SAFEmine (part of Hexagon Mining) Baarerstrasse 133, CH-6300 Zug Switzerland www.hexagon.com SAFEMINE CAS INSTALLATION GUIDE Firmware V3.0 Version Control Date Version Author Description 21.10.2014 0.1 RGR Outline 13.02.2015 0.2 RGR Corrections after review 24.02.2018 0.
SAFEmine (part of Hexagon Mining) Baarerstrasse 133, CH-6300 Zug Switzerland www.hexagon.com Topic: This document is the reference manual for the installation, configuration and operation of SAFEmine units and tools. Document Nr: DRA_CAS_QC2_150224 Date: May 30, 2018 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.
SAFEmine (part of Hexagon Mining) Baarerstrasse 133, CH-6300 Zug Switzerland www.hexagon.com Table of Contents 1. Preface 5 1.1. Objective of this document ..........................................................................5 1.2. Operation Safety Precautions ......................................................................5 1.3. Installation Safety Precautions ....................................................................6 1.4. Legend of Symbols ................................
SAFEmine (part of Hexagon Mining) Baarerstrasse 133, CH-6300 Zug Switzerland www.hexagon.com SAFEmine Ltd | www.safe-mine.com | support@safe-mine.
SAFEmine (part of Hexagon Mining) Baarerstrasse 133, CH-6300 Zug Switzerland www.hexagon.com 1. Preface 1.1. Objective of this document This document is the main reference manual for the installation and configuration of SAFEmine CAS MainUnits and its associated accessories. It shall serve the technical personnel to correctly set up installations and enable them to maximize the SAFEmine CAS performance. 1.2.
SAFEmine (part of Hexagon Mining) Baarerstrasse 133, CH-6300 Zug Switzerland www.hexagon.com 1.3. Installation Safety 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. 1.4. Legend of Symbols Attention Symbol: Indicates a required actions and conditions. Information Symbol: Indicates best practices and recommendations.
SAFEmine (part of Hexagon Mining) Baarerstrasse 133, CH-6300 Zug Switzerland www.hexagon.com 2. Introduction 2.1. Purpose of the CAS system The main task for SAFEmine QC2xx 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. 2.2.
SAFEmine (part of Hexagon Mining) Baarerstrasse 133, CH-6300 Zug Switzerland www.hexagon.com Pressing the button for 3 seconds or longer seconds will restart the SAFEmine unit. All alarms are indicated during a minimum of 1.5 seconds to allow the operator to see and react to it. The alarm will stop once the threat is gone or if one of the two vehicles stops.
SAFEmine (part of Hexagon Mining) Baarerstrasse 133, CH-6300 Zug Switzerland www.hexagon.com 3. Hardware Components 3.1. Main Unit 3.1.1. Overview The main unit houses the GPS receiver, RF 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. The main unit is produced in six different models: QC230, QC235, QC220, QC24x, QC250 and QN555.
SAFEmine (part of Hexagon Mining) Baarerstrasse 133, CH-6300 Zug Switzerland www.hexagon.com 3.1.3. QC220 & QC24x The QC24x and QC220 models provide networking capability through GSM/LTE connectivity and are meant to be operated with and external display. This is in addition to the functionality offered by the QC230 and QC230. This enables the support of online vehicle tracking.
SAFEmine (part of Hexagon Mining) Baarerstrasse 133, CH-6300 Zug Switzerland www.hexagon.com 3.2. Displays 3.2.1. Overview An external display is required for all Main Units to work correctly. The only exceptions are the QC235 and the QC220 units. The QC235 have an inbuilt display and thus do not necessarily require an additional external display. The QC220 main application is vehicle tracking which does not require anti-collision and can work without the indication of nearby SAFEmine CAS systems.
SAFEmine (part of Hexagon Mining) Baarerstrasse 133, CH-6300 Zug Switzerland www.hexagon.com 3.3. Antennas 3.3.1. Overview The antennas provided by SAFEmine are customized and combined GPS and RF antennas especially designed for the harsh environments of mines.
SAFEmine (part of Hexagon Mining) Baarerstrasse 133, CH-6300 Zug Switzerland www.hexagon.com 3.3.3. Through Hole Antennas SAFEmine recommends the installation of through whole antennas (QF012 GPS/RF, QF020 GPS/GSM and QF036 GPS/RF/WiFi) for all permanent installation for its superior stability even in heavy vibration. This type of antenna is equipped with a threaded tube at the bottom to secure its position. The antenna is equipped with 15cm pigtail of coaxial cable with 50Ω wave impedance.
SAFEmine (part of Hexagon Mining) Baarerstrasse 133, CH-6300 Zug Switzerland www.hexagon.com 3.4. Accessories 3.4.1. Overview Several accessories are available to extend the SAFEmine CAS system functionality. All accessories, with exception of the QR310 TrackingRadars, can be easily installed on existing basic SAFEmine CAS Systems and extended further when needed. As regarding the TrackingRadars, specific training of your technical staff is required. All accessories require FW upgrades for activation.
SAFEmine (part of Hexagon Mining) Baarerstrasse 133, CH-6300 Zug Switzerland www.hexagon.com 3.4.3. QL460 DriverID Reader The QL460 DriverID Reader enables the CAS system to verify the authorization of the operator through contactless RF-ID cards. The installation of QL460 DriverID Reader requires a QS430 SerialExtender. For in-depth information on SAFEmine DriverID configuration and the installation of QL460 keycard reader please consult with your support responsible or contact support@safe-mine.com.
SAFEmine (part of Hexagon Mining) Baarerstrasse 133, CH-6300 Zug Switzerland www.hexagon.com 3.5. Connectors 3.5.1. Overview The available interfaces on the CAS main unit depend on the models in question. In the following section each of this connectors is specified in detail in order to provide all necessary information for correct connection.
SAFEmine (part of Hexagon Mining) Baarerstrasse 133, CH-6300 Zug Switzerland www.hexagon.com 3.5.3. RF Connector SAFEmine includes RF transceiver chips with typically less than 1% duty cycle and effective radiated power (ERP) is below 15mW. The CAS main units make use of the freely available industrial, scientific and medical (ISM) radio frequency bands for short range devices (SRD) and is thus license free.
SAFEmine (part of Hexagon Mining) Baarerstrasse 133, CH-6300 Zug Switzerland www.hexagon.com 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) and TKIP security encryption. The typical transmit power is 17dBm for 801.11b, 15dBm for 802.11g/n. The sensitivity is -97dBm @ 1Mbps to -71dBm @65 MBps.
SAFEmine (part of Hexagon Mining) Baarerstrasse 133, CH-6300 Zug Switzerland www.hexagon.com power’ is announced every 30 seconds on the speaker as long as the supply voltage is sufficient to do so. 3.5.7. Display / Serial Connector (only QC230 & QC235) The QC230/35 MainUnit has a female 4-pin M8 display connector and is placed next to the main connector interface.
SAFEmine (part of Hexagon Mining) Baarerstrasse 133, CH-6300 Zug Switzerland www.hexagon.com wired to pin 7 of the main interface and can be used in the same fashion as the GPIOs on the I/O connector. Pin Color Symbol Function Min.
SAFEmine (part of Hexagon Mining) Baarerstrasse 133, CH-6300 Zug Switzerland www.hexagon.com 3.6. Cables 3.6.1. QD221 and QD222 Display Extension Cables The QD221 and QD222 display extension cables provide 1.5m and 5m of cable in order to place the QD200 RemoteDisplay or QD204 ScopeScreen visible to the operator and remotely from the main CAS unit. The cable features a male and a female 4-pin plug with a pinout corresponding to the serial interface described in this chapter. 3.6.2.
SAFEmine (part of Hexagon Mining) Baarerstrasse 133, CH-6300 Zug Switzerland www.hexagon.com 3.6.5. QM105 Power Saving Display Cable The QM105 Power Saving display cable is used to power the QD204 ScopeScreen from ignition, in order to safe power when the ignition is turned off. The CAS MainUnit will remain powered on thanks to its direct connection and continues to provide its service regardless of the ignition status.
SAFEmine (part of Hexagon Mining) Baarerstrasse 133, CH-6300 Zug Switzerland www.hexagon.com Hardware Installation Instructions 4. 4.1. General Rules and Best Practices Please check on the following conditions before beginning any work. Differing installations will void the warranty of SAFEmine systems: Installations may only be carried out by trained electricians. Only antennas supplied by SAFEmine may be used.
SAFEmine (part of Hexagon Mining) Baarerstrasse 133, CH-6300 Zug Switzerland www.hexagon.com 4.2. Main Unit 4.2.1. Prior considerations The selected installation spot must be dry and reasonably free from dust. Install the Main Unit so that it does not interfere with any of the vehicles operations. The CAS MainUnit must not be placed where it could obstruct the operator’s field of view.
SAFEmine (part of Hexagon Mining) Baarerstrasse 133, CH-6300 Zug Switzerland www.hexagon.com 4.3. Displays 4.3.1. 4.3.2. Prior Considerations The display should be positioned such that the front panel LEDs are in direct view of the Operator, the acoustic warning tone can be heard loud and clearly and control button can be operated easily. The view on the front panel display may not be obstructed at any time. The display may never interfere with the operation of the vehicle (incl.
SAFEmine (part of Hexagon Mining) Baarerstrasse 133, CH-6300 Zug Switzerland www.hexagon.com 4.3.3. 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. This is ideal for installations where the owner of the vehicle does not permit to drill holes in the dashboard.
SAFEmine (part of Hexagon Mining) Baarerstrasse 133, CH-6300 Zug Switzerland www.hexagon.com 4.4.2. Antennas on Haul Trucks It is not always possible to position the antenna 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 antenna on the top rather impractical. In this case SAFEmine recommends using a pole on which the antenna can be mounted. The best position for the antenna is one of the front corners.
SAFEmine (part of Hexagon Mining) Baarerstrasse 133, CH-6300 Zug Switzerland www.hexagon.com Be vigilant of the maximum cable length. Re-rout if necessary. Consult the below list for more information. If you plan to cut your coaxial cables to length and crimp the connectors yourself please attain to the following: The maximum acceptable attenuation for cables and connectors is 3dB/10m @ 900MHz Better: The required overall attenuation for a cable and its connectors must be below 5dB.
SAFEmine (part of Hexagon Mining) Baarerstrasse 133, CH-6300 Zug Switzerland www.hexagon.com Wear and damage to the RF and GPS antenna cables is not covered under warranty. SAFEmine Ltd | www.safe-mine.com | support@safe-mine.
SAFEmine (part of Hexagon Mining) Baarerstrasse 133, CH-6300 Zug Switzerland www.hexagon.com 4.4.5. SMA Coaxial Cable Connectors Waterproofing connection: The coaxial cables contain a white plastic separator between the screen shield and the center core conductor. This plastic is a dielectric material which has the property to absorb water. SMA connectors are not sealed and thus tend to permit water entry from rain and condensation.
SAFEmine (part of Hexagon Mining) Baarerstrasse 133, CH-6300 Zug Switzerland www.hexagon.com First, protect the RF cable in a braided sleeve for the whole length of the coaxial cable, from the antenna to the CAS unit. Use zip-ties at the beginning and the end of the cable to tie the braided sleeve to the coaxial cable Do not cut the left-over of the zip tie to ensure the coaxial cable does not move freely inside conduit.
SAFEmine (part of Hexagon Mining) Baarerstrasse 133, CH-6300 Zug Switzerland www.hexagon.com In order to secure the antenna mounting with the provided insulating washer and nut it is necessary to have access to the backside of the mounting surface. Metallic Surface: It is compulsory to use a metallic surface as a mounting platform. The metallic surface provides an effective shield against ground reflections of the GPS signal and helps to improve RF connectivity.
SAFEmine (part of Hexagon Mining) Baarerstrasse 133, CH-6300 Zug Switzerland www.hexagon.com In the picture above, the cables in the cable conduit of the through-hole antenna should have a free cable portion of 15 to maximum 30 cm until the first attachment to the pole or frame. Keep a gentle curve of the cabling but don’t permit the free portion of the cable to be too long. Otherwise the cabling is in danger of braking through bending fatigue. 4.4.8.
SAFEmine (part of Hexagon Mining) Baarerstrasse 133, CH-6300 Zug Switzerland www.hexagon.com 4.4.9. Adhesive Mount Antennas (QF028, QF034) The adhesive mount antennas are designed to be attached to a non-conducting surface, preferably the front windshield. The QF024 antenna is a GSMonly antenna meant to be installed in the cabin with QC24X MainUnits in addition to a GPS+RF roof antenna (either QF012 or QF024).
SAFEmine (part of Hexagon Mining) Baarerstrasse 133, CH-6300 Zug Switzerland www.hexagon.com 4.5. GPIO Connections The CAS system offers to interact with its environment through eight general purpose input/output ports. The outputs may drive (source or sink) 400mA each and at the same time. The inputs are designed to work on switches, providing either pull-up or pull-down configurations. Due to the multi-purpose nature of the CAS GPIO input/outputs it is not possible to galvanically isolate them.
SAFEmine (part of Hexagon Mining) Baarerstrasse 133, CH-6300 Zug Switzerland www.hexagon.com Appendix A FCC COMPLIANCE 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.
SAFEmine (part of Hexagon Mining) Baarerstrasse 133, CH-6300 Zug Switzerland www.hexagon.com Appendix C IC COMPLIANCE Industry Canada Notice and Marking 7.1.2 if detachable antenna This radio transmitter RS9110N1122 and NRF905 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.
SAFEmine (part of Hexagon Mining) Baarerstrasse 133, CH-6300 Zug Switzerland www.hexagon.com Appendix D LEGAL STATEMENT 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 (part of Hexagon Mining) Baarerstrasse 133, CH-6300 Zug Switzerland www.hexagon.com INDEMNIFICATION Customers agree to indemnify and hold harmless SAFEmine Ltd.
