tray collision warning system

PRODUCT MANUAL TRAY COLLISION WARNING SYSTEM

Part No. 16186 | 16212

2 | 16 M1268.docx | Rev 1.0 | Modified on 5/05/2021 | © Remote Control Technologies Pty Ltd

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M1268.docx | Rev 1.0 | Modified on 5/05/2021 | © Remote Control Technologies Pty Ltd 3 | 16

Contents

General Safety Warnings 4

Personal Safety 4 Machine 4 Product 4

Product Overview 5

Features and Functions 5

Operation and Use 6

Alarm States 6 Configuration Screen 6

Installation Guide 7

Wiring Connections 7 Mounting Dimensions and Isometric View 8 System Wiring (704t) 9 Loom Configuration (707c) 10 Ultrasonic Sensor Junction Box Internal Wiring (417w) 11 Programming the Ultrasonic Sensors 12 Factory Settings When Ordered with Kit 13

Technical Specifications 13

Compliance 14

Parts List 14

16186 Tray Collision Kit 14 Programming/Spare Parts 14

Troubleshooting 14

Glossary 15

Warranty 15

Revision History 15


Table of Figures

Figure 1 Muirhead® Tray Collision Warning system ......................................................................................... 5

Figure 2 Control buttons on the controller ........................................................................................................ 5

Figure 3 Controller mounting dimensions ......................................................................................................... 8

Figure 4 Drawing 704t – System wiring ............................................................................................................ 9

Figure 5 Drawing 707c – Loom configuration ................................................................................................. 10

Figure 6 Drawing 417w – Ultrasonic sensor junction box internal wiring ....................................................... 11

Figure 7 Screenshot – Factory settings .......................................................................................................... 13

General Safety Warnings

Personal Safety

■ Everyone is responsible for safety. ■ The installer/service personnel should be trained and authorized to complete the required work. ■ Ensure that the machine is safely isolated during installation and testing to protect all personnel. ■ Complete all required risk assessments and job safety analysis (JSA) before commencing work. ■ Observe all site-specific and machine OEM procedures regarding the following:

– working at heights – working in heat – working in confined spaces – all other site-specific occupational health and safety (OH&S) procedures

Machine

■ Carry out all pre-start operations as per site and machine OEM procedures. ■ Ensure the machine is safely isolated during installation and testing to protect the machine and other

equipment in the area. ■ Do not operate any machine with a known fault and report all findings to the supervisor in writing. ■ Test and operate machine as per machine OEM and site procedures. ■ Read and understand machine and site-specific operational and testing instructions.

Product

Before applying power to the equipment, the user/repairer/installer must read all product instructions. If in doubt, seek assistance.

■ Ensure electrical connections are made as per RCT’s recommendations. Test circuits prior to connecting power to any component.

■ The equipment contains no user-serviceable parts inside. Return the unit to RCT for repairs. ■ Retain product and installation instructions for future use. ■ Ensure that RCT’s recommended service procedures are included in the machine’s service routine. ■ Observe all machine, site and RCT product warnings. ■ Follow all machine, site and RCT product operating procedures at all time.

The application of safety should not be limited to the above recommendations.


Product Overview

Figure 1 Muirhead® Tray Collision Warning system

The Muirhead® Tray Collision Warning system, part number 16186, has been designed to provide an operator a visual and audible warning of an impending tray collision when operating in a height-restricted-working area. This system utilises a programmable ultrasonic sensor with two configurable switching outputs that provides the operator with a three-stage visual and audible alert.

Features and Functions

Simple and easy to install

Three-stage visual and audio alert

Compact and robust control panel design

Can help prevent machine damage

Surface or underground applications

Ultrasonic sensor is programmable to customer requirements

Optional warning and alarm switching outputs for customer convenience

Figure 2 Control buttons on the controller

Controller Ultrasonic Sensor Junction Box

Up button

Down button

Back button

Enter button


Operation and Use

Alarm States

1. When the machine is turned on and the tray is not raised, the device will be in an idle state.

TRAY DOWN – OK

2. When the controller senses that the tray has been raised but the sensor does not detect any close obstructions, the display will show a visual alert to warn the operator that the tray is raised.

The raised tray output will also become active.

When the tray returns to the lowered position, the display will return to its idle state.

STAGE 1 – AWARENESS

3. When the controller senses that the tray has been raised and that the sensor’s first trip point has been reached (1 m by default), the display will change to the stage 2 warning and begin to flash. The audible alarm will also begin to pulse on and off.

The alarm output will turn on, pulsing with the audible alarm. The tray raised output and stage 2 output will be on solid.

When the sensor detects that the obstruction is no longer within this set distance, the display will revert to the stage 1 warning.

STAGE 2 – COLLISION RISK

4. When the controller senses that the tray has been raised and that the sensor’s second trip point has been reached (0.5 m by default), the display will change to the stage 3 warning and continue to flash on the screen. The audible alarm will remain sounding during this stage.

The alarm, tray raised, stage 2, and stage 3 outputs will all remain on during this stage.

When the sensor detects that the obstructions is no longer within this set distance, the display will revert to the stage 2 warning.

STAGE 3 – STOP ESSENTIAL

Configuration Screen

The configuration screen provides the user with some further options to customise or review their device.

1. Open configuration menu

Press the Up or Down button to scroll through the screens until the configuration screen is displayed (will also show software version).

To open the menu, press the Enter button.

2. Display brightness

From the configuration screen, press the Enter button to start adjusting the screen brightness, using the Up or Down buttons to select your desired level.

When the correct level is highlighted on the screen, press the Enter or Back button to accept.

Note

The sensor’s set points are configurable. Refer to Programming the Ultrasonic Sensors section further in this manual for the configuration instructions.

Fleet1 Software – 1234

6685d85

100%


Installation Guide

1. Install the service monitor in a suitable location.

2. Refer to the wiring table below and the wiring diagram in this manual to connect the service monitor. We recommend that you install the wiring alongside the OEM wiring, ensuring that it is secured at regular intervals. This will provide protection from heat and abrasion, and any other excess damage that may occur with extended vehicle operation. When securing the wiring to the OEM wiring, ensure that the loom is away from moving vehicle parts which could lead to loom damage.

Wiring Connections

Pin No. Function Description

1 Power Supply Connect the power supply to the ignition. We recommend that you ensure that the switched ignition power supply has a fuse rated at 5 amps installed just after its supply point.

2 Ground Ground.

3 Input 1 Not used.

4 Tray raised Input Connect the tray raised input to the OEM tray raised sensor. The device considers the tray as raised when a ground signal is detected.

5 Ultrasonic SW 1 Input This input is used to trigger the stage 2 functionality. The device will look for the absence of a positive signal to consider this input active.

6 Ultrasonic SW 2 Input This input is used to trigger the stage 3 functionality. The device will look for the absence of a positive signal to consider this input active.

7 Input 5 Not used.

8 Alarm output This puts out a positive output at the same voltage seen on pin 1. This output is on whenever the audible alarm is on.

9 Tray Raised output This puts out a positive output at the same voltage seen on pin 1. This output is on whenever the tray raised input is active.

10 Stage 2 output This puts out a positive output at the same voltage seen on pin 1. This output is active whenever stage 2 or stage 3 is active.

11 Stage 3 output This puts out a positive output at the same voltage seen on pin 1. This output is active whenever stage 3 is active.

12 Output 5 Not used.

13 Ethernet 1 Not used.


15 Output 8 Not used.

16 NC Not connected.

17 Input 6 Not used.





22 CAN0H Not used.

23 CAN0L Not used.

24 PROGTX Not used.

25 PROGRX Not used.

26 PROGGND Not used.


Mounting Dimensions and Isometric View

Figure 3 Controller mounting dimensions

The ultrasonic sensor should be strategically located at the underside of the skip above the truck cabin.

It is recommended that the wiring loom from the controller to the ultrasonic sensor be run alongside the machine’s original looms. Ensure the loom is secured to the original loom at regular intervals. All connectors should be environmentally sealed using additional electrical protective sprays and tapes as required.

Notes

Refer to drawing 704t to complete the installation.

The switched ignition power supply must have a fuse rated at 5 amps installed, just after its supply point.

12.5

4

Ø35

R2.5

70° 70°

(40.9

7)

(65)(125)

MOUNTING DIMENSIONS

ISOMETRIC VIEW

SIDE VIEWBOTTOM VIEW

Ref: TS0069


System Wiring (704t)

Figure 4 Drawing 704t – System wiring

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Ultrasonic Sensor Junction Box Internal Wiring (417w)

Figure 6 Drawing 417w – Ultrasonic sensor junction box internal wiring

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Programming the Ultrasonic Sensors

1. Apply power to the ultrasonic sensor, then run the Ultra 3000 program on the desktop of a PC or laptop computer.

The software, Ultra3000 program can be downloaded from the following link:

https://www.pepperl-fuchs.com/australia/en/classid_1805.htm?view=productdetails&prodid=34800

Once downloaded, extract the zip file, right-click the Setup.exe file and select Run as administrator.

2. When program opens, a window with a progression bar will appear and begin reading the data from the sensor.

3. Once the data in the sensor has been read, the following screen will appear. Refer to the image below for information on setting up the sensor to suit your needs.

Note

Each time the setting is changed, you MUST tab out of the box you have changed; this informs the program to write the data to the sensor.

4. When the switch points have been set and are now ready for operation, this plug must be put back on the sensor.

Ensure that the letter ‘T’ lines up with the notch on the base of the plug.

This displays in mm how far away the surface is that the

sensor is pointed at.

■ Click the Switch tab

■ Input desired distance (in mm) to trigger stage 2 – 1000 mm by default

■ This should remain as N/C

■ Input desired distance (in mm) to trigger stage 3 – 500 mm by default

■ This should remain as N/C

Ensure the letter ‘T’ lines

up with the notch on the base of the

sensor.

https://www.pepperl-fuchs.com/australia/en/classid_1805.htm?view=productdetails&prodid=34800


Factory Settings When Ordered with Kit

Figure 7 Screenshot – Factory settings

Technical Specifications

Dimensions, controller only: Length: 121 mm | Width: 63 mm | Height/Depth: 40 mm

Dimensions, boxed for freight: Length: 220 mm | Width: 120 mm | Height/Depth: 420 mm

Weight, controller only: 0.2 kg

Operating voltage: 11 to 36 Vdc

Operating temperate range: −20 °C to +60 °C

Connection types: 26-pin receptacle

Inputs: Switch inputs, battery supply, ground

Min & max input voltage: 0 to 36 Vdc

Circuit protection: Inbuilt 10 A fuse, onboard transient voltage suppressors, polarity protection

Maximum current ratings Input = 3.5 A

Individual outputs 1, 2, 3 and 4 = 2 A max.

Outputs 5 and 6 = 0.5 A max.

Combined output = 3.5 A

Maximum current consumption (no outputs):

Input voltage and software-dependent, absolute max @ 12 V, 300 mA

Enclosure type: ABS

Environmental protection IP rating: IP65

Programming/adjustment: Refer to the section, Programming the Ultrasonic Sensors.

Note

Specifications are subject to change without notice.


Compliance

TBA

Parts List

16186 Tray Collision Kit

Part No. Description Quantity

16212 Controller Tray Collision Warning 1

16185 Tray Collision Warning Loom 1

10323 Ultrasonic Sensor with Rock Cover 1

Programming/Spare Parts

Part No. Description

8322 Programming Lead

6206 Ultrasonic Sensor

Troubleshooting

Fault Possible Cause

The device is not working Check wiring and connections

Intermittent fault Check wiring and connections

The device will not register, the tray is raised

check the OEM tray sensor is switching correctly and has a negative output

The device is warning too early or too late

the sensor settings may be incorrect, refer to the programming section of this manual to confirm or change the settings

If you encounter any issues not listed above, contact your nearest RCT branch with a detailed description of the fault and the current software version of the device. The software version can be found on the configuration screen of the device.


Glossary

A Amp (Ampere) MIN Minimum

ac alternating current mm millimetres

AMS Advanced Management System mW Milliwatts

Aux Auxiliary Output N/A Not Applicable

CAN Controller Area Network N/C Normally Closed

CMIO ControlMaster® Input Output PCB N/O Normally Open

CMR ControlMaster® Receiver OEM Original Equipment Manufacturer

CMT ControlMaster® Transmitter O/P Outputs

CM2200 ControlMaster® 2200 Remote Set Out Output

COMMS Communications PB Push Button

CPU Central Processor Unit PC Personal Computer

dc direct current PCB Printed Circuit Board

E.G. For example PIN Personal Identification Number

ETR Energised To Run PLC Programmable Logic Controller

ETS Energised To Stop POT Potentiometer

ESD Engine Shutdown PPM Pulses Per Metre

FET Field Effect Transistor PWM Pulse Width Modulation

GND Ground PWR Power

H Hours Rev Revision

HEX Hexadecimal Numbering System RF Radio Frequency

ID Identity RH Relative Humidity

i.e that is rpm Revolutions per minute

In Input Rx Receiver

IP Ingress Protection RS232 Recommended Standard (number 232) for serial data transfer

kg Kilogram SYS System

km/h Kilometres Per Hour ToV Text On Video

LCD Liquid Crystal Display Tx Transmitter

LED Light Emitting Diode USB Universal Serial Bus

LK Link V Volts

M Minutes °C Degrees Centigrade

mA Milliamps # Number

MAX Maximum < Less Than

MCU Multi-Control Unit > Greater Than

MFU Multi-Function Unit % Percentage

MHz Mega Hertz (million(s) cycles per second)

Warranty

Please see the RCT standard warranty, available on our website - www.rct-global.com.

Revision History

Rev Date By Details of change

1.0 05/05/2021 NMarsh/AF Initial document draft and approval.

http://www.rct-global.com/

Discover more: www.rct-global.com [email protected] AUSTRALIA: +61 (0) 8 9353 6577 AFRICA: +27 (0) 83 292 4246 CANADA: +1 705 590 4001 RUSSIA / CIS: +7 (910) 411 11-74 SOUTH AMERICA: +56 3 5229 9409 USA: +1 801 938 9214

tray collision warning system

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