MultiDAT 5. Hardware installation guide for the MultiDAT datalogger. Rev. 3 - May Copyright 2007 FERIC. All rights reserved.

Transcription

1 MultiDAT 5 Hardware installation guide for the MultiDAT datalogger Rev. 3 - May 2008 Copyright 2007 FERIC. All rights reserved.

2 Contents Hardware installation guide for the MultiDAT datalogger...1 Contents...2 Before you begin...3 Identify your objectives for MultiDAT...3 Make sure that you have all the parts required...3 Introduction...6 Overview...6 Consult the connection guides...6 Technical support...6 License and limitation of warranty and responsibility...6 Installation...7 Using the datalogger in the office...7 Installation of the MultiDAT in the machine...7 Electrical connections...8 Installing the GPS antenna...10 Confirming that the datalogger is working properly...12 MultiDAT Senior (with operator interface)...12 MultiDAT Junior (no operator interface)...13 Setting the motion sensor...13 Initializing the MultiDAT...14 Installing labels...14 Maintenance...15 Replacing the battery...15 The datalogger s case...15 Appendix 1. Troubleshooting guide for the MultiDAT datalogger Confirm that the datalogger is receiving power...16 What could be wrong? Confirm that GPS signals are being received...17 What could be wrong?...17 Appendix 2. Hardware specifications...18 General characteristics...18 Digital inputs...18 Operator interface (not available with the MultiDAT Junior)...18 GPS receiver (optional)...19 Operating environment

3 Before you begin Identify your objectives for MultiDAT The MultiDAT datalogger system is designed to record productive time and other operating information for heavy equipment. MultiDAT lets you track the following aspects of the utilization of your machine: Recording utilization times for your machine, ranging from engine hours to the use of specific components. With the optional GPS receiver, monitoring the position and travel speed of your machine and the times when it enters and leaves certain locations in your operating area. Determine which data you wish to obtain prior to installation as it will determine which connections will be required. Make sure that you have all the parts required To install the MultiDAT hardware, you must have the following components: MultiDAT datalogger, in one of the following configuration: MultiDAT junior MultiDAT junior Garmin 15 MultiDAT junior SX1 MultiDAT senior MultiDAT senior Garmin 15 MultiDAT senior SX1 Note: The MultiDAT Junior is identical to the MultiDAT Senior, except that it lacks an operator interface that lets workers input operator identification numbers, stop codes, and activity codes. 3

4 The following accessories (included with all MultiDAT units): Fuse and fuse holder 2 sets of 4 mounting screws (1 set of self-tapping, 1 set of hex machine screws) White cable used for power supply connection and additional channel connections 4

5 Additionally, if you purchased a unit with either GPS option: GPS antenna GPS Garmin 15 (Low Resolution) GPS SX1 (High Resolution) And, optionally: GPS Protector and Anchoring Block The mechanic responsible for installing the hardware must have the following materials available: appropriate tools for making electrical connections tools for mounting the hardware components of the system inside the machine appropriate sensors (e.g., pressure switches) if specific machine systems, such as hydraulics, are to be monitored. More details on each component are provided in Appendix 2 Hardware Specifications. 5

6 Introduction Overview The datalogger can be configured to meet the needs of a wide range of machines and operations. Users can choose which machine functions they want to record as well as the recording frequency for each function using the MultiDAT PC software. This manual only covers the installation and connection of the recorder in the machine to be monitored. Refer to the PC software help file for details on configuring the data logger, downloading the data and preparing meaningful reports. Consult the connection guides Several guides are available to FERIC member companies to help you make the necessary connections between the datalogger and the machine being monitored, including instructions on your options for installing the sensors (e.g., pressure switches) required to monitor specific machine functions on several classes of machine (e.g., harvesters, skidders). Consult the MultiDAT website at for the most recent version of these guides. Technical support Before contacting us to report a problem, please consult the troubleshooting guide provided in Appendix 1 (page 16). This guide includes our recommended solutions to all problems that have been reported by users to date. To get technical support for the MultiDAT datalogger and the accompanying software, please contact your MultiDAT reseller or consult the address and telephone number printed on the cover of this manual. License and limitation of warranty and responsibility This user manual and the software that accompanies it are protected by Canadian copyright law (Copyright 2001, 2002, 2003, 2004 the Forest Engineering Research Institute of Canada [FERIC]); all other products are the intellectual property of their respective manufacturers or developers. With the exception of the names MultiDAT and FERIC, all other names are the trademarks of their respective owners. By choosing to install the MultiDAT equipment and software, you indicate your acceptance of the terms of this license and limitation of warranty and responsibility. Users assume all risks related to using these products, and neither FERIC, the manufacturer nor any distributor authorized to sell this product will be responsible for any damages or losses that are incurred by its use. 6

7 Installation Using the datalogger in the office In general, you will only use the datalogger in your office when you configure the datalogger for the first time, before installing it in the machine you will monitor. This requires you to connect the datalogger to a source of power and to your desktop or laptop computer. To connect the datalogger in your office: Attach the external AC power adapter to the datalogger, then plug it into an electrical supply. Connect the datalogger to your computer's serial port using the cable provided with the MultiDAT system. Page: 7 Note: the cables described above are supplied as part of the cable kit only. They do not come with each MultiDAT purchased. Installation of the MultiDAT in the machine We strongly recommend that a competent mechanic install the datalogger; the installer should have sufficient expertise to modify the electrical circuits of the vehicle or equipment on which the datalogger will be installed. See Appendix 2 ( Hardware specifications ) on page 18 for details on how to power the device and other information relevant to the installation. We recommend installing the datalogger itself inside the cab, in a dry, safe location sheltered from impacts and easily accessible to facilitate connection of the data shuttle or a portable PC when required. You can use the bolts provided with the device to attach the datalogger to the inside walls of the cab. A very common practice, that gives excellent results, is to install the MultiDAT in a window corner so that the view is not obstructed. For such an installation, use industrial velcro, precoated with adhesive. 7

8 Note: For the motion sensor to function properly, vibrations from the machine must reach the datalogger clearly. Avoid attaching the datalogger to a part of the cab that vibrates excessively or that attenuates vibrations excessively; both can produce unexpected results from the motion sensor. Electrical connections The datalogger comes with a multi-stranded 10-foot-long (3 m) connection cable. Each of the six wires (Figure 1) should be cut to the desired length to minimize the amount of electromagnetic interference and should be connected as follows: Figure 1. The datalogger's connection cable. Never connect the MultiDAT channel wires to a machine digital network (such as CanBus or OpenCan). Most recent harvester computers use such a network. Doing so could damage the machine computer or produce unexpected activation of its functions. 8

9 Wire Black Red Blue, brown, green, and white Connect to ground the machine s chassis, or the battery s negative terminal Use one of the two following options: 1. connect to a circuit that is active only when the machine s key is in the ignition position, or a circuit that is only active when the engine is running (like the circuit that feeds the engine hour meter if available) 2. Connect to the master switch The datalogger must be protected by the one A fuse that comes with the device. The datalogger uses less than 300 ma when idle (850 ma when drawing a full load) and can thus be connected to most existing machine circuits with no fear of overloading the circuit. The datalogger can be connected to a 12 V or 24 V electrical system without adjusting the voltage. These wires correspond to channels 1, 2, 3, and 4, respectively. If a channel is being used, connect it to a signal source with a voltage of between 5 and 28 V or to a channel that can be switched to ground, depending on what is available to you. Take note of the type of connection used and communicate this information to the person who will configure the datalogger using the PC software. See the section of the online help Configuring the datalogger for more information on the possibilities and limitations. Most standard configurations and reports assume that you connected channel 1 and 2 to the primary function of the machine (grab arms or saw activation for example) If you connected the red wire to the master switch, it is recommended to connect channel 4 to a circuit that is active only when the machine s key is in the ignition position, or a circuit that is only active when the engine is running (like the circuit that feeds the engine hour meter if available) Note: Replacement cables are available if you must transfer the datalogger to another machine and the original cable has become too short after cutting it to fit the original machine. 9

10 Installing the GPS antenna If the datalogger includes the optional GPS unit, another connector appears to the right of the power cord at the base of the datalogger (Figure 2). The GPS antenna attaches to this connector, with the antenna itself installed at a point high on the machine, unobstructed as much as possible by any part of the machine to improve the reception of signals from GPS satellites; if obstructions (e.g., an excavator s boom) block the antenna from seeing part of the sky, positioning accuracy can decrease greatly, and in some cases, the receiver may stop providing data until the situation is corrected. Figure 2. Connector to connect the GPS antenna to the datalogger. To install the antenna: 1. Choose an appropriate location for the antenna, generally on the roof of the cab. 2. Attach the antenna at this location. If the surface is steel, simply set the antenna in position at the chosen location; it will be held in place by its magnetic base. If the surface isn t steel, we suggest attaching a steel plate at this location to which the antenna can be attached. Note: Modification of a machine s cab with a drill or welder can reduce the protection offered by the cab's protective structures. To attach the antenna without using its magnetic base, use part of the machine such as the protective grill around the lights or another existing support rather than drilling or welding the cab. 10

11 Do not bend the wires. Mount so that the wires are not sharply bent. 3. Guide the antenna s cable from the antenna to the datalogger. Protect it against damage and avoid pinching the cable or bending it too abruptly. 4. Connect the antenna cable to the datalogger. A protective dome for the antenna is also available. (Contact the supplier of the MultiDAT system for details on pricing.) This protection should be used on any machine that works under forest cover. For harvesting machines, we recommend replacing the dome s magnetic clamps with bolts. 11

12 Confirming that the datalogger is working properly MultiDAT Senior (with operator interface) When you turn on the datalogger, it runs a self-test routine to test the indicator lights behind the buttons, the backlighting behind the labels, and the audible indicator, all of which are activated for a short period (Figure 3). Figure 3. Self-test routine for the MultiDAT Senior. After the test is complete, only the buttons for the operator code, stop code, and activity code should remain lit. The datalogger is then ready to be initialized. Then, depending on its configuration, the MultiDAT may show the following behavior: If the ability to capture stop codes has been enabled in the configuration file, the 0 button lights up while the machine is considered to be working and turns off when the machine is considered to be stopped (based on the signals received from the channel or channels defined in the configuration file). Flashing of the "X" confirms that the GPS receiver is operating properly. A single flash every few seconds indicates that a GPS position has been recorded; a double flash indicates that a corrected GPS position (using WAAS) has been recorded. 12

13 MultiDAT Junior (no operator interface) The MultiDAT Junior is equipped with two indicator lights at the base of the case, beside the connectors (Figure 4). When the datalogger s power is turned on, it goes through a self-test routine during which the red and green indicators light up for a few seconds. Figure 4. Self-test routine for the MultiDAT Junior. The datalogger can be configured so that the green indicator lights up whenever the motion sensor or data from a channel indicates activity. (See the section online help on "Configuring the datalogger" for details.) Flashing of the red indicator lets you confirm that the GPS receiver is operating properly. A single flash every few seconds indicates that a GPS position has been recorded; a double flash indicates that a corrected GPS position (using WAAS) has been recorded. Setting the motion sensor The motion sensor measures the machine s vibrations along three axes and is thus relatively insensitive to the orientation in which the datalogger is installed. However, each machine and even each position on a given machine can produce different vibration patterns, so the sensitivity of the motion sensor must be adjusted after each installation to accommodate these differences. The motion sensor s threshold can be set using either the data shuttle or a portable PC on which the MultiDAT software is installed. Refer to the PC software documentation or the shuttle software documentation for instructions on adjusting the motion sensor. 13

14 Initializing the MultiDAT Each MultiDAT can be configured using the PC software to record different information at different times. Once the MultiDAT is installed, connected and has its motion sensor adjusted, it must be initialized to receive the instructions about the way it will operate. Refer to the PC software documentation or the shuttle software documentation for instructions on MultiDAT initialization. Installing labels Note: These instructions don t apply to the MultiDAT Junior. If the datalogger has been configured to record activity codes or stop codes using the "labels" mode (see the online help for details), you can add these labels to the front of the datalogger to help the operator use the right codes. If not, you must develop some other means of identifying the three-digit codes that operators must enter. The labels are printed using the MultiDAT PC software. Note: Paper labels can deteriorate when wet, so if you print labels on paper, we recommend applying adhesive tape to the back of the paper to increase their rigidity and make it easier to insert and remove the labels. Cut out the labels along the guidelines and insert them beneath the datalogger s front membrane (Figure 5). Figure 5. Insertion of labels under the front membrane of the datalogger. 14

15 Maintenance There is very little maintenance required by the datalogger: Replacing the battery The datalogger comes with a non-rechargeable long-life battery that lets you retain data in the device s memory while the datalogger is not connected to a power supply. This battery should last at least 5 years when the datalogger is used under normal conditions, and cannot be replaced by the user; if it fails prematurely or reaches the end of its useful life, return the datalogger to the supplier for replacement of the battery. The datalogger s case The datalogger s case is sealed and should not be opened. To clean the case, use a non-abrasive cloth and gentle soap; solvents can damage the plastic membrane. For any repairs to the case, return the datalogger to the supplier. 15

16 Appendix 1. Troubleshooting guide for the MultiDAT datalogger This guide is designed to help you solve the most common problems that users of the MultiDAT datalogger have reported to us. Before contacting technical support for help, follow the three-step troubleshooting process in this appendix: 1. Confirm that the datalogger is receiving power. 2. Confirm that GPS signals are being received. 3. Confirm that you can communicate with the datalogger. 1. Confirm that the datalogger is receiving power The senior and junior versions of the datalogger indicate differently whether they are receiving power: Senior: The Operator, Stop, and Activity lights should be on at various times if the datalogger is receiving power. Unplugging and reconnecting the circular power connector at the bottom of the case will cause the datalogger to beep, and all the lights on the control panel will flash briefly to confirm that power is being received. Junior: The red and green lights at the bottom of the case will be on at various times if the datalogger is receiving power. Unplugging and reconnecting the circular power connector at the bottom of the case will cause the red and green lights to flash for about 1 second if power is being received. What could be wrong? If the datalogger is not receiving power: The red or the black wires may have become detached or broken due to vibration of the machine, contact with a moving part, or other problem. If that s the case, reattach the two wires securely. The red or the black wires may not be connected properly. The red wire should connect to a positive 12 or 24 volt DC source, and should receive power when the engine is turned on. The black wire should be connected to ground. The 1-amp fuse installed in series with the red wire in the datalogger s cable or the fuse in the machine circuit that powers the datalogger may have blown. If so, confirm that there is no problem with the power supply that is creating overvoltages and then replace the fuse. More than 30 volts DC was applied between the red and black wires, thereby damaging the datalogger. This can happen if the machine s alternator failed recently. Confirm that the alternator is now working correctly and then replace the damaged datalogger. The datalogger cable that connects to the circular central connector on the datalogger has been damaged, thus preventing power from reaching the datalogger. If so, replace the cable. 16

17 The center circular connector has been damaged. (Look for bent or broken pins. An undamaged connector has six pins that form a half-circle pattern.) If so, replace the connector. If none of these problems has occurred, contact technical support to have the datalogger repaired. 2. Confirm that GPS signals are being received If the GPS option has been installed, a round, 1/2-inch GPS antenna connector will be present to the right of the circular connector on the datalogger s case. If the datalogger is receiving power (see step 1 in this appendix), confirm that the GPS receiver is working properly. The process differs slightly for the senior and junior models: Senior: When the GPS receiver is receiving signals, the button will flash briefly every 10 seconds. Junior: When the GPS receiver is receiving signals, the red light on the bottom of the datalogger will flash briefly every 10 seconds. This confirms that the GPS antenna is in good working order, that the coaxial cable between the antenna and the datalogger is undamaged, and the GPS module inside the datalogger is working. What could be wrong? If the datalogger is not receiving GPS signals: Check the cabling to ensure that none of the cables or their connectors has been damaged, and that all cables are securely connected. If necessary, reattach loose cables or replace damaged cables or connectors. Confirm that the GPS antenna has an unobstructed view of the sky. Obstructions such as a boom can interfere with signal reception. If necessary, move the antenna to a new position that offers an unobstructed view of the sky. Confirm that the datalogger has been configured to record GPS information. If none of these steps solves the problem, contact technical support to determine whether it is necessary to have the GPS receiver repaired. 17

18 Appendix 2. Hardware specifications General characteristics Number of recordings (approx.) Resolution of the internal clock 1 second Data transfer to the PC Serial port Retention of data when the datalogger 5 years (with battery) isn t connected to a power supply Digital inputs Number of channels 4 Signal input voltage 5 to 28 V Type of contact Normally Open (NO) or Normally Closed (NC) Type of recording Timer, counter, or frequency counter Minimum signal duration in timer mode 1 second Maximum count per recording in 999 counter mode Frequency range possible in frequency 2 to 300 cycles per second mode (Hz) Interval between recordings in counter 1 minute to 1 hour or frequency mode Operator interface (not available with the MultiDAT Junior) Information that can be captured Operator identification (numbers available) Stop or activity codes possible (range) Operator number, stop code, activity code 000 to 999 Label mode 0 to 9 Numeric mode 000 to 999 Other characteristics Backlighting; visual and audible warnings Identification of stop and activity codes Printed labels (defined by the user) that can be mounted on the MultiDAT 18

19 GPS receiver (optional) Garmin Type of receiver GPS 25/15 SX-1 CSI Wireless Number of channels (10 when tracking WAAS) Post-processing No No Accuracy (approx.) 15 m/3 to 5 m <1 m with DGPS; <5 m without selective availability Additional interface n/a An additional connector lets you connect additional devices, such as a GPS navigation system. Operating environment Overall dimensions 23x13x6 cm Range of operating temperatures 40 to 85 C Input voltage Current Nominal Maximum 9 to 30 VDC 300 ma 850 ma 19

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