Deployment and Commissioning Procedure For Cat® Detect Proximity Awareness {7605, 7610, 7620} Caterpillar

Machine Control & Guidance Products

PROXIMITY AWARE (S/N: PA31-UP)

Introduction

This Special Instruction provides instruction procedure for deployment and commissioning of Cat Detect Proximity Awareness.

Reference: System Operation, UENR3246, "Cat^® Detect Proximity Awareness Onboard User Guide".

Reference: Operation and Maintenance Manual, SEBU8802, "Cat^® Detect Proximity Awareness Onboard System".

Reference: Special Instruction, REHS9127, "Machine Dimension Measure-Up Procedure for Cat^® Detect Proximity Awareness".

Reference: Fleet 4.0 Release Downloads & Documentation available at https://mining.cat.com/fleetsupport.

Reference: Cat ^® MineStar System Site Wireless Communications available at https://mining.cat.com/fleetsupport.

Reference: Cat ^® MineStar Onboard Compatibility Matrix_v7 June 2015 available at https://mining.cat.com/fleetsupport.

Important Safety Information

Do not perform any procedure in this Special Instruction until you have read this Special Instruction and you understand this information. Use only proper tools and observe all precautions that pertain to the use of those tools. Failure to follow these procedures can result in personal injury. The following procedures should also be observed.

Work safely. Most accidents that involve product operation, maintenance, and repair are caused by failure to observe basic safety rules or precautions. An accident can often be avoided by recognizing potentially hazardous situations before an accident occurs.

A person must be alert to potential hazards. This person should also have the necessary training, skills, and tools in order to perform these functions properly.

Safety precautions and warnings are provided in this instruction and on the product. If these hazard warnings are not heeded, bodily injury or death could occur to you or to other persons. Caterpillar cannot anticipate every possible circumstance that might involve a potential hazard.

Therefore, the warnings in this publication and the warnings that are on the product are not all inclusive. Ensure that any tool, procedure, work method, or operating technique you use that is not recommended by Caterpillar is safe.

Ensure that the product will not be damaged or the product will not be made unsafe by the operation, lubrication, maintenance, or repair procedures used.

Read and Heed foreword

The latest available versions of MineStar Office, Fleet Onboard, Interface Module firmware, GPS receiver firmware, and Terrain Onboard must always be used when enabling Proximity Awareness. This guide list the steps and some basic settings for the deployment of Detect Proximity Awareness. Do not take actions until you have read and fully understand the steps in this guide. After the initial configuration is completed, end users must ensure that to adjust the configurable settings to ensure that the system operates in a manner that aligns with the site-specific safe operating practices already in place.

This system relies on reliable site wireless infrastructure. It will not operate properly without infrastructure that meets the minimum site wireless requirements as listed on Mining.cat.com.

This system relies on accurate positioning data provided by the onboard GPS and the sites Positioning Base Station. Any hardware deficiencies in the onboard GPS systems, inaccuracy in the site survey, inaccuracy in the GPS app file, or site CRM broadcast issues will cause the system to not operate properly.

This system relies on correct Onboard configuration and MineStar files. Onboard files must be created and maintained in the Office and distributed to the onboard in sync. Onboard File Assistant should be used to perform this work. If the onboard configuration files and MineStar files are not of the latest available version from the Onboard File Assistant, the system will not work correctly.

This system relies on accurate machine dimensions. If the machine dimensions (Body Area, Avoidance Area, Path Extensions, and Path Scalars) are not correctly measured and entered into the Office, followed by machine type file generation and onboard activation, the system will not operate properly.

Pre-work Procedure

Prior to the deployment of Proximity Awareness, a site evaluation should be completed to ensure that all wireless infrastructure and server hardware meet the minimum requirements for the deployment of Proximity Awareness. Details on these requirements are maintained on Mining.cat.com.

If the sites infrastructure and hardware meet the minimum requirements the following pre-work must be completed prior to the deployment of Proximity Awareness.

1. Verify that the sites infrastructure meets the minimum requirements to support proximity awareness. Communication guide is available on Mining.cat.com.

2. Verify that the communications are acceptable by running heat by using the comms tool and by observing that corrections and All Machine Position (AMPs) are available.

3. Verify that all machines to have Detect enabled, have the latest display software versions installed by using the "Main Executable" column in MineStar Office Onboard File Assistant. Current software version can be found by referencing the "Cat MineStar Onboard Compatibility Matrix" located at https://mining.cat.com/detectsupport. If software is not up-to-date, it should be updated prior to enabling Proximity Awareness. Instructions on software updates are reference in the previously mentioned matrix.

4. Verify that the MineStar Office build is the most recent available version with all patches installed. This can be done by selecting the Help > About menu in MineStar Office. The most recent versions of MineStar Office can be reference at Fleet 4.0 Release Downloads & Documentation located at https://mining.cat.com/fleetsupport. If software is not up-to-date, it should be updated prior to enabling Proximity Awareness.

5. Identify a MineStar Champion who will be responsible for the management of the Proximity Awareness system at a site level.

6. Request a MineStar Office Detect License Key. Contact your MineStar support representative for details.

7. Request Terrain Onboard License Keys for all Terrain Onboard displays. Contact your MineStar support Representative for details.

8. Machine Measure Ups following the guide lines of Special Instruction, REHS9127, "Machine Dimension Measure-Up Procedure for Cat^® Detect Proximity Awareness" should be taken and recorded for later entry into MineStar Office and Onboard Topeconfig.txt files.

9. Onboard Machine Configurations must be created by updating the machine class configuration in the MineStar Onboard Baseline folder. Do not send configuration files with Proximity Awareness enabled at this time. Sending Onboard configurations will be completed later in this guide. The GPS antenna X, Y, and Z values from Step 4 will need to be entered into the class-specific Topeconfig.txt files. See appendix for reference and UENR3246 for more details.

10. Enable Multicast.

    1. In MineStar Supervisor, enable MultiCast.

    2. In Supervisor CommsServer, enable MultiCast.

    3. Update the office and Onboard Configurations for AMP Messages.

       1. Change update period to a value that meets the sites requirements.

       2. Change publish period to a value that meets the sites requirements.

       3. Disable unicast address in machine configuration and in the Office.

          Note: If combining Terrain Office with MineStar Office, ensure that the machine IDs are identical between the two systems. The machine and machine type MWFs will be sent from MineStar office once the "Detect" feature set is enabled.

11. PR2 Update rates in MineStar Supervisor under Setup > System Options > Machine Broadcast.

    1. Update the office Configurations for PR2 intervals when using the "Build Card" process for managing Tope Configurations.

       • Period of time between PR2's = 5s

       • Distance between PR2's = 150

       • Minimum period of time between PR2's = 0.48

    2. Publication rates

       Note: If the "Build Card" process is not used, then the Topeconfig.txt files must be manually updated.

       • Position Time Interval = 5.0

       • $Position Distance Interval = 150

       • $ Position Time Minimum Interval = 0.48

12. AMP configuration. AMP distribution is configured in MineStar Supervisor under Setup > System Options > Machine Broadcast.

    1. Enable Machine Broadcast = Check

    2. Enable Multicast Delivery = Check

    3. Multicast URL = IP / Port

       Note: This IP and port also needsto be applied to the topeconfig.txt file as the "$ Multicast Address 0 =224.100.100.100" and the "$ Multicast Port 0 =13000" keys.

    4. Multicast URL = Uncheck

    5. Update Period = 0.5

    6. Publication Period = 1

    7. Maximum Time Between Update = 300

    8. Startup GPS Timeout = 300

    9. Clock Accuracy = 1

       Note: This value may need to be increased depending upon the site network.

    10. Machine Off Inclusion Period = 60

    11. Compressed AMP = Yes

    12. Publish Latency Statistics = No

13. Stop and Restart MineStar services to apply changes.

14. Coordinate Transformation System.

    For sites using Survey Meters no changes to the coordinate system are required to WKT

    1. Calculate the WKT system in DD format.

       Note: Need DC file and CT Tool Box.

    2. From Option Sets, select GPS Coordinate Transform.

    3. Uncheck "Enable Coorindate transformations".

    4. Select WKT and copy the WKT system in DD format to the WKT text area and click the Apply button.

    5. Publish Coordinate System once completed.

    6. Stop and Restart MineStar services to apply changes.

15. Incident messages - Check that all messages contain the required heading information. Remove those that do not. Table 1 is a list of messages that contain the correct position information.
    Show/hide table

    Table 1

    Correct	Incorrect	No Impact
    PositionReport2	Shutdown	ZoneUpdate
    ProximityIncident	Startup	ZoneUpdateResponse
    SpeedIncident	OperatorChange	AllMachinePositions
    ZoneIncident	RemoteOperatorLogin	Startup2
    Shutdown2	StateChange	Startup3
    	Mayday	TimeAdjust
    		GoTo
    		GoToResponse

16. For the machines that will have PA enabled in the Office Client, go to "PitLink Machine Finder".

    1. Remove Machine Broadcast message line. This will prevent issues should multicast and unicast both be enabled.

    2. Select the Proximity Awareness feature set for the machine

17. Thin Client Map

    1. Make Spacial Stores as required.

    2. Restart services.

18. Changed the Map Service Location from localhost:7070 to http://NATCPMS0002:7070, if not already completed.

    1. Restart as needed to apply change.

Instruction For Enabling Proximity Awareness

1. Add Detect Office License Key with Detect support, minestar.lic, to the appropriate folder of the Office server.

   1. Restart Services

2. Enter the Machine Dimensions recorded during Step 3 of the "Pre-work Procedure" section into each machine class. The preferred method to do is through the Class Editor in the MineStar thin client.

3. Enter the machine class speed limits. The preferred method to do is through the Class Editor in the MineStar thin client.

4. Create any Proximity Zones that will be utilized by the site.

5. After all Machine dimensions have been entered, generate a new machine type mwf file using the Office Onboard File Assistant. Once that file has been created ensure that the file is sent to all machines.

6. For the machines utilizing Proximity Awareness or Fleet Onboard software, build a new Topeconfig.txt file using MineStar Office Onboard File Assistant. Once the file is built, review and ensure that each machine class has a unique version number and the keys required to enable Proximity Awareness. The MineStar Champion will determine the version numbers and site configuration key requirements.

   Note: Refer to Special Instruction, REHS9122, "Procedure for Installing Cat^® Fleet Onboard Application Software on the Caterpillar Color Multi-Purpose Display (CMPD)" for software installation and configuration.

System Check Out and Validation

1. Ensure that the Proximity Awareness system is operating and meets the following functional requirements.

   • Submission of PR2 messages

   • Submission of Incident event messages

   • Reception of AMP messages

   • Visual proximity alarms

   • Audible proximity alarms (when equipped with an alarm

   • Capture and visualization of events in the Office

   • Business Objects reporting of proximity events

2. Availability of Detect Reports

   • DE001

   • DE002

   • DE003

   • DE004

   • DE005

3. Use the "Triangle" check-out process to validate that the machine body area is visualized correctly onboard and in the office.

   1. For Validation of avoidance and body areas on a rotational machine create a triangular zone or waypoint with one corner based at the origin of a machine. The second corner located at the body area of the machine and the third at the avoidance area of the machine. Rotate the machine and ensure that the boundaries align visually within a tolerance of reported GPS accuracy.

   2. For Validation of avoidance and body areas on a linear machine create a rectangular zone or waypoint over a chock ditch that will consistently locate machines of similar class in the same location. The rectangular zone should be the same size as the machine body area for the machine class to be validated. Drive the machine into the chock ditch and ensure that the boundaries align visually within a tolerance of reported GPS accuracy.

PM interval or Continued System Check-Out

System components

The system should be inspected every 500 hours for physical defects in the following components:

• Display touch screen

• GPS antenna

• GPS antenna cable

Network latency

The network must bewell maintained and should continue to meet the site communications requirements.

This should be checked monthly or after and major site network maintenance has been performed. Contact the network provider or your Caterpillar dealer for details.

Specific Scenarios

Specific scenarios to observe operations in are listed below. Observe system behavior. Ensure that and machine interactions that result in boundary violations submit the appropriate messages to the office.

• Loading

• Shovel Loading

• Single side

• Double side

• Wheel Loader Loading

• Clean up around shovel (if applicable)

• Spotting and backing under loader

• Straight Haul Roads - Same Direction of Travel

• Straight Haul Roads - Opposite Direction of Travel

• Curved Haul Roads - Opposite Direction of Travel

• Machines at intersection

• Truck Dump with Dozer

• Alarm Filter During Loading

• Light vehicle passing Haul Truck (if allowed at site)

• Speed limit

Troubleshooting

For General Issues Related to the Onboard Software

1. Ensure that the issue encountered does not have a documented cause and solution by checking the latest Service Magazine and Technical Information Bulletins available on SIS web.

2. Ensure that the latest production software is installed and that other system software are updated to as per the compatibility matrix.

3. Ensure that latest MineStar MWF files have been sent to the machine and activated.

4. Ensure that the correct configuration file has been sent to the machine.

5. Ensure that the correct window or display window configuration has been sent to the machine.

6. Ensure that the most up-to-date GPS application file with site coordinate details has been sent.

7. Ensure that the Onboard and Office IPs are correct and have been configured with the correct ports. Check the Onboard Initial Configuration. Check the machine in Machine Finder in MineStar Office.

8. Reboot the onboard system by cycling power to the system.

9. If issue continues identify the feature related to the issue and review troubleshooting material related to that feature.

For Issues Related to the Onboard Hardware

1. If any component or harness has recently been replaced ensure that the connections have been correctly made and the component is configured correctly.

2. Check all components in the system for battery power, key switch power, and ground.

3. Ensure that power indication lights are powered and indicate normal operation.

4. Check communication cables and wiring between all components. Inspect connectors for damage and extracted or cut wires. Inspect GPS cables for exposed coax shield.

5. For Ethernet based components check communications from the office to the component and from the switch to the component through ping methods.

For Issues Related to Site Infrastructure

Identify where the system fault is by narrowing the issue.

Communications:

• All Machine Position Message (AMP)

• Corrections

• Machine position reporting (PR and PR2s)

• Machine to Machine communications (P2P)

Customer supplied Ethernet switch:

• Is the switch powered.

• Can the office communicate with the switch.

• Can components connected to the switch communicate.

• If the switch is configurable, are the appropriate ports open.

• Are the speed and communication settings correct.

GPS Issues

1. Check whether the GPS module is powered.

2. Check whether the system detail indicators are properly illuminated for Power, Corrections, and Satellites.

3. Check whether the harness is correct for system connection.

4. Check for the antenna cable connections tight.

5. Check whether the antenna is free from major damage.

6. Check whether the cable is free from damage and worn shielding.

7. Check whether the correct appfile is been loaded with site-specific coordinate details.

8. Check whether a new baseline appfile is been downloaded, system coordinates is imported, and installed to ensure that the current appfile is not corrupted.

9. Check whether the corrections are available near 100% of the time.

10. Check whether the firmware is up-to-date and matching with the compatibility matrix.

Onboard Software Issue

Is the issue related to a single unit or multiple units.

Single unit:

1. Run the file system, erase tool, and reinstall the software.

2. Ensure that the latest configuration and MWF files are sent from the Office.

Multiple units:

1. Typically a corrupted or incomplete file was sent from the Office.

2. Ensure that the latest software has been installed. Only the most recent versions of Onboard software are able to recover from incomplete or corrupt files.

3. Reboot all displays using either, MineStar Office, Remote Tools, or Onboard machine keyswitch.

4. Verify that Office MWF files are correct and complete and resend.

Machine information

1. For machines equipped with VIMS or NonCat Health compatible with MineStar Onboard systems.

2. Ensure that the correct connection to the Onboard System has been made.

3. Ensure that a compatible version of software has been installed.

4. Ensure that the communications have been configured correctly.

For Issues Related to the Detect Office

1. Refer to the MineStar Office help documentation packaged with the product.

2. Follow the site-specific support plan for contacting MineStar Support.