Zonar Systems V3R V3R User Manual

Zonar Systems Inc V3R

User Manual

REV:02/14/13
Zonar Systems’ V3R™ Hardware Installation TipsFor Professional InstallersZonar Systems’ equipment will provide years of reliable service if properly installed and maintained.Zonar equipment is typically installed in heavy vehicle applications and is often subject to extremetemperatures, dust, dirt, vibration, and shock. Proper installation is the critical first step to equipmentlongevity and optimal performance.This guide is meant to be a general guideline for the professional installer and technician. While weattempt to point out the most common installation questions and issues; common sense, goodhousekeeping procedures, attention to detail, safety adherence, and technical competence of theprofessional installer is critical for a successful installation.Please refer to your specific vehicle manufacturer guidelines for the installation of electrical componentsand wiring.A professional team of Zonar support technicians and engineers are available to answer your installationquestions. Contact Zonar at 1-877-843-3847 or by email at customercare@zonarsystems.com.Thank you,Andre J HorochiwskyTechnical Training Manager – Zonar SystemsAs Zonar Systems is continuously improving the Product, Zonar may make changes to the Product at any time which may not be reflected in this document.INTRODUCTION2
V3R™Introduction ................................................................................................2System Overview........................................................................................4V3R Equipment .........................................................................................5General Guidelines .....................................................................................6V3R Mounting ............................................................................................7V3R Cable Management.............................................................................8Power Cable Wiring Guidelines...................................................................9External GPS Antenna Installation.............................................................10System Check..........................................................................................11System Checklist......................................................................................12System Components and Specifications ..................................................13Installation Examples ................................................................................14System Installation Diagram......................................................................15Troubleshooting...................................................................................16-17Warranty & Notices - FCC Compliance.....................................................18TABLE OF CONTENTS3© 2013 Zonar Systems • EVIR, ZPass,Ground Traffic Control and V3R are trademarks of ZonarSystems. All Rights Reserved.Products and services protected by one or more of the following US patents: 6671646, 6804626,7117121, 7362229, 7557696, 7564375 and Australian patent: 2002322510REV: 02/14/13
SYSTEM OVERVIEW4CUSTOMEROn-Site LocationZONAR Secure ServersCELL TOWERINTERNET
V3R EQUIPMENT5Fuse HoldersATC StyleFusesCrimpableButt SplicesV3R POWER CABLEZONAR V3R™INSTALLATION HARDWAREMountingHardware
Layout1) V3R unit must be located a minimum of 8” from any person.2) Do not place Zonar RFID tags, cables, or other equipment inany location or position which may compromise human orequipment safety.3) Verify placement acceptability with State DOT/Law enforcementprior to installation.4) V3R has a temperature range of -40˚C (-40˚F) to +85˚C (+185˚F). Do not mount V3 in hot engine compartments or near hotexhaust components.5) Lay all components out prior to installation to check for propercable length and interference issues.6) Avoid mounting Zonar equipment, antennas and wiring nearother radio equipment (e.g.,two-way radios), PA equipmentand high energy electrical sources (e.g., cables, relays,amplifiers, etc.).Electrical1) Consult the vehicles manufacturer for specificinstallation guidelines. (HIGHLY RECOMMENDED forMultiplex electrical systems)2) All power leads (Red and White Power leads) must beconnected to the vehicles protected circuitry (e.g. fuse panel,circuit breaker panel, protected circuits). Never electricallyconnect Zonar equipment to unprotected circuits (e.g. directlyto battery).3) It is also required that all power leads (Red and White Powerleads) be protected with a 3 to 5 amp fuse and inline fuseholder (included) for optimal system protection.4) Electrical fuses should be installed as close as possible tothe source of power.Do not open V3R housing. To do so will voidthe warranty and possibly lead to moistureintrusion.Drill Holes1) Do not drill into the V3R unit. This will void the warranty.2) Capture all drill chips during drilling operations. Do not allowchips to fall onto equipment, furnishings, etc.3) Deburr all drill holes on both sides of drilled surface. Exampledeburr tool:4) All drill holes must have a rubber grommet or similar anti-chaffing system installed to protect cable assemblies (e.g.plastic conduit).5) Seal all penetration drill holes which may pass rain water.Cable Management1) Strain relieve and support all cable installations.2) Avoid sharp bends and tight radius installations of cables.3) Avoid moving components (e.g. doors, steering shafts, handles,fans, etc.).4) Provide an adequate “Service Loop” i.e. “cable slack” to allowfor servicing of equipment.5) Avoid routing cables thru doors, windows, and other pinchpoints.6) Avoid routing cables in high personnel traffic areas.7) Avoid routing antenna cables near radio and PA equipment.GENERAL GUIDELINES6INCORRECT• Bend radius too tight• Hole has sharp edges• Hole has no grommetCORRECT• Bend radius adequate• Hole has grommetGeneral Housekeeping1) Capture all drill chips during drilling operations. Do not allowdrill chips to fall onto electrical equipment, furnishings, heatingducts, etc. Magnets, sticky tape, vacuums, physical barriers,etc. may all be used to accomplish this task.2) Remove excess sealant. Sealant should be debris/contaminantfree (e.g. drill chips), consistent, and uniform in appearance.Clip excess wire tie protrusions.
V3R Mounting1)Follow all General Guidelines as specified on page 6.2) Suggested mounting areas: See page 14.A) Box type trailers - Left side rooftop (preferred) orfront vertical surface (alternate)B) Construction equipment - Protected from movingequipment, impact damage and high heat areas3) Antenna Configurations:A) GPS antenna - V3R utilizes an internal GPS antenna. Thisantenna works well when the unit has a clear view of thesky (e.g. atop box trailer. If the V3R does not have aclear/unobstructed view of the sky (e.g. enginecompartment) an external GPS antenna must be used.B) GSM (cellular antenna) - V3R utilizes an internal GPSantenna. Cellular signals are quite robust and are noteasily degraded. As a general rule, if your cellular telephoneworks in the location you have installed the V3R, thisshould satisfy the GSM/Cellular requirements of the V3R.Fig. 7-14) Mount onto interior flat surface large enough to accommodatefootprint.5) Avoid mounting equipment in difficult to access areas.6) If enclosing in a radio-shielded area (e.g., metallic enclosure)an external GPS antenna will be necessary for proper operationand performance.7) Avoid mounting Zonar Equipment, antennas and wiring nearother radio equipment (e.g.,two-way radios), PA equipmentand high energy electrical sources (e.g., cables, relays,amplifiers, etc.).8) Avoid mounting equipment in dirty, dusty, or damp areas.9) Please take note of:• GPS ID number – Found on white sticker on GPS unit• Vehicle or Asset number (e.g. Bulldozer #56)Note: Your Zonar Customer Care Representative or Ground TrafficControl Administrator will need this information.V3R MOUNTINGFig. 7-2BoltMount(Provided)MagneticMount(Provided)7Mount V3R FacingSkyward7
1) Follow all General Guidelines as specified on page 6.2) It is strongly recommended to keep Zonar electrical connectionsoutside "master kill" circuitry. Failing to do so may lead toinaccurate data (See caution notice this page).3) Connecting V3R to negative/ground side "master kill" circuits(commonly found on construction equipment) may lead to falseidle times.4) All power leads must be connected to the vehicle’s protectedcircuitry (e.g. fuse panel, circuit breaker panel, protected circuits).Never electrically connect Zonar equipment to unprotectedcircuits (e.g. directly to battery).5) It is also required that all power leads (Red and White leads),be protected with a 3 to 5 amp fuse and inline fuse holder(included) for optimal system protection.6) Electrical fuses should be installed as close as possible to thesource of power.7) Power Bundle wiring – 4 Pin, 3 wiresA. Red – Constant DC (+8 VDC - +30 VDC), dependent on system typeB. Black – Ground must be less than 1 ohm (measure from 4 Pin connector to chassis attachment point) C. White - Switched PowerThe White wire must be connected to a power source thatis active only when the engine is running or the systemwill not track idle time properlyi. Engine running (+8 VDC to +30 VDC)ii. Engine NOT running (0 VDC)iii. Engine NOT running (key position ACC or Accessory) Mode (0 VDC)Electrical Requirements and Cabling InformationV3R CABLE MANAGEMENT821’ Power CableIf power cabling is not connected and powered asdescribed in paragraph 7, one or more of the followingmay occur, contact Zonar for additional info:A. Cold Start flags (an indicator that a unit lost and regainedconstant power)B. Inaccurate idle and stop timesC. Inaccurate hour meter dataD. Inaccurate mileage dataE. Missing path dataF. Straight line data segmentsPlease contact the vehicle manufacturer for any vehiclespecific electrical questions.
Wiring Guidelines for Zonar Power CablesThe recommended method for power termination on the ZonarV3R system is the use of Add-a-Circuit fuse taps. Wheneverpossible, use fuse taps for power termination. If, due to the particularmake/model/year of the vehicle being installed, fuse taps cannotbe used then the poke and weave method of termination can beutilized. All wiring terminations MUST be fused regardless of Add-a-Circuit or poke and weave.When installing Add-a-Circuit fuse taps, ensure that the fuse tapseats fully in the correct location. If another fuse, a relay, or anyother object in the fuse panel prevents the fuse tap from seatingfully, relocate the fuse tap. It is not permissible for the fuse tap torub or make contact with other items in the fuse panel. In addition,you must be able to re-secure the fuse panel cover or door oncethe fuse tap is installed. Whenever possible, use an empty locationin the fuse panel that does not have an existing fuse. If it is notpossible to use an empty location, ensure that the existing fuse isplaced in the correct location on the fuse tap.See Fig. 9-1Whenever it is not possible to utilize Add-a-Circuit fuse taps thenthe poke and weave method should be used.1) First locate the proper wire where the poke and weave methodis to be installed. Strip 3/4” to 1” of insulation from the wire inthe vehicle to be installed. Spread the wire strands apart asshown. See Fig. 9-22) Strip 1” to 1 1/2” of insulation from the wire in the fused linkto be installed. See Fig. 9-33) Insert the wire from the fused link into the spread wire in thevehicle. Wrap around the wire several times. See Fig. 9-44) Cover the exposed wires with several wraps of electrical tapeor mastic. Place one wire tie over the electric tape over theexact location where the wires are 'wrapped' together. Placeanother wire tie 1” to 2” from the first wire tie, to secure the twowires together and as stress relief. See Fig. 9-5Fig. 9-1Wire TieFig. 9-5Fig. 9-4Fig. 9-3Fig. 9-2WIRING GUIDELINES9CAUTION: Only “LittleFuse”(www.littlefuse.com) Add-A-Circuit taps are authorized foruse with Zonar Equipment.Full size: (ATO) P/N FHA200Mini version: P/N FHM200
External GPS Antenna and Double Sided Adhesive(Optional)1) Required when the V3R does not have an upward facing clearview of the open sky.2) Suggested mounting area - as high on the vehicle as possible,facing upward. Protect from moving machinery and fallingdebris.3)Follow all General Guidelines as specified on page 6.4) May be magnetically mounted or mounted via optional aluminumplate and screw for non-magnetic surfaces, see Fig. 10-1.5) Ensure a clear antenna view of the open sky.6) Maintain a minimum of 6 inches from any rooftop edge or ledge,see Fig. 10-1.7) Drill, deburr, grommet, weather seal, cable thru hole as required.Drill hole size - 1/2” (.500”); grommet size - 3/8” (.375”).8) Protect exposed GPS cable with automotive grade impact andcut resistant loom.Note: For optimal system performance Zonar recommends rooftopmounting with a clear view of the sky.Fig. 10-2ANTENNA INSTALLATION10• Allow a minimum of6 inches from anyedge or ledge• Drill hole size: 1/2” (.500”)• Grommet size: 3/8” (.375”) I.D.• Drill, Deburr, grommet, weatherseal, cable thru hole as required1” - 2”recommendedFig. 10-1
System Check:1) Installers are required to perform a full functional check toverify proper installation and operation. A complete functionalcheck includes Ground Traffic Control™ confirmation.2) Constant (RED wire) power checkA. Remove inline fuse on constant power (Red wire) andmeasure voltage at red fuse holder.3) Switched power (White wire) power checkA. Power to this lead should only be present when theengine is on and/or GPS tracking is desired. Wiring thisto constant power will lead to high and inaccurate idletimes.B. Remove inline fuse on switched power (White wire) andmeasure voltage at fuse holder:Engine running = 8 to 30 VDCEngine Off = 0 Volts4) Final checkA. Turn engine on for 4 minutes or more, then turn off engine.B. In Zonar’s Ground Traffic Control™ export path CSV (GPS,path report), ensure exported CSV contains:1. Cold Start2. Power-On event3. Power-Off event4. Idle Event (idles must be over 1 minute)Note: A proper and complete functional check requires the engineto be running.Contact Zonar at 1-877-843-3847 or by email atcustomercare@zonarsystems.com if you encounter anyissues or difficulties.SYSTEM CHECK11
INSTALLER SIGNATURE DateV3R SYSTEM CHECKLIST12Customer: Yard: Date: Asset #:Installer: Location: GPS ID:Vehicle Odometer Value: Vehicle I.D. (e.g., Vin, Plate#, Make, Model, Year)Vehicle Hour Meter value (if monitoring engine hours)System Check Value NotesGeneral LayoutGeneral condition - components level, even, straight, etc?System layout conforms to your established standard?Drilling and CuttingAll drill holes grommeted (or otherwise protected), deburred,sealed (weather penetrations only)All chips captured?Cable ManagementAll cables properly ran (tight radius, interference, strainrelieved, supported, service looped)?ElectricalSystem hookup complies to your established standard?Red lead voltage verified? (8 -30V constant)White lead voltage verified? (8 -30V engine on, 0V engine off)Black lead continuity verified? (Grounded to vehicle chassis)Crimp integrity verified?Fuse holder and fuse installation verified?Ground Traffic Control™ System checkoutCold start present?Power-on checkPower-off checkIdle time check? (Requires an idle of over 1 minute)GPS Position uploaded to GTC website?Post JobKey accounted for?Vehicle secure?Lights, electrical off?All debris, refuse, chips removed?
Important NoticeIt is the Owner's sole responsibility to install and use the Zonarproducts in a manner that will not cause accidents, personal injuryor property damage. For the purposes of this notice, "Owner","you" and "your" means the party (including any person authorizedby that party to use and/or install the Product) that has either: (a)purchased the Product; or (b) leased the Product from ZonarSystems, Inc or its related companies. The Owner of this productis solely responsible for observing safe driving practices. Thechoice, location, and installation of all components of the Productis critical. If installation is not correct, the Product may not performat its designed potential or specifications. If in doubt, consult yourvehicle's manufacturer.SYSTEM SPECIFICATIONS13System Components & SpecificationsCOMPONENTS• V3R™ GPS Unit• 3 wire power harness magnetic and bolt-thru mounting kitsOptional Accessories:• External GPS AntennaSPECIFICATIONS• Operating Temp: -40˚C (-40˚F) to +85˚C (+185F)• DC Input Range: 8.0Vdc to 30.0VdcGPS Receiver• Very High Sensitivity Receiver• Rapid Acquisition of Satellites• GPS Signal Acquisition, Tracking and Navigation• Onboard GPS Data StorageDIMENSIONS• Length: 9.485 in.• Width: 8.313 in.• Height: 2.534 in.COMMUNICATIONGSM Cellular Transceiver• Quad Band 850/1900 900/1800• GPRS
Mount V3R FacingSkywardINSTALLATION EXAMPLES14Trailer, Left SideRoof Mount -PreferredTrailer Left SideFront High Mount-AlternateYellow Iron -Top of CabPreferredYellow Iron -Inside Back CabAlternateMin. 8” from Operator -External GPS AntennaRequiredNote: The V3R needsa clear view to theopen sky to track GPSsatellites. If this is notpossible, installoptional external GPSantenna.Note: Securewire/cable every6 inches.
External GPS Antenna(Optional Accessory)Part#: 10006Cable Length: 16.5 ft.SwitchedPower (White)GND (Black)Constant Power SupplyInput Voltage: 8-30VDCEngine Running: 8-30 VDCAcc/Accessory mode, Engine Not Running: 0 VDC+12VDC (Red)3A-5ASYSTEM INSTALLATION153A-5AZonar V3R™Part#: 1008320 AWG
16TROUBLESHOOTINGCommon V3R™ issuesThe majority of all V3R issues fall into six broad categories:•GPS Signal Strength Issues. The V3R must be given a clearview to the open sky to operate correctly. If this cannot beaccomplished an external GPS antenna with a clear view to thesky must be utilized.• Cellular Signal Strength Issues. The V3R cannot transmitin areas that are not covered by cellular towers (typically remoteareas). The V3R will store information until cellular reception isrestored and then forward all stored data.• Cold Starts: These are the most serious issue because theyrepresent a lack of integrity in the constant power supply to thedevice. Before any other issue can be resolved, it is importantto ensure that the V3R has reliable constant power.• Issues with the Engine Run Signal: These lead to falsereporting of engine hours. The problem can be false positive(e.g. V3R records engine hours even if the asset is not running)as well as false negative (e.g. V3R does not record engine hourseven though the asset is running)• V3R™ Issues: Inside every V3R is a Zonar V3R™ GPS unit.Therefore, typical V3R issues can arise with any V3R. Sincemuch of the V3R troubleshooting information references LEDswhich are hidden inside the waterproof V3R enclosure, in mostcases you will need to contact Zonar Customer Support forhelp.White Wire (WW) / Switched Power Electrical Test1. Engage the equipment master switch.2. Connect Zonar harness to V3R case3. Connect the negative meter probe to the Zonar GND wire.4. Turn engine off.5. Refer to Figure 1-16 and locate the WW pin on the 35-pinconnector. Probe this pin with the positive meter probe.6. To pass the inspection, the meter must show less than 1V.7. Turn engine on.8. Probe the WW pin. To pass, the meter should read greater than5V.Inspection ResultsIf both steps 6 and 8 result in PASS, the V3R passes the electricalinspection. However, if the equipment is acting up only under certainconditions (i.e. hot day, rainy weather) the test should be performedagain under those conditions.If either test results in FAIL, perform the WW continuity tests. Oncethe wiring has been verified, repeat this test. If the result is FAILagain, swap in a new V3R and repeat.If the inspection does not pass even after swapping in a new V3R,note the failure condition, and contact Zonar support.Figure 1-16 V3R Cable Pin Assignments
17TROUBLESHOOTINGPower and Ground Electrical TestsUnexplained cold starts are the most serious issue because theyrepresent a lack of integrity in the constant power supply to thedevice. Before any other issue can be resolved, it is important toensure that the V3R has reliable constant power. Simply followingthis procedure may not be enough. However, if the equipment isacting up only under certain conditions (i.e. hot day, rainy weather)the test should be performed again (and again?) under theseconditions.1. Engage the equipment master switch2. Connect Zonar harness to V3R™ case3. Prepare multi-meter to measure volts.4. Connect the negative meter probe to Zonar GND wire.5. Refer to Figure 1-16 and locate the V+ pin on the 35-pinconnector. Probe this pin with the positive meter probe.6. To pass the inspection, the voltage must be at or near batteryvoltage. If not, perform the Power and Ground WiringInspection. Then repeat this test.7. If the test passes, power cycle the V3R, and confirm that a ColdStart event occurred on GTC. Otherwise, note the failurecondition, and contact Zonar Support.Test ResultIf the Electrical test passes, but the V3R continues to showunexplained cold starts, note the conditions under which the coldstarts occur. Repeat the Power and Ground Wiring Inspectionprocedure and the above procedure under those conditions. Ifpossible, mount the meter in the operator’s cab and run the testcontinuously for several hours.
18WARRANTY & NOTICESFCC/IC COMPLIANCELimited WarrantyLIMITED WARRANTY: Zonar warrants that the Hardware providedunder this agreement is free from all material defects in workmanshipunder normal use and service. Zonar’s warranty period for itsHardware is as follows:V3 Product Line - 5 YearsEVIRTM - 3 YearsAll Other Hardware - 1 YearThe above warranty periods run from the date of shipment. Providedthat the Hardware is used and handled as intended, Zonar willreplace any failed or functionally impaired Hardware with equivalentHardware in terms of performance and functionality.This warranty does not apply to any Hardware that has beenmisused, altered, willfully abused or that has been damaged dueto improper installation by the customer.† Hardware installationsmust follow Zonar’s equipment specific installation guidelines.† Ifproduct returned is determined to be damaged due to any of theaforementioned circumstances, the Customer will be charged theprice of a refurbished unit plus shipping and handling.CUSTOMER’S SOLE AND EXCLUSIVE REMEDY AND ZONAR’SENTIRE OBLIGATION UNDER THESE LIMITED WARRANTIES fordefective equipment is the repair and replacement of the equipmentfree of charge by Zonar. Zonar shall not be liable to Customer orany third party for any general, special, punitive, incidental, indirector consequential damages, or any lost profits or business, arisingout of Zonar’s Subscription Agreement.Warning: (Part 15.21)Changes or modifications not expressly approved by Zonar Systemscould void the user's authority to operate the equipment. Caution: RF Exposure (OET Bulletin 65)To comply with FCC RF exposure requirements for mobiletransmitting devices, the antenna(s) used for this transmitter mustbe installed to provide a separation distance of at least 20cm (8Inches) from all persons and must not be co-located or operatingin conjunction with any other antenna or transmitter. Users andinstallers must be provided with antenna installation instructionsand transmitter operating conditions for satisfying RF exposurecompliance.Use only supplied and approved antenna's. Use of unauthorizedantenna's or modifications could impair signal quality, void yourwarranty and/or result in violation of FCC regulations.FCC Compliance Statement (Part 15.19)IC Compliance Statement (RSS-210)This device complies with Part 15 of the FCC Rules and with RSS-210 of Industry Canada (IC). Operation is subject to the followingtwo conditions:1. This device may not cause harmful interference, and2. This device must accept any interference received, includinginterference that may cause undesired operation.Cet appareil est conforme aux normes CNR exemptes de licencedíIndustrie Canada. Le fonctionnement est soumis aux deuxconditions suivantes :(1) cet appareil ne doit pas provoquerdíinterfèrences et(2) cet appareil doit accepter toute interfèrence,y compris celles susceptibles de provoquer un fonctionnementnon souhaitè de líappareil.
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© 2013 Zonar Systems • All Rights Reserved.REV:02/14/13V3R™ USERS MANUAL& INSTALLATION GUIDE

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