CAS-GPS IVU BASIC SYSTEMS INSTALLATION MANUAL DOCU0085 rev Q Digital Mining Technology 3-Co-Wyn Close, Fountaindale NSW, 2258 Australia www.wabteccorp.com The information contained in this document may contain confidential, proprietary and/or privileged material of either Wabtec Corporation or one of its subsidiaries.
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) DMc 19/11/2015 H Doc No.
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 lading. If there are shortages or evidence of physical damage, notify Digital Mining Technology immediately. Notify Digital Mining Technology within 7 days 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: • Vehicle manufacturers instructions. • National/local & site regulations relevant to the location of install. • The installation procedures defined by Digital Mining Technology and only performed by authorised and qualified installers. This radio transmitter IC: 8903A-PROD08422 & IC: 8903A-PROD08472 has been approved by Industry Canada to operate with the antenna types listed below with the maximum permissible gain indicated.
Warning Consult with the client to confirm all equipment mounting locations and power connections! Do not weld on ROPs! Do not drill through ROPs! Note: It is solely the responsibility of the Installer to ensure the installation is compliant with the vehicle manufacturer’s instructions, national/local statutory and site regulations.
Specialty Tools / Adhesives Required ▪ 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 ▪ Heat gun ▪ Torx Security Bit – T25 ▪ Metric Allen Key – 4mm ▪ Nutsert Tool – TOOL0253 ▪ Deutsch pin removal Tool – TOOL0256 CAS-GPS IVU BASIC SYSTEMS INSTALLATION MANUAL DOCU0085 Revision Q 8
Specialty Tools / Adhesives Required ▪ 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 Metre tape measure ▪ Coaxial connector tightening tool, TOOL0264 CAS-GPS IVU BASIC SYSTEMS INSTALLATION MANUAL DOCU0085 Revision Q 9
In-Vehicle Unit (IVU) PROD0842 PROD0847 Note: All IVUs have their “PRODXXXX” part number labelled on the flat underside of the housing.
Input Power & Signal Connections Serial number Hardware build letter code • Service Panel SIM Card USB Card Auxiliary USB External Cables LAN Display RF Antenna GPS Antenna GSM Antenna, (PROD0847 only) V2V Antenna WiFi/WAN Antenna CAS-GPS IVU BASIC SYSTEMS INSTALLATION MANUAL DOCU0085 Revision Q 11
Input Power & Signal Connections IVU Status LEDs 24-Way Deutsch (Vehicle Electrical Connections) Display CAS-GPS IVU BASIC SYSTEMS INSTALLATION MANUAL Power & Signal connector (Shown with cover in place) DOCU0085 Revision Q 12
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 • It is easily accessible for servicing • It is protected against rock fall and other damaging hazards • It does not obstruct walkways, access or egress • It is never left loose in the vehicle • If mounting through a blind panel the supplied nutserts should be used to
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. • Cabling must be kept away from air bags, fire extinguishers & suppression systems in accordance with local regulations.
Light Vehicle Note: IVU preferably mounted inside the Operator’s cabin Notes: • Antennas must be kept a minimum of 37 cm away from occupants in accordance with MPE Radiation Regulations. • Consideration must be given to EMI with the vehicle’s ECU when cable runs are being planned in accordance with local regulations and vehicle manufacturers recommendations.
Light Vehicle V2V Bracket used here is ATOM0033 GPS GPRS Note: Antenna Spacing between V2V and GPRS should be a minimum of 300mm.
Haul Truck Notes: • Antennas must be kept a minimum 37 cm away from occupants in accordance with MPE Radiation Regulations. • Consideration must be given to EMI with the vehicle’s ECU when cable runs are being planned in accordance with local regulations.
Haul Truck Antenna to protrude above the tray by 100mm. Ensure the antennas will clear any working obstacles. Standard fitment on opposite side of the vehicle from the operator’s cabin. Specific antennas deployed will depend on IVU type. TRAY OPERATOR’S CABIN Adjust the mast length to suit the installation.
Haul Truck CAS-GPS IVU BASIC SYSTEMS INSTALLATION MANUAL DOCU0085 Revision Q 20
Haul Truck WiFI or GPRS/GSM ANTENNA V2V ANTENNA GPS ANTENNA NOTE: 1. WHERE No WiFi OR GPRS ANTENNA IS DEPLOYED, MOUNT GPS ANTENNA AT POSITION 1 2. SECURE NUTS WITH LOCTITE 243 STEE0690 WASHER LOCK WASHER NUT POSITION 1 POSITION 2 Note: An extended depth socket spanner may be required to tighten the antenna fixing nuts within the bracket channel.
Haul Truck Note: TOOL0264 is required to tighten the antenna coax within the bracket channel.
Haul Truck Stauff clamp sizes used must be correctly chosen for the handrail tube size from the Size 6 heavy series Stauff clamping system Available rubber inserts are: 32mm, 33.7mm, 35mm, 38.7mm, 40mm, 42mm, 45.5mm, 48mm, 51mm, 53.4mm, 56.4mm. Available clamp bodies are: 38mm, 42mm, 44.5mm, 48.3mm, 50.8mm, 55mm, 57mm, 60.3mm, 60.5mm, 65mm, 70mm.
Heavy vehicle (excluding Haul Truck) Note: IVU preferably mounted inside the Operator’s cabin Notes: • Antennas must be kept a minimum of 37 cm away from occupants in accordance with MPE Radiation Regulations. • Consideration must be given to EMI with the vehicle’s ECU when cable runs are being planned in accordance with local regulations and vehicle manufacturers recommendations.
Heavy vehicle (excluding Haul Truck) Note: An extended depth socket spanner may be required to tighten the antenna fixing nuts within the bracket channel.
Display Unit (PROD0839A) Serial number Hardware build letter code CAS-GPS IVU BASIC SYSTEMS INSTALLATION MANUAL DOCU0085 Revision Q 26
Display Unit (PROD0839A) The client should be consulted to ensure Display Unit is mounted in a mutually agreed position. The Display Unit should be mounted such that: • It is compliant with vehicle manufacturer’s instructions, national/local and site regulations. • It does not to create any additional blind spots. • The machine operator can easily reach the screen. • Located within the field of view of the operator. • It is not a hazard when operator is entering / exiting the machine cabin.
Display Unit (PROD0839A) 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 CAS-GPS IVU BASIC SYSTEMS INSTALLATION MANUAL DOCU0085 Revision Q 28
Display Unit (PROD0839A) 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 CAS-GPS IVU BASIC SYSTEMS INSTALLATION MANUAL DOCU0085 Revision Q 29
Display Unit (PROD0839A) Connector: Electrical connection for power and signals RAM Mount: Multi – axis adjustable mounting bracket CAS-GPS IVU BASIC SYSTEMS INSTALLATION MANUAL DOCU0085 Revision Q 30
CAS-CAM/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 CAS-GPS IVU BASIC SYSTEMS INSTALLATION MANUAL DOCU0085 Revision Q 33
Interconnections – 4CAM/4RF Expansion Unit “DISPLAY” output 12 way military connector Reference Pin Colour 12 way Deutsch connector on PROD0180 cable Pin 24 way Deutsch connector at IVU Reference Pin VOUT + A RED 1 PWR+ (Battery) 6 GND B BLACK 2 GND 5 CAMEX+ C GREEN 3 Video+ CAMEX- D YELLOW 4 RS485+ E WHITE 5 Wire Colour Signal/Wire Marking Deutsch Connector CONN0340 Deutsch Connector CONN0341 CABL0114 Wire colour 19- Way MILSPEC Connector RED VIN+ 1 1 Brown 18AWG
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) IGNITION SIGNAL 12 WAY DEUTSCH CONNECTOR INTERFACE PROD0181 DISPLAY UNIT INPUT CABLE 6 WAY DEUTSCH CONNECTOR INTERFACE PROD0182 DISPLAY TO IVU/CAMERA RF CABLE VEHICLE SIGNALS AND POWER FROM VEHICLE BATTERY PROD0183 CAMERA TO RF UNIT CABLE PROD0118 CAMERA UNIT CAS-GPS IVU BASIC SYSTEMS INSTALLATION MANUAL DOCU0
Interconnections – 1CAM/1RF 12 way Deutsch connector (PROD0181) 24 Way Deutsch Connector CASGPS IVU RED 1 PWR+ (Battery) 6 BLACK 2 GND 5 GREY 7 REV+ (DI3+) 16 VIOLET 8 REV- (DI3-) 17 WHITE/BLACK 11 FWD+ (DI4+) 22 PINK/BLACK 12 FWD- 23 ORANGE 9 BRAKE (DI2) 10 Ignition (DI1) 4 Camera / RF Cable (PROD0182) (DI4-) 6 way Deutsch connector (PROD0182) 24 Way Deutsch Connector CASGPS IVU +12V A RED 1 +12V 12 GND B BLACK 2 GND 11 VID+ C GREEN 3 Video+ 21 VID-
Interconnections – Light Vehicle CASGPS IN-VEHICLE UNIT (IVU) PROD0850-xM CASGPS IVU TO DISPLAY CABLE VEHICLE POWER VIA FUSE CASGPS DISPLAY LIGHT VEHICLE RF UNIT (PROD0295) REVERSE SIGNALS AND IGNITION SIGNAL 6 WAY DEUTSCH CONNECTOR INTERFACE PROD0296 LV RF INPUT CABLE CAS-GPS IVU BASIC SYSTEMS INSTALLATION MANUAL DOCU0085 Revision Q 37
Interconnections – Light Vehicle LV Power, 6 way Deutsch connector (PROD0296) 24 Way Deutsch connector CASGPS IVU 6 way Military connector RF Unit (PROD0296) 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 Brake (DI2) 10 CAS-GPS IVU BASIC SYSTEMS INSTALLATION MANUAL DOCU0085 Revision Q 38
Input Power & Signal Connections – Basic CAS-GPS CAS-GPS IVU BASIC SYSTEMS INSTALLATION MANUAL DOCU0085 Revision Q 39
Input Power & Signal Connections – Gear Decoder CAS-GPS IVU BASIC SYSTEMS INSTALLATION MANUAL DOCU0085 Revision Q 40
Deutsch Connector VOUT DI4 CONNECTIONS TO THE IVU ARE MADE USING DEUTSCH DRC26-24SA DO1/2 COM2 VIDEO DI3 If CAS CAM RF or CAT GEAR decoder fitted Pin Designation IVU Function Heavy Vehicle CAS-GPS Signal 1 COM1 RS232 txd or RS485+ TXD SmartCap or CASCAMRF LV 2 CAN CAN High CAN High Self Test Node or LFM 3 USB5V USB supply out USB +5V - Subsystem/ Device 4 Yellow DI1 Input 1+ Ignition +ve Ignition +ve Vehicle switched +ve supply 5 Black GND Ground Ground Ground Vehicl
Input Power & Signal Connections Input Power (Vin) • Vin+ should be sourced after the isolator. • WARNING: - • The IVU remains powered for up to 14 hours after the input power has been Isolated. Input power / ignition pickup point must have inline short circuit protection, use supplied circuit breakers from installation kit. - 4A Resettable Circuit Breaker to be used on all vehicles for Ignition. - 4A Resettable Circuit Breaker to be used on all vehicles for VIN+.
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 4 Amp 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 • 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.
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 heatshrink and 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 Heatshrink 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. Move the heatshrink up over the ferrule, and shrink into place using a heat gun This will aid in preventing moisture ingress to the termination. Heatshrink here 8. Repeat steps 1-7 for the other end of the cable.
Testing Antenna cable terminations Test completed cable for continuity and short circuits by completing the following: 1. With both ends of the cable disconnected. Measure the resistance between the inner and outer conductors.
Testing Antenna cable terminations 2. Short the inner to the outer conductor on one end of the cable. 3. Measure the resistance from the inner to the outer conductors on the opposite end. Must be low resistance (<1Ω). 0.2 Shorting link 4. If available, measure the SWR of the completed cable with a 50Ω dummy load installed in place of the antenna. SWR of cable should remain around 1 in the frequency range of 800MHz to 2.6GHz if terminations are good quality. 5. An SWR of 1.04 or higher should be corrected.
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 self-amalgamating tape over the cable/antenna connection. This will prevent loosening and provide environmental protection • Caution! Thread locking compounds are an electrically insulative material.
Configuration The following pages instruct on the configuration process for CAS-GPS. They are straight forward with no laptop being required. Configuration is programmed through the Graphic User Interface. (Display) Note: The Installer will need to obtain the site specific passcode from the Site Supervisor to complete the following process.
Configuration – Installation Measurements GPS antenna Width (from LHS) The measurements indicated here 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) CAS-GPS IVU BASIC SYSTEMS INSTALLATION MANUAL DOCU0085 Revision Q 57
IVU Orientation (examples) Orientation Number 1 Orientation Number 7 IVU mounted on the internal floor surface IVU mounted inside cabin behind the rear seat CAS-GPS IVU BASIC SYSTEMS INSTALLATION MANUAL DOCU0085 Revision Q 58
Configuration Use the button at bottom of Display to access CAS-GPS CAS Installer window.
This ICON will change once the Object Type has been chosen Configuration Setup Record the IVU orientation here. Click on the Orientation drop down box and select from the list of numbers which refer to the table listed previously in this manual. Enter the Asset Name (usually the vehicle’s ID) using the Keyboard below The Asset type provides a record of the make and model of the vehicle.
Network Configuration Network Addresses are by default Dynamic until manually assigned in the Network Settings Page at which point they will be stored as static addresses. Static Addressing must be assigned by your network administrator to avoid conflicts. 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 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 node can be installed to provide another position from which a heading can be determined. To provide the minimum error the antenna connected to the IVU and the node should be installed as far apart as possible on the machine. The IVU’s GPS antenna ( A A on diagram) should be located near the operator’s cab.
Shovel IVU Configuration – Setup Tab Configuration should only be completed once the IVU and node are installed and have power.
Shovel IVU Configuration – Self-Test Tab On the “SelfTest” tab, settings in this tab relate to the node that will provide the second GPS signal: • CAN Bus B-Width • Node Enable: This box must be checked • Comms Type: This should be set to “CAN Bus”. To change this box you must enter the passcode. • Location: This is the location of the node GPS antenna (B) B relative to the front left corner of the body. • Sync: Press this button to synchronise the stored RX and TX values.
Node Installation Refer to DOCU0088 CAS-GPS SELF-TEST SUB-SYSTEM INSTALLATION MANUAL CAS-GPS IVU BASIC SYSTEMS INSTALLATION MANUAL DOCU0085 Revision Q 65
Shovel Heading Testing The second status icon indicates the communication status to the node: • 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 GPS information.
Shovel Heading Testing The GPS icon operating. should always be green when a Shovel with Heading is correctly installed and If the GPS icon change to yellow, this indicates that the IVU no longer has a valid heading. Potential causes: • Loss of communication between IVU and node (will be indicated by the status icon • Loss of GPS signal to IVU or node (indicated by poor HDOP reading >4). • Poor GPS signal to IVU or node (indicated by poor HDOP reading >4).
Configuration & Install Record On completion of the physical installation: • Complete the Installation Checklist to ensure & record that the system is installed correctly and is operating as expected.
Record Keeping • Take photographs of the completed installation (for future reference and record of installation). • Provide all completed installation records to the Site Supervisor.
Trouble Shooting - No power / Blank screen Is the vehicle’s battery connected & fully charged? No Connect / charge and retest Use this diagram to troubleshoot an apparent loss or blank screen: Yes Are all connectors plugged into the IVU & display? No Connect and retest Yes Is the LED on the IVU on? No Has the fuse blown? Yes Is the power LED green on the IVU? Yes Yes Is the cable between the IVU and display in good condition (no cuts and breaks)? No Is the power LED blue on the IVU? No Y
Trouble Shooting – GPS problems Is the GPS icon Red? No No fault detected by the system. If it is not functioning correctly, contact an authorized representative Yes Does the antenna have an unobstructed view of the sky? No Position vehicle to have a clear view of he sky and retest The GPS signal status is indicated by the colour of the ICON at the top of the display.
Trouble Shooting – V2V problems Is V2V icon Red No fault detected by the system. If it is not functioning correctly, contact an authorized representative No 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 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 that no cables a
Decommission ▪ Removal of the system should only be 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.
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. WABTEC CORPORATION 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.
