ZOLL Road Safety RS-4000 Installation guide

Road Safety RS-4000
System Overview and Installation
Version 4.13
ZO 5.2.0.85
Updated 6/28/16

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Z O L L D o c u m e n t a t i o n
PURPOSE
The purpose of this document is to provide the reader all the necessary information for the installation,
configuration, activation and testing of the ZOLL Road Safety RS-4000 devices. In addition to instructional
information, this document will also provide the forms necessary to accurately document the individual
installations for future reference.
INTENDED AUDIENCE
The mechanical tasks detailed in this document should only be performed by an experienced and certified
professional vehicle technician. This document is NOT intended to be an instructional manual on vehicle
mechanics/modification.
As detailed in the next section, the ZOLL Online configuration information covered in this document is just as
important to successful implementation as the proper physical installation of the devices. The system will not
work if either one of these tasks are not completed or completed incorrectly. The ZOLL Online section (Appendix
F) of this document can be completed by either the professional vehicle technicians, the agencies Road Safety
Administrators or any combination of the two.
ZOLL Online’s Road Safety & the RS-4000’s
For the RS-4000 devices to function correctly, two tasks must be completed:
1. The devices must be physically installed in the vehicles following the guidelines in this document.
2. Road Safety settings must be configured using the web based, ZOLL Online Road Safety application.
Failure to complete 1 & 2 for every unit will result in a non-functional vehicle(s).
ZOLL Online’s Road Safety application is the back end interface tool for managing and configuring the RS-4000
devices. In the final section of this document (Appendix F), you will find all of the details necessary for using ZOLL
Online to properly prepare the vehicles and devices for a successful installation.
USING THIS DOCUMENT
As with most modern documentation used today, this RS-4000 Installation and Overview is available in an Adobe
PDF format which makes it easy to view on—and print from—most devices. It also makes it very easy to distribute
to others via printed copies, e-mail, jump drives or internet file sharing sites.
We recognize that in a real-world, working garage environment it’s most likely installers will work off of a printed
version of this document and reference it as needed. However, to achieve the full benefit of this PDF, it is best
viewed from a desktop/laptop computer with an internet connection. Utilizing an internet connected computer
provides the additional benefit of quick access to related video content and the latest information/documentation
available on the Road Safety system. Clicking on PDF icons (located throughout the document) will display PDFs in
a new browser window from which you can read, print or save to your computer, and the video button will open
up a viewing dialog box and play video content.
IMPORTANT: Prior to beginning the installation of any RS-4000 unit, ensure the vehicle and device have
been properly configured in the agency’s ZOLL Online Road Safety system.

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ZOLL ONLINE ELEARNING COURSE
A large section of this document is dedicated to the ZOLL Online configuration of the RS-4000 units. Although this
section does include all of the necessary information needed to setup the devices and make them operable,
addition details and training on the full scope of the Road Safety product is available at no additional charge.
TABLE OF CONTENTS
On the following pages you’ll find the Table of Contents. If you’re viewing this document on your computer you
can click on listed items to be taken directly to that section.

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CONTENTS
Purpose ........................................................................................................................................... 1
Before You Start.............................................................................................................................. 1
What To Expect............................................................................................................................... 1
Wiring Practices .............................................................................................................................. 1
Safety Precautions .......................................................................................................................... 1
Build Sheet ...................................................................................................................................... 1
Firmware ......................................................................................................................................... 1
Parts Inventory................................................................................................................................ 2
Supplies Needed ............................................................................................................................. 2
Recommended Tools ...................................................................................................................... 2
RS-4000 Overview........................................................................................................................... 3
Embedded Computer............................................................................................................... 3
System:........................................................................................................................... 3
Communications: ........................................................................................................... 3
Video: ............................................................................................................................. 3
Wi-Fi: .............................................................................................................................. 3
User Interface................................................................................................................. 3
Controller Area Network Buses (CAN)..................................................................................... 3
VCAN:....................................................................................................................................... 4
ZCAN: ZOLL CAN....................................................................................................................... 4
Vehicle Dynamics..................................................................................................................... 4
GPS:................................................................................................................................ 4
Accelerometer:............................................................................................................... 4
Inputs/ Outputs ....................................................................................................................... 4
Digital I/0........................................................................................................................ 4
Single Ended Inputs:....................................................................................................... 4
Differential Inputs: ......................................................................................................... 4
High Speed Inputs: ......................................................................................................... 4
Digital Outputs: .............................................................................................................. 5
Audio: ............................................................................................................................. 5
Miscellaneous: ............................................................................................................... 5
RS-4000 & Digital Ally Integration .................................................................................................. 5
Hardware Identification and Inventory Sheet ......................................................................... 6
Optional items that can be purchased from ZOLL by the agency.................................. 8
Component Locations and Connectivity Overview ........................................................................ 9
RS-4902 –Spotter Switches:.................................................................................................... 9
RS-4000 - On-Board Computer .............................................................................................. 10
RS-4202 –Window Mount GPS Antenna .............................................................................. 10
RS-3211-1 - Driver ID Receptacle........................................................................................... 11
RS-4301 - Audio Speaker ....................................................................................................... 11
Connectivity Overview........................................................................................................... 12

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ZOLL Online Prerequisites............................................................................................................. 13
Hardware Installation ................................................................................................................... 14
STEP 1: Vehicle inspection ..................................................................................................... 14
STEP 2: Identify component installation locations ................................................................ 15
STEP 3: Mount the RS-4000 On-Board Computer in the vehicle........................................... 15
STEP 4: Prepare harnesses for looming and appropriate routing ......................................... 16
STEP 5: Mount the RS-4301 Audio Speaker........................................................................... 19
STEP 6: Mount the RS-3211-1 Driver ID Receptacle.............................................................. 20
STEP 7: Mount the Spotter Switches (RS-4902 Kit) ............................................................... 21
STEP 8: Connecting the Seatbelt Input .................................................................................. 23
STEP 9: Mount the RS-4202 Window Mount GPS Antenna .................................................. 24
STEP 10: Connecting Turn Signal Inputs ................................................................................ 25
STEP 11: Connecting the Reverse input................................................................................. 25
STEP 12: Connecting the Parking Brake input ....................................................................... 25
STEP 13: Connecting Emergency Lights Input ....................................................................... 25
STEP 14: Connecting Siren Inputs .......................................................................................... 25
STEP 15: Connecting the Power and Ground Inputs ............................................................. 26
STEP 16: Connecting the chassis Grounds............................................................................. 26
STEP 17: Connecting Digital Outputs..................................................................................... 26
STEP 18: Connecting a Cellular Modem or Wi-Fi................................................................... 27
Ethernet Connection .................................................................................................... 27
Wi-Fi Connection.......................................................................................................... 27
STEP 19: Completing the installation..................................................................................... 34
Connecting the Diagnostic Viewer................................................................................................ 34
Diagnostic Viewer Menu Options.......................................................................................... 34
Testing.................................................................................................................................... 35
Calibration.............................................................................................................................. 37
ZOLL Online Setup of the RS-4000 On-Board Computer ............................................. 37
Test drive and final check with ZOLL Online................................................................................. 38
Required Documentation ............................................................................................................. 39
Form 1: Vehicle Inspection Diagram...................................................................................... 40
Form 2: Vehicle Inspection Form........................................................................................... 41
Form 3: Build Sheet ............................................................................................................... 42
Form 4: Post Installation Verification Worksheet ................................................................. 43
Form 5: Serial Number Assignment Form ............................................................................. 44
Appendix A: Printable Component Locations Diagram ................................................................ 45
Appendix B: Orientation Index ..................................................................................................... 47
Orientation Index 1-4............................................................................................................ 48
Orientation Index 5-8............................................................................................................ 49
Orientation Index 9-12.......................................................................................................... 50
Orientation Index 13-16........................................................................................................ 51
Orientation Index 17-20........................................................................................................ 52
Orientation Index 21-24........................................................................................................ 53

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Appendix C: Wiring Assignments ................................................................................................. 55
Appendix D: High Speed Digital Input Installation & Setup.......................................................... 56
Purpose .................................................................................................................................. 56
High Speed Digital Input Interface......................................................................................... 56
Engine RPM Scale Values ............................................................................................. 56
Vehicle Speed Scale Values .......................................................................................... 56
Calibrating Speed and RPM Scale Values .............................................................................. 56
Appendix E: ZOLL Online’s Road Safety Application.................................................................... 60
1. Supported browsers .......................................................................................................... 60
2. Log into ZOLL Online .......................................................................................................... 60
3. Main screen-Home page.................................................................................................... 61
4. Product administration screen .......................................................................................... 62
5. Road Safety Administration screen ................................................................................... 62
6. Vehicle screen.................................................................................................................... 63
7. Road Safety Configurations screen –Vehicle Group Settings ........................................... 64
8. Road Safety Configurations screen - Inputs ...................................................................... 68
9. Road Safety Configurations screen - Devices .................................................................... 71
10. Vehicle Installation Verification....................................................................................... 72
Appendix F: Digital Ally / RS-4000 Trigger connection and setup ............................................... 76
What is Digital Ally................................................................................................................. 76
DVM-250/250+ Installation ................................................................................................... 76
DVM-250/250+ Configuration Manager / Camera Setup ..................................................... 78
Configuration Manager Installation............................................................................. 78
Launching the Configuration Manager & the File Tab................................................. 78
The General Tab ........................................................................................................... 79
The Recording Tab........................................................................................................ 80
Motion Tab................................................................................................................... 81
Sensors ......................................................................................................................... 82
Distributing the Configurations.................................................................................... 83
Accessing Recorded Video Files ................................................................................... 84
Preparing the RS-4000 Output 2 ........................................................................................... 85
Configuring the RS-4000 DIGITAL OUTPUT 2 to Send Triggers.................................... 85
Testing the RS-4000, Digital Ally DVM-250/250+ Integration............................................... 87
Testing prerequisites.................................................................................................... 87
Test procedure ............................................................................................................. 87
RS-4000 / Digital Ally Trouble Shooting Summary ................................................................ 88
Appendix G: Installation Quick Reference Sheet.......................................................................... 89

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PURPOSE
This guide provides an overview of the components of the RS-4000 system, suggestions on component location,
mounting recommendations, configuration, testing, and a suggested installation work flow.
BEFORE YOU START
A typical ambulance installation takes approximately 8-12 hours. Supervisor vehicles, fire apparatus, and other
non-standard vehicles may take longer due to their size and complexity. Due to the degree of disassembly needed
to perform the installation, the vehicle will not be able to be placed in service until the installation is completed.
WHAT TO EXPECT
Are you and your agency ready for the Road Safety Installation? How do you even know if you’re ready? We’ve
put together a comprehensive video to help to ensure both the agency and the installer have all the knowledge
they need when it comes being properly prepared. Click the video content button to be taken directly to view the
video.
WIRING PRACTICES
You must make all the connections with solder or standard crimp connectors. Solder is preferred for all
connections where practical, ScotchLok wire taps (or similar) are not to be used. All ground connections should be
to their own chassis ground point, do not splice into a ground wire on another system.
SAFETY PRECAUTIONS
Make sure to always follow vehicle manufacturer and up-fitter safety procedures and specifications on
disassembly and reassembly of vehicle components such as torque specs, airbag disconnect, and testing of
electrical system components. Personal injury hazards such as needle sticks and biological hazards may be present
and the installers should be aware of the procedures to avoid injury.
Oxygen Cylinders - Prior to starting the in-vehicle installation of the RS-4000 device, all oxygen cylinders should be
removed (by agency staff members) from the vehicle. Working on electrical components in close proximity to
oxygen cylinders can greatly increase the risk of an explosion resulting in severe injury or death.
BUILD SHEET
ZOLL does not have access to all year/make/model vehicles and some research by the installers will likely be
required. Input/output and connection information including vehicle wire colors and common connection points
can be obtained (when available) by calling ZOLL Road Safety Support at 1-800-663-3911 option 9. When
completing Build Sheets (page 42, Form 3) you must have the year, make, model, & engine size for accurate
documentation. Other vehicle information may be required on a case by case basis.
FIRMWARE
“Firmware” is permanent software that lives on and works with the Road Safety device. Basically it’s responsible
for communicating with the vehicle, the speaker, the device itself and the Road Safety software. Occasionally,
behind the scenes, ZOLL pushes out updated firmware to the Road Safety devices. Once this “push” is complete
the very next time the ignition of the vehicle is turned off, the new firmware will be automatically installed onto
the device.
Although it’s very unlikely that anyone will even notice that this update is occurring a failure is possible if power to
the device is disconnected while it’s preforming this installation. If this situation occurs a notification message will
be displayed on the LCD of the device and ZOLL support should be contacted for assistance.

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PARTS INVENTORY
Use the ZOLL-Hardware Identification + Inventory Sheet (pages 6 - 8) to inventory the ZOLL provided hardware. To
order additional or replacement parts, such as Driver ID tags, Call ZOLL support for additional information: 1-800-
663-3911 option 9.
SUPPLIES NEEDED
Cable ties
Heat shrink tubing - 1/16”-1/2”, various sizes
Electrical tape - Scotch super 33+ recommended
JB Kwik epoxy - or equivalent product
Lead free solder
16-18 gauge Butt splices.
Wire loom –¼” and ½”
RTV Silicone - if installing roof mount antenna
RECOMMENDED TOOLS
Drill (with screwdriver bits, 1/2” & 1” step-bits, and 5/16” nut driver)
Utility knife
Inline wire strippers
Wire cutters
Crimping tool.
Digital Multi-meter
1/4” + 3/8” ratchets and extensions or equivalent
Electric soldering gun
3/8” drive deep socket assortment (10-18mm +21mm)
Electric heat gun
1/4” drive standard & metric assortments (3/16”-7/8” and 5mm-12mm)
Torx bits or Torx screwdriver kit
Combination wrench assortment (1/4”-7/8” & 5mm-15mm)
Fish rods/tape or metal coat hanger for wire fishing
Level
Laptop with Wi-Fi
4 Port switch with two Ethernet cables

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RS-4000 OVERVIEW
The ZOLL 4000 is an on-board driver modification and data acquisition system that
monitors and reports vehicle speed, vehicle RPM, 16 additional user definable digital
single ended inputs and 6 differential inputs. There are 2 digital outputs. The digital
outputs may be programmed to turn on vehicle components or other devices when a
user defined parameter has been met or the on-board computer receives a user
generated command from ZOLL Online.
The on-board computer internal memory configuration includes 32 GB data memory
and 1 Gb RAM, 2 USB 2.0 ports, 2 Ethernet and 1 RS232 data port, as well as 1 802.11
b/g/n Wi-Fi capability.
The system identifies and databases activities by vehicle. Optional driver
identification allows the system to also record and store activities by driver. The
system administrator may set parameters to activate an audible alarm if the vehicle is operated without a valid
driver identification logged onto the system.
EMBEDDED COMPUTER
SYSTEM:
Intel® Atom™ CPU n455 1.66 MHz
32 Bit Bus.
Windows Embedded Standard Operating System.
1.0 Gb RAM Memory
32 Gb SATA Hard Drive
COMMUNICATIONS:
2x USB 2.0 Ports
2x RJ45, Gigabit Ethernet Ports
1x DB9 (Male), RS-232
VIDEO:
1x HD15 (Female), VGA
WI-FI:
802.11 b/g/n
150 Mb/s
USER INTERFACE
2 Line x 16 Characters Lighted LCD Display.
Membrane Switch Pad with Up, Down, Left, Right and Enter Arrows.
CONTROLLER AREA NETWORK BUSES (CAN)
Two CAN (OBD-II, J-1939) busses are available. One CAN bus is used for communications with the vehicles OBDII
system. The other is a proprietary ZOLL CAN bus.

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VCAN:
HD15 (Male), Vehicle CAN
ZCAN: ZOLL CAN
DB9 (Female), ZOLL CAN
VEHICLE DYNAMICS
A GPS receiver and accelerometer are incorporated to measure vehicle movement and safe operation.
GPS:
Continuous Multiple Satellite WAAS Enabled Receiver
Minimum Receiver Sensitivity -185dbW
Acquisition time: 1s all data known; 38s ephemeris unknown; 45s no data; <2s Reacquisition.
< 15 Meters Accuracy with GPS Standard Positioning Service, Velocity .1 knot RMS.
< 3 Meters Accuracy with DGPS (WAAS)
999 knot, 3g Dynamics
ACCELEROMETER:
3 Axis
±1.5g, ±3g, ±6g, ±12g
INPUTS/ OUTPUTS
DIGITAL I/0
The RS-4000 incorporates 16 single ended digital Inputs, 6 differential digital Inputs, 1 analog input, and 2 digital
outputs.
SINGLE ENDED INPUTS:
16 single ended inputs are available referencing 0 VDC common.
Input Voltage for Logic 1: 8-18VDC: Absolute Maximum: 40 Volts.
Maximum Input Voltage for Logic 0: 0.75 VDC.
Maximum Input Voltage for Logic 1: 5.0 VDC.
DIFFERENTIAL INPUTS:
6 optically isolated differential inputs are available that allow inputs from a floating common. The input is on when
the difference between the two inputs is greater than 1.5 Volts and off when they are less than 1 Volt.
Voltage Differential: 5-18VDC, Absolute Maximum: 24 Volts.
Maximum Differential Input Voltage for Logic 0: 0.75 VDC.
Minimum Differential Input Voltage for Logic 1: 5.0 VDC.
HIGH SPEED INPUTS:
2 high speed digital inputs are used to measure Vehicle Speed and Engine RPM.
Input Voltage for Logic 1: 8-18VDC: Absolute Maximum: 40 VDC.
Maximum Differential Input Voltage for Logic 0: 0.75 VDC.
Minimum Differential Input Voltage for Logic 1: 5.0 VDC.

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DIGITAL OUTPUTS:
2 optically isolated digital (switched vehicle voltage) outputs available that use a 0 VDC common.
Maximum Current: 1 Amp
AUDIO:
2 audio connections are incorporated. The output is used to give the driver audible warnings. The input
(microphone) is not currently used, but may be incorporated in future enhancements.
1x Audio Out
1x Audio In
MISCELLANEOUS:
Operating Power (Ignition On): ............................ 8-18 VDC @ 25 Watts Maximum
Standby Power (Ignition Off):............................... 8-18 VDC @ 0.18 Watts Maximum
Maximum Input Voltage:......................................18 VDC
Dimensions:.......................................................... 9.652 x 8.068 x 2.815 in., 204.95 x 245.17 x 71.5mm
Mass: .................................................................... 4.56 lbs., 2.07 Kg
Operating Temperature: ...................................... 14 to 176°F, -10 to 80°C
Storage Temperature: .......................................... -40 to 196°F, -40 to 90°C
Shock Operating: .................................................. 30g Peak Acceleration, 11(±1ms) Pulse Width
Shock Not Operating: ...........................................30g Peak Acceleration, 11(±1ms) Pulse Width
Vibration:.............................................................. Tested 5g @ 1-500Hz per IEC 68-2-6
RS-4000 & DIGITAL ALLY INTEGRATION
The Digital Ally video recording system (DVM-250/250+) is an in-vehicle audio/video recording system that can be
tightly integrated with the Road Safety system. Tying the two systems together will provide Road Safety the ability
to trigger recordings based upon the violations it detects.
If possible, the installation of the DVM-250/250+ camera(s) should be done simultaneously with the RS-4000
installations. Running cables and making connections for both devices is obviously easier and more efficient if
preformed at the same time rather than bringing the vehicles in for service twice for similar work.
The Digital Ally system is an optional add-on to the Road Safety system. If it is being installed in conjunction with
the Road Safety, please see Appendix E for additional information on its setup and configuration.
NOTE: A detailed set of installation/integration instructions can be found in APPENDIX E of this document.

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HARDWARE IDENTIFICATION AND INVENTORY SHEET
IMPORTANT: Upon delivery of the RS-400 equipment, the shipment should be inspected for completeness
and condition. Any shortage or damage should be documented and immediately reported to the ZOLL support
RS-3211-R Driver ID
Receptacle
RS-3212-6 Driver ID Tags
(Base System Package of 6)
RS-3910 Seatbelt Sensor
RS-4000 Main Road Safety
In-Vehicle Device
RS-4101 Power/Audio
Harness
RS-4102 Digital I/O Pigtail
RS-4103 Standard Digital
Harness
RS-4107 OBDII Adapter
Cable
RS-4111 Fuse Kit
RS-4120 12 Ft Ethernet
Cable

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OPTIONAL ITEMS THAT CAN BE PURCHASED FROM ZOLL BY THE AGENCY
RS-2213 Driver ID
Programmer Kit
RS-3212-25 Driver ID Tags
(Package of 25)
RS-3144 Sprinter Harness
RS-4105 Standard I/O
Harness
RS-4106 Mercedes
Sprinter DLC Extension
RS-DVM250B Digital Ally
250 - 2 Camera Event Data
Recorder Bundle
RS-DVM250PB Digital Ally
250+ 3 Camera Event Data
Recorder Bundle

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COMPONENT LOCATIONS AND CONNECTIVITY OVERVIEW
RS-4902 –SPOTTER SWITCHES:
When pressed by the vehicle spotter or ground guide, a tone alerts the driver that it is safe to back up the vehicle.
One switch mounted on the rear overhead panel with a clear sight line out the rear window, and one switch
mounted outside the vehicle near the left or right taillight assembly depending on agency policy.
NOTE: Switches should be placed in similar positions on all vehicles in the fleet to assist the crew.
Typical wire harness routing is through the center overhead or outboard exterior light voids.
Connects to: RS-4000 On-Board Computer via the Standard Digital Harness. See Appendix C for wiring assignments.
NOTE: See Appendix A at the end of this document for a one-page version of the component locations and
system overview diagram.

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RS-4000 - ON-BOARD COMPUTER
Records and stores event information. The on-board computer is the main control unit for inputs, outputs, and
driver communication.
Bulkhead mounting. The unit may be mounted in any of 24 three dimensional positions. See Appendix B
for positions and their associated Orientation Index Number.
Acceptable Mounting Location- In the equipment cabinet if there is enough clearance and the harness will
reach, somewhere behind one of the seats or directly on the bulkhead. The location must be within the
OEM imposed length limit for the OBDII/CAN cable of 16 feet (4.87 meters).
*Extensions to the cable are not recommended or supported by ZOLL. DO NOT modify the cable
RS-4202 –WINDOW MOUNT GPS ANTENNA
Determine the installation location of the antenna on the windshield or dashboard. Keep in mind that the GPS
antenna cannot "see" through metal. Unobstructed line of sight is required. The GPS antenna should not be
placed near any physical obstruction like the "A" pillar, rearview mirror, or a 2-way communication antenna.
Always install the antenna as high on the glass as possible if mounting on the windshield. Do not mount the
antenna to a metallic surface.
NOTE: Do not place the antenna where it may interfere with the driver's vision. Some states prohibit
mounting anything on the windshield that may obstruct the driver’s vision.

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RS-3211-1 - DRIVER ID RECEPTACLE
Used to read assigned Driver ID tags that associate a driver to the vehicle for reporting purposes.
Typical Mounting Location - Driver’s side dash in close proximity to the ignition switch.
NOTE: The panel should not be greater than 3/16” (4.76mm) thick and have sufficient room behind it to
fit without interference. A 13/16” hole is required.
Connects to: RS-4000 On-Board Computer via the Standard Digital harness.
RS-4301 - AUDIO SPEAKER
Source of audible feedback including warning and violation tones.
Typical Mounting Location- Driver’s side headliner or bulkhead.
NOTE: Mounting the speaker in other locations further from the driver creates the need for higher
volume settings.
Connects to: RS-4000 On-Board Computer via the Power/Audio harness.

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CONNECTIVITY OVERVIEW
See Appendix C for wiring assignments.

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ZOLL ONLINE PREREQUISITES
As noted early on in this document the physical installation of the RS-4000 device and the proper configuration of
ZOLL Online are equally important. With this being the case, although it is possible to begin the physical
installation of the RS-4000 prior to completing the ZOLL Online setup/configuration, there is a HARD STOP that
should be observed prior to completing the installation.
If the vehicle being installed has not been completely setup in ZOLL Online the install SHOULD NOT proceed past
STEP 17: CONNECTING DIGITAL OUTPUTS.
Each agency must have a tenant account configured in ZOLL Online. Customers using multiple ZOLL Online
applications will use the tenant already in use for their other products. It is not the responsibility of the vehicle
installer to build and configure the customer’s ZOLL Online tenant account but the active account name must be
determined as the RS-4000 serial numbers are pre-configured into that tenant. If the customer does not know the
tenant name, call ZOLL Support at 1-800-663-3911 option 9 to have Road Safety support assist in determining the
tenant name.
Administrative access to ZOLL Online MUST be granted to the installer or the customer with appropriate account
privileges (administrative) must be available to assist in the ZOLL Online configuration portion of the Road Safety
installation.
NOTE: A detailed set of instructions on the ZOLL Online setup and configuration can be found in APPENDIX D of
this document.
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