B175128 - ZoneSafe 2 Installation Operating Manual

B175128 ZoneSafe 2 Installation & Operation Manual

Eureka-iD ZoneSafe2

Installation & Operating Manual

Avonwood Developments Limited

Knoll Technology Centre, Stapehill Road

Wimborne, Dorset, BH21 7ND

Tel: +44 (0) 1202 868000

Fax: +44 (0) 1202 868001

Email: [email protected]

Web: www.avonwood.co.uk

ZoneSafe 2 System Installation & Operation Manual

B175128 Copyright 2008 Avonwood Developments Ltd of 40



Contents

1 Introduction 5

1.1 Master Control Unit 6

1.2 Master Wakeup Antenna 8

1.3 Driver and Operator Tag. 8

1.4 Slave Control Unit 9

1.5 Slave Antenna Unit. 10

2 System Specification 11

2.1 Master Control Unit 11

2.2 Driver’s Master Wakeup Antenna 11

2.3 ZoneSafe 2 Driver/Operator Tag 12

2.4 Slave Control Unit 12

2.5 Slave Antenna 12

3 Hardware Installation 13

3.1 ZoneSafe 2 Master Unit Connection Details 13

3.2 ZoneSafe 2 Slave Unit & Slave Antenna Connection Details. 16

3.3 Hardware Set-up & Test 19

4 System operation 20

4.1 Enable Keyswitch 20

4.2 Normal System Operation sequence. 20

4.3 Operational Time Window 21

4.4 Stopped Timeout 22

4.5 Unit Numbering 22

5 Software 23

5.1 Software Installation 24

5.2 Menu Bar 25

5.2.1 File 25

5.2.2 Options 26

5.2.3 Password 27

5.2.4 Help 28



5.3 Configure Parameters 29

5.3.1 Relays 30

5.3.2 Unit Address 31

5.3.3 Stopped Timeout 31

5.3.4 Stopped Tag Search Time 31

5.3.5 Stopped Tag Timeout 31

5.3.6 Driving Tag Search Time 31

5.3.7 ‘Driving Tag Timeout’ 32

5.3.7 Operation Time Control 32

5.3.8 Unit Time 32

5.3.10 Stopped Input Blind Time 32

5.3.11 Command Buttons 33

5.4 Set Drivers and Operators 35

5.4.1 Add New Driver or Operator 36

5.4.2 Edit Driver or Operator 36

5.4.3 Delete Driver or Operator 36

5.4.4 Set Drivers or Operators 36

5.4.5 Read Drivers or Operators 36

5.5 Uploading Events 37

5.6 Status & Information Features 39

5.6.1 The Status Bar 39

5.6.2 Information Display 40



1 Introduction

ZoneSafe 2 System (Model EURiDK4957) provides a flexible solution to help prevent the

unauthorised use of mobile plant and refuse vehicles.

Based around a high performance wireless communication system comprising:-

1 ZoneSafe 2 Master Control Unit ( EURiDD5070 )

1 ZoneSafe 2 Master, Antenna, ( EURiDA5026 )

1 ZoneSafe 2 Slavel Unit ( EURiDD5070 )

2 ZoneSafe 2 Slave Antennas, ( EURiDA5120 )

2 ZoneSafe Operator Tags ( EURiDT4956 )

The following items are supplied separately for use with the system :-

1 USB/RS485 Data Cable I (EURiDK5107)

1 ZoneSafe 2 Distribution CD (EURiDK5130)

USB/RS485 Data Cable & CD (Supplied Crimps & Connectors



1.1 Master Control Unit

Located in the vehicle’s cab and housed in a rugged aluminium enclosure the ZoneSafe 2

control unit contains the control, transmitter and receiver electronics.

The Master Unit should be mounted in the cab so that the driver has access to the On/Off

Keyswitch.

Master Unit Features: (Front Panel)

• RS485 COMMS port to allow communications with an external device such as a laptop.

• System status LED indicator.

• Low tag battery LED indicator.

• OverrideOn/Off key-switch to allow the system to be bypassed should the need arise.

• Buzzer to provide indication of system operations.



Unit Features: (Rear Panel)

• 4 relay outputs with n/o and n/c contacts. Each output has individually configurable

timeouts and polarity of operation, with the option of power or signal relays for each.

• 2 inputs for “Ignition On” and “In Neutral” detection.

• Master antenna drive outputs.

• RS485 Communication connection to slave unit.

The ZoneSafe 2 Master control unit generates a wakeup field through the Master antenna

(situated near the driver’s seat ) to wake up the driver’s tag. The control unit receives data

from the driver’s tag, checks it for errors and activate relays as necessary when it sees a

driver is present.

Each unit is assigned a unit system number which defines the wakeup field numbers of the

Master and Slave unit wakeup fields in a particular system. The range of the wakeup field is

factory adjustable to suit environment and conditions. The unit also contains a real-time clock

to keep track of time/date information, with internal memory to store the event data plus

inputs to monitor the vehicle’s status.

The real-time clock uses the daylight saving scheme (BST correction), where the time is

automatically moved forward an hour from 1am on the last Sunday in March, until 1am on the

last Sunday of October where it is moved back an hour.

(Note: DO NOT update the real-time clock during the period from 0:00am to 1:00am on the

day BST ends)



1.2 Master Wakeup Antenna

The master wakeup antenna must be fitted in a suitable position within the vehicles cab.

Ideally the antenna should be mounted in a vertical orientation, on the right hand side, at the

foot of the driver’s seat. This antenna produces a “Wakeup” field, which activates the Driver’s

tag which should be suspended from the driver’s belt loop on the right hand side..

1.3 Driver and Operator Tag.

Every authorised driver or operator for the vehicle must wear an RFID tag as shown below.

The tag MUST hang vertically from a belt loop on the right side of a driver or operator to

ensure it is in the best orientation to respond to the wakeup field at the master or slave

antennas which must also be mounted vertically. When the tag enters a wakeup field it

transmits its tag identity data. When the Master Control unit is configured tag identities must

be authorised to act as a Driver, an Operator, or both Driver & Operator.

Driver’s tag

suspended from

belt loop.

Master Antenna



1.4 Slave Control Unit

The Slave Control unit is mounted at the back of a vehicle and connected by a single 4 core,

screened cable to the Master unit. The Slave unit is powered when the vehicle ignition is on.

The Slave unit has its own wakeup field generator, antenna and tag data receiver.

The Slave Control unit MUST be mounted with the long face vertical and outward. The

incoming cable from the Master unit enters via one cable gland and the Wakeup generator

cable leaves via the other cable gland and goes to the Slave Antenna units. The typical

arrangement is as shown below:-

To Slave Antennas

Slave Control Unit Slave

Wakeup

Antenna

24V DC & RS485 To/From Master

Control & PSU

Tag data

Receiver

Wakeup

generator.

Driver

Cab

Master

Slave Antenna

SLAV

E

Slave Antenna

Master Antenna



1.5 Slave Antenna Unit.

The Slave Antenna unit(s) are fitted on either side at the back end of a vehicle, and are driven

via a single cable from the Slave Control unit. The Slave Antennas are fed with the same RF

wakeup signal as the Slave Control unit’s own antenna and together they generate an RF

wakeup field around sides and end at the back of the vehicle.

The Slave Antennas MUST be mounted with the long face vertical and outward. The

incoming cable from the Master unit enters via one cable gland and the Wakeup generator

cable leaves via the other cable gland and goes to the Slave Antenna units.

The typical area covered by active wakeup fields are as shown below:-

Driver

Cab

Master

Slave Antenna

SLA

VE

Slave Antenna

Master Wakeup fieldSlave Wakeup fields



2 System Specification

2.1 Master Control Unit

Dimensions: 175mm x 110mm x 65mm

Housing: Anodised aluminium extrusion

Power requirements: 18V to 30V DC Input

Current Consumption: Approx 30mA (Low power mode)

Maximum 200mA (System active)

Relay: ( Standard Power relay type )

Type: DPCO

Relay Contact Rating: 16A @ 125VAC

16A @ 30VDC

( Note:- Actual current rating may be limited by connector & cable types used for installation.)

(Signal Relay type – Fitted to special order only....)

Type: SPCO

Relay Contact Rating: 0.5A @ 125VAC

2A @ 30VDC

Memory Capacity: 512Kb

Wakeup Range: up to 4m – depending on tag type & tag orientation.

Wakeup Transmit Frequency: 125KHz

Tag Data Receive Frequency: 868.4MHz

RS485 Data Rate: 19,200 baud

Input Voltage Range: VHigh > 5V and VLow < 2V ( Pulsing. )

Status Indication LEDs: Green - System Status Indicator

Red - Low Battery Indicator

Connectors: RS485 Front panel DIN & Rear Panel Molex

Relays - 3Way 0.156” Molex (Supplied)

Antenna/DC In - 4Way 0.156” Molex (Supplied)

Fixings: 4 off M5

Approvals: TBA

2.2 Driver’s Master Wakeup Antenna

Dimensions: 110mm x 35mm diameter

Housing: Grey plastic tube with end caps.

( Mounted using 2 plastic P Clips supplied)

Cable Length: 5m Supplied (Max extension to 10m)



2.3 ZoneSafe 2 Driver/Operator Tag

Operating Temperature: - 10°C to + 55°C

Typical Read Time: approx 250ms

Receive Frequency: 125KHz

Transmit Frequency: 868.4MHz

Transmit Data Rate: 19,200 baud

Approvals: CE, IR2030, ETSI 300-220

2.4 Slave Control Unit

ABS IP65 Enclosure 200 x 120 x 57 mm

Power requirements: 18V to 30V DC Input

Current Consumption: Maximum 200mA (System active)

Operating Temperature: - 10°C to + 55°C

Typical Read Time: approx 250ms

Wakeup Range: up to 4m – depending on tag type & tag orientation.

Wakeup Transmit Frequency: 125KHz

Tag Data Receive Frequency: 868.4MHz

RS485 Data Rate: 19,200 baud

Approvals: CE, IR2030, ETSI 300-220

2.5 Slave Antenna

ABS IP65 Enclosure 200 x 120 x 57 mm

Cable Length: 10m Maximum.

Recommended cable type 2 Core Screened ( Belden 8762 060U500 or equiv.)



3 Hardware Installation

3.1 ZoneSafe 2 Master Unit Connection Details

Image below shows the ZoneSafe 2 Master Control Unit connections.

Master Unit Fixing The Master Unit should be mounted in the cab so that the driver has access to the On/Off

Keyswitch. The unit is usually fixed beneath the dashboard with the Keyswitch and antenna

facing forward. It is fitted using the two fixing bars on top of the Master unit and secured by 4

M5 fixings. The fixing bars are placed in a standard position during manufacture, but can be

adjusted if necessary.

Wiring to the connectors at the back face of the unit should be fitted in a neat and secure

way. The cables must be strain relieved to avoid stress on the connectors. To avoid

malfunction cable terminations to the rear connectors must be insulated such that users

cannot touch, or have less than 10mm creepage distance of any exposed termination.



The ZoneSafe 2 unit is normally connected as shown in the wiring diagram shown below, but

specific changes to the wiring and unit parameter setup for different vehicle types and

models.

Stop Vehicle

Input

Start Vehicle

Input

0V

+24V DC

In Neutral

3A Fuse

Ignition Switch

0V +24V DC Ignition Neutral

Master Antenna RS485B RS485A 0V

Master Antenna

N/O Com RL1 N/C

N/O Com RL2 N/C

N/O Com RL3 N/C

N/O Com RL4 N/C Slave Unit

+24V DC RS485A RS485B 0V Slave Ant + Slave Ant 0V

Slave Antenna Slave Ant + Slave Ant 0V

Slave Antenna Slave Ant + Slave Ant 0V

Inverted Engine On

Control Relay

Engine On

Control Relay

Inverted Operator

Present Control Relay

Inverted Driver

Present Control Relay



Master Unit DC Power Supply & Input Connections

Pin No Description

1 0V

2 +24VDC ( Via accessible 3A Fuse ) See Note 1

3 Ignition Input & +24V DC supply to Slave Unit

4 Neutral Input

Earth Point Screen See Note 2

Note 1 :- +24V DC supply is direct from vehicle battery and is NOT normally

disconnected when the ignition is off. Ensure this line is connected via an

accessible 3A fuse to protect wiring under fault conditions.

Note 2 :- Cable screen must be connected to earth point on back of Master Unit.

Master Unit Antenna & RS485 Connections

Pin No Description Colour

1 Master Antenna Drive Antenna White

2 RS485A RS485 White

3 RS485B RS485 Green

4 0V for RS485 & Master Antenna Antenna & RS485 Black

Note:- Cable screens must be connected to earth point

Master Unit Relay Connections RL1 to RL4

Pin No Description

1 N/O

2 COM

3 N/C

Note:- Cable screens must be connected to earth point

The Keyswitch on the Master Unit front panel is wired to turn off the Master Unit control relays

so that the ZoneSafe 2 equipment is effectively taken out of use. In this state all 4 relays are

unpowered, so the connections to the vehicle control system must be wired to have no effect

when the relays are in this state – when the Normally Open contacts will be open and the

Normally Closed contacts will be closed.



3.2 ZoneSafe 2 Slave Unit & Slave Antenna Connection Details.

Mount the SafeZone 2 Slave unit, with the front panel vertical, at one side near the rear of the

vehicle at about waist height from the ground. Run a screened 4 cable to the Slave Control

Unit from the Master Unit. Connect the 4 cable cores to the 4 way screw terminal block on

the Slave Unit PCB as shown below. Secure the plug-in 4 way block to the Slave Unit PCB

socket using the cable tie provided in the installation kit to prevent the screw terminal

connector plug being vibrated out of the socket.. Wire the cable screen to the case mounted

screw terminal block so that it can be connected to the cable screen of another outgoing

cable.

Fit the two Slave antenna units, with the front panel vertical, at about waist height from the

ground – one in a central position on the back end of the unit, and one on the opposite side of

the vehicle to the main Slave Control unit. Run a two core screened cable from the Slave

Control unit to a Slave antenna on one side and then on to the second Slave antenna on the

other side, as shown below. Use the terminal block to connect the cable screen of each

cable to the screen of the cable coming from the Master Unit. Wire the black identified core

and the other core of the Slave antennas to the incoming black and white wires. On the last

Slave Antenna remove the spare cable gland and fit the blanking plug provided.



IMPORTANT! WIRE BLACK WIRE TO ANTENNA BLACK WIRE,

WHITE WIRE TO THE OTHER ANTENNA WIRE.

Pin 1

Slave Antenna Slave Antenna

From Master

Internal Ferrite Antenna



Slave Control PCB

Pin 1



Slave Unit Power & RS485 Connections


1 +24 V DC Red

2 RS485B RS485 Green

3 RS485A RS485 White

4 0V Black

Note:- Cable screens must be connected together.

Slave Unit Antenna Connections. CONN 2


CONN2/1 Slave Antenna Drive Antenna White

CONN2/2 Slave Antenna 0V Antenna Black

Note:- Cable screens must be connected together.

3.3 Hardware Set-up & Test

During installation, take care to connect the relevant cables to the control unit before

connecting to the vehicle systems. Ensure vehicle ignition is OFF before making connections.

The vehicle systems to be controlled (i.e. engine, braking etc) must be connected to the

relevant relay outputs. A typical wiring diagram is shown above, but must be customised for

the vehicle and operational requirements at this installation. Suitable “cut-in” points must be

identified and wires run to the control unit. Relay operation must be considered (i.e. normally

open or normally closed) and connected as required (see section 3.1). This is important for

the system to be bypassed correctly using the key-switch, See section 5.3.1 for further

details.

With the relevant connections now made, the unit will be powered on and the tag wakeup

ranges should be tested. An “LED Test Tag” is available if required, to simplify this process.

With the vehicle ignition turned on the Slave Unit at the rear should be on and generating a

wakeup field to detect tags at the back of the vehicle. The antenna in the Slave unit and its

associated Slave Antennas should generate a continuous RF field around the back of the

vehicle. An LED test tag carried around the back of the vehicle should show a continuous

field, without dead spots. If one or more antennas are wired in the wrong polarity they will

oppose the other antennas and dead spots will be seen between the antennas.

Connect the RS485 cable (supplied separately) via the Master Unit front panel DIN

connector. Run the ZoneSafe 2 PC Software. Configure the Master Unit as described in

section 5 below.

Once performance tests are completed satisfactorily the installation is finished.



4 System operation

When the Vehicle Ignition is Off the ZoneSafe 2 system is in its low power state and monitors

the ignition input continuously. In this state the wakeup antennas are turned off. The Master

Unit can be set up or monitored using the RS485 to USB converter cable assembly supplied

separately. The RS485/USB cable plugs into the Master Unit front panel DIN connector.

4.1 Enable Keyswitch

The Keyswitch on the Master Unit front panel turns off the control relays so that the ZoneSafe

2 equipment is effectively taken out of use. With the Keyswitch Off all 4 relays are

unpowered ( Normally Open contacts open, and Normally Closed contacts closed) and the

system must be wired to have no effect when the relays are in this state.

The Master unit monitors the state of the Keyswitch and keep a record of when Enable or

Disable events occur.

4.2 Normal System Operation sequence.

With the vehicle ignition OFF and the ZoneSafe 2 Master Unit enabled ( Keyswitch On ) the

system is in its low power state, continuously monitoring the ignition input.

A driver climbs into the driver’s seat wearing an authorised driver tag suspended from his belt

and turns the ignition ON. The control unit leaves its low power state and turns on the

wakeup antennas to search for an authorised driver’s tag at the seat or an authorised

operator tag at the back of the vehicle. A timed, dated “Ignition ON” event is recorded.

The green system status LED indicator begins a short flash cycle indicating the system is

working - subject to an operational window (see section 4.2. The tag wakeup fields make any

nearby driver or operator tags transmit data to the Master or Slave control units which decode

the tag identity messages and check the tags are authorised for use by that vehicle.

When a valid driver’s tag is detected an audible tone alerts the driver that the system is active

and a “Driver Present” event is recorded showing the time, date and driver’s tag number. The

system status LED lights continuously to indicate a valid driver has been detected and the

relays operate as configured.

The relays are normally wired to make the vehicle start automatically when a valid driver is

present, even though the driver does not turn the ignition key to the Start position, always

subject to the normal safety requirements such as being in Neutral with the brake on.



The wakeup field is now disabled for a short period of time so the tag batteries are not

drained continually. Periodically the wakeup field is re-enabled to confirm the driver is still

present.

The driver can put the vehicle into forward or reverse and operate the vehicle as normal. For

safety reasons the main engine control relays ( RL1 & 2 ) will not change while the vehicle is

driving ( the Neutral input if off ), even if a driver’s tag is no longer seen.

Relay 1 & 2 will operate if the ignition is On and Either a Driver’s tag or an Operator’s tag has

been seen. RL3 will operate if a Driver’s tag has been seen, and for the delay period after the

tag was last seen. RL4 will operate if an Operator’s tag has been seen, and for the delay

period after the tag was last seen.( This allows the presence of a Driver or Operator to control

specific vehicle functions as necessary – for example to apply a brake if the vehicle is in

Neutral with no authorised Driver tag present. )

When the driver stops the vehicle and returns to neutral the engine will stay on while an

authorised Driver tag is seen in the cab or an Operator tag at the back of the vehicle. If the

driver’s tag leaves the cab leaving the ignition ON, and no operator tag is seen at the back of

the vehicle, the engine will automatically stop after a short, adjustable time. If the driver

returns to the cab, or an authorised operator’s tag is seen at the back of the vehicle, the

engine will automatically start. Timed and dated events are recorded when authorised tags

are first seen in a wakeup field, when a driver tag is seen to have left the cab, and when

control relays time out after tags leave the wakeup area.

Once the driver turns off the ignition and exits the vehicle, the system will deactivate the

vehicle, with an “Ignition OFF” entry being made into the event list.

4.3 Operational Time Window

An operational time window can be set up, using the software application, during which the

vehicle can be operated. Outside this time window the vehicle will remain immobilised.

With the vehicle disabled and the ignition OFF the system is in a low power state and

monitors the real-time clock. At the start time of the operational window, the system can be

operated as normal (see section 4.1) and a “System Timed Start” event will be recorded.

The time is monitored and when the operational window stop time is reached the system will

be disabled at the next available opportunity and a “System Timed Stop” event recorded.

For safety reasons the system cannot be disabled except during the following conditions:

Ignition OFF, stopped timeout or while any relay remains ON.



The Operational Time Window is set using the Configuration Software described in section 5.

4.4 Stopped Timeout

The stopped timeout provides a way of controlling vehicles that are left idling for too long. The

Stopped Timeout function can be turned on or off using the configuration software.

With the vehicle disabled and the ignition OFF the system waits to be enabled and the vehicle

started. Once the system is enabled and the vehicle has its engine running the state of the

neutral input is continuously monitored.

While the vehicle is in neutral with the engine idling, a timer is started. Should the vehicle

remain in neutral for longer than the period defined using the software application, then the

system will be disabled, regardless of whether an authorised driver is present. Should the

driver exit the vehicle before the neutral timeout then the system will follow the normal

shutdown procedure (see section 4.1).

While the engine is running the Stopped Timeout timer will be reset each time the vehicle is

taken out of Neutral.

The Stopped Timeout function is set using the Configuration Software described in section 5.

4.5 Unit Numbering

Each ZoneSafe 2 Unit must be allocated a specific Unit Number ( 01 to 49 ) to identify it when

other similar systems are used in the same location. This prevents tags from one vehicle

affecting other systems nearby. For example, if a depot runs a fleet of 30 vehicles with

ZoneSafe 2 systems fitted, each vehicle must be allocated a different Unit Number. The Unit

Number is set using the Configuration Software described in section 5 below.



5 Software

A CD is supplied with Windows 2000/XP/Vista compatible software to allow communication

between the control unit and computer. To be viewed correctly, a minimum screen resolution

of 1024 x 768 is required.

The software allows the control unit configuration to be modified and updated, so that it can

be uploaded to the internal memory as required. The configuration can be saved and viewed

or modified at a later date.

Once the system is in use, it will generate a list of events, this list can be downloaded anytime

using the supplied application and an event log can be created that can be stored for records.

Additional software is available to analyse the stored event log, this provides detailed

statistics about the use of the vehicle and the drivers that operate it (See the ZoneSafe 2

Analyser Software Help File for further details).



5.1 Software Installation

Insert the CD into a CD-ROM drive (this will auto run) and install the software. Once

successfully installed, run the application.

ONLY RUN PC SOFTWARE WITH IGNITION OFF

After the software has loaded the following screen is displayed:

The first time the software is run the administrator password feature is disabled and full

access to the configuration is allowed, to enable this feature see section 5.2.3.



5.2 Menu Bar

The menu bar across the top of the window contains the following features:

5.2.1 File

The ‘File’ menu contains the following options:

Load Select ‘Load’ to open an existing unit configuration and import the values into the software

application. The unit configuration is stored as an .ini file, to load a file select it using the

standard file browser and click ‘OK’.

Save The ‘Save’ option only becomes enabled when the current unit configuration has changed. To

save a file, select a location and either use the generated file name or enter your own, then

click ‘Save’.

New Select ‘New’ to start a new unit configuration with the default values.

Exit Click ‘Exit’ to close the software application, if any changes have been made to the current

configuration file, a message box will prompt you to either save or discard.



5.2.2 Options

Select the ‘Options’ menu from the menu bar and the following screen is displayed:

Communications The ‘Communications’ tab contains the options to configure the particular computer it is being

run on, to communicate correctly with the control unit.

To select a communications port, click the ‘comms port’ drop-down list box. A list of available

ports will be displayed, select the correct port number and click ‘OK’ to return to the main

screen. Note that the option screen shows the ports that are AVAILABLE, and when the

option menu is opened does NOT necessarily show the port currently selected, if any.

When the software application is used without being connected to control unit, clear the

‘comms enable’ check box. This will disable all communications between the unit and

software, stopping any error messages from appearing. To enable Comms for later use go

back to the Options menu and re-enable the Comms with the required Comm port set.



5.2.3 Password

Some simple read-only features of the ZoneSafe 2 system can be accessed by anyone

connecting to the system. Most other features are visible but “greyed” out and unavailable.

Access to delete information or change the configuration is only allowed after a sign-in

password has been entered,

After the password protection is enabled, to activate all the features and commands of the

application, a system administrator is required to log on with a valid password.

To enable the password protection, the password must be changed from the factory default.

To enter the password, select the ‘Password’ menu from the toolbar, the following screen is

then displayed:

Enter the password in the ‘Enter Password’ text box and press enter. If enabling the

password feature for the first time leave the text box blank. A successful log in will produce

the text ‘Full Access Enabled’. Now the ‘Set New Password’ text box will be enabled and a

new password can be set as required.



5.2.4 Help

About Contains basic information about the current software version.



5.3 Configure Parameters

The control unit configuration can be set-up with the unit connected or not (see section 5.2.2).

To modify the unit configuration, select the ‘Parameters’ tab, the screen appears as follows:-

( Note that the Password has been entered and no boxes are “greyed out” and unavailable.)



5.3.1 Relays

The four relay outputs can be individually configured to suit the application. To enable a relay

output to activate when a valid driver is detected, its corresponding ‘Enable’ check box

should be ticked. The timeout value becomes adjustable from 6 seconds to 59 minutes 59

seconds.

In addition the polarity of the relay activation can be set, to either:-

• Relay energised when active and de-energised when inactive

Or as ‘Invert’

• Relay energised when inactive and de-energised when active

This allows the normally closed connections for the relay to be used, with the system then

holding the relay open while inactive and releasing to make the contacts when active. In this

configuration the system is effectively bypassed if the key-switch is disabled.

Relays 1 and 2 operate when EITHER a Driver OR an Operator tag has been seen, and turn

off when the ignition is turned off.

Relay 3 operates when a Driver tag has been seen, and stays on for the remainder of a relay

time-out period even AFTER the ignition is turned off.

Relay 4 operates when an Operator tag has been seen, and stays on for the remainder of a

relay time-out period even AFTER the ignition is turned off.

To make the event list easier to understand each relay may be assigned a name. To assign a

name, enter the relevant text in the corresponding ‘Name’ text box. The name is stored in the

configuration file in the PC not in the unit memory. To see the relay names when downloading

event data from the unit the correct configuration file for that unit must be loaded.

Once each relay has been configured, the ‘Set’ button should be pressed to upload the new

data to the control unit.

Note that the Driver and Operator presence indications on the event trail are NOT directly tied

to the relay times. Relays can be seen to time out before or after a Driver or Operator’s tag is

seen to have gone.



5.3.2 Unit Address

The ‘Unit Address’ should be unique for each control unit installed at a site. The number

must only be set in the range 1 to 49 and ensures only the correct vehicle is enabled when

vehicles are in close proximity (i.e. in a depot, yard or car park). To program the number use

the up/down arrows and click ‘Set’.

5.3.3 Stopped Timeout

The “Stopped Timeout” timer can be enabled using the ‘Enable Stopped Input’ checkbox. The

‘Stopped Timeout’ can be set from 1:00 minutes to 59:59 minutes. This value is the length of

time the vehicle can be in neutral with the engine running before the engine is disabled.

The “Stopped Timeout” input function “Invert” box can be used to invert the “Neutral” ( or

“Stopped” ) input if it is “High” for Stopped or “Low” for stopped depending on the interface to

the vehicle in use.

When “Stopped Timeout” is disabled the “Stopped Timeout” setting box is hidden. Normal

neutral control functions operate, but relays do not drop out after the “Stopped timeout”

period.

5.3.4 Stopped Tag Search Time

The ‘Stopped Tag Search Time’ is the length of time when stopped ( in Neutral ) that the

Driver’s wakeup field remains off after a valid tag has been read. Disabling the wakeup field

after a tag read greatly increases the battery life of the tag - the larger the value the longer the

battery life. The minimum value this parameter can be set to is 3 seconds with the

recommended maximum being 5 seconds LESS than the shortest relay timeout.

5.3.5 Stopped Tag Timeout

The ‘Stopped Tag Timeout’ is the delay when stopped ( in Neutral ) from when the last

Driver’s tag transmission is seen to when the Driver’s tag is assumed to have gone and a

Driver Absent message is generated on the event trail. The recommended minimum value

should be greater than or equal to the shortest relay time, with the maximum being 59minutes

and 59seconds. A different time can be set when the vehicle is Driving ( Not in Neutral. )

5.3.6 Driving Tag Search Time

The ‘Driving Tag Search Time’ is the length of time whilst the vehicle is driving (Not in

Neutral) that the Driver’s wakeup field remains off after a valid tag has been read,. The

recommended minimum time period should not be set less than the ‘Stopped Tag Search

Time’ value with the recommended maximum, again being 5 seconds LESS than the shortest

relay timeout. The Tag Driving Search Time is normally set much longer than Stopped Search

time as tag presence while driving is not as critical and a longer time helps preserve tag

battery life.



5.3.7 ‘Driving Tag Timeout’

The ‘Driving Tag Timeout’ is the period of time whilst the vehicle is driving (Not in Neutral)

from the last Driver’s tag transmission has been received till a ‘Driver Absent’ event occurs.

The minimum value should be greater than or equal to ‘Stopped Tag Timeout’, with the

maximum being 59minutes and 59seconds.

5.3.7 Operation Time Control

The real-time clock can be used to define an operational window, with a start and stop time.

Only during this time window will the unit allow the relays to be activated. To activate this

feature click the ‘Enable’ checkbox, select a working day from the drop down box and adjust

the start/stop times as required. The time is displayed in 24hr format and the ‘stop time’ must

be a least 1minute greater than the ‘start time’, also the ‘start time’ must be earlier than 23:59.

5.3.8 Unit Time

The ZoneSafe control unit contains a real-time clock used when logging system events. It is

advisable to update the system time before using it. To do this, click the ‘Set’ button in the

‘unit time’ frame, this will take the current date and time shown by the computer and send it

to the control unit. The time is then read back and the result will be displayed in the text box.

The time is maintained during power down by a battery support clock chip within the

ZoneSafe control unit.

5.3.10 Stopped Input Blind Time

To avoid glitches on the vehicle ‘In Neutral’ input caused by transients, such as going from

Forward to Reverse, a blind time is used when reading the state of the input (de-bouncing).

This ensures the state of the input is stable by requiring the value to maintain a steady value

for the timer period. The timer period can be set from a minimum of 1second to a maximum of

59seconds and is independent of all other timers.



5.3.11 Command Buttons

Read Parameters The ‘read parameters’ button allows the control unit’s internal configuration to be viewed. All

the values are read from the unit and imported into the relevant software application fields.

Set All Parameters When each individual parameter is changed the nearby “Set” box turns red to indicate that

the value in the PC is different to that in the unit. Individual values can be sent to the unit by

pressing the nearby Set box. However if changing a lot of values a ‘set all parameters’ button

is provided in addition to the individual parameter ‘set’ buttons. This will set all the control

unit’s internal configuration parameters with a single click.

Test Connection To test the connection between the control unit and software application, click the ‘test

connection’ button. A coloured box will be displayed in the status bar (see section 5.6) at the

bottom of the screen, indicating whether successful. Green for a successful connection, if a

red box is displayed check the connections and try again. If comms to the unit is disabled the

status box is blue.

Synchronise Press the ‘synchronise’ button to ensure the connected control unit (parameters and drivers)

and unit configuration *.ini file are consistent with the values currently on the screen. Data is

downloaded from the current values on the screen to the unit and you are prompted to store

the new values in a “.ini” configuration file.



Reset To Defaults The ‘reset to defaults’ button commands the control unit to return to the factory default

parameter settings, as shown below:



5.4 Set Drivers and Operators

Once the system parameters have been set-up, the list of authorised drivers and operators

for the vehicle can be configured as required. Select the ‘Drivers’ tab and the following

screen will be displayed: Up to 10 tags can be programmed, and assigned to be “Driver”,

“Operator” , or “Driver & Operator”” tags.



5.4.1 Add New Driver or Operator

To add a new driver click the ‘new driver button’ and the ‘driver edit frame’, along with the

‘accept’ and ‘cancel’ buttons will become enabled. Enter the driver or operator’s name and

the allocated tag number in the format” 0123” ( tag number is normally located on the tag

base ) in the relevant fields and set the ‘enable’ check box to allow this driver to operate the

vehicle.

The tag must be configured as a “Driver Only”, an “Operator Only” or as a “Driver &

Operator.” Press either the ‘accept’ or ‘cancel’ button to add or discard the entry.

The ‘no of drivers’ value shows how many drivers are currently entered, with the ‘enabled’

value showing how many are authorised to operate the vehicle.

5.4.2 Edit Driver or Operator

When a driver has been added, the information is displayed in the window. To edit a driver’s

details, select the entry row and the details will appear in the ‘driver edit’ frame. Make the

relevant changes then press either the ‘accept’ or ‘cancel’ button to add or discard the

modifications.

5.4.3 Delete Driver or Operator

When a list of drivers has been entered, to remove an entry select it from the list and click the

‘delete’ button.

5.4.4 Set Drivers or Operators

Once the list of drivers is complete, click the ‘set drivers’ button to update the control unit’s

internal driver list. Note that ONLY ENABLED TAGS are actually set in the unit. Tags that

are not marked as Enabled are held in the PC software and in the Driver List File, but are not

sent down to the Master Unit.

5.4.5 Read Drivers or Operators

To read back a Master control unit’s list of drivers, click the ‘read drivers’ button and the list

will be read and displayed in the window. Only tags that are Enabled are held in the master

Unit, and their data is marked as “Set” when read back from the Master unit. Other tags may

be displayed and not marked as “Set” indicating that they are not enabled and not held in the

Master Unit.



5.5 Uploading Events

As the system is used it will log certain events and store them in memory. The following is a

list of the events that can be recorded and there meaning:

• Power On

• System Enabled

• System Disabled

• Ignition ON

• Ignition OFF

• Stopped

• Driving

• Driver Present “Name” – “Number”

• Driver Absent “Name” – “Number”

• Operator Present “Name” – “Number”

• Operator Absent “Name” – “Number”

• “Relay Name” OFF (Where “Relay Name” is the name configured in the software

application, for that particular relay output, on that particular vehicle)

• System Timed Start

• System Timed Stop

• Low Tag Battery “Name” – “Number”

• Invalid Tag – “Number”

• Stopped Timeout

This information can be uploaded to a software application when required and an event log

created for records.

Two Event Log files are created – one is in easily readable form, the other is in minimal data

format that can be used by data analysis software.



To upload the event list from the control unit, select the ‘Events’ tab; the following screen will

be displayed:

Click the ‘Recall Event List’ button. Up to 8000 timed, dated events can be stored and it

may take a while to retrieve this amount of data stored in the event list. A message box will

be displayed when the upload is complete. Once the data has been uploaded the ‘Create

Event Log’ button will be available, click this button to create a text file report that can be

saved as required. The saved Event Log file is allocated file name showing the date and

time..



5.6 Status & Information Features

5.6.1 The Status Bar

Located at the bottom of the screen the ‘status bar’ (shown below) consists of the following

fields (left to right):

File/path name

Control unit model and firmware version

Coloured control unit connection indicator

Red Not connected

Green Connected

Blue Communications Disabled

Date

Time



5.6.2 Information Display

The information display (shown below) is located at the top of the screen, below the menu

bar. Its purpose is to provide additional information about the control unit and will show any

inconsistencies between the control unit and software configuration settings.

The ’machine type’ and ‘site’ fields allow extra information to be stored against the

configuration settings. The ‘driver status’ and ‘parameter status’ frames contain the text, ‘file’

and if communications are enabled (see 5.2.2) ‘unit’ will also appear. The text is colour coded

to show the current status, green indicates that the information matches and red indicates

that there is an inconsistency between the data sets.

When the software is first loaded the text has no colour, when an existing file is loaded the

‘file’ text turns green as the parameters being displayed match the saved file. The ‘unit’ text

turns red, as the current control unit connected, may not have the displayed parameters set in

memory.

If any changes are made to the displayed values and the set button is pressed, the ‘file’ text

will turn red. This indicates the displayed values no longer match the saved file, when the

changes have been saved (see section 5.2.1) then text will return to green.

The ‘unit’ text will remain red until all the control unit’s internal parameters match those being

displayed on the screen (i.e. click the ‘set all parameters’ button).

The same principle applies to both the ‘driver status’ and ‘parameter status’ frames, where the

‘driver status’ refers to the driver information and the ‘parameter status’ refers to the

parameter information.

B175128 - ZoneSafe 2 Installation Operating Manual

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