MINING HxGN MineProtect CAS 10 Installation Manual Technical Reference Manual Version No.1.
HxGN MineProtect CAS 10 Installation Manual v1.5 This document and any information or descriptive matter contained therein is communicated in confidence and is the copyright property of Hexagon AB. Neither the whole, nor any extract may be disclosed, loaned, copied, or used in manufacturing or tendering purposes without their written consent. © 2022 Hexagon AB and/or its subsidiaries and affiliates. All rights reserved. All trademarks or service marks used herein are property of their respective owners.
Revision History Date Document Version Software Version Author 31.5.2021 1.0 10.0 HBAR initial 6.7.2021 1.1 10.0 HBAR Added Display mount/dashboard mount Added Visitor Kit assembly Other added information 22.7.2021 1.2 10.0 HBAR Added par. 10.1 Error Codes Added GPIO Reverse Switch Added Mast information 7.12.2021 1.3 10.0/10.2 HBAR Added par. 8.1.2 Radio Interference Power Modes added par 5.17 Insert hint of antenna position in par 5.
Table Of Contents 1 Document Introduction ..................................................................................................6 1.1 Document Conventions ................................................................................................ 6 2 Operation Safety Procedures ........................................................................................7 2.1 Contacting Support ......................................................................................................
6.3.1 Setting of blind-rivets to dashboard ................................................................. 32 6.3.2 Alternative QD1400 Mounting Option: U-Bracket............................................ 33 6.4 QD200 Remote Display ............................................................................................. 35 6.5 Installation of QD200 Remote Display ....................................................................... 36 7 CAS 10 Visitor Unit .........................................
Document Introduction 1 The HxGN MineProtect CAS 10 Installation Manual is part of the Hexagon Mining reference manual suite. The HxGN MineProtect CAS 10 Installation Manual is to be used as a technical reference manual for the hardware installation. Configuration and how to set up the system and features are described in the technical reference manual HxGN MineProtect Configuration Manual.
2 Operation Safety Procedures A vehicle equipped with the HxGN MineProtect CAS 10 System must be operated in the same safe manner as if the HxGN MineProtect CAS 10 System was not installed. The system is not a substitute for normal safe driving procedures and may never be relied upon. The HxGN MineProtect CAS 10 System will provide no warning for some hazards, such as vehicles, obstacles, and other objects not equipped with properly operating HxGN MineProtect CAS 10.
3 Product Introduction 3.1 Overview The main task for HxGN MineProtect series products is to support the operator while he scans the space ahead and around the vehicle with his own eyes, and other (technical) aids. HxGN MineProtect CAS 10 products are simple to use and are designed not to distract the operator from operating the vehicle. The main components are QC1000 Smart Antenna and as display options QD1400 Display 5 (default) or the QD200 LED Display. 3.
or safety information in the form of symbols, icons and text. It provides both location and type of vehicle of nearby opponent vehicles. It features a touch display for operator input if required. QD200 LED Display provides a directional information of nearby traffic and danger as well as for acoustical warnings (beeping over buzzer) and one button for input. The Smart Antenna receives position and movement information from an internal high-sensitivity dual-band, multi-constellation GNSS module.
4 Hardware Overview 4.1 Main Components and Accessories Material SAP Material Short Description 902712 QC1000 HxGN MineDiscover Smart Antenna Smart Antenna including Mount Module QL1212 for bracket mount. 902717 QD1400 HxGN MineDiscover Display 5 5’’ LCD Display with Touch Functionality 929039 QL1212 Through-Hole Mount Module Smart Antenna Through-Hole mount module QC1000 Smart Antenna. Spare part only.
916132 QM1111 Junction Harness Smart Antenna Light Junction harness to branch out PWR-SER-ETH-3xGPIO from Cable Smart Antenna light; Typically used for LV and Visitor Unit 931480 QM1113 Cable, CAS 10 Ethernet Harness Harness between Junction Harness, Ethernet Switch and Display 5 939550 QM1114 Cable, Ethernet M88F to M12-4M, 0.
- flying leads (red/black 10m) - ring tongue terminals for battery connectors - Blind rivet nuts for QC1400 mount on dashboard. Special tools are required to mount blind rivet nuts and DEUTSCH connectors. Special tools are NOT part of installation kit. 950251 QL1230 CAS 10 Visitor Unit Suitcase Robust suitcase with organized inlay for all Visitor Unit items. Fits QN1910 and QN1911 with QD200. QL1230 is the empty suitcase.
5 QC1000 HxGN MineDiscover Smart Antenna 5.1 Electrical Specifications Parameter Range Note Input power nominal 9-36VDC Power consumption at 12V nominal 350 mA Interfaces 1x ETH, 2x CAN, 4x GPIO, 1x RS-232 GNSS Multi-band GNSS module with integrated multi-band RTK, allowing for 4 concurrent constellations RF 868/902-928 MHz 4 Hz refresh rate. See also par 5.4 RF 2.4-2.5 GHz See also par 5.5 NB: Early versions, QC1000 RA, do not support this feature UWB ToF integrated See par 5.
5.2 Mechanical Specifications Parameter Range Diameter Ø 169 mm (6.65 inch) Height 105 mm (4.1 inch) Weight 980 g Housing material Polycarbonate (white)/Aluminum Alloy (black) Including Hexagon branding Status LED Multi-color See par 5.11 5.3 Environmental Specifications Parameter Range Storage Temperature -40 to 85°C Operation Temperature -20 to 70°C IEC 60529 Ingress Protection IP69K/IP67 Flammability UL94 / IEC 60695-2-12 5.
5.5 2.4 GHz Radio Specifications This is used for vehicle-to-vehicle (non-safety) communications and used for specific applications to do ranging. Early versions, QC1000 RA, do not support this feature. Region Band (MHz) Max. output power all 2.4 – 2.5GHz 10 [dBm] 5.6 UWB ToF Radio Specifications There is an on-board UWB ToF Radio inside the Smart Antenna. Region Band [MHz] Center Bandwidth [MHz] Frequency [MHz] EU 3328 … 4659.2 3993.6 1331.2 South Africa 3328 … 4659.2 3993.6 1331.
Ethernet/Serial/PWR connected to Junction Harness QM1110/QM1111 To QC1000 Smart Antenna QM1113 CAS 10 Ethernet Harness Ethernet/Serial/PWR to QD1400 Display 5 QX1120 CAS 10 Ethernet Switch Ethernet Cable to external (not part of any set). See options for commercial cables in table below Please note: Hexagon recommends using industrial connectors (M12) instead of RJ45. Cable Detail Model Industrial M12 M12D4-MS-MS-PVC TYPE B-1.
5.9 LTE The LTE module acts as an alternative to the WiFi. The module supports the following bands: • • LTE FDD: B1/B2/B3/B4/B5/B7/B8/B12/B13/B18/B19/B20/B25/B26/B28 LTE TDD: B38/B39/B40/B41 With a maximal output power of 23±2 [dBm]. In case of using the 902-922 [MHz] band for ISM radio, the BAND-8 of the LTE module is disabled due to overlapping of frequencies. 5.
Pin Name Description 17 CAN2-L High level CAN bus input/output line → dedicated CAN for VIS 18 CAN1-H High level CAN bus input/output line → for the communication with Radars / PA … → the same signal as on Pin 12 19 CAN1-L Low level CAN bus input/output line → for the communication with Radars / PA … → the same signal as on Pin 2 5.11 Face plate/Label Description A label is placed at the lower side of the QC1000 indicating Model, Article Number, Manufacturer and compliance statements.
QC1000 running ERROR RED Based on ambient light Short blink every 2s QC1000 running IDENTIFICATION RED /ORANGE/ GREEN Based on ambient light Blink each color for a couple of times. Identification is a request from an external tool. The intent is to make a visible indication on a selected QC1000, so that it can be distinguished from other QC1000s on the same vehicle. After identification mode, LED bar indication reverts back to the correct indication based on status. 5.
Split spring lock washer M5 2 see par. 6.3 DEUTSCH connector, DTM06-12SD PWR Junction Harness to Battery 1 Connection of PWR, GPIO, CAN See par. 5.16 DEUTSCH Crimp contacts for DTM06-12S / TE1062-20-0122 12 DEUTCH Wedge Lock WM-12S 1 Flying lead, 1mm2 10m, red 1 Power, connection to battery Flying lead, 1mm2 10m, black 1 Power, connection to battery Cable Tie 400 x 4.8mm, Polyamide 6.6, 215.
5.16 Pin-out Deutsch Connector (QM1110/QM1111) Deutsch Connector Fitting of Deutsch connector with pins must be performed according to standard installation procedures provided by manufacturer and customer-specific configuration.
5.17 General Purpose Input Outputs (GPIOs) A versatile scheme of relaying environmental information from and to the QC1000 unit is available through the GPIOs. Item Min GPIO input voltage to GND (digital & analog) Typical 0 Max Unit +Batt V GPIO leakage current: GPIO high output voltage to GND +Batt -1.5 +Batt -0.5 +Batt V GPIO low output voltage to GND 0 0.5 1.5 V 0.4 A GPIO output current to GND -0.4 max ±1.5mA @ 24V max ±1mA @ 12V 5.17.
- Drain Protect: Battery supply voltage drops below critical threshold. This mode is designed to use minimal power to increase supply battery life for starting the vehicle. CAS System is not operational anymore. A low power mode kicks in when a vehicle is detected to be “parked” i.e. in stand-still for more than 10 minutes (determined by its GNSS location). Stand-still has a slightly lower power consumption than when vehicle is moving. However, this has marginal impact on battery life.
Battery state \ Move mode Supply Voltage = 24 V Normal Battery normal Driving Parked (typical values) (typical values) 5-6W Display in Sleep Mode Comment Normal behaviour 0.21-0.25A 4-4.5 W 0.17 - 0.19 A Power Save Mode Same as normal - Entering when battery voltage drops below 23.2 V plus 12 hours - leaving when battery Voltage rises again above 23.8V 3.5 - 4W Power saving. 0.15 - 0.17A Drain Protect 0.5 W NO SAFETY - Entering when battery voltage drops below 21.
QL1212 Through-Hole Mount Module QL1220 L-Bracket with U-bolts and screws/bolts © Hexagon AB Commercial in Confidence 25
Tube diameter min: 1.5’’ (37.4mm) Tube diameter max: 2’’(48.3mm) 5.19.2 Installation of QC1000 with magnetic mount QL1210 Mag Mount Smart Antenna QC1000 provides optionally the QL1210 Mag Mount Smart Antenna. Replace the through-hole mount module with QL1210 Mag Mount using the same screws. QL1210 is fitted with very strong magnets. This magnetic base attaches to any reasonably magnetic material.
5.20 Compliance 5.20.1 CE – Declaration of conformity Hereby, Hexagon Geosystems Services AG, declares that the radio equipment type QC1000 is in compliance with Directive 2014/53/EU and other applicable European Directives. To receive a copy of the latest Declaration of Conformity (DoC) for the product, either contact your local sales representative or contact us via http://hexagonmining.com/customer/portallogin. 5.20.2 FCC compliance statement This device complies with part 15 of the FCC Rules.
5.20.4 Compliance Statement Brazil - Agência Nacional de Telecomunicações Este equipamento não tem direito à proteção contra interferência prejudicial e não pode causar interferência em sistemas devidamente autorizados. Este produto não é apropriado para uso em ambientes domésticos, pois poderá causar interferências eletromagnéticas que obrigam o usuário a tomar medidas necessárias para minimizar estas interferências. This is a class A Product.
Displays 6 To convey information for collision avoidance and traffic awareness as well as other system and operational information to the user, a UI/UX interface must be installed. The CAS 10 solution provides two options to choose from: 6.
6.2 Installation of Displays Rules: • • • • 6.3 The display should be positioned such that the front panel is in direct view of the Operator, the acoustic warning tone can be heard loud and clearly and control button/touch display can be operated easily. The view on the front panel may not be obstructed at any time. The display may never interfere with the operation of the vehicle (incl. emergency procedures) Special attention is required to not reduce the operator’s field of view.
Assemble QL1421, QL1422 and QL1423 QL1422 Arm, QL1423 Base plate Find mounting location by having an operator sitting in normal driving position and taking into account the rules of par 6.4 and agree with customer. Drill holes for Blind Rivet nut and set blind rivets to dashboard using special tool Hexagon recommends fixed installation of Displays to the dashboard using screwed connection with supplied blind-rivet nuts (part of QN1999 Vehicle Installation Kit).
6.3.1 Setting of blind-rivets to dashboard Step Picture Drill holes d=7.
Blind rivet set (flat in dashboard) 6.3.2 Alternative QD1400 Mounting Option: U-Bracket If primary and recommended option as described above is not possible (e.g. because drilling into dashboards it not allowed), there is alternative option using a U-Bracket which can be attached to the dashboard by means of adhesive tapes. The U-Bracket provides a larger footprint than the RAM-base for this purpose. Step Items Mount QL1425 to back of QD1400 using provided screws and spring washer.
Alternative: mount Display on upper position. No additional material required. Careful! Small screws, do not overtorque and use small Torx Allen keys for screwing and unscrewing. Attachment to dashboard Hexagon does not make recommendations for the adhesive technology such as double-sided tape, velcro or other. Depending on surface and topology (flat, rounded) different methods may be more suitable. Attachment has to be tested for suitability of application.
6.4 QD200 Remote Display The QD200 Remote Display offers the following attributes: • • • • • Indication of surrounding vehicles through 12 dual color LEDs (red/green) in a circle Status Indication through 4 dual color LEDs (red/green): Power, GPS, Reverse and Mode Multifunction push-button Piezoelectric buzzer Ambient light sensor The maximum length of the display cable is 15m. This can be achieved be connecting several display extension cables together.
6.5 Installation of QD200 Remote Display • • • 36 The QD200 Remote Display has a male M8 type connector with 4 contacts. It connects to the QD221 and QD222 extension cables. The back side of the display’s aluminum housing includes two 8mm deep M4 blind threads, so that the housing can easily be secured. Forcing screws longer than 8 mm into the nuts may cause damage and voids warranty. The remote display is light enough to be fixed with 3M dual lock.
7 CAS 10 Visitor Unit CAS 10 Visitor Unit suits temporary CAS 10 installations on vehicles for visitors of a mine or short-term contractors to ensure all vehicles are protected by CAS. CAS 10 Visitor units contain QC1000 Smart Antenna with a magnetic mount and QD1400 Display 5 with RAM mounts and suction cups for quick installations. Part of the set is the QX1300 CAS 10 Battery pack as an independent power source.
Blinking at 2.5 Hz None Power Supply is not present Push button 7.3 Charger error Indicates battery charge level when pushed Front Panel Door to battery compartment. Open to remove battery. Connector to QM251 Charger or QL318 for cigarette lighter 7.4 Connector QD221/QD222C able to QD200 LED Display Connector QM1108 Cable and QC1000 Connector QM1130 Cable and QC1400 Battery Specifications QC1300 features a Li-Ion-Rechargeable Smart Battery Pack Li-Ion 14.40V / 6.90Ah / 99.40Wh.
For more details, please refer to Manufacturer Specifications. 7.5 QN1910 Visitor Kit Assembly For logistics reason, QN1910 Visitor kits may require local assembly.
2 1 QC1000 HxGN MineDiscover Smart Antenna 3 1 QL1210 Mag Mount Smart Antenna 4 1 QM1108 Cable Smart Antenna 6m straight Visitor 5 1 QD1400 HxGN MineDiscover Display 5 6 1 QM1130 Cable Display 5 2.
2. Take a Smart Antenna out of its box (item 2) and disassemble its QL1212 Through hole mount module (plastic part). We recommend keeping it as a spare part otherwise throw it away. 3. As next step unpack, QL1210 Magmount Module (item 3), take the enclosed screws (3x M5x16), the spring lock washers (3x for M5) and the washers (3x Ø5.3/10/1), put them into the foreseen holes as displayed. Note the order of the fasteners. Then mount the Magmount from underneath into the QC1000 Bottom Part with 1.2Nm torque.
14 2 13 5 10 7/8/9 12 10. Close the Suitcase.
8 System Installation 8.1 General Rules and Best Practices Please check on the following conditions before beginning any work. Differing installations will void the warranty of Hexagon MineProtect systems: ▪ ▪ Installations may only be carried out by trained electricians. Only antennas supplied by Hexagon may be used. Unless certified, installation and operation of HxGN MineProtect systems must be on the basis of non-interference with existing equipment.
within 1 km of an operating QC1000 must be checked against potential radio interference. Please submit the following properties to Hexagon Technical Support: frequency, band width, Tx Power, Duty Cycle, antenna gain. Any metallic objects above QC1000 installation plate shall have a distance of at least 1 meter. 8.1.3 Connection to Battery pending 8.2 Light Vehicles 8.2.
8.3 Visitor Unit 8.3.
8.4 Haul Trucks 8.4.1 System Diagram 8.4.2 QC1000 Location It is not always possible to position the QC1000 on the topmost location. On haul trucks the bucket might be covering the entire structure of the vehicle and thus making the installation of an QC1000 on the top rather impractical. In this case Hexagon recommends using a pole on which the QC1000 can be mounted. The best position for QC1000 is one of the front corners.
• • THE LEFT PICTURE SHOWS AN ANTENNA DIRECTLY UNDER THE CANOPY . THE ANTENNA ’S RECEPTION IS VERY BAD . IN THE RIGHT PICTURE THE ANTENNA IS POSITIONED LOWER BUT STILL HAS BAD RECEPTION DUE TO BEING UNDER THE CANOPY . QC1000 positions in the above drawings improve from left to right: • • THE THIRD PICTURE SHOWS AN ACCEPTABLE POSITION . THE ANTENNA IS NOT COVERED BY THE CANOPY AND IS AT LEAST 1M FROM ANY METAL STRUCTURE SUCH AS THE CANOPY , THE HANDRAIL OR THE CABIN PLATFORM .
Internal Documents Do not Distribute Commercial in Confidence © Hexagon AB
© Hexagon AB Commercial in Confidence 49
Internal Documents Do not Distribute Commercial in Confidence © Hexagon AB
8.5 Other Heavy Vehicles In this category fall heavy vehicles that do not require a mast installation as there is no obstruction by a canopy as in a haul truck. Typically, this applies to dozers, graders, wheel loaders etc. 8.5.1.1 System Diagram 8.5.2 Tracked Vehicles On tracked vehicles, the antenna must be mounted as close as possible to the axis of rotation. 8.6 Fixed Assets This is the set typically installed on fixed assets which are intended to make visible on the CAS 10 systems in vehicles.
8.7 Shovels and Excavators Some vehicles can turn or rotate and hence change their heading without any forward or backward movement, such as shovels and excavators. In such cases, it is recommended that a second QC1000 unit (called beacon) is added so that the direction of movement of the vehicle is always defined. 8.7.1 Rotating Vehicle with Single Antenna Vehicles with unknown heading (e.g. non-moving, tracked, rotating vehicles) are calculated as circular objects.
8.7.2 Rotating Vehicle with Dual Antenna (Shovel) 8.7.2.1 System Diagram The QC1000 should be installed in the corner of the vehicle, the second QC1000, referred to as a beacon antenna, should be installed in the opposite corner. It is necessary to have both antennas as far away as possible but at a minimum of 5 meters.
Limitation The center of rotation is assumed to be in the middle of the vehicle for the rotation prediction. If there is a significant difference between the true axis of rotation and the center a slight positional error will result. 8.8 Pre-Configuration After mechanical installation and correct cabling, QC1000 must be pre-configured to connect to the MPData Server. Once this pre-configuration is correctly done, QC1000 can be updated remotely via the server and network.
9 Boot-up Process After connection of components and power up, the boot up process starts automatically. 1. QC1000 LED turns green, goes into green blink every 10s Power up process of QC1000 can take up to 90 seconds until all network capabilities are up and running. 2. In parallel, the QD1400 boots up a. Splash Screen with progress bar advancing b. Operator ID login (for testing purposes: type in any number) c. Traffic Awareness Screen i.
10 Troubleshooting 10.1 Error Codes on Display 5 Example: Error – Connection lost – Code: 100 Error Code Title Description 80 Error Insufficient GNSS fix. No position of own vehicle can be determined in sufficient quality for Collision Avoidance and Traffic Awareness. No GNSS Signal Error should resolve when driving to area with open sky view. 100 Error No connection between QD1400 and QC1000 could be established.
Appendix E: Legal statement WARNING OF PERSONAL INJURY As with all traffic awareness, collision avoidance and personal alert devices, Hexagon Mining products may not detect all threats within the detection window. Hexagon Mining products are intended as an additional tool in determining potential traffic threats, supporting an alert and conscientious driver.
11 Glossary Term Definition AP Access Point CAS Collision Avoidance System FMS Fleet Management System GNSS Global Navigation Satellite System GPS Global Positioning System HP High Precision IP Internet Protocol LP Low Precision MAC Media Access Control RTK Real Time Kinematic SOPs Standard Operating Procedures 58 Internal Documents Do not Distribute Commercial in Confidence © Hexagon AB
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