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.