Woodway Opti-Link Guide

INSTALLATION & OPERATION
Opti-Link
ENGINEERS FOR THE EMERGENCY WARNING INDUSTRY

Opti-Link WOODWAY Installation and Operation
Woodway Engineering Ltd OPTINS-4.0 Rev 4 Page 1 of 9
December 2007
Disclaimer
This document is intended to be used as a reference guide for the installation and operation of the Opti-Link Control
System.
Every effort has been made to ensure the reliability and accuracy of the information contained in this manual at the time of
going to press. However, specifications and procedures are subject to change due to our constant endeavours to meet
customer requirements, and to maintain a research and development process of continuous improvement for all
Woodway products.
Woodway Engineering Ltd reserves the right to make changes in product and documentation specifications and
procedures at any time and without notice. The information contained in this manual is believed to be reliable and
accurate with regard to the Opti-Link Control System. The company shall not be held liable for improper installation,
operation, or maintenance of the system in circumstances where procedures and specifications have not been followed
correctly. It is essential therefore, that you follow the specifications, procedures, and recommendations outlined in this
manual.
©2005 Woodway Engineering Ltd. All Rights Reserved
Important Installation and Safety Notes
Modules and connectors are not waterproof. Install modules and cables in a dry
location away from excessive heat, humidity and any components likely to
damage the system.
It is the installer’s responsibility to ensure that;
the method of installation does not damage or interfere with vehicle
equipment and wiring.
if the vehicle is fitted with airbags, the installation does not interfere
with the operation or effectiveness of the airbags or will cause the
equipment to become a projectile that could cause death or injury.
all connections to chassis are taken direct to the battery.
fuse ratings are changed to suit specific applications.
The proximity of certain radio equipment may interfere with Opti-Link data
transmission. To reduce this possibility, Opti-Link and radio equipment wiring
should always be kept well apart and should not, under any circumstances, be
harnessed or fastened together.
The installers should supply all mounting fixings.
It is the user’s responsibility to ensure that;
the system is used in a safe and responsible manner to ensure the
safety of both themselves, their passengers, other road users and
pedestrians.
the system and its installation are properly maintained to ensure its
effective operation.
Failure to follow these notes and safety guidelines may result in damage to the
product and/or vehicle and may cause injury to personnel or bystanders.

Opti-Link WOODWAY Installation and Operation
Woodway Engineering Ltd OPTINS-4.0 Rev 4 Page 2 of 9
December 2007
Contents
THE OPTI-LINK CONTROL SYSTEM............................................................................................................................3
SUPPLY CHARACTERISTICS:.............................................................................................................................................3
APPROVALS:.....................................................................................................................................................................3
THE KEYPAD INTERFACE MODULE............................................................................................................................3
THE OUTPUT/RECEIVER MODULE..............................................................................................................................3
SYSTEM OPERATION ......................................................................................................................................................4
WALK TEST.......................................................................................................................................................................4
SLEEP/WAKE UP FUNCTION ............................................................................................................................................4
AUDIBLE AND VISUAL WARNINGS.....................................................................................................................................4
AUTOMATIC ARRIVAL SWITCHING ....................................................................................................................................4
EXTERNAL 999 SWITCHING..............................................................................................................................................4
PA MICROPHONE..............................................................................................................................................................4
MOUNTING ........................................................................................................................................................................4
DEFAULT PROGRAMME.....................................................................................................................................................4
KEYPAD PROGRAMMING...............................................................................................................................................5
KEYPAD LOCKOUT ............................................................................................................................................................5
TO PROGRAM P1: .............................................................................................................................................................5
SWITCH SELF-CANCELLING MODE:...................................................................................................................................5
TO PROGRAM THE BUTTONS FOR SELF-CANCELLING MODE:...........................................................................................5
TO PROGRAM THE BUTTONS FOR MOMENTARY OR LATCHING OPERATION:....................................................................5
SPECIAL STROBE SETTING:..............................................................................................................................................5
EXTERNAL 999 INPUT.......................................................................................................................................................5
CHANGING AND FITTING THE SWITCH LEGENDS..................................................................................................6
TO FIT THE SWITCH LEGENDS:..........................................................................................................................................6
TROUBLESHOOTING.......................................................................................................................................................7
OPTI-LINK SYSTEM INSTALLATION WIRING DIAGRAMS......................................................................................8
SYSTEM WIRING...............................................................................................................................................................8
AUXILIARY RELAYS ...........................................................................................................................................................9
BETA SIREN INSTALLATION –HANDS FREE CONTROL....................................................................................................9

Opti-Link WOODWAY Installation and Operation
Woodway Engineering Ltd OPTINS-4.0 Rev 4 Page 3 of 9
December 2007
The Opti-Link Control System – Fig 1
The Opti-Link Control System provides a flexible and intuitive
control interface between the driver and the vehicle’s
equipment. The complete system typically comprises the Opti-
Link Keypad, Keypad Interface Module and a data-encoding
Output/Receiver Module.
Supply characteristics:
Supply voltage: 12Vdc
Current draw: Maximum (All switches active) 6.8A Minimum
(Sleep Mode) 0.01Amps
Approvals:
VCA Approved to 72/245/EEC amendment 95/54/EC
CE Marked
PITO AES Specification 5 Issue 9
The Keypad Interface Module – Fig 2
The Keypad connects to the Keypad Interface Module
(Figure 2) via a ‘keyboard’ style cable which should be
secured with a tyrap to the cable tie post after connection. The
Keypad Interface Module encodes the Keypad Module status
and provides power and data output which may be routed to
individual Receiver/Output Modules (Figure 3) or the
Woodway Lightbar via copper wire. PA volume adjustment
can be made from the top of the Interface Module via a blue
single-turn variable resistor. (See figure 2). To increase the
volume turn clock wise and anti-clockwise to reduce the
volume.
The Output/Receiver Module – Fig 3
The Output /Receiver Module decodes the data and activates
the required outputs via a 14-way connector (note that position
14 on this connector is not used). A green ‘Data OK’ led
flashes to indicate that the data link is functioning. The switch
outputs from the Output /Receiver Module interface directly
with the low current control wiring of Woodway-supplied light
bars, sirens, and strobe power supply systems. The outputs
may be used to control high current auxiliary equipment via
automotive relays. The output circuits incorporate back emf
protection eliminating the need for diodes to be placed across
the coils of any relay used.
The output channels of the Output Receiver module are self
limiting to prevent damage should the load on any channel
exceed approximately 0.5 amps. In order to prevent damage to
the electronics within the receiver the overload protection
operates instantaneously when this current is exceeded.
Devices that contain capacitors will cause high in rush currents
which may cause the unit to self limit. This will be even more
evident when the engine is running due to the higher battery
voltage.
We strongly recommend that with the exception of low current switching Woodway light bars all devices to be
controlled are connected via relays as shown on page 9 of the installation information.
Keypad
ZE0175 Interface ZE0167 Output/Receiver
ZE0169
Keyboard cable ‘tie’ post
See notes below
PA Volume Adjust Access

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Woodway Engineering Ltd OPTINS-4.0 Rev 4 Page 4 of 9
December 2007
System Operation
The Keypad has 13 control switches (1 – 13), 2 programmable switches (P1 & P2) and a Reset/Walk Test switch (14).
Pressing any switch will give a corresponding output from the Output/Receiver. i.e. SW1 will switch output 1 on the
Output/Receiver, SW2 output 2 etc. Switches 1-12 can be set to latching or momentary operation. Switches 13, P1 and
P2 are latching only. Switch 14 has preset functions and cannot be changed. Latching switches once pressed remain
active until pressed again; momentary switches are active only when pressed. A bank of switches can also be set as ‘self-
cancelling’, which means that only one switch in the bank can be active at any one time. Switch 14 will cancel all active
switches.
The keypad has a permanent backlight for low light viewing and each active latching switch is illuminated when active.
Momentary switches are illuminated only when pressed. Under low light conditions a light sensor will lower the illumination
intensity of all active switches to prevent driver distraction. The sensor for this is situated at the bottom of the keypad and
should not be covered if the Auto Dim feature is to function.
Keypad legends can be factory fitted according to the customer’s requirements or customer fitted.
Soft switching prevents large current surges on the vehicle electrical system by staggering the programmed switch
activation.
Walk Test
By pressing and holding down switch 14 for 4 secs, switches 1 – 13 will be made sequentially active to allow the operator
to confirm that both the system and the equipment that it is controlling are functioning. When running this facility, switch 1
will remain active for 10 seconds to allow the operator time to exit the vehicle; thereafter subsequent switches whether
latching or momentary will remain active for 4 seconds. (Latching switches will illuminate when active momentary switches
will illuminate briefly) Switch 14 will flash whilst the test is in progress. When the test is complete the keypad will
automatically reset.
Sleep/Wake Up Function
The system will automatically shut down (sleep) after approximately 1 hour if no channels are active and the supply
voltage is less than 13.5V. (i.e. the vehicle is not running) The system will ‘wake up’ when a switch is pressed, the voltage
exceeds 13.5V or the door is opened (if connected).
The system will not go to sleep if any channel is active, the voltage is O13.5V or if the ‘door switch’ sense is negative.
Audible and Visual Warnings
As a reminder that the panel is active, the led at the top of the panel will flash and the system will beep every 30 seconds.
The led will flash continuously when the battery voltage falls below 9.5V.
When the door and handbrake are connected to the Interface unit, if the door is opened when the handbrake is not
applied the system will sound a warning beep.
Automatic Arrival Switching
When the door and handbrake are connected to the Interface unit, and P1 (pursuit) is active, if the handbrake is applied
and the door is opened, the system will switch to P2 (arrival).
If this function is required the ‘External 999 Switching’ cannot be used.
External 999 Switching (This is not available on systems with ZE0169i1 keypads)
When required the door switch signal can be used to switch the system to the programmed switch P1.
If this function is required the ‘Automatic Arrival Switching’ cannot be used.
PA Microphone
The Keypad incorporates a public address microphone for use with a Woodway siren with PA capability and is made
active via a PTT (Press-To-Talk) switch located on the side of the keypad. When the switch is operated it will mute any
active siren tones. The volume is factory set but may be adjusted to suit operator preferences. See Figure 2.
Mounting
A number of installation options are made possible through the availability of various fascia mounting brackets. The
Keypad can be positioned either vertically or horizontally allowing the best use of limited mounting space.
Default Programme
The keypad may be supplied with a default programme which does not give the desired control. To disable the
programme disable the lockout and press and hold SW11 and SW14 until a confirmation beep is heard. Enable the
lockout

Opti-Link WOODWAY Installation and Operation
Woodway Engineering Ltd OPTINS-4.0 Rev 4 Page 5 of 9
December 2007
Keypad Programming
WARNING! Keypad programming should only be carried out with either the
data wire to the receiver disconnected or the receiver output connector
removed to prevent un-intentional operation of the vehicle equipment.
Changes to the keypad settings should not be carried out with the vehicle engine
running.
Keypad Lockout
In normal use the keypad is locked to prevent changes to the keypad function. Keypad
functions cannot be changed until the lock is disabled. To disable the lock press and hold
switches 1, 4, 7, 12 and 14 until a beep is heard. The led at the top of the panel will be
permanently on. To enable the lock press and hold SW13 and SW14 until a beep is
heard. The keypad will de-activate. To re-activate press any key.
To program P1:
1 Press and hold down P1 until the confirmation beep is heard (5 seconds approx).
P1 will flash and the current program setting, if any, will be activated. All
programmed switches will be illuminated.
2 Select the new combination of buttons to activate with P1 by activating/de-
activating buttons 1 to 13, leaving only those buttons required illuminated.
3 When the selection is complete, do not press any other button until the beep is heard to confirm the programme.
(Approximately 10 seconds from the last selection). P1 will stop flashing when programmed.
4 Reset the keypad by pressing the Reset button.
5 To program P2, repeat as for P1.
Switch self-cancelling mode:
In some situations it may be preferable to have buttons self-cancelling, i.e. if one button in the row is active pressing
another one in the same row will cancel it. This is possible for individual rows of buttons, i.e. 1 - 3, 4 - 6, 7 – 9, 10 -12 and
a self cancelling bank 7 – 12
To program the buttons for self-cancelling mode:
Press and hold down the first button on the row, i.e.1, 4, 7 or 10 and, at the same time, press and hold down SW14 until a
beep is heard. Repeat this procedure for further row settings.
Buttons 7to 12 may be a self-cancelling bank. To set this option, press the Reset Button and button 12.
To cancel the self-cancelling mode, repeat the above procedures.
To program the buttons for momentary or latching operation:
The default setting for switches 1-12 is latching. To change any switch from latching to momentary operation or vice-
versa;
1 Press and hold down SW13 and the switch to be changed for 5 secs until a confirmation beep is heard
2 Release both switches and press SW14.
Special Strobe Setting:
The special strobe setting is only applicable to switches 1 to 3 and is usually set when the system is used to control ‘360’
light selection on a Woodway lightbar. When this option is set pressing SW1 will also activate SW2 and SW3.
1 Press and hold down SW14 and switch 2 until a confirmation beep is heard.
2 Release both switches.
3 To cancel the setting, repeat the procedure.
External 999 Input
To enable this function.
1 Press and hold SW6 and SW14 until a beep is heard.
To cancel the setting, press SW3 and SW14 until a beep is heard

Opti-Link WOODWAY Installation and Operation
Woodway Engineering Ltd OPTINS-4.0 Rev 4 Page 6 of 9
December 2007
Changing and Fitting the Switch Legends
The keypad switch legends are factory fitted when customers have specified the legend layout required. A comprehensive
list of standard legends is available on request. Users may change the legends at any time by following the procedure
below.
To fit the switch legends:
1 Disconnect power from the switch panel.
2 Before removing the bezel note the current legend layout and orientation.
3 Remove the two screws at the top of the panel and one in the centre of the panel
4 Place a small screwdriver blade into the hole at the top left edge of the bezel and gently lift the bezel. Slide the
blade around the edge to prise the bezel completely away from the keypad.
5 Each switch button is made up of three parts, the button pad, the legend and the lens. Remove the button to be
changed and slide the button lens left or right to remove it from the button assembly.
6 Fit the new legend in the correct orientation and slide the lens back onto the button.
7 Replace all the button assemblies onto the keypad.
8 Holding the keypad firmly to prevent the button assemblies from being dislodged, locate the bezel tabs into the
slots at the bottom edge of the keypad and press the bezel firmly in place.
9 Before re-fitting the screws check the action of the buttons. If necessary remove the bezel and refit.
10 Re-fit all the screws. Do not over tighten the screws as this may distort the plastics and prevent the correct action
of the switches
11 Check that all the buttons are free and operate reliably before reconnecting the switch panel.

Opti-Link WOODWAY Installation and Operation
Woodway Engineering Ltd OPTINS-4.0 Rev 4 Page 7 of 9
December 2007
Troubleshooting
The following table is a guide to the most common problems and assumes that the equipment under control is fully
functioning.
Problem Possible Cause(s) Solution(s)
Total system failure Blown fuse. Check power supply and connections to
modules.
•Single switch operation on handset
is ok but multiple switch operation
fails or causes system shutdown.
•Lightbar control failure
Communications fault. •Check Data link connections are
secure.
•Check inputs and cable ends are
clean.
Low voltage. Check battery voltage has not dropped
below 12V.
•Red LED illuminated on
Output/Receiver module
•When selecting more than one
switch function some lights are on
others are not.
•Light operation appears to be
‘haywire’
Excessive current draw on one or
more channels. (Maximum working
current is 0.5 amps (500mA) per
channel).
To locate the faulty channel, Operate
each switch individually until the Red
LED illuminates.
•Check for short circuit in wiring.
•Check for faulty equipment.
If problem still persists replace
Output/Receiver Unit
No output from Output/Receiver.
‘Data OK’ led is not flashing Communication fault. Check Data link connections are secure.
High pitch ‘whistle’ from the speaker
on PA operation Volume set too high. Turn the pot anti-clockwise to reduce the volume. (See Fig. 2)
Keypad and speaker too close
together Increase the physical separation between the keypad and the speaker
The Keypad led is flashing. Low Voltage
Check that the voltage is healthy. For 12V systems >9.5V
The keypad led is permanently on
and the system is not functioning Internal eprom fault Replace keypad
One or more switches will not remain
on. Switches are set for momentary operation. Reset the switches to latching operation (See Keypad Programming on Page 6)
Pressing one switch ‘On’ turns the
previous one ‘Off’. Switches are set to ‘self-cancelling’. Reset the switches. ( See Keypad Programming on Page 6)
When selecting ‘360’ the lightbar is
not functioning Switches are incorrectly set. For the ‘360’ to function correctly when connected to a Woodway lightbar only
SW1 can be used as 360 and the
‘Special Strobe Function’ must be set.
(See Keypad Programming on Page 5)
Switch panel cannot be programmed. Keypad has lockout still enabled. Disable lockout (see page 5)
Switches 3, 13 and 14 have no
output. A ‘special’ programme setting has been enabled. To disable the programme setting put the keypad into programming mode and
press and hold SW11 and SW14 until a
beep is heard.
When the door is opened a beeper is
heard. Door switch has been connected but the handbrake has not been
connected or the handbrake has not
been applied.
If the door switch is connected into the
system, the handbrake must also be
connected. The beeper acts as a
‘handbrake off’ warning.

Opti-Link WOODWAY Installation and Operation
Woodway Engineering Ltd OPTINS-4.0 Rev 4 Page 8 of 9
December 2007
Opti-Link System Installation Wiring Diagrams
System Wiring

Opti-Link WOODWAY Installation and Operation
Woodway Engineering Ltd OPTINS-4.0 Rev 4 Page 9 of 9
December 2007
Auxiliary Relays
Beta Siren Installation – Hands Free Control
Figure 5
Socket SK3
Pin Wire Colour Function
1
2
3 White/Orange Hands Free
Plug P3
Pin Wire Colour Function
1
2
3 White/Orange Hands Free
Socket SK4
Pin Wire Colour Function
1 White/Blue Mic +
2 White/Black Mic -
3
4 White/Violet PTT
Plug P2
Pin Wire Colour Function
1 Red/White Not Used
2 White/Green Horn Ring
3 White/Brown Wail
4 White/Red Yelp
5 White/Orange Hands Free
6 White/Yellow Not Used
7 White/Violet PTT
8 White/Black Mic -
9 White/Blue Mic +
Figure 4: Output/Receiver Relay Connections Figure 4a: Auxiliary Equipment Relay Connections
Note: A diode must be fitted across the coil to
p
revent back emf.