued SAFEmine Configuration Tool (do not use)
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 25 of 56 March 2011 Configuration file A unique configuration file must be compiled and uploaded for each vehicle. The file name should consist of the individual "Plant Number" of the vehicle and end with .cfg Example: HT10.cfg Maintaining a repository of all files allows for easy configuration of replacement units. Syntax:  Parameter = value  The "#" character at the beginning of a line indicates a comment. Comments are ignored and have no effect on the function of the configuration file. Sample configuration files for various vehicles are available from SAFEmine. We strongly recommend that you submit your configuration files for review to info@safe-mine.com. NOTE: Values not set in a configuration file are automatically treated as default value. For instance, if there is no “volume = xxx” entry in the configuration file, it will be set to “100”. Mandatory parameters which must be present in every configuration file are marked in red. Sample configuration file # Sample SAFEmine configuration for Loader ######################################### # do not modify! ######################################### channel = 287 hopping = 1 # site specific configurations ######################################### # all alarm exceptions activated alarmexceptions = 0xffffffff # vehicle specific configuration below, please adapt ######################################### # speaker volume volume = 20 distfar = 80 distnear = 40 distclose = 10 vehtype = 52 vehmanu = CAT vehmod = 988H Loader vehid = 741 vehlength = 6 safetylength = 0 vehwidth = 3 safetywidth = 0 vehheight = 4 antennaaft = 3 antennaright = 1 antennaup = 3.3 minturnrad = 0
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 26 of 56 March 2011 Site Specific Parameters Site specific parameters are the same and must be set on all units. Radio Channel Keyword Description Unit Range Default Example CHANNEL RF Radio Channel - 117 - 381 - 117 Sets the frequency of the radio transmission 117: for Europe / Africa 287: North / South America 301: North America countries under FCC regulation 122: New Zealand 381: Australia 357: Israel Channel Hopping Keyword Description Unit Range Default Example HOPPING Number of channels to use for hopping - 1 - 50 1 1 50: North America countries under FCC regulation 1: All other areas Transmit Power Keyword Description Unit Range Default Example RFPOWER Transmit Power Setting. - 0 - 3 3 3 Sets the transmit power of the radio. A setting of 3 results in maximum power and range of the radio 2: North America countries under FCC regulation (lower power setting required to comply with FCC) 3: All other areas
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 27 of 56 March 2011 Minimum required parameters Vehicle ID Keyword Description Unit Range Default Example VEHID Vehicle ID, e.g. mine plant number - max 6 char - LV007 Must be unique within the site Vehicle Type Keyword Description Unit Range Default Example VEHTYPE Vehicle Type - 10 - 100 - 31 Vehicle Type VEHTYPE Examples Light Vehicle 10 Fort F150,F250 Small Tractor 11 Small Service Truck 13 Ford 750 Bus 15 Haul Truck 21 Komatsu 730E, Dump Truck 22 Water Tanker 23 CAT 777 Lomak Trucks 24 Lomak, Freightliner ADT 31 Fuel Bowser 32 Service Truck 33 Low Bed Truck 35 Mobile Crane 34 Rear Tip Truck 36 Excavator 41 CAT 385C, PC4000 Shovel 42 PC 43 Dozer 44 Dragline 45 Drill 46 Atlas Copco PV271 Large Front End Loader 51 Small Front End Loader 52 CAT 988H Tire Handler 53 Cable Handler 54 Grader 55 TLB, JCB 56 Large Tractor 57 Train 61 Stockpile Stacker 71 Test Station 72 Stockpile Dozer 73 Lighting Plant 74 Beacon 100
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 28 of 56 March 2011 Vehicle Dimensions Keyword Description Unit Range Default Example VEHLENGTH Vehicle length, overall meter 1 - 655 - 12.8 VEHWIDTH Vehicle width, overall meter 1 - 655 - 3.4 VEHHIGHT meter 0 - Antenna position Keyword Description Unit Range Default Example ANTENNAAFT Distance between front of vehicle and antenna. meter 0 - 655 - 3.4 ANTENNARIGHT Distance between left side of vehicle and antenna. meter 0 - 655 1.2 ANTENNAUP Elevation of antenna above ground meter 0 - 2.1 Figure 6 Vehicle dimension and antenna position parameter Optional parameters LED Notification Distances Keyword Description Unit Range Default Example DISTFAR Green LED indicates vehicle closer than disfar meters; taken from outer boundary of “alarm area” meter 1 - 500 150 180 DISTNEAR Steady Red LED indicates vehicle closer than disnear meters; taken from outer boundary of “alarm area” meter 1 - 250 40 40 DISCLOSE Flashing Red LED indicates vehicle closer than disclose meters; taken from outer boundary of “alarm area” meter 1 - 250 5 5 For best situation awareness it is recommended to keep the DISTFAR value larger than the maximum breaking distance of any vehicle in the mine, typically about 110m.
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 29 of 56 March 2011 Safety Length Keyword Description Unit Range Default Example SAFETYLENGTH Extends the alarm region in percent of vehicle dimension. % of length 0 - 100 0 20 SAFETYWIDTH % of width 1 - 100 0 5 Example: A vehicle with length 5m sets SAFETYLENGTH = 30 thus will have an additional safety area of 1.5m ahead AND behind the vehicle. Setting above values too high (typically > 30) may result in unwanted "nuisance alarms" as alerts will sound even though there is no danger of collision. Recommended values are 30 for haul trucks and 10 for light vehicles Vehicle data Keyword Description Unit Range Default Example VEHMANU Vehicle Manufacturer - max. 31 characters - KOMATSU VEHMOD Manufacturers model name - max. 31 characters - 785 Buzzer volume Keyword Description Unit Range Default Example VOLUME Volume of the buzzer of the display in percent of full volume -1: automatic (not yet implemented) % 0 - 100 100 60 User Interface Mask Individual user interface components can be deactivated (e.g. buzzer, LED circle) Keyword Description Unit Range Default Example UIMASK Deactivatesselecteduserinterfacecomponents,e.g.buzzer,LEDcircle.Individualuserinterfacecomponentscanbedeactivated(e.g.buzzer,LEDcircle).Flags 0 – 0xFF 0xFF 0xE2 RefertotheUIMASKUtilityinordertoenterthecorrectparameter.0x01Buzzer0x02WarningLED(Compassrose)0x04Voice0x08GPSstatus(buzzerandvoiceonly)0x10Infobeep(invertedlogic,cleartoenable)0x20AllLEDReducing nuisance alarms Infobeep All Infobeep functions are still in a ‘BETA’ state and may only be used for testing! “Infobeep” instead of DM Alarm on passing vehicles To enable the new “Infobeep”, clear UIMASK bit number 5 e.g. with UIMASK = 0xEF
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 30 of 56 March 2011 Conditions for triggering an Infobeep: - The other vehicle could . - I can see the other vehicle at +- 30 degrees from my direction of travel - The other vehicle has a heading that is opposed to mine with a max deviation of +- 30 degrees - The other vehicle is within DISTFAR (otherwise it is not shown on the display and should not be announced) A vehicle that has been announced through “Infobeep” will never generate a DM alarm (beeping) on approaching, as it is assumed that the operator is aware of the approaching vehicle and will avoid it. Alarm Suppressions Keyword Description Unit Range Default Example ALARMSUPPRESSION - 0- 0xFFFFFFFF 0 0FFFFFFFF To avoid unnecessary ‘nuisance alarms’ several alarm exceptions detailed below have been implemented which suppress alerting for certain DM (dangerous movement) alarms. To allow flexibility, they can be switched on or off by setting ALARMSUPPRESSIONS in the configuration file accordingly. If ALARMSUPPRESSIONS is not set, by default all suppressions are switched off (there will be an alarm in the described situations). To edit the settings, sum up the listed codes (hex) and set ALARMSUPPRESSIONS (hex) to the total result. Use of this parameter will permanently disable some alarms when vehicles approach each other. code My vehicle My vehicle is moving Type of other vehicle I am approaching Direction where I come from off on Light Vehicle forward Light Vehicle anywhere 0 0x1Small Tractor 0 0x2backwards Light Vehicle anywhere 0 0x4Small Tractor 0 0x8Small Tractor forward Light Vehicle anywhere 0 0x10Small Tractor 0 0x20backwards Light Vehicle anywhere 0 0x40Small Tractor 0 0x80ADT forward PC anywhere 0 0x100Small Front End Loader forward ADT side 0 0x200Dump Truck side 0 0x400Rear Tip Truck side 0 0x800Large Front End forward Haul Truck side 0 0x1000
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 31 of 56 March 2011 Loader Dump Truck side 0 0x2000Tire Handler forward Grader side 0 0x4000Service Truck side 0 0x8000Fuel Bowser side 0 0x10000Small Front End Loader side 0 0x20000Large Front End Loader side 0 0x40000Tyre Handler side 0 0x80000Haul Truck side 0 0x100000Water Tanker side 0 0x200000Dump Truck side 0 0x400000Haul Truck all Excavator anywhere 0 0x800000PC side 0 0x1000000Dump Truck all PC anywhere 0 0x2000000Rear Tip Truck all PC anywhere 0 0x4000000Excavator all Haul Truck anywhere 0 0x8000000PC all ADT anywhere 0 0x10000000Dump Truck anywhere 0 0x20000000Rear Tip Truck anywhere 0 0x40000000Dozer all Dozer anywhere 0 0x80000000 Example: Following suppressions turned on: My vehicle I am moving Other vehicle I am approaching Direction where I come from code for switching on: Light Vehicle forward Light Vehicle anywhere 0x1Small Tractor 0x2Small Tractor forward Light Vehicle anywhere 0x10Small Tractor 0x20Large Front End Loader forward Haul Truck side 0x1000Dump Truck side 0x2000Tyre Handler forward Service Truck side 0x8000 All other exceptions turned off  sum of all codes = 0x4 + 0x8 + 0x40 + 0x80 + 0x1000 + 0x2000 + 0x8000 = 0xB033  the following line has to be added into the configuration file: ALARMSUPPRESSIONS = 0xB033 Note that the number entered for the parameter ALARMSUPPRESSIONS is hexadecimal. A single digital hex number can range from 0 to 15, so letters are used to represent numbers greater than
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 32 of 56 March 2011 9, i.e., 10=A, 11=B, 12=C, 13=D, 14=E, and 15=F. Hence when numbers are added they are done one column at a time. If the total for a column is greater than 9 letters between A and F are used to represent the hex number. To eliminate some of the work, if only some few exceptions have to be turned off, the associated on-codes can be subtracted from the value 0xFFFFFFFF. Maximum exception speed Keyword Description Unit Range Default Example MAXEXSPEED Limit of alarm suppression km/h 0 - xx 0 10 If MAXEXSPEED [km/h] is set in the configuration file, all active suppressions are only suppressing beeping if my vehicle is moving below that speed. If MAXEXSPEED is not set, there will be no limiting speed for alarm suppressions. Use 0 to disable this feature (default). Put another way, Suppressions only have an effect when vehicle speed > MAXEXPTSPEED. Example: On a Large Front End Loader, MAXEXSPEED = 5 and ALARMEXCEPTIONS = 0xB033 are set in the configuration file. Therefore there will be no DM (beeping) alarms if the Large Front End Loader approaches a Dump- or Haultruck from the side, except if the Large Front End Loader is going faster than 5km/h.
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 33 of 56 March 2011 Parameter Description Unit Example Keyword Weight Maximum vehicle weight (including load) Ton 350 VEHWEIGHT Max Speed Rev Maximum speed in reverse. Alarm will sound on speeding (optional. Requires Option QP117) 0: disabled km / h 5 MAXSPEEDREV Turning radius Turning radius SAE (set to 0 for rotating, e.g. tracked vehicles). See additional instructions below Meter 28 MINTURNRAD Driver Pos Aft Distance between front of vehicle and driver Meter 1.5 DRIVERAFT Driver Pos Right Distance between left side of vehicle and driver Meter 1.5 DRIVERRIGHT Driver Pos Up Elevation of driver above ground Meter 4 DRIVERUP
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 34 of 56 March 2011 Optional Features Speeding Alert Alerts are issued through the LED display and the voice output if the vehicle goes faster than MAXSPEED. Rollover alert Keyword Description Unit Range Default Example ROLLOVER Maximum roll angle. Alarm will sound on higher angle Requires Option QP 0: disabled ° degrees 0 - 90 0 40 Rollover alarm is currently deactivated on very bumpy roads to avoid nuisance alarms. Voice output All voice output functions are still in a ‘BETA’ state and may only be used for testing! [intro] Voice is currently available in English and Spanish. More languages can be ordered through your SAFEmine dealer. The 'announce all on button press' works again, however the vehicle must meet the conditions described below to get re-announced. Voice plays for the first time if its predicted trajectories come within DISTVOICE. 0 suppresses all vehicle alarms The distance to the other vehicle is no longer announced, as the announcement took too long. Conditions for Clustering: I see the vehicles within +-40 degrees and between them there is less than DISTFAR/2 distance. Clustered vehicles are announced as “n Vehicles”. Data Recording Log interval Keyword Description Unit Range Default Example LOGINTERVAL Log interval for track and data recording. seconds 1 - 255 1 2 The internal flash memory will overwrite the oldest logs after about 80h of vehicle movement (if 1 second interval is chosen). Log interval is multiplied by 60 when vehicle is stationary to save memory. Each position record also contains information on the accumulated RMS (Root Mean Square) vibration since the last log entry. It also contains the movement mode (for easier data analysis) Keyword Description Unit Range Default Example VOICEFILE File name of voice audio file 0 sm_EN_M_1.1.voc DISTVOICE AUDIOVOLUME Controls speaker volume independent of the buzzer volume % 0 - 100 80
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 35 of 56 March 2011 Note: Analysis of vibration data is not yet supported by the PC software. Fatal errors that lead to a device reset are now recorded. Note: Analysis of this data is not yet supported by the PC software. Vehicles are only recorded if they trigger a sound alarm, or if a sound alarm was suppressed by an alarm exceptions setting. Obstacles Fixed obstacles can be defined. If a vehicle approaches these obstacles the operator will be warned. Obstacle data must be placed in a separate file named “obst.ini”. It may be updated through the Sync Station The syntax of an obstacle entry is: OBST = <type>,<geometry type>,<geometry> You may also use “;” as delimiting characters. The fields are: <type> A number, where: 0 -> Generic Obstacle (announced as ‘Obstacle’) 10 -> Building 21 -> Power line 22 -> ‘Stop’ sign 23 -> reduced speed area 71 -> Coal valve 72 -> Stockpile edge <geometry type> one of the following 1d: circular obstacle 2d: line obstacle (i.e. conduit, cable) <geometry> depends on geometry type. For 1d: <lat>,<lon>,<radius> For 2d: <lat><lon>,<lat>,<lon> (designating the start and endpoint of the conduit) <lat> latitude, decimal notation (decimal sign is the period “.”), followed by “N” or “S” character. E.g.: 48.1234N (trailing zeros may be omitted) coordinates must be in WGS84 system <lon> same as lat, but using “E” or “W” character. E.g.: 167.987552W. <radius> radius in meters, decimal notation. Examples: # This is a "line" obstacle, issuing "power line" voice alerts OBST = 21;2d;37.845N,122.243W;37.847N,122.243W # This is a circular obstacle, issuing "obstacle" voice alerts OBST = 0;1d;37.841343N,122.248W;5.3 The maximum number of obstacles is 25. The maximum numbers of characters in a line is to 80.
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 36 of 56 March 2011 Distance to obstacles is calculated from the GPS antenna of the vehicle, no vehicle dimensions and antenna locations are considered! This will be improved in future releases. Areas Areas allow to automatically change parameters based on the location of the vehicle, e.g. to have different maximum speed limits on site and on the highway. See separate documentation for details on how to program areas. Stockpile Collision Avoidance Special modes are available to support stockpile collision avoidance system application. This includes warnings for stackers, reclaimers, coal valves and vehicles operating on the stockpile. Please contact SAFEmine for additional information.
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 37 of 56 March 2011 Special configurations Test Station [Intro] A Test Station may be in command of an electric boom gate for automated access control. Any SAFEmine equipped vehicle within the range of the Test Station will cause the digital output to go high. The output will remain high until the vehicle is again out of range. The approaching vehicle will have its LED flash red along with a buzzer alarm when it is within its DISTNEAR setting. To use the Test Station mode, set vehicle type VEHTYPE to 72 and DISTCLOSE to the range in meters where it is desired to be activated. The unit must be purchased as option QP141 per price list. Setting DISTCLOSE to 0 will make the unit behave as if it was approached by a vehicle, this is the test mode to test the digital output. Test stations do not trigger on any vehicle in the vicinity but look at the location and direction of travel. Only vehicles that drive ‘IN’ will be detected and shown by the test station. Add the keyword ‘moving’ to the VEHMOD parameter to limit detection to forward moving vehicles Keyword Description Unit Range Default Example VEHTYPE Set to 72 72 0 72 VEHMOD Determines behavior ‘from left’ or ‘from right’ ‘moving’ - FROM LEFT MOVING FIXHEADING Orientation ° degrees 0 - 360 - 53 DISTCLOSE Range m 0 - 255 5 40
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 38 of 56 March 2011 Examples Right hand traffic (traffic keeps to the right side of the road) The example below uses the following parameters: VEHMOD = from left FIXHEADING = 330 DISTCLOSE = 50 Left hand traffic (traffic keeps to the left side of the road) The example below uses the following parameters: VEHMOD = from right FIXHEADING = 150 DISTCLOSE = 50
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 39 of 56 March 2011 Rotating Vehicles (Patent Pending) Minimum Turn Radius Vehicles with unknown heading (e.g. non moving, tracked, rotating vehicles) are calculated as circular objects. No threat heading can be displayed to the operator of such vehicles. The parameter minturnrad should be set to zero for tracked vehicles and other vehicles where the orientation of the driver may differ from the direction of travel. Setting minturnrad = 0 will result in the motion filter discarding heading information once the vehicle enters standstill. Setting a value greater than 0 will disable this behavior. To determine the heading of rotating vehicles (e.g. tracked dozers etc), two units must be mounted. The main unit can be mounted as normal, except that its antenna should be mounted towards a corner of the vehicle. The minimum distance between the antennas of the units is 5 meters for vehicles operating on the surface of the mine and 15 meters for vehicles active in regions with more than 30% obstruction of the sky. Contact SAFEmine if these restrictions cannot be met. It is essential that both antennas are not obstructed by any part of the vehicle and have a 360° view of the horizon (except for terrain obfuscation).  Configuring the main unit Set BEACON = XXXXXXXXXXX Where XXXXXXXXXX is the serial number of the beacon unit, e.g. “70011855000”. Also, accurately enter the position of the slave (beacon) antenna: BCNANTENNAAFT = XX.X meters BCNANTENNARIGHT = XX.X meters BCNANTENNAAUP = X.X meters  Configuring the beacon unit Set VEHICLETYPE = 100 (required!) It is essential that both the main and the beacon unit have their antenna positions programmed accurately.  Usage The main unit's "Reverse" LED is flashing red if no valid beacon signal is received. The LED of the beacon unit will flash green at 1Hz and 50% duty cycle and the "reverse" LED is always off".  Limitations The center of rotation is assumed to be in the middle of the vehicle for the rotation prediction. Rotating vehicles Some vehicles can turn or rotate and hence change their heading without any forward or backward movement, such as in the case of track dozers and shovels. In effect, these vehicles have a turning radius of zero. In such cases, it is recommended that a second antenna be added so that the direction of movement of the vehicle is always defined. Installing Hardware The principal antenna should be installed as close to the center of rotation of the vehicle as possible and the second antenna, referred to as a beacon, should be installed in a corner location such that
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 40 of 56 March 2011 the distance between the principal and beacon antennas is as large as possible. Both antennas require their own SAFEmine main unit. The principal main unit can be either a QC230 with a remote display or a QC235; the beacon main unit does not require a display and often a QC230 without a remote display is used here. For convenience, both main units are often mounted close together in the cab of the vehicle, in a piggy-back or side-by-side fashion. It is recommended that the distance between the two antennas be at least 5 meters. For vehicles that operate in regions of the mine where more than 30% of the view of the sky is obstructed, this distance is increased to 15 meters. Contact SAFEmine if these restrictions cannot be met. It is essential that both antennas are not obstructed by any part of the vehicle and have a 360° view of the horizon (except for terrain obfuscation). Software Configuration For the system to operate properly, the principal main unit needs to recognize the beacon main unit. This is accomplished by means of the main unit serial number. By including the beacon main unit serial number in the configuration file of the principal main unit, the two antennas can be linked. It is also critical that the relative position of the two antennas be known. This is also done by means of special parameters in the principal main unit configuration file, such that the relative position of the beacon antenna is stored in the principal main unit. By knowing the position of the principal and beacon antennas and the distance and angle between the two, the heading of the vehicle can easily and accurately be determined. To do this, add the following to the standard configuration file of the principal main unit: Minturnrad = 1 (Rotating vehicles using only a single antenna are vehicles of unknown headings and are calculated as circular objects. No threat heading can be displayed to the operator. In such cases of rotating vehicles, where only a single antenna is used, minturnrad is set to 0). BEACON = XXXXXXXXXXX where XXXXXXXXXX is the serial number of the beacon unit, e.g. “70011855000”. BCNANTENNAAFT = XX.X BCNANTENNARIGHT = XX.X BCNANTENNAAUP = XX.X where XX.X is the distance measured in meters. These configuration file parameters are defined as follows: BCNANTENNAAFT - distance measured from the front of the vehicle to the beacon antenna BCNANTENNARIGHT - distance measured from the left side of the vehicle to the beacon antenna BCNANTENNAAUP – distance measured from the ground level to the beacon antenna.
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 41 of 56 March 2011 It is essential that both the main and the beacon unit have their antenna positions programmed accurately for proper operation! Now add the following to the configuration file of the beacon main unit to set its vehicle type to 100: VEHICLETYPE = 100 Performance The LED of the beacon unit will flash green at 1Hz, 50% duty cycle, and the "reverse" LED is always off. However, the main unit's "Reverse" LED will flash red if no valid beacon signal is received. Limitations The center of rotation is assumed to be in the middle of the vehicle for the rotation prediction. If there is a significant difference between the true axis of rotation and the center a slight positional error will result. Dual Zone vehicles Keyword Description Unit Range Default Example VEHBASELENGTH Length of the vehicles body m 0 - 655 0 20 Some Vehicle types can be configured to have a base-length (configuration value “vehbaselength”). This allows Haul-Trucks and Dump-Trucks to reverse towards the loading boom of an excavator or shovel without causing an alarm. Also no alarm will be given to the operator of the excavator or shovel when swinging the boom over the haul truck. This behavior only occurs in interactions between shovels/excavators (VEHTYPE = xx / xx) and haul- and dump trucks (VEHTYPE = 21 / 22) Vehicles with configured vehbaselength are currently exempt from collision de-escalation. Digital I/O The digital IO module can be used to monitor and record vehicle parameters such as: door open, seatbelt, handbrake, etc. Another use of this module is the switching of cameras based on movement direction or surrounding vehicles and obstacles. This option requires additional hardware, contact SAFEmine for evaluation. Visual Displays and Alarms The visualization of rollover alarm, obstacle alarm and over speed alarm are as follows:
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 42 of 56 March 2011 These special alarms are not shown with other alarms together. Therefore they only appear if no other more important alarm was found. Alarm "Hysteresis" All alarms are show for a minimum of 1.5 seconds to allow the operator to see and react to it. Changes to higher alarm levels are immediate, lower levels only after showing higher level for 1.5 seconds. Inside detection The unit automatically detects when the vehicle is inside (e.g. a garage) and goes into standby mode. This prevents nuisance alarms due to bad GPS coverage and also prevents spurious GPS ok/not ok signals while being parked inside. When the unit detect that it is inside, the ‘Ready’ LED changes to red. Button press recording Short button presses are being recorded and are visible in the CSV file as ‘BUTTON’ Entry. This can be used to flag special situations, e.g. incidents or situations where the user believes the SAFEmine device does not perform as expected. Obstacles, Powerlines Rollover Rollover Overspeed
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 43 of 56 March 2011 Error codes The unit performs a self-test upon power up. Errors are indicated by flashing of all status LED in red while showing the error code(s) on the circular display and also sending it to the serial port. Debugging of error codes is best done with a PC running a terminal program (e.g. Hyperterm) connected to the serial port. On first restart after updating a "non fatal" error may be displayed for 30 seconds due to the additional configuration options (green flashing status lights and one green light on the compass display) Error code LED # Subsystem Severity Cause 01 1 Flash Memory (Fatal) Flash memory failure; non-fatal if operational, but data lost. Fatal if operation is not possible. 02 2 Serial Fatal Serial number invalid, contact support 04 3 GPS receiver Fatal 05 1 & 3 GPS Antenna Fatal GPS antenna defective or bad connection 08 3 Power Fatal Power supply defective or low/high voltage RF transceiver Fatal Microphone Buzzer Fatal Ambient Light Sensor Acceleration Sensors Fatal Flash Memory Flash File System 16 4 User Interface Fatal 32 5 Config (Fatal) Configuration file contains errors, or loading default configuration 64 6 Firmware Fatal Firmware corrupt, upload new firmware 128 7 Generic Generic error Speaker Only when configured for Speaker use 255 8 Unknown
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 44 of 56 March 2011 Limitations  Distance to obstacles is calculated from the GPS antenna of the vehicle, no vehicle dimensions and antenna locations are considered!  Only the following obstacle types are implemented in the voice output: “Power Line”, “Obstacle”.  Vehicles with unknown heading (e.g. non-moving, tracked vehicles) are not calculated with their exact dimensions / behavior. Will be resolved in next revision.
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 45 of 56 March 2011 Section 3 – Installation and Maintenance
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 46 of 56 March 2011 Installation General Advice Unless certified, installation and operation must be on the basis of non-interference with and no hazard to the existing equipment installed for safe operation. When certified, installation and operation must be done according to certification procedures in order to comply with official regulations and requirements. After installation, an appropriate entry should be made in the vehicle’s technical logs and a check is to be made that the installation is in no way detrimental to the mechanical or electrical performance of other vehicle’s systems (e.g. radio). The unit serial number and software version is to be recorded in the vehicle’s technical log. We highly recommend establishing a “Radio Map”, containing all intentional transmitters and their operating frequencies. This map will help to minimize radio interference. Recommended installation procedure Create list of all vehicles, with properties as required, for the configuration files. Create one configuration file for each vehicle. These files must remain readily available to maintenance so they can be used anytime a unit needs to be replaced. See Appendix C: Installation Checklist for mandatory installation checklist to be filled out and kept on file for each vehicle.
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 47 of 56 March 2011 Maintaining the System Contact your local dealer to find out about available maintenance services. See Appendix D: Maintenance Checklist for a sample maintenance checklist to be filled out and kept on file for each vehicle. The housing should only be cleaned with a slightly moist non-abrasive cloth without any cleaning agents. All electrical connection and cables should be controlled regularly and the GPS antenna should not be covered by snow or a thick mud layer. If new firmware is available, it should be uploaded to the device at earliest convenience. It is highly recommended to install a "Test Station", available through SAFEmine on site (e.g. in the brake test area and at site access), where all vehicles and their units can be tested for proper operation before use. Solar panels on Test stations must be inspected every week. Any dust, snow or ice buildup must be removed immediately. This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) this device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation. The user shall be cautioned that changes modifications not approved by the responsible party could void the user’s authority to operate the equipment. DECLARATION OF CONFORMITY SAFEmine Ltd., CH-6340 Baar, Switzerland, declares that in typical configuration the Hardware Version 1 meets the requirements of the CE Mark. The radio conforms with the requirements of EN 300 220-3:2000 (Power Class 9). The EMC conforms with EN 301 489-3:2002-08 for a Class 3 SRD Device (equipment type I). It is a Class 1 item of radio equipment as defined by R&TTE Directive. The necessary tests and certification were undertaken by TRAC-KTL, Unit E, South Orbital Trading Park, Hedon Road, Hull, HU9 1NJ, UK. These documents may be inspected at the premises of SAFEmine Ltd. by arrangement through: info@safe-mine.com Schwyz, September 2008
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 48 of 56 March 2011 Appendix A: Recommended parts These parts have been tested by SAFEmine and allow an installation with highest reliability. Please consult with SAFEmine before substituting with non listed parts 3M "Dual Lock" Type 3550 / 51 / 52 Heat shrink tubing HellermannTyton HISA-9/3-PEX-BK Self-Fusing Silicone Rubber Electrical Tape 3M Scotch® 70 Braided Sleeving Polyamide HellermannTyton TMEGA10MM Clean Cut PET Expandable Sleeving Techflex CCP0.50 Low loss 50Ohm coaxial cable RF-195 / LMR-195 / HDF195 / LMR 400 SMA connectors SMA connectors, crimp and strip tools are specific to the cable type. Information below is for the HDF195 cable. Male: Wellshow P/N C01AA31058A04A Female: Wellshow P/N C02AA31058A12 Crimp tool: .213 Hex Strip tool: Paladin CST Vario 3-Stage Coax Cable Stripper Solder - .5mm or 23 gauge 60/40 Rosin Core Small Torch for shrink tubing
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 49 of 56 March 2011 Appendix B: Additional Figures and Drawings Antenna Cable TBA Battery Cable TBA
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 50 of 56 March 2011 Appendix C: Installation Checklist Item Date installed Installation technician Configuration technician SAFEmine serial number Firmware version loaded Configuration file loaded Vehicle ID (Plant number) Vehicle type Initial Comment GPS antenna is at highest point of vehicle Antenna bolt and main housing are insulated from vehicle frame Main unit secured to vehicle Maximum one connection in RF cable All coaxial (RF/GPS) cable connections well covered by adhesive lined heat shrink or silicone tape Maximum total RF cable lengths 8m RF cables sleeved if outside or where chafing is possible Unit powered up with no error messages after installation Ready LED green after <3 minutes (if vehicle is outside) 3A fuse on Power and GND if it is not connected to chassis Buzzer (speaker if installed) unobstructed Driven by test station Signoff vehicle owner
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 51 of 56 March 2011 Appendix D: Maintenance Checklist To be performed before vehicle is released after a regular PM Item Date checked Responsible Configuration technician SAFEmine serial number Firmware version loaded Configuration file loaded Vehicle Plant number Initial Comment Check cables, abrasion, UV damage Visual inspection of housing for damage Firmware updated to latest version Buzzer (speaker if installed) unobstructed and working Ready LED green after <3 minutes (if vehicle is outside) Press button (> 5 seconds) for reset -> light, beep, self test Driven by test station
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 52 of 56 March 2011 Appendix E: Troubleshooting guide Find the failure case in the table below. Click on the links in the “Troubleshooting Instructions” column for more detailed instructions on how to resolve failure. Consult Installation Manual for further information. LED OFF LED ON green LED flashing green LED ON red LED flashing red Normal working system moving forward reporting one distant vehicle to the right: Mode Reverse Ready Power
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 53 of 56 March 2011 Symptom Failure Description Troubleshooting Instructions All LED OFF No power indication main unit - Check vehicle has power - Ensure main unit is connected to power cable, power connector fully engaged, no bent pins. - Check fuse - Check power cable properly attached to battery - Replace main unit with known good unit No power indication remote display Check all items above. If problem persists: - Check main unit is connected to remote display by cable - Check for bent pins on remote display, cable, and main unit - Replace remote display with known good unit No GPS - Ensure Antenna has unobstructed view of sky - Check Antenna connected to main unit - Check Antenna cable intact - Check Antenna cable crimp contacts - Check Antenna for damage - Replace Antenna with known good unit - Replace main unit with known good unit Bad configuration file - Check configuration file for errors - Upload known good configuration file Mode Reverse Ready Power Mode Reverse Ready Power Mode Reverse Ready Power
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 54 of 56 March 2011 No indication of nearby vehicles No radio communication - Check Antenna connected to main unit - Check Antenna cable intact - Check Antenna cable crimp contacts - Replace Antenna with known good unit - Replace main unit with known good unit Indication of vehicles where no vehicles are Bad GPS - Vehicles inside buildings or next to walls may obtain an inaccurate GPS position. If such an inaccurate position is reported to another vehicle it may indicate a vehicle where none is. Mode Reverse Ready Power
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 55 of 56 March 2011 Main Unit Power Power Cable Check for bent pins on the main unit power connector. Screw power cable onto connector until fully engaged. Fuse Fuse holder is usually placed in line with the power cable close where power cable is attached to vehicle power (i.e. battery). Open fuse holder. Remove fuse and check if intact. Remote Display Connection Check for bent pins on the main unit remote display connector and on the remote display as well as the cable. Carefully connect remote display cable. Note that there are no locking pins. The contacts prevent the connector from rotating when it is screwed on and can bend.
INSTALLATION AND MAINTENANCE GUIDE Version 110301, Preliminary Page 56 of 56 March 2011 Antenna and Cable Connection Ensure antenna cable is connected to main unit and antenna. Two cables exit the antenna, one carrying the GPS signal, the other carrying the RF signal. Both cables need to be connected and fully engaged. The main unit has a port labeled GPS and a port labeled RF. If not sure which cable connects to which port try both combinations until main unit lights ready LED. Crimp Contacts Check the crimp contacts of the RF and GPS cable for any damage. Re-crimp if needed or use new cable.

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