<B>Installation and Configuration of the Driver Safety System Forward Facing Camera for Mining Applications</B> {7347, 7348} Caterpillar

Machine Control and Guidance Products

CATSAFETY (S/N: SSX1-UP)

Introduction

Do not perform any procedure in this Special Instruction until you have read the information and you understand the 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 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

When configuring the Driver Safety System Forward Facing Camera, it is important that the parts are labeled with the configured address and that those configured addresses are associated with a machine to be installed on. Failure to do so can result in mismatched video.

When configuring the frame rate and quality guide lines, follow the recommendations or consult with your technical representative. Failure to do so will limit the black box recording time frame available.

Safety Section

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Do not operate or work on this product unless you have read and understood the instruction and warnings in the relevant Operation and Maintenance Manuals and relevant service literature. Failure to follow the instructions or heed the warnings could result in injury or death. Proper care is your responsibility.

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Climbing equipment may be required to access this service point. Refer to the Operation and Maintenance Manual, "Mounting and Dismounting" topic for safety information.

Required Parts

Depending on region, the camera kit may be available only as a reference. Order the parts in the parts list if the kit is not stocked in your regional distribution center.

Accessory parts may be required for some installations. Review the installation accessory table for reference and ensure that someone familiar with the machine and the CAT Driver Safety System has reviewed this installation instruction.

Additional items for configuration

• DSS Software Version 4.5 or greater

• Power Supply

• Lab harness to power system

• List of IP addresses that can be assigned to the DSSM Forward Facing Camera

• List of MAC addresses of existing DSS installations

• Technician Laptop Computer

• Orlaco Camera Configurator (Download from Dealer.Cat.Com)

• DSS Bench ECM to Validate Camera Configuration

• Ethernet Switch

Additional items for installation

• Metric socket set

• Drill bit set

• Cable ties

Configuring the Forward Facing Camera With a Static IP Address

The section below covers the configuration of the Forward Facing Camera for use with a Static Address. Ensure that the appropriate networking accommodations have been made and the connection scenarios in the Camera Connection and Networking Options section have been reviewed.

Unconfigured Unit Connection

1. Power the 512-8671 Camera using the 565-5974 Wiring Harness and a 12-24 Vdc power supply. Power is location 1 and ground is location 2.

   Reference: Refer to the wiring details at the end of this document.

2. Download the ORLACO Camera Configurator from Dealer.Cat.com.
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3. Launch the configurator.

4. Select "Run DHCP Server."

5. Note the IP address provided by the DHCP Server
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6. Enter the IP address and 8001 Port Number into the Camera IP address box.

   Note: Configuration of the technicians PC may be required for static connections. Set the PCs Ethernet address to an address in the subnet of the camera to connect.

7. Select Connect.
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8. The configuration page will open with default settings input.
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9. Do not adjust the Stream Protocol.

10. Enter the DSS Control Module IP address, MAC Address, and Port Number of 50004 into the Stream Destination.

11. Disable DHCP.

12. Set Stream at Boot to Stream.

13. Set Dynamic Range to HDR.

14. Set Overlay to Enable.

15. Set VLAN at 0.

16. Program a Camera IP address and Subnet provided by the customer in the EMOS box.

17. Set Stream Source Port Number to 50004.

18. Set the Communication Port Number to 8001.

19. ROI Configuration Overhead Mounting (Cat^® logo upside down)

    1. ROI Index: 1

    2. Max Bit Rate: 50

    3. Frame Rate: 2

    4. Video Compression: JPEG

    5. Image Width: 640

    6. Image Height: 480

    7. Corner P1 (X,Y): 1280, 960

    8. Corner P2 (X,Y): 0, 0

20. ROI Configuration Dash Mounting (Cat^® logo right side up)

    1. ROI Index: 1

    2. Max Bit Rate: 50

    3. Frame Rate: 2

    4. Video Compression: JPEG

    5. Image Width: 640

    6. Image Height: 480

    7. Corner P1 (X,Y): 1280, 960

    8. Corner P2 (X,Y): 0, 0

21. Select Apply and reboot the camera by cycling power for the changes to take effect.
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    Note: Reconnecting to the Camera using the configuration will show default values from the tool, not the programmed values. Any changes will require all values to be reprogrammed.

    Note: Higher frame rates can be programmed, but black box time periods will be limited.

22. After the camera reboots, if a DSS system is available, configure the application to communicate with the camera and restart the DSS system.

23. The camera view can be verified by connecting to the DSS technician interface and navigating to the Diagnostics Page.

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DSS Application Configuration

Existing DSS Installation

1. Connect the Ethernet cable harness to the DSS system through an Ethernet Switch.

2. Log in to the DSS IVS webpage.

3. Navigate to Configuration, Peripherals, Forward Facing Camera.

   1. Enable the FFC using IP Address.

   2. Enter the IP Address

   3. The High-Quality Profiles and Low-Quality profiles will need to be configured here or a configuration IVSconfig.xml can be loaded if requested through the Zendesk support.
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4. High-Quality Output Settings

   1. Grayscale: Unchecked

   2. Quality: 100

   3. Resolution Divider: 1

5. Low-Quality Output Settings

   1. Grayscale: Checked

   2. Quality: 30

   3. Resolution Divider: 0.33
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6. Each Event type has options to include FFC images. These images should be configured in accordance with customer requirements.
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7. The manual events have Quality options and DFC options. These images should be configured in accordance with customer requirements.

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Forward Facing Camera Enablement Using the Installation Wizard

The following window allows the DSS FFC to be configured during the manual software installation process. All configuration values for Events and Quality should then be included in the DSS IVCconfig.xml. The configuration file can be requested through application support using the Zendesk support system

Either the MAC or IP address is required for this type of configuration.

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Installation Procedure

Physical Installation of the Driver Safety System Forward Facing Camera

Prior to installation of the camera identify a location the meets any customer requirements and will allow the camera view forward of the machine to be unobstructed.

Many machines offer an overhead accessory rail or visor support that can be used for mounting the camera.

The harness will be routed from the Camera back to the DSS Control Module or onboard network switch. The camera is not powered by the ECM. Switched power and an adequate ground are required to power the camera. Select a protected circuit to power the camera and wire a connection terminating to a 155-2270 Connecting Plug Kit to be connected to the 565-5974 Wiring Harness for the camera.

The communication architecture must be understood prior to installation. Review the networking scenarios in the Camera Connection and Networking Options section.

Camera Dimensions and Mounting Options

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Camera Harness Wiring Diagram

The 565-5974 Wiring Harness for the camera is 5 meters in overall length. It features M12 D code connector and 271-5590 Connector Plug As at the camera end and a RJ45 plug and 151-9278 Receptacle As at the machine end.

Illustration 16	g06400135

Camera Connection and Networking Options

For machines utilizing the Base Machine Data Interface, the camera can be connected to Ethernet 2. The DSS Module will be connected to Ethernet 3. Ethernet 1 will be for communications to customer Radios or Ethernet Switches. Ethernet 4 will be for Service.

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For machines utilizing a customer Router or Ethernet Switch, the camera can be connected to an available Ethernet port.

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For machines utilizing the Internal Wireless or Cellular Modem of the DSS 4.0 Module, the camera can be connected to the Modules Ethernet port.

Illustration 19	g06400188

For machines utilizing the Base Machine Data Interface, the camera can be connected to Ethernet 2. The DSS Module will be connected to Ethernet 3. Ethernet 1 will be for communications to customer Radios or Ethernet Switches. Ethernet 4 will be for Service.

Illustration 20	g06400191

For machines utilizing a customer Router or Ethernet Switch, the camera can be connected to an available Ethernet port.

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Reference Installation

The camera can be mounted on the interior or exterior of the cab. The camera can be mounted in the standard or inverted position. The reference installation below shows the camera mounted in the cabs interior in the inverted manner. This has been found to reduce the need to clean the camera lens, provide the best field of view, and reduce operator obstruction.

In some instances, a customer bracket or mounting adapter may be required. Evaluation of the machine prior to installation is recommended.

Prior to mounting the camera, it is recommended that the networking architecture is understood, and that the camera is configured.

1. Identify the mounting location.

2. Ensure that a slot of 6 mm (0.24 inch) by 40 mm (1.570 inch) or two 6 mm (0.24 inch) holes with 40 mm (1.570 inch) of spacing between the holes are available to mount the camera. If not, evaluate the mounting location and drill two 6 mm (0.24 inch) holes allowing 40 mm (1.570 inch) of space between the holes as required.

   Note: Ensure that the holes will not interfere with existing machine components or electrical wiring runs.

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   Illustration 22	g06400394
   6mm x 40mm mounting hole location

3. Identify the camera harness routing path.

4. Remove the necessary cabin panels and trim to allow access to route the harness.

5. Assemble the camera.

   1. Insert the 10mm bolts into the mounting base.

   2. Insert the camera to the bracket.

   3. Insert the lock washers into the mounting base.

   4. Mount the bracket into the mounting base.

   5. Insert the pivot bolt and the Nylock nut.

   6. Mount the assembly to the previously drilled 6mm holes or slot location on the machine. Reference Test step 2.

   7. Insert the two washers and thread the two nylock nuts onto the 10mm mounting bolts.

   8. Adjust the camera to the desired alignment and tighten all bolts.
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   Illustration 23	g06400401
   camera and mounting parts included in the 512-8671 Camera

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   Camera mounted in the inverse position (Cat® Logo Inverted)

6. Connect the M12 connector of camera to the camera harness.

7. Connect the 2-pin power and ground connection of the camera to the camera harness.

8. Route and secure the harness towards the DSS Module, PLE, Radio, or Ethernet switch to be used for communications.
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   Illustration 25	g06400418
   Typical Install showing overhead Cab Wire Routing

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   Illustration 26	g06400421
   View from Operators position

9. Connect the RJ45 connection to the appropriate communications connection.

10. Connect the 2-pin power connector to an appropriate power connection. Use the 155-2270 Connecting Plug Kit from the reference parts list to make this connection.

    Note: This connection is made to a protected switched circuit.

11. Configure the DSS Module to communicate with the Forward Facing Camera. Reference the DSS Application Configuration Section.

12. After the installation and configuration have been completed, the validation in the next section can be completed.

13. After successful validation, the harness should be secured, and the panels and trim removed should be reinstalled.

Validation of the Installation and Configuration

Once the physical connections of the camera have been made and the configuration is complete. Events can be created to validate the capture of both camera views.

Communication to Zendesk support that testing will occur can be done to allow events to be classified as testing.

Manual Image (4.0 Camera Only)

Manual images can be taken at any time. Ensure that the manual capture is configured. The enable mode does not need to be met. Press and hold the camera LED on the bottom side of the camera for 3 seconds. After 3 seconds audible feedback will be heard indicating that the image was captured. The image will then be uploaded to DSSi and the notifications will occur based on the customer-specific requirements.

Illustration 27	g06400427
Manual Recording with Forward Image Only (configurable)

Manual Video (4.0 Camera Only)

Manual videos can be taken at any time. Ensure that the manual capture is configured. The enable mode does not need to be met. Press and hold the camera LED on the bottom side of the camera for 1 second. Audible feedback will be heard indicating that the video was started and the LED on the camera will flash while the record takes place. The video will then be uploaded to DSSi and the notifications will occur based on the customer-specific requirements.

Illustration 28	g06400430
Manual Recording with Forward and Driver Video (configurable)

Set the DSS system to always enabled mode for the Fatigue Event through the interface configuration. Create a fatigue event by closing your eyes while in the cameras field of view. Fatigue settings can vary by site, ensure that you are able to meet the controlled closure threshold. Once the fatigue alarms have played the event will be uploaded to DSSi and the notifications will occur based on the customer-specific requirements.

Illustration 29	g06400432
Fatigue with Forward and Driver Video

Set the DSS system to always enabled mode for the Distraction Event through the interface configuration. Create a distraction event by moving your on head orientation outside of the distraction limits while in the cameras field of view. Distraction settings can vary by site, ensure that you are outside of the viewing limits for the configurable threshold. Once the distraction alarms have sounded the event will be uploaded to DSSi and the notifications will occur based on the customer-specific requirements.

Illustration 30	g06400436
Distraction with Forward and Driver Video