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

© 2016 ZOLL Data Systems, Inc. All rights reserved. ii CONFIDENTIAL TRADE SECRETS –DO NOT DISCLOSE.
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.
Requests for enrollment in this course can be made by emailing tra[email protected].
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.