GKD SENSORZONE User manual

PROXIMITY WARNING SYSTEM
(WIFI) V2.0
M4000002 V2.5 - 05/2022
COPYRIGHT NOTICE
Intended audience: This document contains sensitive
information. It may not be shared with other parties without
the express written permission of GKD Technologies Ltd.
INSTALLATION MANUAL

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CONTENTS
Page
1 SAFETY AND WARNINGS 4
1.1 General 4
1.2 Devices Containing Batteries 4
1.2.1 Tags 4
1.2.2 Base Stations and Tag Test Units 5
1.3 Antenna 5
1.4 Magnets 5
2 GENERAL INTRODUCTION 6
2.1 System Summary 6
2.2 System Components 6
3 PLANNING / SITE SURVEY 7
4 MACHINE INSTALLATION 8
4.1 Antenna 8
4.1.1 Operator Tag Considerations 10
4.2 Base Station 10
4.3 Display 10
4.4 Beacon Sounder 11
4.5 Testing of Exclusion Zone 11
4.6 Final Fixing and Verification 11

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Page
5 INTEGRATION WITH HANDBRAKE OR DEAD MAN’S HANDLE 12
6 SITE INSTALLATION 14
6.1 Tag Test Unit 14
7 CONFIGURATION 15
7.1 Login Screen 15
7.2 Configuration Page 16
7.3 Log Page 18
7.4 Tag Page 19
7.5 Logout 19
7.6 Advanced Page 20
APPENDIX A - WIRING DIAGRAMS 21
APPENDIX B - HOW TO MAKE A CONNECTOR 25
APPENDIX C - TRACKUNIT CONNECTION 26

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1 SAFETY AND WARNINGS
1.1 General
The SensorZone proximity warning system is supplied as an audible and/or visual alert
system. It is not a protective device. The system does not initiate or perform any safety
related functions.
The SensorZone system is to be installed by professional installers who have completed
appropriate training.
All electrical installation must follow local regulations and be made by qualified installers.
The SensorZone proximity warning system is only to be used as a complement to existing
Health and Safety measures and practices.
The use of SensorZone does not replace professional machinery safe operating processes
and procedures.
It is recommended that all personnel on site receive training as to the operational
procedures of the SensorZone system.
This device complies with part 15 of the FCC Rules. Operation is subject to the following
two conditions: (1) This device may not cause harmful interference, and (2) this device must
accept any interference received, including interference that may cause undesired operation.
1.2 Devices Containing Batteries
1.2.1 Tags
The tags contain Lithium Thionyl Chloride batteries having 0.7 grams of Lithium.
BATTERY WARNING:
Fire, explosion and severe burn hazard. Do not recharge, crush, disassemble, heat above
100ºC, incinerate, or expose contents to water.
Follow all local regulations for the shipping of Lithium batteries.
For optimum battery life, tags should be stored in a cool, regulated (preferably around 20ºC
and never more than 30ºC), dry and ventilated area away from possible sources of heat and
open flames. Avoid exposure to direct sunlight for long periods of time.
The battery in the tag cannot be recharged, and attempting to do so can create fire,
explosion and severe burn hazard.
Tags that have reached end of life or are no longer required must be disposed of according
to local regulations.

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1.2.1.1 Damaged Tags
If you suspect the tag has suered impact or maybe damaged in any way that may damage
the battery DO NOT USE.
The tag should be removed and quarantined.
DO NOT attempt to take the tag apart.
Follow local regulations for the safe disposal of units containing damaged batteries.
1.2.2 Base Stations and Tag Test Units
The base stations and tag test units contain a CR2032 Lithium coin cell.
BATTERY WARNING:
Fire, explosion and severe burn hazard. Do not recharge, crush, disassemble, heat above
100ºC, incinerate, or expose contents to water.
For optimum battery life, base stations and tag test units should be stored in a cool,
regulated (preferably around 20ºC and never more than 30ºC), dry and ventilated area away
from possible sources of heat and open flames. Avoid exposure to direct sunlight for long
periods of time.
1.3 Antenna
Personnel wearing Active Medical Implants should keep a minimum distance of 21cm
from any antenna.
1.4 Magnets
If fitted, the magnets used on the base station and antenna mounting plates and the
beacon/sounder are Neodymium magnets. These are much stronger than other magnets
and care should be taken handling them.
Keep a safe distance of at least 30cm from any device that can be damaged by magnetism.
These might include (but are not limited to) heart pacemakers, CRT displays and televisions,
mechanical watches, credit cards and magnetically stored media such as hard drives and
video tapes.
Personnel using pacemakers should keep a safe distance from the magnets and should
move away from the magnets if they notice any eect.

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2 GENERAL INTRODUCTION
The SensorZone Proximity Warning System (PWS) is complimentary to (and not a
substitute for) existing safe systems and procedures of work.
SensorZone is a robust, high-quality Collision
Avoidance System – also known as a Proximity
Warning System – with a proven track record for
improving safety in the workplace.
2.1 System Summary
SensorZone PWS generates a low frequency
magnetic field, referred to as the exclusion zone,
around the antenna. This zone may be set at
between 3m and 10m (or 9ft to 32ft) radius. The
zone is nominally elliptical in shape. The exclusion
zone can be established by a single antenna for
small/medium sized vehicles or with two antenna
for larger vehicles. Users should familiarise themselves with zones in use.
A tag entering the range of the exclusion zone detects the magnetic field and replies to
the base station. The tag will warn the wearer with two pulses of vibration. The base station
initiates a visual and audible warning to the machine operator via the display, as well as to
personnel in the vicinity via external sounders and beacons.
Every tag detection is recorded in the built-in Datalogger
2.2 System Components
Base StationSounder / Beacon
(optional)
Antenna
(one or
two) ANDAND ANDAND
Vibrating Tag(s) Tag Test Unit
ANDAND
Operator
Display
Push Button
Display
OROR OROR
Details for the operation of the base station, displays, tag test and limiter units are contained
in the relevant operators manuals.
Watch our SensorZone
introduction to find out
how the system works.

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3 PLANNING / SITE SURVEY
The installation and commissioning of the SensorZone system requires consideration of the
safety objectives of the site, the types of equipment in use and the nature of the operation.
The following steps are envisaged:
1) Obtain a map of the site
2) Visit the site with the site management and identify the following:
a. Areas where equipment and pedestrians will be together, and the system is required to
warn of potential danger
b. Areas where pedestrians are safe and no coverage is required
c. Areas where warnings are not required as pedestrians are safe, but equipment may be
nearby and would normally cause warnings to occur
d. A clear trac and pedestrian movement plan e.g. designated walkways, trac flow
restrictions etc
3) Review the types and sizes of equipment to understand:
a. Will single or double antenna systems be required
b. What range is required
c. Which display type is required
d. Where base stations will potentially be installed
e. Where the antennas will potentially be mounted
f. Where and how the alarm/beacon will be mounted (if required)
g. Cabling requirements
h. Power supply sources and connectivity
4) Review site access points to determine where and how many tag testers will be
required, considering:
i. Throughput required (number of tags to be tested)
ii. Number of entry/exit points on the site
5) Conduct a site survey to assess potential sources of radio interference:
a. Power substations
b. Radio / TV broadcast stations
c. Mobile phone base stations
6) Run a test at the site to ensure that any system installed operates as expected.
Temporarily power a base station from an auxiliary socket and verify that the system
operates as expected by testing the exclusion zone at various points around the site.

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4 MACHINE INSTALLATION
There are four parts of the system to install in the vehicle:
The wiring for the in-vehicle components is dependent on the type of display and number
of antennas. The wiring diagrams for the four combinations are given in Appendix A.
For permanent installations, the supply voltage connections should be permanently
connected via a 2A fuse to a switched 12V or 24V vehicle supply such that the system is
active whenever the vehicle is operating.
The wiring of the system to the machine should be carried out by an approved or qualified
technician.
4.1 Antenna
The antennas are provided with a base plate and can be attached to the vehicle
with magnets, glue or bolts.
The placement of the antennas is critical to achieving the required exclusion
zone(s) around the machine. For small or medium sized machines, a single
antenna is usually sucient. For larger machines, a second antenna can be
added to create a larger exclusion zone, or to create two distinct zones.
Place the antennas in the expected locations but do not make a permanent fixing at this time.
Connect the antenna cable to the base station according to the appropriate wiring diagram.
The cable should be cut to length and wired to a connector (for details see Appendix B).
Important Note: The exclusion zones are elliptical
rather than circular, with the long axis along the
length of the antenna. This should be considered
when planning the location of the antenna.
Some example locations for antenna placement on
construction machines are given opposite. The same
principles will apply with other machines. Note that
these are indicative only and the actual position will
need to be verified as part of the installation process
to ensure the desired coverage is achieved.
Additional Note: The operators tag must be in the exclusion zone for the system to start
up (see Operator Tag Considerations below).
Antenna
(one or two)
Base Station Operator Display
(or Push Button)
Sounder / Beacon
(optional)
(8ft - 26ft)
(8ft - 26ft)
(9ft - 32ft) (9ft - 32ft)

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Excavator – rear and sides monitoring
Excavator - all round monitoring
Dozer – As a rule all around
monitoring is required.
Recommended installation
position is on the vehicle roof.
Wheel Loader - As a rule all
around monitoring is required.
Recommended installation
position is on the vehicle roof.
For an Articulated Dump Truck
with two antennas, the rear
antenna can be located under
the dumper bed or on the rear
chassis.
For guidance on
detection zone
sizing, scan here.

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4.1.1 Operator Tag Considerations
The operator of the machine must be wearing a tag. As this is a requirement of the
initialisation of the system, the exclusion zone must include the cab or operators position of
the machine.
If a rear detection range
is required, then move the
antenna, and ensure the field
penetrates the cab.
The operator tag will not
be seen when the operator is
in the cab. Either move the
antenna or increase the range.
The operator tag
will be seen when the
operator is in the cab.
4.2 Base Station
The base station is provided with a base plate and can be
attached to the vehicle with magnets, glue or bolts.
The base station can be located in any convenient place
on the machine, such as in the cab, engine bay or storage
compartment. A typical location is underneath or behind
the operator’s seat.
The plastic caps provided should be fitted on all unused connectors on the Base Station. This
is to ensure the IP rating of the base station and prevents the possibility of water entering.
The base station should be mounted in a place that is protected from jet washing.
4.3 Display
The display is fitted inside the cab and should be
installed so that the indicating LEDs are within the
view of the operator and the acknowledge button
is within easy reach.
Connect the display cable to the base station
according to the appropriate wiring diagram
(see Appendix A).
When using the operator display, the attached cable
allows connection to the machine power.
When using the push button display, connect the vehicle power supply directly to the base
station according to the wiring diagram (see Appendix A). Vehicle power supply must be a
switched vehicle supply.

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The operator display should be mounted in a place that is protected from heavy rain and jet
washing, and is normally intended to be mounted inside the cab. Where out-of-cab or open
cab operation is required, the push button display should be used.
4.4 Beacon Sounder
The beacon sounder should be mounted such that it is visible
to pedestrians outside of the machine. Typically, this will be on
top of the cab.
Connect the beacon sounder cable to the base station
according to the appropriate wiring diagram (see Appendix A).
The beacon sounder should not be jet washed as per the
operator display.
4.5 Testing of Exclusion Zone
Before fixing all parts of the system into place, the exclusion zone should be verified.
This should be completed for each machine.
1) With all parts connected, and with only the operator in the exclusion zone,
turn on the vehicle and activate the system.
2) Acknowledge the operator tag.
3) Configure the range required - see Section 7.2 page 16.
4) With the operator tag still inside the exclusion zone, walk another tag into the
zone and verify that the range for detection is as expected for the range set
and that the beacon sounder is visible and audible.
5) Repeat this around the vehicle to ensure that the coverage is as required and
appropriate for the vehicle. As a minimum, this should be verified at the front, back,
each side and the corners. Note: when leaving the exclusion zone, the tag must remain
outside of the zone for at least one minute before the tag will activate again.
6) If the coverage is uneven around the vehicle, reposition the antenna.
7) If the coverage is even but the wrong distance, adjust the range in the configuration.
8) If the beacon sounder is not visible or audible, reposition it.
4.6 Final Fixing and Verification
Once the testing of the exclusion zone is complete, the antenna, base stations, display and
beacon sounder can be installed with the appropriate fixing for the vehicle.
After fixing all the parts of the system, repeat the testing of the exclusion zone to ensure
that it is as required. This should be completed for each machine and a record kept of the
verification.

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5 INTEGRATION WITH HANDBRAKE OR DEAD MAN’S HANDLE
5.1 Warnings
The integration with the handbrake or dead man’s handle causes the operation of the PWS
system to change. Please read the document completely and understand the implications
for the operation of the system before undertaking this integration.
5.2 Summary
The GKD Proximity Warning System (PWS) can react dierently when a handbrake or dead
man’s handle is applied. There are two dierent modes and they can be used independently
or together.
1) Silence the alarms
2) Change the size of the detection zone (Range Select)
The decision to use, or the choice of these modes should be considered by the installer and
site operator to fit with the normal and desired operating conventions on the site.
The handbrake or dead man’s handle must be connected into the SensorZone Operator
Display for these modes to become active.
They cannot be connected to either the SensorZone Push Button Display or the Wireless
Display.
5.3 Description of the modes
5.3.1 Mode 1 – Silence the alarms
The white wire of the 8 Core Supply Cable, must be connected for this feature to be
active (please see information on page 13 and wiring diagrams in Appendix A for further
information.
In this mode, when the handbrake is applied or the dead man’s handle is raised, the alerts in
the cab are silenced. Specifically:
1) The external sounder/beacon (if fitted) does not activate during an incursion
2) The SensorZone Operator Display will not beep
Other alerts are still activated. Specifically:
1) The pedestrian SensorZone Tag will still vibrate on incursion
2) The SensorZone Operator Display will still illuminate the LEDs
These alerts are maintained so that the driver is aware of the presence of the pedestrian
close to the vehicle, even if the vehicle is stationary.
5.3.2 Mode 2 – Change the size of the detection zone (Range Select)
The blue wire of the 8 Core Supply Cable, must be connected for this feature to be
active (please see information on page 13 and wiring diagrams in Appendix A for further
information.
The SensorZone Base Station can be configured at
installation with two ranges, and the range used can
be selected through the SensorZone Operator Display
handbrake or dead man’s handle functions.
For guidance on
detection zone
sizing, scan here.

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The ranges should be determined for the specific vehicle, considering the desired operating
working practices and conditions, as well as implications to the range when considering
obstructions and other objects in the vicinity of the SensorZone system.
This mode can be used to reduce the occurrence of alerts when pedestrians are required to
make authorised approaches to a stationary vehicle. Due consideration should be given to
the warnings that are given to pedestrians close to the vehicle before it starts to move again.
5.4 Installation
Referring to the Operator Display connections section of this manual, the White wire
(handbrake or dead man’s handle) controls the silencing of the alarms, while the Blue wire
(Duty) controls the selection of the coverage zone.
The full specification table for the 8 core supply cable to the display is:
8 Core Supply Cable
Red (Positive Supply) Positive (powered) Supply either 12V / 24V fused (2A)
Black (Negative Supply) Negative Supply 0V
Green Relay 1 N/C to Positive (powered) Supply
Yellow Relay 1 N/O to Positive (powered) Supply
Brown Relay 2 N/C to Positive (powered) Supply
Violet Relay 2 N/O to Positive (powered) Supply
White (handbrake or
dead man’s handle)
Positive (powered) or no connection = normal operation
GND (0V) = Silenced Alarms
Blue (Range Select /
SmartBubble)
Positive (powered) or no connection = normal operation
GND (0V) = Range Select on
The relay outputs are not part of the handbrake or dead man’s handle integration but
provide additional controls to activate external beacons / sounders.
5.5 Configuration
There is no configuration of the Base Station required for the handbrake or dead man’s
handle input to silence the alarms.
To set the Range 1 and Range 2 coverage zones, follow the instructions in the Configuration
section on page 17 of this manual to set the desired ranges. No other configuration is
required for changing the coverage zones.
5.6 Test
If the handbrake or dead man’s handle modes are enabled at installation a full test of
functionality should be conducted prior to signing o the installation.
5.7 User Guidance
If the handbrake or dead man’s handle modes are enabled this functionality should be
included in onsite Driver and Pedestrian training or briefings.

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6 SITE INSTALLATION
In addition to the vehicle installation, the following equipment is installed on the site:
6.1 Tag Test Unit
The tag test unit should be installed in a convenient place that
allows all personnel going onto or leaving the site to test their
tags. The tag test unit is typically fixed to a wall and is powered
from an AC power adaptor.
The unit should be positioned for ease of use to reach the
button and see the indicating LEDs.
After installation, test that the
tag test unit is functioning correctly by testing a known
verified tag.
Clear operating instruction should be available at each
installation and recommendations as to procedures to be
followed if a tag is deemed to have not passed test.

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7 CONFIGURATION
The WiFi Base Station should work with any device and has been tested with PCs, Macs,
(Android and Apple) tablets and phones.
As long as the device is set to receive an IP address via DHCP, no configuration is required
apart from connecting to the required WiFi network.
Each WiFi base station creates a WiFi Network with a network name:
WBSxxxxx (Base Station) or WTTxxxxx (Tag Test Unit)
Connect to the WiFi network of the base station that you wish to configure or monitor.
The WiFi passcode is a unique random passcode and is printed on the label on the base
station. This can be changed once connection has been made to the base station.
Having connected your PC to the WiFi network, open a browser window and browse to:
http://192.168.4.1
Important Note: While the PC is connected to the base station, the PC will not have
internet access. Close all other programs and web pages on the PC while configuring the
Base Station.
The WiFi base station is configured and monitored via the WiFi interface as described on
the following pages.
7.1 Login Screen
Enter the appropriate username and password and click Log In
Default usernames can be user, installer and distributer. Installer has permissions to
configure the system, user has permissions to monitor and download log files but not to
change the configuration.
Important Note: Below are the default username and passwords.
**Please change these once you have logged into the system.**
For SensorZone User: Username: user Password: user
For SensorZone Installer: Username: installer Password: installer

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7.2 Configuration Page:
The default page after logging in is the configuration page. Note that options available on
this page may be dierent depending on the level of the logged in user.
1
2
3
1Displays the latest recorded system events
2Displays basic information about the base station, system set up and the firmware
versions installed. Note that changes are made in section 3. [Print System Info] provides a
printable version of the information for the system.

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3Configuration changes:
a. Use [Set Time/Date] to set the base station time and date to match the settings
from the browser/PC
b. Use [Range 1] and [Range 2] to set the ranges for the exclusion zone as described
in Section 2 above
c. Use [Set Wireless Display ID] if the base station is to be used with the Wireless
Display (see Wireless Display Manual).
d. Use [Set Machine ID] to change the machine ID to another name or number if you
would like the WiFi SSID to be something else.
e. Use [Set Driver Tag ID] if you want the system to only operate when a specific
Operator Tag is detected
f. Select [Tag Type]:
i. Standard – Any tag can be used to initialise the system. Where the first one in
the exclusion zone will be used as the operator tag.
ii. Driver – An operator tag must be used to initialise the system.
g. Select display [Set Button Function] to determine if:
i. Latched – silences the alarms for a tag that has entered the exclusion zone and
does not alarm again unless the pedestrian leaves and re-enters the exclusion
zone.
ii. Un-latched – only silences the alarms while the button is being held. The
alarms will reactivate when the button is released if the pedestrian is still in the
exclusion zone.
iii. Driver visible – the operator tag is still visible to other machines and will activate
the alarms of another machine if that comes too close. This is the recommended
setting for cab-less machines where the operator is not physically protected by
the cab. This setting protects the operator from other machines if they leave
their seat with the system active and are still in range of their own machine.
iv. Driver hidden – the operator tag does not activate the alarms of other machines
if they come close, unless the operator leaves the cab and steps outside of the
exclusion zone of his machine (or the machine is turned o).
h. [Latched Tag Limit] allows for setting a limited number of tags that can be latched.
Above this limit, the tags will still be detected and alarms raised, but they cannot be
latched.

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7.3 Log Page:
All events recorded on the base station are stored in a log file.
4
5
6
4To access the log file, click on [Read Log]. Note that this can take several minutes
depending on the size of the log file. The Read Progress bar will show the status of the
read.
5Events read from the log will be displayed in the Log Events section.
6Once the log file has been read, it can be saved to the PC either as a TXT or CSV file by
clicking on [Save to TXT File] or [Save to CSV File].

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7.4 Tag Page:
This page provides information about tags in range.
8
7
7Click on [Update Tag List] to populate the list of tags that are currently in the exclusion
zone.
8Tags in the exclusion zone will appear in the tag list box.
7.5 Logout
To logout, click the Logout Tab. Before logging out, remember to save any configuration
changes. There is no confirmation required to log out.

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7.6 Advanced Page
The advanced tab can be used for setting WiFi configurations and updating user passwords.
10
9
9[User Configuration] can be used for changing the dierent user passwords and
usernames. Users can only change information for their own user level login or lower.
The user needs to select the user to configure from the drop down list, then set the
username and new password below.
10 [WiFi Configuration] is used to change the basestation’s WiFi settings. The default
settings for the WiFi in the base station are to use channels 1 to 11 with maximum output
power of 20dBm in order to be compatible with all jurisdictions. This can be changed
for specific regions if that is required. It is the responsibility of the installer to ensure
that this is set correctly for the region of operation.
The WiFi channel can be set. The default is to use channels 0 to 9 based on the last
digit of the serial number of the base station. This can be changed to any channel
allowed by the region setting if interference is found on the site.
The WiFi passcode can be set. The default is a random passcode that is unique for each
base station. For convenience, this is printed on the label on the side of the base station.
If the WiFi passcode is lost, contact your distributor or GKD for assistance.
11 [Date Format Configuration] can be used to modify how the date is displayed.
11