Industrea Mining Technology PROD08422 Collision Avoidance System User Manual CASLITE Installation Manual

Download:
Mirror Download [FCC.gov]
Document ID	2975130
Application ID	H0jeWGnZi4z0hDfV9ic0cQ==
Document Description	User Manual_20160322_v1 - CAS GPS Installation Manual RevG1 160323.pdf
Short Term Confidential	No
Permanent Confidential	No
Supercede	No
Document Type	User Manual
Display Format	Adobe Acrobat PDF - pdf
Filesize	362.55kB (4531847 bits)
Date Submitted	2016-04-28 00:00:00
Date Available	2016-06-12 00:00:00
Creation Date	2016-02-17 14:59:19
Producing Software	Adobe PDF Library 10.0
Document Lastmod	2016-02-17 14:59:39
Document Title	CASLITE Installation Manual
Document Creator	Acrobat PDFMaker 10.1 for PowerPoint
Document Author:	David McCarthy and Spencer Waterman

CAS GPS
Collision Avoidance System
Installation
Manual
Rev G1
GE Mining
Industrea Mining Technology
PO Box 5107
Fountaindale, New South Wales
Australia, 2258
Tel: +61 2 4336 1800
Fax: +61 2 4336 1888
Email:
EnquiriesIMT@geindustrea.ge.com
Web: www.ge.com/au
Document Control
REV
DESCRIPTION
Review
Approval
Date
Added shovel heading
19/11/2014
Fixed inconsistent pinouts on 24way connector
27/03/2015
Added Compliant Antenna Information (Page 6)
D.Mc
19/11/2015
CAS GPS Installation Manual Rev G1
2/17/2016
Transport
All possible precautions are taken to protect the equipment against damage or losses
during shipment, however before accepting delivery, check all items against the
packing list or bill of loading. If there are shortages or evidence of physical damage,
notify GE Mining immediately.
Notify GE Mining within 7 days (maximum) in case of shortages or discrepancies,
according to the packing list. This will help ensure a speedy resolution to any
perceived problems. Keep a record of all claims and correspondence. Photos are
recommended.
Where practicable do not remove protective covers prior to installation unless there
are indications of damage. Boxes opened for inspection and inventory should be
carefully repacked to ensure protection of the contents or else the parts should be
packaged and stored in a safe place. Examine all packing boxes, wrappings and
covers for items attached to them, especially if the wrappings are to be discarded.
CAS GPS Installation Manual Rev G1
2/17/2016
Storage
Where the equipment is not to be installed immediately, proper storage is important
to ensure protection of equipment and validity of warranty.
Storage Temperature: -30 deg C to +85 deg C
Storage Location: dry low humidity location
CAS GPS Installation Manual Rev G1
2/17/2016
Unpacking of Equipment
The method of packing used will depend on the size and quantity of equipment.
Take care when unpacking the equipment to avoid damage to the equipment and
ensure the use of correct manual handling techniques.
CAS GPS Installation Manual Rev G1
2/17/2016
Installation
Installation should be in accordance with the installation procedures defined by GE
Mining and only performed by authorised and qualified installers.
This device has been designed to operate with the antennas listed below, and having
a maximum gain listed. Antennas not included in this list or having a gain greater
than those listed are strictly prohibited for use with this device. The required antenna
impedance is 50ohms.
GE
Part#
Relevant Product
CAS-GPS Port
Nominal
Impedance
Gain
Operating
Frequency
PROD0852
PROD084x-2
V2V
50 Ω
+4dBi
902-928MHz
PROD0874
PROD084x-1
V2V
50 Ω
+4dBi
821-896MHz
PROD0853
PROD084x-x
GPS (Receive Only)
50 Ω
+26dBi
1574.42-1576.42MHz
PROD0854
PROD0843-x, PROD0847-x
GSM / 3G
50 Ω
0dBi
+1.7dBi
+2.9dBi
698-960MHz
1710-1990MHz
2100-2700MHz
PROD0833
PROD0842-x, PROD0847-x
Wi - Fi
50 Ω
<+5.0dBi
2400-2484MHz
(x = any variant)
CAS GPS Installation Manual Rev G1
2/17/2016
WARNING:
Consult with the client to confirm all equipment mounting
locations and power connections!
Do not weld on ROPs!
Do not drill through ROPs!
CAS GPS Installation Manual Rev G1
2/17/2016
Specialty Tools Required / Adhesives
CAS GPS Installation Manual Rev G1
2/17/2016
Specialty Tools Required / Adhesives

Coax Crimpers – Tool0112 & Tool0254 for RG 58/214

Coax Cable Stripper – Tool0113 for RG 58/59

Coax Cable Stripper – For RG 214

Soldering Iron – Butane

Torx Security Bit – T25

Metric Allen Key – 4mm

Nutsert Tool – Tool0253

Deutsch pin removal Tool – Tool0256
CAS GPS Installation Manual Rev G1
2/17/2016
Specialty Tools Required / Adhesives
 Deutsch pin Crimping Tool – Tool0068 or Tool0101 / Tool0102
 Digital Multi-Meter
 Hole Saws: 20mm – 25mm
 Self Amalgamating Tape – Plas0684
 Loctite 243 – Chem0002
 Loctite 248 – Chem0044
 30 Meter tape measure
10
CAS GPS Installation Manual Rev G1
2/17/2016
In Vehicle Unit (IVU) (PROD0842)
11
CAS GPS Installation Manual Rev G1
2/17/2016
Input Power & Signal Connections
Service
Panel
SIM Card
USB Card
Auxiliary USB
External
Cables
LAN
Display
RF
Antenna
GPS Antenna
TOF1 Antenna
V2V Antenna
WiFi/WAN Antenna
TOF2 Antenna
12
CAS GPS Installation Manual Rev G1
2/17/2016
Input Power & Signal Connections
Status LEDs
24-Way Deutsch (Vehicle Electrical Connections)
13
CAS GPS Installation Manual Rev G1
2/17/2016
IVU Mounting
The IVU should be mounted such that:
• The Preferred IVU mounting location is inside the cabin / electrical compartment
(this will assist with future expansion)
• It is in the preferred location for that vehicle type
• The units location is easily accessible for servicing
• It is protected against rock fall and other damaging hazards
• Not to obstruct walkways, access or egress
• If mounting through a blind panel the supplied Nutserts should be used to enable
easy removal for servicing
• Remember to record the orientation of the IVU as this is critical for the Calibration
of the 3 Axis Accelerometer. Refer to pages 60-61 of this manual.
14
CAS GPS Installation Manual Rev G1
2/17/2016
Mounting Locations & Cable Runs
The following diagrams show the preferred mounting locations and cable paths for
each vehicle type. Ensure the hardware supplied in the kit is being utilised.
Ensure there is a clear line of sight from all directions for the Antennas. It is a
recommendation on all Haul trucks the Antennas are to protrude above the Tray by
100mm, by doing this it creates a clear line of sight for the Antennas on all vehicles.
Keep in mind any working obstacles.
Ensure the correct size Stauff Clamp is used and matched to the specific handrail for
that machine and antenna mounting post diameter. Regular clamp bodies are
available in the following sizes: 38mm, 42mm, 44.5mm, 48.3mm, 50.8mm, 55mm,
57mm, 60.3mm, 60.5mm, and 70mm.
Stauff Clamp Rubber inserts are also available in all kits to maintain the correct
clamping on all Hand rail sizes and Antenna mounting post. Rubber inserts are
available in the following sizes: 32mm, 33.7mm, 35mm, 38.7mm, 40mm, 42mm,
45.5mm, 48mm, 51mm, 53.4mm, 56.4mm
Ensure all stauff clamp assemblies are tightened and secured correctly.
Ensure Loctite 243 is used to secure all Antenna mounting fasteners, or the equivalent
to this is Loctite 248. Loctite 248 (perfect for transporting by air as it is a paste).
15
CAS GPS Installation Manual Rev G1
2/17/2016
Mounting Locations & Cable Runs









Follow existing cable runs where possible
All cables to be secured using P-Clamps where possible
Cable ties should be used as a last resort where there is no provision for P-Clamps
Ensure cable ties are cut flush to avoid sharp edges
Cables should be secured at a minimum every 300mm
Avoid running cables near hot spots and pinch points
Glands should be used on cables running through bulkheads
It is recommended that a service loop be created on all the Antenna Coax Cables
this will especially aid in servicing of the system. i.e. Break in termination at either
end of the Coax cables.
Service loops are acceptable in the Coax and Display cables. Ensure if a service
loop is placed in the Coax Antenna cable that it is placed in a position that it is not
going to create a hazard, also ensure the service loop radius is not to small.
If mounting through a blind panel the supplied Nutserts should be used to enable
easy removal for servicing
16
CAS GPS Installation Manual Rev G1
2/17/2016
Light Vehicle
Note: IVU preferably mounted
inside the Operator’s cabin
17
CAS GPS Installation Manual Rev G1
2/17/2016
Light Vehicle
V2V
Bracket used here is the ATOM0033
GPS
GPRS
Note: Antenna Spacing between V2V
and GPRS should be a minimum of
300mm.
18
CAS GPS Installation Manual Rev G1
2/17/2016
Haul Truck
Note: IVU preferably mounted inside
the Operator’s cabin or the
electrical compartment
19
CAS GPS Installation Manual Rev G1
2/17/2016
Haul Truck
ANTENNAS TO PROTRUDE ABOVE TRAY BY 100mm. ENSURE
ANTENNAS WILL CLEAR ANY WORKING OBSTACLES.
20
CAS GPS Installation Manual Rev G1
2/17/2016
21
CAS GPS Installation Manual Rev G1
2/17/2016
22
CAS GPS Installation Manual Rev G1
2/17/2016
23
CAS GPS Installation Manual Rev G1
2/17/2016
Stauff Clamp Sizes chosen to
suit Handrail sizes.
24
CAS GPS Installation Manual Rev G1
2/17/2016
Heavy vehicle (excluding Haul Truck)
Note: IVU preferably mounted
inside the Operator’s cabin
25
CAS GPS Installation Manual Rev G1
2/17/2016
Heavy vehicle (excluding Haul Truck)
26
CAS GPS Installation Manual Rev G1
2/17/2016
Display Unit (PROD0839)
27
CAS GPS Installation Manual Rev G1
2/17/2016
Display Unit (PROD0839)
The client should be consulted to ensure Display Unit is mounted in a mutually agreed
position.
The Display Unit should be mounted such that:
• It does not to create any additional blind spots
• The machine operator can easily reach the screen
• Located within the field of view of the operator
• It is not a hazard when operator is entering / exiting the machine cabin
• It has appropriate support so as not to damage any part of the machine
• Cable routes are carefully considered
• All machines of the same type have the screen located in the same place
• Mounting provides sufficient support for the Display (self tapping screws into the
Dash board is not acceptable)
28
CAS GPS Installation Manual Rev G1
2/17/2016
Display Unit (PROD0839)
Status Bar: Current status of system
components
Approaching Vehicle: Vehicle ID, Speed
Indicator and Distance
Your Vehicle: Vehicle ID and Speed
Indicator
Special Functions Buttons: Menu,
Configuration, GPS Data, Camera
selection and Data
29
CAS GPS Installation Manual Rev G1
2/17/2016
Display Unit (PROD0839)
Screen: 7” High Brightness LCD Touch
Screen with auto dimming for all lighting
conditions
Audio: Voice and tone output
Sensors: Light sensor for automatic screen
dimming
LED: LED output for system status
indication
30
CAS GPS Installation Manual Rev G1
2/17/2016
Display Unit (PROD0839)
Information: Product Code, Serial
Number an Approval Stamps
Connector: Electrical connection for
power and signals
Mount: Multi – axis adjustable mounting
bracket
31
CAS GPS Installation Manual Rev G1
2/17/2016
RF Installations
RF Installations
This section describes the interconnections
between the CASCAM/RF system and CAS GPS
system.
Refer to the CASCAM/RF installation
documentation for the camera and RF
installation procedure.
33
CAS GPS Installation Manual Rev G1
2/17/2016
Upgrades
If upgrading a previous CASCAM/RF installation the installed CASCAM/RF
Display (PROD0119) will be removed and replaced with the CAS GPS Display.
All cables may be reused (provided they are in a serviceable condition). Some
power input requirements may change depending on the requested
functionality of the system. In this case modifications may need to be made
to the existing connections.
A full system health check should be completed before upgrade works start!
Any repair work to the existing installation may need to be charged back to
the customer.
34
CAS GPS Installation Manual Rev G1
2/17/2016
Interconnections – 4CAM/4RF
CASGPS INVEHICLE UNIT (IVU)
PROD0850-xM
CASGPS IVU TO
DISPLAY CABLE
CASGPS DISPLAY
24 WAY
DEUTSCH
CONNECTOR
INTERFACE
PROD0161-CL
EXPANSION UNIT
IGNITION SIGNAL
12 WAY DEUTSCH
CONNECTOR
INTERFACE
VEHICLE
SIGNALS AND
POWER
PROD0180
EXPANSION UNIT
TO DISPLAY
CABLE
PROD0179
EXPANSION UNIT
INPUT CABLE
PROD0184
EXPANSION UNIT
TO CAM/RF
CABLE
CONNECTIONS TO CAMERA
UNITS AND RF UNITS
CHANNEL 6: FRONT
CHANNEL 5: LEFT
CHANNEL 4: REAR
CHANNEL 3: RIGHT
35
CAS GPS Installation Manual Rev G1
2/17/2016
Interconnections – 4CAM/4RF
Expansion Unit “DISPLAY” output
12 way military connector
Reference
Pin
Colour
12 way Deutsch connector on
PROD0180 cable
24 way Deutsch connector at IVU
Pin
Reference
Pin
Vin +
RED
Ignition (DI1)
GND
BLACK
GND
CAMEX+
GREEN
Video+
21
CAMEX-
YELLOW
Video-
20
RS485+
WHITE
RS485+
13
RS485-
BLUE
RS485-
19
REV+
GREY
REV+ (DI3+)
16
REV-
VIOLET
REV-
17
FWD+
WHITE/BLACK
11
FWD+ (DI4+)
22
FWD-
PINK/BLACK
12
FWD- (DI4-)
23
PWR+ (Battery)
(DI3-)
36
CAS GPS Installation Manual Rev G1
2/17/2016
Interconnections – 1CAM/1RF
PROD0850-xM
CASGPS IVU TO
DISPLAY CABLE
CASGPS IN-VEHICLE
UNIT (IVU)
CASGPS DISPLAY
24 WAY DEUTSCH
CONNECTOR
INTERFACE
HEAVY VEHICLE RF
UNIT (TYPICALLY
PROD0169)
POWER FROM BATTERY
12 WAY DEUTSCH
CONNECTOR
INTERFACE
PROD0181
DISPLAY
UNIT INPUT
CABLE
6 WAY DEUTSCH
CONNECTOR
INTERFACE
PROD0182
DISPLAY TO
CAM/RF CABLE
PROD0183
CAMERA TO RF
UNIT CABLE
PROD0118
CAMERA UNIT
VEHICLE
SIGNALS AND POWER
FROM IGNITION
37
CAS GPS Installation Manual Rev G1
2/17/2016
Interconnections – 1CAM/1RF
Display Input Cable (PROD0181)
Reference
Pin
Colour
24 Way Deutsch Connector CASGPS IVU
Deutsch (12 way)
Reference
Pin
Vin +
RED
Ignition (DI1)
GND
BLACK
GND
REV +
WHITE
REV+ (DI3+)
16
REV -
BLACK
REV-
17
FWD +
YELLOW
11
FWD+ (DI4+)
22
FWD -
BLACK
12
FWD- (DI4-)
23
PWR+ (Battery)
Display to Camera/RF Cable (PROD0182)
(DI3-)
Deutsch (6 way)
+12V
RED
+12V
12
GND
BLACK
GND
11
VID+
GREEN
Video+
21
VID-
YELLOW
Video-
20
RS485+
WHITE
RS485+
13
RS485-
BLUE
RS485-
19
38
CAS GPS Installation Manual Rev G1
2/17/2016
Interconnections - LV
CASGPS IN-VEHICLE
UNIT (IVU)
PROD0850-xM
CASGPS IVU TO
DISPLAY CABLE
VEHICLE
POWER
CASGPS DISPLAY
REVERSE
SIGNALS AND
IGNITION SIGNAL
LIGHT VEHICLE
RF UNIT
(PROD0295)
6 WAY DEUTSCH
CONNECTOR
INTERFACE
PROD0296
LV RF INPUT
CABLE
39
CAS GPS Installation Manual Rev G1
2/17/2016
Interconnections - LV
LV Power
Pin
CASGPS IVU (24 way)
Colour
Reference
Deutsch (6 way)
Pin
RF Unit
Pin
Reference
Colour
PWR+
RED
PWR+
Vin
RED
GND
BLACK
GND
GND
BLACK
+12
BROWN
BUZZER
BLUE
COM1 RX
RS232 TX
GREEN
COM1 TX
RS232 RX
YELLOW
REV+ (DI3+)
16
REV- (DI3-)
17
Ignition (DI1)
40
CAS GPS Installation Manual Rev G1
2/17/2016
Input Power & Signal Connections
41
CAS GPS Installation Manual Rev G1
2/17/2016
24 WAY DEUTSCH
CONNECTOR
REVERSE –
REVERSE +
FORWARD –
FORWARD +
3A
Fuse
GND
5A
Fuse
IGNITION
4 23 22 17 16
PWR
6 5
42
CAS GPS Installation Manual Rev G1
2/17/2016
6 5
4 23 22 17 16
43
CAS GPS Installation Manual Rev G1
2/17/2016
Deutsch Connector
24 Pin Deutsch
Connector
Wire Colour
Basic Signal Wiring
CAT Gear Decoder Signal Wiring
Red
Input Power +ve (Fused Battery)
Input Power +ve (Fused Battery)
Black
Ground
Ground
Yellow
Ignition +ve (Key Switch) (Ground
Referenced)
Ignition +ve (Key Switch)
16
Grey
Reverse +ve
Reverse +ve
17
Violet
Reverse -ve
Reverse -ve
22
White / Black
Forward +ve
Forward +ve
23
Pink / Black
Forward -ve
Forward -ve
44
CAS GPS Installation Manual Rev G1
2/17/2016
Input Power & Signal Connections
Input Power (Vin)
• Vin+ should be sourced after the isolator
•
•
WARNING:
– The IVU remains powered for up to 14hrs after the input power has been
Isolated
Input power / ignition pickup point must have inline short circuit protection, use
supplied fuse holders and fuses from installation kit.
– 5A blade fuse on VIN+ located as close as possible to the power source for LV
– 3A Resettable Circuit Breaker to be used on all HV for Ignition
– 5A Resettable Circuit Breaker to be used on all HV for VIN+
– Fuse location should be accessible for servicing and be clearly labelled using
the supplied labels from kit and located if possible on or close to the existing
fuse panel. Fuse label is identified by ‘CAS’
– Direct battery power should be used with independent fuse
– Do not use other electrical circuit power supplies
45
CAS GPS Installation Manual Rev G1
2/17/2016
Input Power & Signal Connections
Ground
Ground pickup point is the vehicle chassis. A ring terminal on a designated
grounding point should be used.
Ignition Signal
Vehicle ignition should be protected by an independent 3Amp fuse. Although the
system does not draw operating current from this source, the vehicle’s circuit should
be protected against inadvertent shorts.
Basic Reverse & Forward Signals
Unless using a CAT Gear Decoder (see below) the reverse signal should be obtained
from the vehicle’s reverse buzzer or alternatively the reverse lights. The forward
signal may be wired from a suitable forward gear indicator, with the forward
negative signal is tied to ground. Pickup should be made on the output side of the
relays.
CAT Gear Decoder Reverse & Forward Signals (PROD0587 CAT B,C & D or PROD0724 CAT E & F)
For vehicles using the CAT Gear Decoder, Reverse and Forward signals should be
obtained directly from the decoders outputs observing the correct polarity when
connecting to the IVU. Basic Reverse & Forward Signal wiring is not required when
using the Reverse & Forward Signals from the CAT Gear Decoder.
46
CAS GPS Installation Manual Rev G1
2/17/2016
General Wiring Principles
• Blanking plugs or caps are supplied and must be in place for all unused connectors
i.e. 24 way Deutsch Connector on the IVU for example
• All cable joins/splices should be soldered and heat shrink insulation applied
• All wires are to be labelled i.e. IGN, VIN+ ,GND , REV using the supplied labels
• DO NOT use clamp type splice devices to tee into vehicle wiring
• Crimp type ring terminals should be used for all terminal blocks
• All wiring should be run in the supplied flexible conduit along with the boot ends
also supplied in the kit
47
CAS GPS Installation Manual Rev G1
2/17/2016
Antenna cable terminations
48
CAS GPS Installation Manual Rev G1
2/17/2016
Antenna cable terminations
• You need to have received the proper
training before attempting to terminate
antenna cables
• Antenna cable terminations are one of the
most critical components of the system
49
CAS GPS Installation Manual Rev G1
2/17/2016
Antenna cable terminations
1. Strip cable jacket, braid, and dielectric to dimensions in the table below for the
appropriate cable and connector. All cuts are to be sharp and square. Important:
Do not nick braid, dielectric, and centre conductor.
Cable Type
A (mm)
B (mm)
C (mm)
RG58 TNC
15.5
3.5
RG58 N
15.1
6.8
RG214 TNC
16.8
7.3
4.7
RG214 N
15.1
6.8
50
CAS GPS Installation Manual Rev G1
2/17/2016
Antenna cable terminations
2. Slide outer ferrule onto cable as shown
3. Flare slightly end of cable braid as shown to facilitate insertion of inner ferrule.
Important: Do not comb out braid.
Contact on Cable centre conductor
Outer Ferrule
Cable dielectric
4. Place contact on cable centre conductor so that it butts against cable dielectric.
Solder contact in place.
51
CAS GPS Installation Manual Rev G1
2/17/2016
Antenna cable terminations
5. Install cable assembly into body assembly so that inner ferrule portion slides
under braid. Push cable assembly forward until contact snaps into place in
insulator. The tip of the centre contact should be level with the face of the
connector.
6. Slide outer ferrule over braid and up against connector body. Crimp outer
ferrule using Die Set Cavity in table above.
52
CAS GPS Installation Manual Rev G1
2/17/2016
Antenna cable terminations
7. Apply Self Amalgamating tape to Co – ax Termination this will aid in keeping out
any moisture that may get into the Co – ax Termination.
Self Amalgamating tape here
8. Repeat steps 1-7 for the other end of the cable
53
CAS GPS Installation Manual Rev G1
2/17/2016
Testing Antenna cable terminations
Test completed cable for continuity and short circuits by completing the following:
A.
With both ends of the cable disconnected. Measure the resistance between
the inner and outer conductors. Must be open circuit (>10MΩ)
>10M
54
CAS GPS Installation Manual Rev G1
2/17/2016
Testing Antenna cable terminations
B.
C.
Short the inner to the outer conductor on one end of the cable
Measure the resistance from the inner to the outer conductors on the
opposite end. Must be low resistance (<1Ω).
0.2
D.
Shorting link
If available, measure the VSWR of the completed cable
55
CAS GPS Installation Manual Rev G1
2/17/2016
Antenna Cable Connection Security
•
Antenna cable connection points can be prone to loosening with cable
movement
•
Tighten antenna cable connections with adequate force to prevent
loosening
•
Apply a small amount Loctite 243 or 248 thread locker to prevent
unwanted loosening
•
Caution! Thread locking compounds are an electrically isolative material.
If all threads are covered with thread locker the antenna may not work!
Ensure electrical conductivity after installation.
56
CAS GPS Installation Manual Rev G1
2/17/2016
Configuration
The following pages refer
to the configuration
process for CAS GPS.
Easy and straight
forward no laptop
required.
Conveniently
programmed through
the Graphic User
Interface. (Display)
57
CAS GPS Installation Manual Rev G1
2/17/2016
Configuration – Installation Measurements
GPS antenna Width (from LHS)
GPS Antenna Length (from front)
Vehicle Length (m)
The following
measurements are
the dimensions of
the machine and
GPS Antenna
location. These
measurements are
crucial for the GPS
to perform
correctly and
accurately.
GPS antenna location
Vehicle Width (m)
58
CAS GPS Installation Manual Rev G1
2/17/2016
Configuration – Installation Measurements
Measurements shown here are an example
of a Haul truck.
A = Truck Length
59
CAS GPS Installation Manual Rev G1
2/17/2016
Configuration – Installation Measurements
Measurements shown here are an example
of a Haul truck.
C = GPS antenna height
B = Truck Width
60
CAS GPS Installation Manual Rev G1
2/17/2016
IVU Orientation
•
The orientation of the IVU must be
recorded so that the 3 axis accelerometer
can be correctly calibrated
•
The table (right) should be used to
determine the orientation number of the
installed IVU
•
The orientation is referenced to the vehicle
if viewed from above when travelling
towards the top of the page (as shown by
the vehicle diagram)
61
CAS GPS Installation Manual Rev G1
2/17/2016
IVU Orientation (Examples)
Orientation
Number 1
Orientation
Number 7
IVU mounted on
the roof
IVU mounted
inside cabin
behind the rear
seat
62
CAS GPS Installation Manual Rev G1
2/17/2016
Configuration
Use the
button at bottom of Display to access CAS GPS
CASInstaller window
Configuration Button
63
CAS GPS Installation Manual Rev G1
2/17/2016
Configuration
Enter the Asset Name (usually the
vehicle’s ID) using the Keyboard
below
Once the object type is selected it
automatically populates the
typical dimensions for the
particular vehicle type.
Ensure the location of the GPS
Antenna (Length, Width and
Height) is correct for the install
When completed enter the
passcode before pressing Save
button on the lower right hand
side of the screen, this
configuration is now stored and
system is now ready to use.
> > >
Select the Object type by clicking
on the object type drop down box
and select the correct vehicle for
the installation.
This ICON will change
once the Object Type has
been chosen
The Asset type is not critical but
provides a record of the make and
model of the vehicle.
CASGPS
Vehicle
CASInstaller
Network
192.168.1.5
Wi-Fi IP
Asset Name: HV1234
Asset Type: CAT793
Object Type: Heavy Vehicle Truck
Orientation: 1
Input 3
Forward:
Input 2
Reverse:
Length(m): 10.00 Width(m): 10.00 Heigth(m): 10.00
GPS Antenna
Length(m): 10.00
Width(m): 10.00 Heigth(m): 10.00
Clear
Back
Shift
Space
PassCode:
Record the IVU orientation
here.
Click on the Orientation
drop down box and select
from the list of numbers
which refer to the table
listed on page 39 of this
manual.
Key Board
Ent
Char
Save
Cancel
64
CAS GPS Installation Manual Rev G1
2/17/2016
Shovel with Heading
Shovel with Heading Overview
The difficulty with rotating equipment such as
shovels is that the heading cannot be determined
by 1 normal GPS receiver. To overcome this a
secondary IVU can be installed to provide
another position from which a heading can be
determined.
XGPS1
To provide the minimum error the 2 IVU
antenna’s should be installed as far apart as
possible on the machine.
The primary IVU (1 on diagram) should be located
near the operators cab. The secondary IVU (2 on
diagram) should be located on the opposite side
and to the rear of the Shovel.
The primary IVU (1) is installed exactly the same
as a normal Shovel installation (with the
exception of configuration).
Length
Y2
Y1
YGPS1
Width
66
CAS GPS Installation Manual Rev G1
2/17/2016
Primary IVU Configuration
•
Help button opens a window describing
the required measurements
•
ZGPS is the height of the Primary GPS
antenna
•
XGPS1 is the horizontal distance
between the primary and secondary
antennas
YGPS1 is the vertical distance between
the primary and secondary antennas
•
Side indicates the location of the
operators cabin (Left or Right side of the
boom)
•
•
•
# is the serial number of the secondary
IVU
Y1 is the distance from the rear of the
shovel to the center of rotation
Y2 is the length of the body of the
shovel (excluding the boom)
XGPS1
GPS Heading Solution
ZGPS: 10.00
Help
Side: R
XGPS1: 10.00
#: 847613050001
•
CASGPS
Vehicle
CASInstaller
Network
192.168.1.5
Wi-Fi IP
Asset Name: SH1234
Asset Type: P&H4100
Object Type: Shovel with heading
Orientation: 1
Input 3
Forward:
Input 2
Reverse:
Length(m): 10.00 Width(m): 10.00 Heigth(m): 10.00
Configure the vehicle section as normal
> > >
•
YGPS1: 10.00
Y1: 10.00
Clear
Y2: 10.00
Shift
Space
PassCode:
Y2
Back
Lengt
Y1
YGPS1
Ent
Width
Char
Save
Cancel
67
CAS GPS Installation Manual Rev G1
2/17/2016
Primary IVU Configuration
Right Hand Side Cab
Left Hand Side Cab
XGPS1
XGPS1
Length
Y2
Y1
YGPS1
Width
Length
Y2
YGPS1
Y1
Width
68
CAS GPS Installation Manual Rev G1
2/17/2016
Secondary IVU Installation
Key points:
• Secondary IVU GPS antenna to be located as
far away as practical from the primary GPS
antenna
• IVU needs to be configured via the Display
interface prior to installation
• The IVU is installed without Display
• Install sealing caps on all unused ports
69
CAS GPS Installation Manual Rev G1
2/17/2016
Secondary IVU Wiring
• Fused (5A) power (pin 6) and
ground (pin 5) are the only signals
required for the secondary IVU
• Ignition input (pin 4) should be
hardwired to the fused input
power
• Unused pins sealed with sealing
plugs
70
CAS GPS Installation Manual Rev G1
2/17/2016
Secondary IVU Configuration
•
Orientation, Forward and Reverse are
not used.
Heigth(m): 0.00
Clear
Back
Shift
Space
PassCode:
•
Network
•
Object type should be set to Other
Heading
CASGPS
Vehicle
CASInstaller
Wi-Fi IP
Asset Name: SH1234
Asset Type: Heading unit
Object Type: Other Heading
Orientation: 1
Input 3
Forward:
Input 2
Reverse:
Length(m): 0.00
Width(m): 0.00
> > >
•
Set the Asset Name to be the same as
the primary IVU
Ent
Char
Save
Cancel
The Length, Width and Height by
default will be set to 0.00 and should be
left as zero.
71
CAS GPS Installation Manual Rev G1
2/17/2016
Shovel Heading Testing
The secondary IVU status icon indicates the
communication status to the secondary IVU:
• Green indicates good
• Yellow indicates warning, no message
received in the last 5 seconds
• Red indicates error, no message
received in the last 5 minutes
Pressing the
button displays the primary
and secondary IVU’s GPS information.
72
CAS GPS Installation Manual Rev G1
2/17/2016
Shovel Heading Testing
The GPS icon
should always be green when a Shovel with Heading is
correctly installed and operating.
Should the GPS icon change to yellow, this indicates that the primary
IVU no longer has a valid heading. Potential causes:
• Loss of communication between primary and secondary IVU’s (will be
indicated by the Secondary IVU status icon
• Loss of GPS signal to primary and/or secondary IVU (indicated by
poor HDOP reading >4)
• Poor GPS signal to primary and/or secondary IVU (indicated by poor
HDOP reading >4)
73
CAS GPS Installation Manual Rev G1
2/17/2016
Configuration & Install Record
On completion of the physical installation:
• Complete the Installation Checklist to ensure that the system is installed
correctly and is operating as expected.
• Complete the Installation Record carefully filling in all of the required details
(including – orientation, GPS location, vehicle size, vehicle ID)
74
CAS GPS Installation Manual Rev G1
2/17/2016
Configuration & Install Record
CAS GPS CHECKLIST:
75
CAS GPS Installation Manual Rev G1
2/17/2016
Configuration & Install Record
CAS GPS ITP:
76
CAS GPS Installation Manual Rev G1
2/17/2016
Record Keeping
• Take photographs of the completed
installation (for future reference and record of
installation)
• File all documentation appropriately
77
CAS GPS Installation Manual Rev G1
2/17/2016
Trouble Shooting
No power / Blank screen
Is the vehicle’s battery connected and fully
charged?
No
Connect/charge
and retest
No
Connect and
retest
Use this diagram to troubleshoot
an apparent loss or blank screen:
Yes
Are all the connectors plugged into the IVU
and display?
Yes
Is the power LED on the IVU on?
No
Has the fuse blown?
Yes
Is the power LED green on the
IVU?
No
Yes
No
Contact an
authorised
representative to
inspect
Is the cable between the IVU and display in good
condition (no cuts or breaks)?
No
Yes
No
Is the power LED blue on the
IVU?
Yes
Yes
Switch the vehicle ignition to the “On”
position. Does the power LED turn green?
No
Yes
Replace and
retest. If fuse
blows again
contact
authorised
representative to
inspect
Replace cable
and retest
The system was
in a low power
mode.
78
CAS GPS Installation Manual Rev G1
2/17/2016
Trouble Shooting
GPS Problems
Is the GPS icon
Red
No fault detected
by the system. If it
is not functioning
correctly contact
an authorised
representative
No
Yes
Does the antenna have an
unobstructed view of the sky?
No
Position vehicle to
have clear view of
the sky and retest
No
Replace antenna
and retest
No
Tighten connectors
and retest
No
Replace antenna
cable and retest
Yes
Does the antenna have signs of physical
damage?
The GPS signal status is indicated by the colour
of the
ICON at the top of the display.
Green: position and heading – no faults
Yellow: position fix but no heading – no faults
Red: No GPS signal or GPS error – fault or no
signal
Yes
Are the connectors securely tightened at the
antenna and the IVU?
Yes
Is the antenna cable in good
condition (no cuts or breaks)?
Yes
Contact an
authorised
representative to
inspect the system
79
CAS GPS Installation Manual Rev G1
2/17/2016
Trouble Shooting
V2V Problems
Is the V2V icon
Red
No fault detected
by the system. If it
is not functioning
correctly contact
an authorised
representative
No
Yes
Does the antenna have signs of
physical damage?
No
Replace antenna
and retest
No
Tighten connectors
and retest
No
Replace antenna
cable and retest
The Vehicle to Vehicle communication is indicated by
the colour of the
ICON at the top of the display.
Green: Communicating with other vehicles – no faults
Yellow: No other vehicles in range – no faults
Red: Radio error – fault or error detected
Yes
Are the connectors securely tightened at the
antenna and the IVU?
Yes
Is the antenna cable in good
condition (no cuts or breaks)?
Yes
Contact an
authorised
representative to
inspect the system
80
CAS GPS Installation Manual Rev G1
2/17/2016
Service and Maintenance
Scheduled System Servicing

It is recommended that the system undergo preventative scheduled
maintenance and inspections. These should be carried out by trained and
authorised personnel every 6 months or 1500hrs (which ever occurs first)
Software Updates

Software updates are automatically pushed out to all IVU’S connected to the
CAS server and will be scheduled with the end-user.
Equipment Maintenance
 If the system is not functioning as expected, refer to the Troubleshooting
section. If a fault cannot be resolved please contact your nearest authorised
representative.
81
CAS GPS Installation Manual Rev G1
2/17/2016
Service and Maintenance
 Equipment Service
 Display Unit
– Clean screen surface with a clean dry soft cloth – Do Not use solvents or
cleaners on the screen surface
– Check for physical damage to screen surface
– Check the cable connector is securely connected at the rear of the screen –
finger tighten only if loose
– Check the mounting bracket is secure – finger tighten only if loose
 System
– Check visually that all antennas are in good condition and the antenna cables
are connected
– Check visually that no cables are loose or damaged
– Verify that the system is working correctly prior to starting the vehicle and
during operations
82
CAS GPS Installation Manual Rev G1
2/17/2016
Decommission

Removal of the system should only performed if authorised by the owner of the
vehicle

Removal should only be performed by a qualified Auto Electrician

All system components and wiring should be removed

All vehicle wiring should be restored back to original condition

Dispose or store removed system in accordance with this manual
83
CAS GPS Installation Manual Rev G1
2/17/2016
Disposal
The electronic equipment discussed in this manual must not be treated as general
waste or disposed of into landfill.
By ensuring that this product is disposed of correctly, you will be helping to prevent
potentially negative consequences for the environment and human health which
could otherwise be caused by incorrect disposal of this product.
The IVU unit contains a Lithium Ion battery and should be disposed of in accordance
with local regulations.
The electronic equipment is RoHS compliant 2002/95/EC (Lead Free).
84
CAS GPS Installation Manual Rev G1
2/17/2016
Disclaimer
• The CAS product is a driver’s aid and should not be relied upon as the
primary means of reducing the risks of high potential interactions
between Heavy Vehicles, Light Vehicles, infrastructure and personnel.
• GPS based proximity detection may not operate when satellites are not
fully visible in the sky (e.g. in a deep mining pit near a high-wall or under
a workshop roof). Consideration should be given to supplementing GPS
with RF proximity detection and visual aids using cameras.
• Alarm logic should be determined via site specific risk assessment based
on the end-users specified high risk interactions.
• The CAS product does not take control of the vehicle although can
provide inhibit signals to prevent movement from a stationary position –
implementation will require approval from the vehicle OEM, vehicle
owner and GE and a detailed risk assessment conducted.
85
CAS GPS Installation Manual Rev G1
2/17/2016
Disclaimer
These materials are provided for information purposes only, "as is," without
express or implied warranty of any kind. GE MAKES NO ANY EXPRESS OR
IMPLIED WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR A
PARTICULAR PURPOSE OR ANY OTHER EXPRESS OR IMPLIED WARRANTY
REGARDING ANY PRODUCTS DESCRIBED IN THESE MATERIALS. TO THE
MAXIMUM EXTENT PERMITTED BY LAW, GE DISCLAIMS ANY AND ALL
IMPLIED WARRANTIES THAT MIGHT OTHERWISE ARISE OR APPLY, INCLUDING
ANY IMPLIED WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR A
PARTICULAR PURPOSE. GE further makes no representation or warranty of
accuracy of these materials and neither GE will have no responsibility or
liability for any error or omission in these materials.
86
CAS GPS Installation Manual Rev G1
2/17/2016
Contact Details
87
CAS GPS Installation Manual Rev G1
2/17/2016
88
CAS GPS Installation Manual Rev G1
2/17/2016

---

Source Exif Data:

File Type                       : PDF
File Type Extension             : pdf
MIME Type                       : application/pdf
PDF Version                     : 1.5
Linearized                      : Yes
Author                          : David McCarthy and Spencer Waterman
Create Date                     : 2016:02:17 14:59:19+11:00
Keywords                        : September 22, 2004 – Version 1.1
Modify Date                     : 2016:02:17 14:59:39+11:00
TB4 Template Type               : onscreen
TB4 Template Version            : 4
Wiz Kit Template Type           : Onscreen
Wiz Kit Template Version        : 4
Tagged PDF                      : Yes
XMP Toolkit                     : Adobe XMP Core 5.2-c001 63.139439, 2010/09/27-13:37:26
Metadata Date                   : 2016:02:17 14:59:39+11:00
Creator Tool                    : Acrobat PDFMaker 10.1 for PowerPoint
Document ID                     : uuid:a6de68c4-3db8-4453-85ed-e70c74131776
Instance ID                     : uuid:d22c69fe-4393-4c5e-892d-939e03d72000
Format                          : application/pdf
Title                           : CASLITE Installation Manual
Creator                         : David McCarthy and Spencer Waterman
Producer                        : Adobe PDF Library 10.0
Company                         : GE
Comments                        : General Electric Company 2004
Palette                         : GE Template
Wiz Kit 0020 Template 0020 Type : Onscreen
Wiz Kit 0020 Template 0020 Version: 4
TB40020template 0020version     : 4
TB40020template 0020type        : onscreen
Page Layout                     : SinglePage
Page Count                      : 88

EXIF Metadata provided by EXIF.tools