Safemine QC250B Collision Avoidance System User Manual UserManual

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INSTALLATION AND MAINTENANCE

GUIDE

for

SAFEmine COLLISION AVOIDANCE

SYSTEMS

Firmware Version 2.61

SMTool version 2.0.7

July 31 , 2014

Switzerland

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:

May 23, 2016

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

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)

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

SECTION A Introduction

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

of above specified products other than regular warranty according to SAFEmine Ltd. General

Terms and Conditions.

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.

In addition, SAFEmine Ltd.'s current "General Terms and Conditions of Sale" apply.

SECTION B Hardware and Installation

3 Hardware

3.1 Main units

Main unit overview 3.1.1

The 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

Analog Input

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!

Through Hole Mount Antenna (QF036) 3.2.1

The 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)

3.2.2

The 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 3.3.1

See Appendix B : Specifications (QC250)

Main unit interfaces and connectors 3.3.2

3.3.2.1 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

brown

Power (+9 to +28VDC) overvoltage and polarity

protected

Power in

white

Digital I/O (IO1 in chapter 3.4 I/O Connections)

Input /

Output

blue

Audio (voice) out (may be left NC)

Output

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)

grey

pink

CAN listener (may be left NC) (typically J1939, ISO

11898)

IO H L

green

yellow

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

RF gain

3 dBi

3.4 I/O Connections

Hardware capabilities 3.4.1

SAFEmine 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.

Name

Connector

Pin #

IO0

n/a

IO1

Power

IO2

I/O

IO3

I/O

IO4

I/O

IO5

I/O

IO6

I/O

IO7

I/O

IO8

I/O

I/O Specifications 3.4.2

3.4.2.1 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

 Input voltage range: 0..24V

 Input Resistance: 300k Ohm

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 4.2.1

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.

 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 4.2.2

The 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

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 4.3.1

The 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.

Vertical cut of a QF036 after installation

Magnetic Mount QF037 4.3.2

The 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) 4.3.3

The 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!

Coaxial cable type

Max. length RF

Max. length GPS

RG174 / RG58

Do not use

HDF-195/CFD-195

LMR -195/ RF 195 LMR-200

15m

LMR 400

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

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.

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.

6 Configuration parameter specifications

6.1 Site specific parameters:

Site specific parameters must be set on all units

Radio Channel 6.1.1

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 6.1.2

Keyword

Description

Unit

Range

Default

Example

HOPPING

Number of channels to use for hopping

1 - 50

50: North America countries under FCC regulation

1: All other areas

Transmit Power 6.1.3

Keyword

Description

Unit

Range

Default

Example

RFPOWER

Transmit Power Setting.

0 - 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

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 6.2.1

Vehicle 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

Parameter

Description

Unit

Range

Default

Example

VEHTYPE

Vehicle Type

10 - 100

Vehicle Dimensions

Parameter

Description

Unit

Range

Default

Example

VEHLENGTH

Vehicle length, overall

meter

0 - 655

12.8

VEHWIDTH

Vehicle width, overall

meter

0 - 655

3.4

VEHHEIGHT

Vehicle height, overall

meter

0 - 50

2.34

Description

VEHTYPE value

Examples/ Remarks

Light Vehicle

Ford F150,F250

Small Tractor

Haul Truck

Komatsu 730E,

Dump Truck

Caterpillar 789C

Water Tanker

CAT 777

ADT (Articulated Dump Truck)

Volvo A25E

Fuel Bowser

Service Truck

Mitsubushi Canter; Volvo Fm12

Mobile Crane

Franna AT 20

Low Bed Truck

Rear Tip Truck

Excavator

CAT 385C

Shovel

Liebherr 3994, Bucyrus 495HR2

Komatsu PC 4000

Dozer

Cat D9T

Dragline

Drill

Atlas Copco PV271

Large Front End Loader

Le Tourneau L1850

Small Front End Loader

CAT 988H

Tyre Handler

Cable Handler

Grader

Cat 24H , Cart 16M

TLB, JCB

John Deere 110 TLB, (Back Hoe)

Large Tractor

CAT 992C

Train

Stockpile Stacker

Test Station

Stockpile Dozer

Lighting Plant

Alight 22KVa , Multiflo ??

Stockpile Reclaimer

Boomgate

Beacon

100

Highly recommended vehicle parameters 6.2.2

Vehicle Weight

Parameter

Description

Unit

Range

Default

Example

VEHWEIGHT

Maximum vehicle weight (with no load)

Ton

0 -1500

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

DISTCLOSE

Flashing Red LED indicates vehicle

closer than disclose meters

meter

0 - 250

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

SAFETYWIDTH

Extends the alarm region in percent of

vehicle width.

% of

width

1 - 100

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

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

MAXSPEED

Maximum speed before alert.

Km/h

0 (disabled)

SECTION D Software maintenance

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

Flash Memory

(Fatal)

Flash memory failure; non-fatal if operational, but data

lost. Fatal if operation is not possible.

Serial

Fatal

Serial number invalid, contact support

2&1

Dataport error

Alert

Sending of Dataport Heartbeat message failed.

GPS receiver

Fatal

Unable to communicate with or configure GPS module

1 & 3

GPS Antenna

Fatal

GPS antenna defective or bad connection

Power

Fatal

Power supply defective or low/high voltage

User Interface

Fatal

No user interface connected.

Config

(Fatal)

Configuration file contains errors, or is not present.

Firmware

Fatal

Firmware corrupt, upload new firmware

128

Generic

Various

Generic error, currently not used

256

GPIO error

Fatal

GPIO configuration or hardware problem. See Terminal

output for details.

4095

All

Unknown

Various

Not used.

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

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

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)

Typical installation

Appendix C Additional figures and drawings

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

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

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

Industry Canada Notice and Marking

This radio transmitter 9849A-QC250B 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

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

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,

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.

Safemine QC250B Collision Avoidance System User Manual UserManual

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