Hexagon Geosystems Services QC250A Collision Avoidance System User Manual SAFEmine QC250 user manual

Safemine Ltd Collision Avoidance System SAFEmine QC250 user manual

USERS MANUAL

1 ® INSTALLATION AND MAINTENANCE GUIDE for SAFEmine COLLISION AVOIDANCE SYSTEMS Firmware Version 2.61 SMTool version 2.0.7 July 31 , 2014 © 2009-2014 SAFEmine Ltd. Switzerland
2 Topic: This document is the reference manual for the installation, configuration and operation of SAFEmine units and tools. Document Nr: PRO_CAS_QC2_130207 Date: September 29, 2014 Disclaimer This document and the use of any information contained therein, is subject to the acceptance of the SAFEmine terms and conditions. They can be downloaded from www.SAFE-mine.com SAFEmine makes no warranties based on the accuracy or completeness of the contents of this document and reserves the right to make changes to specifications and product descriptions at any time without notice. SAFEmine reserves all rights to this document and the information contained herein. Reproduction, use or disclosure to third parties without express permission is strictly prohibited. Copyright © 2012, SAFEmine. SAFEmine ® is a registered trademark Version Control Version Modifications PRO_CAS_QC2_101010 August 29th 2011 • Original document PRO_CAS_QC2_130207 • Removed Appendix: Troubleshooting guide. Created a separate document • Added : the main unit enclosure and the metal shrouds of all connectors need to be electrically isolated from the vehicle • Added ‘To assist during installation the ‘Mode’ LED will turn Red to indicate that the digital output has gone high’ to Test Station and Boom gate chapters • SMTool manual was removed. A separate document was added • All features and changes introduced by FW 2.61 were added • Added QC250 specifications (no Wifi configuration)
3 1 SAFEmine device presentation ...................................................... 5 1.1 Objective .................................................................................................................... 5 1.2 Technology ................................................................................................................. 5 1.3 Limitations.................................................................................................................. 5 2 Safety ............................................................................................... 7 2.1 Operating precautions ............................................................................................... 7 2.2 Installation precautions ............................................................................................. 7 3 Hardware .......................................................................................... 9 3.1 Main units ................................................................................................................... 9 3.2 GPS & RF Antenna ..................................................................................................... 9 3.3 Technical specifications and interfaces ..................................................................10 3.4 I/O Connections ........................................................................................................13 4 Installation and operation ............................................................. 16 4.1 General advice ..........................................................................................................16 4.2 Main unit ....................................................................................................................16 4.3 Antennas ...................................................................................................................17 4.4 Antenna cables .........................................................................................................18 5 SAFEmine programming tool (SMTool ) ...................................... 21 5.1 Installation .................................................................................................................21 5.2 Firmware and Configuration File upload .................................................................21 6 Configuration parameter specifications ...................................... 22 6.1 Site specific parameters: ..........................................................................................22 6.2 Vehicle parameters ...................................................................................................22 7 Advanced Troubleshooting .......................................................... 26 7.1 Error codes................................................................................................................26 Appendix A Declaration of conformity.......................................... 27 Appendix B Specifications (QC250) .............................................. 28 Appendix C Additional figures and drawings............................... 29 Appendix D Maintenance Checklist .............................................. 30 Appendix E FCC compliance ......................................................... 31 Appendix F RF radiation ................................................................ 32 Appendix G IC compliance ............................................................ 33 Appendix H Legal statement ......................................................... 34
4 SECTION A Introduction
5 1 SAFEmine device presentation 1.1 Objective The main task for SAFEmine QC250 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. 1.2 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 either 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 QC250 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 enhance the accuracy of position measurements. The predicted driving path of the vehicle, in which a SAFEmine QC250 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 QC250 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 QC250 series products optionally compare the predicted driving path with known static obstacle data, e.g. electric power lines. If a SAFEmine QC250 series product determines the risk of dangerous proximity to another vehicle or to an obstacle equipped with a SAFEmine QC250 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 QC250 series products use a proprietary patent- and copyright-protected protocol. Any non-licensed use, dissemination, copying, implementation or reverse engineering of the SAFEmine QC250 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. 1.3 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
6 of above specified products other than regular warranty according to SAFEmine Ltd. General Terms and Conditions.
7 2 Safety 2.1 Operating precautions 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 QC250 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. 2.2 Installation precautions 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.
8 SECTION B Hardware and Installation
9 3 Hardware 3.1 Main units Main unit overview 3.1.1The main unit houses the GPS receiver, radio transceiver, processor, interface logic and additional sensors. The housing is made of aluminum with plastic end-bezels. All connectors are on the backside of the unit. QC250 WiFi integrated for AVL / IVMS CAS • Integrated display Digital IO 6 Analog Input 2 GSM tracking WiFi tracking • Comment The QC250 model has an WiFi connector and has no integrated display. The QC250 model supports Vehicle tracking via WiFi. In addition to the vehicle’s position, the following status information can be tracked and or recorded: • Vehicle-ID, Serial number, Firmware version and Build number (sent once after system reset) • Supply Voltage • Digital inputs (e.g. seatbelt, handbrake, idling) • Analog inputs (e.g. connected to fuel gauge) The digital IOs of the device can be used to monitor and record vehicle parameters such as: door open, seatbelt clicked, handbrake set, etc. Another use of this functionality is the switching of cameras based on movement direction or surrounding vehicles and obstacles. Please contact SAFEmine if you plan to use this option. The QC250 have two analog inputs. They can be used to monitor fuel gauges, tire gauges or other analog data. 3.2 GPS & RF Antenna The antenna provided by SAFEmine is a customized GPS and RF combined antenna especially designed for harsh environments like mines. The antenna must be professionally installed by trained personnel only and only the antenna supplied with the equipment by SAFEmine may be used!
10 Through Hole Mount Antenna (QF036) 3.2.1The screw mount antenna comes with 10/15cm of cable. The advantage of using short cables on the antenna and then connecting and running 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 (Contact SAFEmine for SWR recommendations). The Through Hole Mount Antenna is ideal for cars with high vibrations (Haul Trucks) where the antenna and cable must be attached firmly. Through Hole Mount Antenna (QF036) Magnetic Mount Antenna (QF037) Magnetic Mount Antenna (QF037) 3.2.2The magnetic mount antenna comes with 3.5m of cable for GPS & RF & WIFI. It can be magnetically attached to any roof top. It allows an easy installation. It is ideal for light vehicles or other vehicles with little vibration. 3.3 Technical specifications and interfaces QC250 main unit specifications 3.3.1See Appendix B : Specifications (QC250)
11 Main unit interfaces and connectors 3.3.23.3.2.1 Power / Interface connector (All devices) The connector is type M12 male, with 8 contacts. QC250 This interface is connected to the vehicle or add-on modules. Power / Interface connector (All devices) QC250 Cable color Pin function Pin type Pin # Ground Power 2 brown Power (+9 to +28VDC) overvoltage and polarity protected Power in 1 white Digital I/O (IO1 in chapter 3.4 I/O Connections) Input / Output 7 blue Audio (voice) out (may be left NC) Output 8 red RS485 (may be left NC) 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 Input (RX) Output (TX) - - grey pink RS 232 (data to display and for updates) Firmware can be updated through this interface. Input (RX) Output (TX) 5 6 grey pink CAN listener (may be left NC) (typically J1939, ISO 11898) IO H L 3 4 green yellow
12 3.3.2.2 GPS antenna connector SAFEmine devices use a 50 channel GPS L1 receiver with SBAS (WAAS, EGNOS) capability, integrated RAIM (Receiver Autonomous Integrity Monitoring) and active multipath detection and elimination algorithms. The receiver is GALILEO ready. The connector is a SMA female for 3.3V active GPS antenna. Only antennas supplied by SAFEmine may be used. 3.3.2.3 RF antenna connector SAFEmine devices use an RF transceiver with typically less than 1% Duty Cycle, Peak Pulse Power below 15 mW (ERP). The license free ISM / SRD bands are software selectable depending on country of use • Europe, Africa: 868.2 and 868.4 MHz, others • Australia: 921MHz • North America: Frequency hopping around 920MHz • South America: Frequency hopping around 920 to 951MHz • Asia: various The country of Origin is Switzerland (Harmonized System Customs Code 852610). The connector for the RF transceiver is a SMA female for 50 Ohm RF antenna Only antennas supplied by SAFEmine may be used. 3.3.2.4 Wifi antenna connector (QC250) The QC250 SAFEmine devices include a self-contained WLAN module. The module is a complete IEE 802.11 b/g/n based wireless device. The module supports WPA2-PSK, WEP (64 and 128 bit) TKIP security. The connector is a SMA Reverse Polarity female. Only antennas supplied by SAFEmine may be used. GPS/RF Antenna Specifications 3.3.3 Parameter QF036 QF037 Mounting type Through Hole Magnetic Weight 480g 620g Dimensions ø107 x 91 mm Power Supply from main unit Connector 3 * SMA Operating temperature -40°C to +85°C Storage temperature -40°C to +85°C Protection rating IP 67 Cable 3 * 20cm, coaxial 3 * 3.5m, coaxial WIFI gain 5 dBi 5 dBi RF gain 3 dBi 3 dBi
13 3.4 I/O Connections Hardware capabilities 3.4.1SAFEmine devices all have extended GPIO (General purpose Input/Output) functionalities. An IO is available on pin 7 of the Power/Interface connector. It is the blue wire on the Power Connector (see pictures below). Power connector on QC250 On the QC250s up to 7 additional IOs can be configured as Input/Output. 7 are available on the I/O connector (see picture below). The I/O connector is type M12 male, with 8 contacts. I/O connector on QC250 The I/O connector can be used to monitor vehicle statuses such as seatbelt, emergency break, and voltages like the fuel gauge. The following table lists the GPIO capabilities of each device type.
14 Name Connector Pin # IO0 n/a n/a IO1 Power 7 IO2 I/O 1 IO3 I/O 2 IO4 I/O 3 IO5 I/O 4 IO6 I/O 5 IO7 I/O 6 IO8 I/O 8 I/O Specifications 3.4.23.4.2.1 Digital inputs A digital input transforms a voltage level into a logical “1” (or “on” state) or “0” (off state). • SAFEmine interprets a voltage of less than 2.2 volts as logical 0, • SAFEmine interprets a voltage of more than 8.7 volts as logical 1. • Each digital input must be configured to incorporate either the 4.7kOhm pull-up or a pull-down resistor in the SAFEmine device: Care must be taken to select the correct input configuration, depending on the characteristics of the vehicle! Wrong settings can influence or even incapacitate the vehicle! Always ensure that after installation the voltage levels are correct 3.4.2.2 Digital outputs The digital output is designed to drive modest consumers, such as relays and lamps. Most units support source and sink driver configuration: Digital Input / Output • FW configurable as digital input • FW configurable "High Side Switch" or “Low Side Switch” • Maximum continuous load current: 0.4A • Can switch capacitive, inductive and resistive loads • On-state resistance: 350mOhm • Short circuit protected • ESD protection: 5kV 3.4.2.3 Analog Input
15 • Input voltage range: 0..24V • Input Resistance: 300k Ohm
16 4 Installation and operation 4.1 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. SAFEmine highly recommends establishing a “Radio Map”, containing all intentional transmitters on the mine and their operating frequencies. This map will help to minimize radio interference. 4.2 Main unit General recommendations 4.2.1The 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. • It must not impede the operation of the vehicle (incl. emergency procedures) and in particular it must not reduce the operator’s 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. • The connectors are tied with a spanner and can’t be removed by hand. Power supply 4.2.2The power supply must be installed such that • The voltage is above 9.6 V at all times. At voltages below 9V the operation of the SAFEmine unit is no longer guaranteed. • The main unit must be connected directly to battery power to ensure continued operation in case of vehicle stopping or breakdown • A 2A fuse must be installed near the vehicles battery on both power and ground. 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. If the voice option is enabled ‘Error Power’ is announced every 30 seconds on the voice output as long as there is sufficient voltage to do so. A sealable fuse holder is highly recommended. Furthermore, the fuse should be secured with a cable tie to make any tampering obvious 51mm 70mm Main unit bottom view
17 4.3 Antennas The external combined GPS & RF antenna supplied with the main unit must be connected. • The main unit will not operate without the antennas. • Follow the recommendations regarding antenna cables in chapter ‘4.4 Antenna cables’ The GPS/RF antennas must be mounted such that: • It is mounted on the highest point of the vehicle, with 360° unobstructed view of the sky and at least 100cm away from any other transmitting antenna. • The position of the antenna is the same for all the vehicles of the same model. As an example all the Toyota Hilux Single Cabs must have the antenna at the same position. • The antennas are connected to the correct inputs. • On tracked type vehicles, the antenna must be mounted as close as possible to the axis of rotation, unless the two-antenna (SAFEmine devices) setup is used. • On haul trucks it may not be possible to install the antenna at the height of the bucket. In such a case place the antenna in one of the front corners of the vehicle i.e not in the center front. Other information regarding antenna installation • Improper installation of the antenna and its cables is the prominent cause for malfunction. • The antenna must be professionally installed by trained personal only. • Only antennas supplied by SAFEmine may be attached to the antenna connectors! • Mounting brackets for various vehicles (Haul Trucks etc.) are available from your local SAFEmine distributor. • Snow and ice buildup reduce the performance of the antenna and must be removed prior to operation. Through Hole Mount QF036 4.3.1The screw mount antenna comes with 10/15cm of cable. To mount the antenna: • The antenna must be mounted on a horizontal metal surface of diameter 1-2cm larger than the diameter of the antenna. For smaller vehicles the diameter can be larger. • A hole must be drilled or punched into the surface. The diameter of the hole must be at least 22mm (0.866") for the antenna and the compulsory insulating washer. (Without the washer 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. To attach the antenna: • After removing the nut feed the cables through the hole seat the antenna on the surface • Add the insulating washer • Attach the nut. The nut should be tight (Torque: 5 ft-lb, ~6.8 nm) 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 mounting screw of the antenna must be isolated from the vehicle to avoid ground loops. Suitable insulating washers are available from SAFEmine. The attached gasket provides a sealant to prevent moisture from entering.
18 Vertical cut of a QF036 after installation Magnetic Mount QF037 4.3.2The magnetic mount antenna comes with 3.5m of cables, both GPS & RF. It can be quickly mounted on vehicles such as light vehicles. For vehicles with a lot of vibration like Haul Trucks it is recommended to use the through hole mount antenna. The GPS/RF antenna (QF037) must be mounted such that: • 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. Wifi Antenna (QC250 only) 4.3.3The Wifi antenna length must not exceed 5 meters. For further information contact SAFEmine. 4.4 Antenna cables The choice of antenna cables and installers must be done carefully. SAFEmine recommends to source cables with SMA connectors already installed: • It is recommended to source cables from a professional local supplier. • Any work on radio RF cabling must be done professionally by trained personnel according to SAFEmine specifications. • Coaxial low loss cables as well as connectors of proper length and high quality must be used. • Respect the maximum cable length (see below) The RF and GPS cables must follow the following rules: • The maximum acceptable attenuation rate for the RF cable is 3dB at 900MHz at 10 meters. • Inner conductor must be solid core Below is the typical maximum cable length between antenna and main unit per cable type recommended by SAFEmine. These values are indications and vary between manufacturers. Please see the datasheet and send it to SAFEmine prior to the installation. Use of other coaxial cable types must be approved in writing by SAFEmine!
19 Coaxial cable type Max. length RF Max. length GPS RG174 / RG58 Do not use 5m HDF-195/CFD-195 LMR -195/ RF 195 LMR-200 8m 15m LMR 400 15m 15m To calculate the attenuation rate, sum up the attenuation of all segments as specified by the cable manufacturer. Add 0.3dB for any connection If the SMA connectors need to be attached, strictly follow the recommendations of the manufacturer as well as the following rules: • Use 3 blade coax strippers (no knife) • Adjust the coax stripper blades as recommended by the SMA connector manufacturer. See below for an example : • • Always solder the center pin (or crimp when not possible) • Only use appropriate crimping tool • Protect the connection with insulating tape. Contact SAFEmine with the datasheets of the cables and SMA connectors prior to installation
20 SECTION C Software and Programming The SAFEmine devices are controlled by a configurable firmware. The firmware as well as its configuration will be explained in the following chapters. Configuration is not only compulsory for the firmware to run but it will also allow the best usage of the device. The SAFEmine device needs a unique configuration file created and/or modified by the installer. Please contact SAFEmine for any question relative to configuration files. The following chapters will present • The software and its features • How to configure the software and the special features Vehicles requiring special configurations as well as additional functionalities of the device are also presented.
21 5 SAFEmine programming tool (SMTool ) 5.1 Installation For the installation and configuration of the Collision Avoidance System firmware the following is needed: Hardware: 1) PC or Laptop running Windows 2000 or later. 2) M8 to USB Cable (QL019) or M8 to serial port cable (QL014) and RS232 to USB converter if PC has no serial port. (A QM109 Y cable must be added for QC250) 3) Power Supply or Battery (12 or 24 volts) Software: 4) SMTool (SAFEmine Software Utility) 5) Microsoft Office 6) Latest Firmware 7) Configuration File generated by a vehicle register 8) USB Driver (if USB port used). 9) Net 3.0 or higher Notes: • 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 SAFEmine if you don’t have a username and password. • The SMTool guide (SMTool 2.0User_Manual(PRO_SMT_120601).pdf) is available upon request or on www.safe-mine.com/support/partners. 5.2 Firmware and Configuration File upload Both the firmware and configuration file need to be uploaded to the SAFEmine device for the system to function properly. Firmware is periodically updated by SAFEmine. Many features and improvements are available by uploading the latest released version. As a helpful feature, the firmware version is displayed during start-up. Three green LEDs are lit sequentially for one second, according to the firmware revision (“2”, “6”, “1”), where “2” is 2 o’clock, and numbers increment clockwise.
22 6 Configuration parameter specifications 6.1 Site specific parameters: Site specific parameters must be set on all units Radio Channel 6.1.1Keyword 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 6.1.2Keyword 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 6.1.3Keyword 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 Keyword Description Unit Range Default Example WIFIPOWER Transmit Power Setting. - 0 - 2 2 2 Sets the transmit power of the wifi. A setting of 2 results in maximum power and range of the wifi 0: North America countries under FCC regulation (lower power setting required to comply with FCC) 2: All other areas 6.2 Vehicle parameters Required vehicle parameters 6.2.1Vehicle ID Parameter 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
23 Parameter Description Unit Range Default Example VEHTYPE Vehicle Type - 10 - 100 - 31 Vehicle Dimensions Parameter Description Unit Range Default Example VEHLENGTH Vehicle length, overall meter 0 - 655 10 12.8 VEHWIDTH Vehicle width, overall meter 0 - 655 4 3.4 VEHHEIGHT Vehicle height, overall meter 0 - 50 3 2.34 Description VEHTYPE value Examples/ Remarks Light Vehicle 10 Ford F150,F250 Small Tractor 11 Haul Truck 21 Komatsu 730E, Dump Truck 22 Caterpillar 789C Water Tanker 23 CAT 777 ADT (Articulated Dump Truck) 31 Volvo A25E Fuel Bowser 32 Service Truck 33 Mitsubushi Canter; Volvo Fm12 Mobile Crane 34 Franna AT 20 Low Bed Truck 35 Rear Tip Truck 36 Excavator 41 CAT 385C Shovel 42 Liebherr 3994, Bucyrus 495HR2 PC 43 Komatsu PC 4000 Dozer 44 Cat D9T Dragline 45 Drill 46 Atlas Copco PV271 Large Front End Loader 51 Le Tourneau L1850 Small Front End Loader 52 CAT 988H Tyre Handler 53 Cable Handler 54 Grader 55 Cat 24H , Cart 16M TLB, JCB 56 John Deere 110 TLB, (Back Hoe) Large Tractor 57 CAT 992C Train 61 Stockpile Stacker 71 Test Station 72 Stockpile Dozer 73 Lighting Plant 74 Alight 22KVa , Multiflo ?? Stockpile Reclaimer 75 Boomgate 76 Beacon 100
24 Highly recommended vehicle parameters 6.2.2Vehicle Weight Parameter Description Unit Range Default Example VEHWEIGHT Maximum vehicle weight (with no load) Ton 0 -1500 50 430 LED notification distances Parameter Description Unit Range Default Example DISTFAR Green LED indicates vehicle closer than distfar meters meter 0 - 500 150 180 DISTNEAR Steady Red LED indicates vehicle closer than disnear meters meter 0 - 250 40 40 DISTCLOSE Flashing Red LED indicates vehicle closer than disclose meters meter 0 - 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. Additional safety distances Parameter Description Unit Range Default Example SAFETYLENGTH Extends the alarm region in percent of vehicle length. % of length 0 - 100 10 20 SAFETYWIDTH Extends the alarm region in percent of vehicle width. % of width 1 - 100 10 0 Example: A vehicle with length 5m sets SAFETYLENGTH = 30 thus will have an additional safety area of 1.5m ahead AND behind the vehicle. Optional vehicle parameters 6.2.3 Parameter Description Unit Range Default Example VEHMANU Vehicle Manufacturer - max. 31 characters - KOMATSU VEHMOD Manufacturers model name - max. 31 characters - 785 Parameter Description Unit Default Example MINTURNRAD This value must be set to 1. Meter 1 1 DRIVERAFT Distance between front of vehicle and driver Meter 1.5 DRIVERRIGHT Distance between left side of vehicle and driver Meter 1.5 DRIVERUP Elevation of driver above ground Meter 4 MAXSPEED Maximum speed before alert. Km/h 0 (disabled) 70
25 SECTION D Software maintenance
26 7 Advanced Troubleshooting A complete troubleshooting guide (Troubleshooting_Guide(PRO_CAS_QC2_111025).pdf) is available upon request. 7.1 Error codes The unit performs a self-test upon power up. Errors are indicated by all 4 status LEDs (left side of the display) glowing red, while the circular display shows the error code(s). More detailed error messages are sent to the serial port. Debugging of error codes is best done with a PC running a terminal program (e.g. HTerm) 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). Troubleshooting guide explains how to react to an error code. Error code LED # Subsystem Severity Cause/Comment 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 03 2&1 Dataport error Alert Sending of Dataport Heartbeat message failed. 04 3 GPS receiver Fatal Unable to communicate with or configure GPS module 05 1 & 3 GPS Antenna Fatal GPS antenna defective or bad connection 08 4 Power Fatal Power supply defective or low/high voltage 16 5 User Interface Fatal No user interface connected. 32 6 Config (Fatal) Configuration file contains errors, or is not present. 64 7 Firmware Fatal Firmware corrupt, upload new firmware 128 8 Generic Various Generic error, currently not used 256 9 GPIO error Fatal GPIO configuration or hardware problem. See Terminal output for details. 4095 All Unknown Various Not used.
27 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 Appendix A Declaration of conformity
28 Parameter Conditions1 Dimensions excl. connectors 81 x 30 x 126 mm3 (3.2 x 1.2 x 5.0 in3) Weight excl cables 260 g (0.57lb) Power Supply Nominal 12 to 28 VDC Power Consumption (@ 12 V) typical < 80 mA Max peak < 150 mA Max standby < 40 mA Input/Output Digital 3x, configurable Input Digital 2x, low < 2.2V, high > 8.7V Input Analog 2x, 0 to 24V GPS 50 channel GPS L1, ISO/TS 16949 qualified, GALILEO ready WiFi Network standard IEEE 802.11 b/g/n Frequency band 2.412 GHz – 2.484 GHz Security 802.11i (AES, TKIP, WPA, WPA 2) Typ. Transmit power 10 dBm (Europe) 7 dBm (North America) Sensitivity -97dBm @ 1 Mbps to -71 dBm @ 65 Mbps Data rates 802.11n: 65 Mbps; OFDM: 6,9,12,18,24,36,48,54 Mbps Traffic alert range Typical 500m (1/3 mile) Refresh Rate Typical 4 Hz Traffic alert range Typical 500m Operating temperature -40°C to +60°C2 Humidity 95%, non condensing Protection rating IEC 60529 IP54 1 All specification are at an ambient temperature of 25°C. 2 SAFEmine devices are designed to run at 85°C. For operator safety reasons the device must not be run at temperatures above 60°C Appendix B Specifications (QC250)
29 Typical installation Appendix C Additional figures and drawings
30 To be performed before vehicle is released 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 Appendix D Maintenance Checklist
31 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. Per FCC Rules, changes or modifications not expressly approved by SAFEmine could void your authority to operate this equipment. NOTE: This equipment has been tested and found to comply with the limits for a Class B digital device, pursuant to part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential installation. This equipment generates, uses and can radiate radio frequency energy and, if not installed and used in accordance with the instructions, may cause harmful interference to radio communications. However, there is no guarantee that interference will not occur in a particular installation. If this equipment does cause harmful interference to radio or television reception, which can be determined by turning the equipment off and on, the user is encouraged to try to correct the interference by one or more of the following measures: —Reorient or relocate the receiving antenna. —Increase the separation between the equipment and receiver. —Connect the equipment into an outlet on a circuit different from that to which the receiver is connected. —Consult the dealer or an experienced radio/TV technician for help. Appendix E FCC compliance
32 RF Radiation Hazard Warning To ensure compliance with FCC and Industry Canada RF exposure requirements, this device must be installed in a location where the antennas of the device will have a minimum distance of at least 20 cm from all persons. Using higher gain antennas and types of antennas not certified for use with this product is not allowed. The device shall not be co-located with another transmitter. Installez l'appareil en veillant à conserver une distance d'au moins 20 cm entre les éléments rayonnants et les personnes. Cet avertissement de sécurité est conforme aux limites d'exposition définies par la norme CNR-102 at relative aux fréquences radio. Appendix F RF radiation
33 Industry Canada Notice and Marking This radio transmitter 9849A-QC250A has been approved by Industry Canada to operate with the antenna types listed below with the maximum permissible gain and required antenna impedance for each antenna type indicated. Antenna types not included in this list, having a gain greater than the maximum gain indicated for that type, are strictly prohibited for use with this device. Le présent émetteur radio a été approuvé par Industrie Canada pour fonctionner avec les types d'antenne énumérés ci-dessous et ayant un gain admissible maximal et l'impédance requise pour chaque type d'antenne. Les types d'antenne non inclus dans cette liste, ou dont le gain est supérieur au gain maximal indiqué, sont strictement interdits pour l'exploitation de l'émetteur. Antennatype QF036 QF037 Mounting type Through Hole Magnetic Weight 480g 620g Impedance 50 Ohm Nominal WIFI gain 5 dBi RF gain 3 dBi GPS gain 5 dBi Under Industry Canada regulations, this radio transmitter may only operate using an antenna of a type and maximum (or lesser) gain approved for the transmitter by Industry Canada. To reduce potential radio interference to other users, the antenna type and its gain should be so chosen that the equivalent isotropically radiated power (e.i.r.p.) is not more than that necessary for successful communication. Conformément à la réglementation d'Industrie Canada, le présent émetteur radio peut fonctionner avec une antenne d'un type et d'un gain maximal (ou inférieur) approuvé pour l'émetteur par Industrie Canada. Dans le but de réduire les risques de brouillage radioélectrique à l'intention des autres utilisateurs, il faut choisir le type d'antenne et son gain de sorte que la puissance isotrope rayonnée équivalente (p.i.r.e.) ne dépasse pas l'intensité nécessaire à l'établissement d'une communication satisfaisante. This device complies with Industry Canada licence-exempt RSS standard(s). Operation is subject to the following two conditions: (1) this device may not cause interference, and (2) this device must accept any interference, including interference that may cause undesired operation of the device. Le présent appareil est conforme aux CNR d'Industrie Canada applicables aux appareils radio exempts de licence. L'exploitation est autorisée aux deux conditions suivantes : (1) l'appareil ne doit pas produire de brouillage, et (2) l'utilisateur de l'appareil doit accepter tout brouillage radioélectrique subi, même si le brouillage est susceptible d'en compromettre le fonctionnement. Appendix G IC compliance
34 WARNING OF PERSONAL INJURY As with all traffic awareness and collision avoidance devices, SAFEmine products may not detect all threats within the detection window. SAFEmine products are intended as an additional tool in determining potential traffic threats, supporting an alert and conscientious driver. SAFEmine products are not designed as a substitute for proper safe driving and visual traffic scanning procedures; a vigilant effective lookout is required at all times. SAFEmine products only warn the operator of the presence of other vehicles that are also fitted with SAFEmine products or warn of obstacles that are stored in the internal database. SAFEmine products do not give any guidance on avoiding action. The operator of the vehicle remains fully responsible for operating the vehicle and ensuring the safety of passengers, pedestrians and other traffic. Never use SAFEmine products for applications other than their intended and authorized use. Never use SAFEmine products as emergency stop device or in any other application where failure of the products could result in personal injury. Before installing, handling, using or servicing SAFEmine products, consult the data sheet, manuals and application notes and make yourself thoroughly familiar with the operations and limitations. Failure to comply with these instructions could result in serious injury or death. LIMITED WARRANTY EXCEPT FOR THE WARRANTIES EXPRESSLY SET FORTH HEREIN, SAFEMINE MAKES NO WARRANTIES, EITHER EXPRESS OR IMPLIED, WITH RESPECT TO THE PRODUCT. ANY AND ALL WARRANTIES, INCLUDING WITHOUT LIMITATION, WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, ARE EXPRESSLY EXCLUDED AND DECLINED. SAFEMINE is only liable for defects of this product arising under the conditions of operation provided for in the data sheet and proper use of the goods. SAFEMINE explicitly disclaims all warranties, express or implied, for any period during which the goods are operated or stored not in accordance with the data sheet. The warranty voids in the case of the following cases: any opening of the housing, inappropriate operations or installation (see the restrictions in the respective manuals) and intellectual property violations. SAFEmine Ltd.’s entire liability and customer’s exclusive remedy for SAFEmine products that fail to conform to SAFEmine Ltd.’s limited warranty, shall be, at SAFEmine Ltd.’s sole option, either repair or replacement of the nonconforming products, or, if neither is practicable, a refund of the fees paid by customer to SAFEmine Ltd. for such products. The warranty for the repaired or replaced product is limited to the scope and remaining duration of the original warranty for the nonconforming product. LIMITED LIABILITY SAFEmine Ltd. does not accept any liability arising out of any application or use of any product or circuit and specifically disclaims any and all liability, including without limitation consequential or incidental damages. All operating parameters, including without limitation recommended parameters, must be validated for each customer’s applications by customer’s technical experts. Recommended parameters can and do vary in different applications. SAFEMINE LTD.’S LIABILITY TO CUSTOMER ARISING OUT OF OR RELATING TO ANY SAFEMINE PRODUCTS SHALL NOT EXCEED THE AGGREGATE AMOUNTS PAID BY CUSTOMER TO SAFEMINE FOR SUCH SAFEMINE PRODUCTS. IN NO EVENT WILL SAFEMINE LTD. BE LIABLE FOR LOST USE, PROFITS, REVENUE, COST OF PROCUREMENT OF SUBSTITUTE GOODS, OR ANY OTHER SPECIAL, INDIRECT, RELIANCE, INCIDENTAL, OR CONSEQUENTIAL DAMAGES, HOWEVER CAUSED AND UNDER ANY THEORY OF LIABILITY RELATING HERETO. Radio band frequency allocation and licensing conditions may vary from country to country. The operator is solely responsible for ensuring that SAFEmine products are operated in Appendix H Legal statement
35 conformity with the applicable telecommunication laws. If the customers uses SAFEmine products for any unintended or unauthorized application, the customer shall defend, indemnify and hold harmless SAFEmine Ltd. and its officers, employees, subsidiaries, affiliates and distributors against all claims, costs, damages and expenses, and reasonable attorney fees arising out of, directly or indirectly, any claim of personal injury or death associated with such unintended or unauthorized use, even if SAFEmine Ltd. shall be allegedly negligent with respect to the design or the manufacture of the product. INDEMNIFICATION 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, including without limitation, reasonable counsel fees, arising from or by reason of any actual or claimed damages, and/or injuries, or any litigation based thereon, which may be incurred by SAFEmine Ltd. with respect to any of the SAFEmine products covered by the order, including use, and such obligation shall survive acceptance of the SAFEmine products and payment therefore by the customer. INFRINGEMENT SAFEmine Ltd. does not warrant that products and its use will not infringe any patent, copyright or trademark. No specification shall constitute a warranty, express or implied, against any claims for infringement of patents, copyrights or trademarks. Customer shall indemnify and hold SAFEmine Ltd., its subsidiaries and affiliates, and their respective successors and assigns, and its customers harmless from any and all third party liability for such infringement, including without limitation damages, costs, expenses (including reasonable counsel fees), and lost profits arising from any claim that the use of any goods supplied under the invoice infringe any patent, copyright or trademark rights.

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