BRiGADE ZS-1000-ECU ZoneSafe RFID Detection System User Manual

BRiGADE ZS-1000-ECU ZoneSafe RFID Detection System

This manual provides information on how to install and configure the ZoneSafe RFID Detection System for optimal performance. The system is not a protective device and should not be used to replace proper job site organization, safeguards, operator training, and relevant vision standards that address safety and the safety of people on job sites.

RFID System Components

The ZoneSafe RFID Detection System consists of a Control Unit and a number of Function Units. Tags are required for any system which uses Antenna Units. For a more comprehensive range of our products please contact our sales team.
NOTE: Tags can be masked by other objects (e.g. mobile phone) so always ensure when using the product (e.g carrying it in a pocket) it’s placed on its own. Active tags are an integral part of an Antenna Unit system and are typically required for a system to work. There are multiple options for tags, and all are purchased separatelv. Please refer to Tag Manual for a more comprehensive guide.

Control Unit

The Control Unit is the brain of the system and includes Wi-Fi connectivity for remote access and control. It comes with a tamper cover located at the bottom, which can be removed for installation purposes. The Control Unit should be wired  o the vehicle, making mandatory connections before any optional connections. The Control Unit should then be connected to the Antenna Unit using the specified cable and setting the Antenna Unit address switch to

What’s In The Box

Listed below are all components included in a ZoneSafe Control Unit.

Control Unit Specification

The Control Unit has the following specifications:

• Model: VSICEAWLEA-1A.8
• Document Number: ZS-1000-UM IG PN 6133

Control Unit Installation Considerations

The Control Unit should be installed in the vehicle cab, within the machine driver / operator’s view and within reach to ensure that they can press the mute button on the front of the Control Unit.
It can be installed using a number of different fixing methods (see 7. Fixings section for further information). Note – The cable assembly will need to be plugged into the bottom of the Control Unit. Once slotted in, remember to tighten up the screws on either side of the plug.
The tamper cover should arrive with you not fitted. However, If you need to remove it once fitted, please see the instruction diagram on the following page.

• The Control Unit should NOT be any closer than 200mm/8″ to the operator.
• The Control Unit and Antenna Unit MUST be spaced at least 750mm/30″ apart.
• The Control Unit should always be installed so the tag slot faces upwards. A forward or backward tilt of up to 45 degrees is allowable.

Removal of tamper cover located at the bottom of the Control Unit

Antenna Unit

The Antenna Unit detects RFID tags within its range and sends a signal to the Control Unit for processing. The Antenna Unit should be installed in a location that provides the desired detection zone and optimum tag position. It should be mounted securely using appropriate fixings and installed at an appropriate distance from other Antenna Units.

What’s In The Box

Antenna Unit Specification

The Antenna Unit has the following specifications:
Model: VSICEAWLEA-1A.8

ZoneSafe Antenna Unit Specifications

Electrical| Voltage
Current Consumption| 12V – 24V DC nom
(11-32V max) 2A max (power comes from the main control unit)
Mechanical| Dimensions (incl. glands) Material Weight Connectors Mounting| 245 x 105 x 90mm/ 9.6″ x 4.1″ x 3.5″
(9 5/8″ x 41/8″ x 31/2″) ABS / PC
1.4kg
Nylon Glands
AMPS Configuration
Communications| Wired| RS485
Environment| Ingress Protection Temperature| IP67
-40°C to +85°C/
-40°F to 185°F
Radio| Transmit Frequency Receive Frequency Range| 125kHz
Region Specific* Transmit: adjustable 3-10m/10′-33’approx. Receive: 50m typ

Antenna Unit Installation Considerations

The Antenna Unit and the Control Unit in the same manner (see System Wiring – Schematic section). Both of these Function Units have specific requirements on where they should be mounted. Please read all the information related to the Function Units you will be installing before making a decision on placement.
Ensure that the Antenna Unit’s location doesn’t interfere with any moving parts on the vehicle. For affixing to the vehicle, there are a number of options ( see Fixings). If you are unsure of your unit’s installation positions, it would be advisable to do a temporary fit prior to permanent fixing so as to allow for any adjustments.

• Ensure no metal is in front or to the sides of the Antenna Unit.
• Mount in a vertical position.
• Always fit the blanking plug to the final antenna in sequence to ensure IP67 rating is maintained.

Antenna Unit Mounting
Distance Between Antennas
Choose the size of the detection zone prior to fitting the Antenna Units. The distance between them should equal the detection zone minus 20%. Use the table below to help set up an optimum detection zone. This setup will help to create a uniform array of detection zones.
Optimum Tag Position
The optimum detection range of the tag can be achieved when the tag and Antenna Unit are level to each other. Changing the angle of the antenna can overcome high mounting issues, but may reduce the effective read range.
Antenna Unit Example Installation Positions
Depending on the size and shape of the vehicle, more than one antenna may need to be fitted to provide a well defined detection zone.
The below drawings illustrate Antenna Unit placement on various types of vehicles. The larger the vehicle, the more units will need to be fitted in order to create an adequate detection zone around the vehicle. Antenna Units can also be fitted to moving parts (such as the boom or dipper arm of a vehicle) to create a moving detection zone.

• One Antenna Unit System fitted to forklift truck

• Two Antenna Unit System fitted to bulldozer

• Four Antenna Unit Systems fitted to shovel loader

• Five Antenna Unit Systems fitted to excavator with Antenna fitted to digger arm

System Wiring – Schematic

The system wiring schematic provides information on how to wire the Control Unit and Antenna Unit together for optimal performance.
NOTE: For 12V systems with long cable runs, a separate supply may be required for the Control Unit and each Function Unit.
Detection accuracy will depend on environmental and installation factors.
IMPORTANT: Ensure power is isolated & vehicle ignition is OFF before making connections. Replace unused gland on the last Function Unit with a blanking plug. Max distance between each antenna is 30 metres.
Mandatory Wiring Table for the Control Unit cable assembly:

Optional Wiring Table:

Antenna Unit Wiring

Antenna Units are linked together using CONN2 and CONN3 for connection of further antennas as illustrated below in the diagram.
Pin numbering and descriptions for CONN2 and CONN3 are identical. CONN2 can be used for the outgoing cable and CONN3 for the incoming cable or vice-versa.
Cable: 3 pair individually screened, Core: 7/0.2 (i.e. Belden 8777, Alpha 6010C, Cable Hub/ FS cables 2203PIFRD)

Antenna Unit Switches

The first switch that needs setting is the address switch SW2. The Function Units need to be numbered sequentially in the order they are wired together, i.e. the first Function Unit connected to the Control Unit should be set to 1, the next one wired to that first Function Unit will be set to 2 and so on.
The second switch is the power setting. Either set SW1 to 0, which is the Wi- Fi setting (recommended), or turn SW1 clockwise to increase power or anticlockwise to decrease power and therefore size of detection zone. If setting SW1 to 0
The range can then be adjusted via Wi-Fi using a mobile smart device such as a mobile phone.
SW2 = ADDRESS. (1=first antenna unit: must be numbered sequentially to the last)
SW1 = POWER. Set 0 for Wi-Fi or manual setting 1(min)-F(max).The location of the switches can be found on the top right side,

Wi-Fi Configuration & Settings

The Control Unit includes Wi-Fi connectivity for remote access and control. The Wi-Fi configuration and settings section provides information on how to connect to the Control Unit over Wi-Fi for remote access and control.

Control Unit Connection

The Control Unit broadcasts a SSID of ZoneSafe_XXXXXX where XXXXXX is the device’s serial number, as printed on the product label on the back of the unit.
From your device, view available Wi-Fi connections and select this network and click Connect. Enter the default security key “ZONESAFE” and click OK.
When the connection has been established, open a web browser and enter URL http://192.168.0.1/ This is the address of the Control Unit.
When prompted, enter the default user name as “admin” and the password “PASSWORD”.
Usernames and passwords are case-sensitive. Summary
The Summary page displays the Control Unit and a separate box for each of the Function Units. Click the Settings button on the respective unit to open the configuration page for this unit.

View & Change Settings – Control Unit

To change system settings, select the ‘Settings’ button in the Control Unit section of the SUMMARY page. Settings can be changed in the following sections:
Date/Time
General
Set number of antennas: 1 (only change this if further antennas are added).
Alarm
Set Volume: Low, Medium or HighAlarm Time: Number of seconds the alarm continues after tag leaves detection zoneAlarm Acknowledge: Disabled, Mute One or Mute All (Mute One is recommended). This is to allow the driver to silence the alarm once a detected tag has been acknowledged.Alarm Tone = Default or Alternative.
Driver
Driver Tag Alarm = Enable (Unit alarms if tag is left in the controller when the ignition is off)
ALL other settings should remain as pre-set.
To change antenna settings, select the ‘Settings’ button in the Antenna section of the SUMMARY page.
Antenna Power
This determines the Antenna power/detection range. Enter: No.1=Min to 15=Max
Note: SW1 on Control Unit must be set to 0 (see ‘Antenna switch settings’ overleaf)
Important! The system has two range levels which must be set depending on the required detection distance. This setting can be located by following:ADMIN \ GENERAL \ RFID
Relay
Configure how the Control Unit relay will operate. Relay can be activated from a number of sources and released by mute or acknowledge push button press under selected conditions
Input
The Antenna Unit can be enabled /disabled via the input 1 signal (either high or low) and the events recorded (see optional wiring table on page 12).
All other settings should only be changed under instruction.

Settings & Information – Antenna Unit

Antenna Unit Power
Adjust the output power from 1-15, 1 being lowest power.

RFID System Operation

The RFID System Operation section provides information on how to turn on and off the system, as well as details on the types of alarms that can be triggered.

On Sequence

NOTE: If the ignition remains on and no driver tag is detected in the holder for a period of time, the “No Driver Tag” alarm will be raised. This is intended to prevent the vehicle being operated by an unauthorised driver.

Off Sequence

NOTE: If the ignition is off and the driver tag  remains in the holder for a period of time, the “No Ignition” alarm will be raised. This is intended to remind the driver to take the tag when leaving the vehicle.

Control Unit Diagram & Alarm Details

Pedestrian Detection
When a person wearing a ZoneSafe Tag enters the detection zone around a vehicle, the alarm will sound. Press the alarm mute button to silence the alarm.
When two people enter the detection zone wearing a ZoneSafe tag, the alarm will sound twice as fast. The mute button can be configured for various functions using Wi-Fi.
For a full range of alarm sounds, please see below.

Types of Alarms

Setup of the Antenna Unit Detection Zone

• Ensure power switches inside Antenna Units are either set to 0 for Wi-Fi control or a manual power level of 1 – F.
• Using an Active Tag, walk around the detection zone that has been set and measure required size of detection zone.
• Adjust the power settings via Wi-Fi or manually via the switch on the PCB inside the Antenna Unit to set the desired detection zone.
• Set the distance required for the vehicle warning and/or alarm threshold.

Troubleshooting

The Troubleshooting section provides information on common issues and how to resolve them.

be removed within a certain time as this is a warning that the tag has been left in the vehicle.
With the ignition on, ensure that the driver tag is inserted.
Check driver tag is inserted correctly (if not using driver tag check disabled in Wi-Fi settings).
Check alternate driver tag to ensure that the issue is not a faulty tag.
Confirm ignition wiring is correct, check the system wiring table.
Pink light pulsing on Control Unit| Check Function Unit wiring & configuration.
Make sure Antenna Unit PCB connectors are wired correctly and inserted fully.
Pedestrian alarm on Control Unit but no tag is thought to be in range of vehicle.| Connect to the Control Unit and view events to identify the tag number the system is detecting. Check to see if this matches the driver tag number, if it does match then either increase the distance between the Antenna Unit and Control Unit or decrease the power of the Antenna Unit.
If the tag number(s) logged in the events does not match the driver tag, then there may be tags that are hidden from view. You can try a combination of moving the vehicle to where it does not alarm, out in the open and away from walls, desks, lockers etc., and reducing the Detection Zone to attempt to locate the problem tag(s).
Two or more vehicles alarm at the same time when just one of them de- tects a tag.| Confirm the that the vehicle IDs do not match one another, if they do, change them so they all have a unique number.
Alarm does not mute when button is pressed.| Check the Alarm acknowledge setting in the controller configuration settings. Make sure it is set correctly for your requirements. If it is set to mute a tag alarm and does not mute the alarm then more than one tag is present in the Detection Zone.
There is a constant alarm tone when leaving the vehicle| Remove driver tag or disable driver tag alarm.

System Units Care

The System Units Care section provides information on how to maintain and care for the system units for optimal performance.

Disclaimer

The Disclaimer section provides information on the intended use of the ZoneSafe RFID Detection System and limitations of the system.

Usage Instructions

1. Read the entire manual to understand the installation and configuration process.
2. Decide where to install the Control Unit and Antenna Unit for optimal performance based on the guidelines provided in the manual.
3. Install the Control Unit, making mandatory connections before optional connections. Connect the Control Unit to the Antenna Unit using the specified cable and setting the Antenna Unit address switch to 1.
4. Install the Antenna Unit in a location that provides the desired detection zone and optimum tag position. Install at an appropriate distance from other Antenna Units to prevent interference.
5. Wire the system together according to the wiring schematic provided in the manual.
6. Configure Wi-Fi settings for remote access and control of the system.
7. Turn on the system using the On Sequence provided in the manual.
8. Monitor the system for any alarms triggered and follow the Off Sequence provided in the manual to turn off the system.
9. Maintain and care for the system units as described in the System Units Care section of the manual for optimal performance.

Introduction

Our active RFID Detection System comprises of one Control Unit and one or more ‘Function Units’. This manual will instruc on best practice for placement of equipment, attachment methods and wiring.

Glossary of terms:

Function Unit : A generic term for the detection units in our system, i.e. Antenna Unit.
Control Unit : This creates visible & audible alerts to the user when either a pedestrian or static object with a tag. All Function Units are wired to the Control Unit and every system requires one.
Detection Zone : Imagine an invisible sphere whose centre point is a Function Unit. When we indicate a range for a Function Unit it means from the centre point of the unit itself, not from the edge of the vehicle. This is why correct installation is the key to getting a system to perform the way you want it to.
Antenna Unit : This is the vehicle mounted Function Unit which detects our active tags and any of our other products that act like tags. The Antenna Unit is primarily fitted when we wish to detect proximity of pedestrians wearing our tags. The range is adjustable from 3-10m/10′-33′, measured from the Detection Zone centre point. The Antenna Unit does not need a clear line of sight.
Tags : Our active RFID tags are detected by the Antenna Unit and are compatible with other products such as the Tag Tester which can be used for tasks such as access control or pedestrian monitoring, for example.
NOTE: ZoneSafe must be fitted and commissioned by an approved installer. No responsibility will be accepted for damage to systems caused by incorrect installation or misuse. Detection accuracy will depend on environmental and installation factors.

Overview of a typical vehicle system installation

Read the sections of this manual which instruct how to install the specific system items and best positioning for the optimal performance. Then you can proceed to installation.

1. Decide where you will fit your ZoneSafe Units to give the detection zone you require, by following the guidelines set out in this manual.

2. Decide on fixings to keep the ZoneSafe Units in place (fixings, mounting plates etc.).

3. Make a note (or take a photo) of the label on the back of the Control Unit, as you will need the serial number for connecting over Wi-Fi. Then you can fix the units in their final position.

4. Identify the vehicle connections.

5. Isolate the vehicle power supply before wiring the system.

6. Wire the Control Unit to the vehicle, ensuring to make the mandatory connections, then any optional connections required.

7. Connect the Control Unit to the first Function Unit (e.g. Antenna) using the cable specified (see Control Unit Connection section). Set the first Function Unit address switch to 1.

8. Connect the first Function Unit to the second (if using more than one), and set this unit’s address switch to 2.
   Now do the same for a third unit and so on, until all the Function Units are connected.

9. When you reach your last Function Unit, fit the blanking plug to the unused hole in the enclosure to ensure a weathertight seal. Make sure all of your Function Units are screwed shut and the glands are tight.

10. Now you can connect the vehicle powe source. Stand near the Control Unit and connect using Wi-Fi direct on a  mobile device to configure your system.

11. Test your system works exactly the way you would like before finishing installation.

Fixings

All ZoneSafe units arrive installed with four M5 threaded inserts in the AMPS hole pattern on the back. These can be fixed directly to mounting plates, which can be fitted to the back of the units.
RAM mounts can be used and we have an additional bracket which has the AMPS hole configuration.

AMPS Hole Configuration

All our units have M5 inserts in the AMPS configuration on the rear. Do not exceed the maxim depth.
Shake-proof washers are recommended and thread locking liquid can also be used. Fasten securely but do not over- tighten.

Mounting plates

An adaptor plate is available for all the units.
These attach via four countersunk M5 nylon patched screws.
The plates provide slots either on the top and bottom.

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References

• Brigade Electronics | Commercial Vehicle Camera Systems

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