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.
Document Control REV DESCRIPTION Review Approval Date E Added shovel heading 19/11/2014 F Fixed inconsistent pinouts on 24way connector 27/03/2015 G Added Compliant Antenna Information (Page 6) D.
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.
Storage Where the equipment is not to be installed immediately, proper storage is important to ensure protection of equipment and validity of warranty.
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.
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.
WARNING: Consult with the client to confirm all equipment mounting locations and power connections! Do not weld on ROPs! Do not drill through ROPs! 7 CAS GPS Installation Manual Rev G1 2/17/2016
Specialty Tools Required / Adhesives 8 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 9 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 • Rememb
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.
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 Antenn
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.
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.
CAS GPS Installation Manual Rev G1 2/17/2016
CAS GPS Installation Manual Rev G1 2/17/2016
CAS GPS Installation Manual Rev G1 2/17/2016
Stauff Clamp Sizes chosen to suit Handrail sizes.
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.
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.
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.
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 Ma
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 + A RED 1 Ignition (DI1) 4 GND B BLACK 2 GND 5 CAMEX+ C GREEN 3 Video+ 21 CAMEX- D YELLOW 4 Video- 20 RS485+ E WHITE 5 RS485+ 13 RS485- F BLUE 6 RS485- 19 REV+ H GREY 7 REV+ (DI3+) 16 REV- J VIOLET 8 REV- 17 FWD+ M WHITE/BLACK 11 FWD+ (DI4+) 22
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 1 Ignition (DI1) 4 GND BLACK 2 GND 5 REV + WHITE 7 REV+ (DI3+) 16 REV - BLACK 8 REV- 17 FWD + YELLOW 11 FWD+ (DI4+) 22 FWD - BLACK 12 FWD- (DI4-) 23 PWR+ (Battery) 6 Display to Camera/RF Cable (PROD0182) (DI3-) Deutsch (6 way) +12V A RED 1 +12V 12 GND B BLACK 2 GND 11 VID+ C GREEN 3 Video+ 21 VI
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+ 6 1 Vin RED GND BLACK GND 5 2 GND BLACK 3 +12 BROWN 4 BUZZER BLUE COM1 RX 7 5 RS232 TX GREEN COM1 TX 1 6 RS232 RX YELLOW REV+ (DI3+) 16 REV- (DI3-) 17 Ignition (DI1) 4 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 6 Red Input Power +ve (Fused Battery) Input Power +ve (Fused Battery) 5 Black Ground Ground 4 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.
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.
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.
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 8 3.5 RG58 N 15.1 6.8 4 RG214 TNC 16.8 7.3 4.7 RG214 N 15.1 6.
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.
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.
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.
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.
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.
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.
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.
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.
Configuration – Installation Measurements Measurements shown here are an example of a Haul truck.
Configuration – Installation Measurements Measurements shown here are an example of a Haul truck.
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.
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.
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
Primary IVU Configuration Right Hand Side Cab Left Hand Side Cab XGPS1 XGPS1 Length 1 Y2 Y1 YGPS1 2 Width Length 1 Y2 YGPS1 2 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 0 1 2 3 4 5 6 7 8 9 Q W E R T Y U I O P A S D F G H J K L Z X C V B N M . 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.
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.
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.
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.
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
Trouble Shooting GPS Problems Is the GPS icon Red No fault detected by the system.
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.
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.
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 th
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.
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.
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.
Contact Details 87 CAS GPS Installation Manual Rev G1 2/17/2016
CAS GPS Installation Manual Rev G1 2/17/2016
