Product Manual. Part number:

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1 Product Manual Part number:

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3 Product Manual SpotMe Warning system comprising flashing warning units and sensors that interact through wireless communication. 3

4 Table of contents: Technical specification...5 Function description...9 Maintenance...17 Recycling...19 Properties & advantages...21 Application areas...25 Installation...31 Troubleshooting...41 List of components...47 Configuration Copyright TMHE Issue:

5 Technical specifications Warning unit and sensor Warning unit Orange Blue Outdoor Technical data Frequency band MHz Output power mw <10 <10 <10 Battery voltage V Battery capacity Ah N/A N/A N/A Dimensions and weight Dimensions (Width x Height x Depth) mm 85 x 536 x x 536 x x 246 x 154 Weight kg Classification and certification RoHS compatible Yes Yes Yes IP classification IP40 IP40 IP55 Operating temperature C CE certification 93/68/EEC 93/68/EEC 93/68/EEC R&TTE Directive 99/5/EC 99/5/EC 99/5/EC Low Voltage Directive 73/23/EEC 73/23/EEC 73/23/EEC Sensor IR Indoor IR Outdoor OP Technical data Frequency band MHz Output power mw <1 <1 <1 Battery voltage V Battery capacity Ah N/A Dimensions and weight Dimensions (Width x Height x Depth) mm 80 x 130 x x 120 x x 110 x 90 Weight kg Classification and certification RoHS compatible Yes Yes Yes IP classification IP50 IP66 IP30 Operating temperature C CE certification 93/68/EEC 93/68/EEC 93/68/EEC R&TTE Directive 99/5/EC 99/5/EC 99/5/EC Low Voltage Directive 73/23/EEC 73/23/EEC 73/23/EEC 5

6 Technical specifications Battery eliminator Eliminator Standard Temp. proof Technical data Input voltage VAC Input current A Frequency Hz Output voltage VDC Output current A Capacity Ah N/A N/A Dimensions and weight Dimensions (Width x Height x Depth) mm 65 x 61 x x 74 x 45 Cable length m Weight kg Classification and certification RoHS compatible Yes Yes IP classification IP40 IP40 Operating temperature C CE certification Yes Yes Low Voltage Directive N/A N/A Electrical safety standard EN60950 EN

7 Technical specifications Battery charger and battery module Battery charger Battery module Technical data Input voltage VAC N/A Input current A 0.5 N/A Frequency Hz N/A Output voltage VDC Output current A 2.7 N/A Capacity Ah N/A 48 Dimensions and weight Dimensions (Width x Height x Depth) mm 100 x 51 x x 169 x 123 Cable length m 1.6 N/A Weight kg Classification and certification RoHS compatible Yes Yes IP classification IP40 IP51 Operating temperature C CE certification Yes 93/68/EEC Low Voltage Directive N/A 73/23/EEC Electrical safety standard EN60950 N/A 7

8 Technical specifications Label The serial numbers of the units are structured as follows: 1. The first group (AS) is text and indicates that the string is a serial number. 2. The second group (XXXX) indicates the production date, in the format YYWW (where Y stands for year and W stands for week number). 3. The last group (XXXXX) is the unit's ID code via the radio protocol. For units that do not communicate by radio, such as battery modules, the last group is only a sequence number for the units produced during that particular week. 4. The sensors are marked with their fixed channel for radio messages (CH:X). Example: AS is a unit that was produced week 16 of 2012 and has radio ID/ sequence number Examples of labels: Part number Serial number Part number Serial number Channel Part number Serial number 8

9 Function description SpotMe warning units The warning unit is the module in the system that issues a warning when a sensor has detected a traffic situation that meets the warning criteria. The warning unit continually listens for detection messages from the various sensors. If a detection message is received, four high-intensity LED lamps in the warning unit flash for a set number of seconds to warn those in the surrounding area of the potential danger. Function Figure 1. SpotMe warning unit Warning units can be set to operate on different channels (A-Z). This makes it possible to use several SpotMe systems in close proximity to each other without interference. A warning unit reacts to all sensors within its sensing range that are set to the same channel as the warning unit. This means that several sensors can be used to activate a single warning unit. The channels are designated with letters. The default channel setting is channel A. The SpotMe Configuration Tool can be used to change channel or flash time (see separate manual). Flash time can be set within the interval seconds. Design for dry environments The unit has four warning lamps in total, positioned in pairs on opposite long sides of the unit. See Figure 1 for an illustration of the unit. When triggered, the lamps flash an amber or blue colour, alternating up and down. The blue light is used by customers wanting a colour that differs from other amber warning lamps. The light scattering from the lamps is distributed so that there is extremely sharp light when you are right in front of the Figure 2. Warning light intensity in unit and weaker light when looking at the lamps from relation to viewing angle the side. The lamps have a 60-degree scattering angle. Intensity dissipates as the angle from the centre of the lamps increases. This is depicted in Figure 2. The positioning and spacing between the light points are designed to attract as much attention as possible and are based on Swedish traffic safety research. The objective of the warning unit is to use the flashing light to cause a sensory reaction (including in the peripheral field of vision), which causes individuals to instinctively pay more attention. The flash frequency is 2 Hz and complies with the applicable directives so as not to affect individuals with a light-sensitive type of epilepsy. 9

10 Function description Unit parts 1. Radio antenna 2. Wall bracket 3. Warning lamps 4. Power supply socket 5. Product marking Figure 3. SpotMe warning unit Design for outdoor environments The warning unit for outdoor environments is designed to withstand this. The unit is encapsulated to protect against rain and must always be positioned horizontally so that the rain protection and solar panel face upwards. See the figure. The warning unit is equipped with solar cells and a battery. Thus, no external power supply is required. With its need for solar recharging, the unit must be not be positioned in an area with constant shadow. Figure 4. Outdoor warning unit A small number of in-sun hours per week is sufficient to charge the batteries. The warning unit can be mounted on a pole with the accompanying pole bracket. Power supply for dry environments The warning unit for dry environments can either be run on battery power (SpotMe battery module) or be plugged into the mains (SpotMe battery eliminator). Both power supply options require use of external units connected to the warning unit. This makes it easy to switch between the two options. The battery option is suitable for customer demonstrations or areas subject to frequent power failures. There is also a temperature-proof eliminator that must be used when the warning unit is positioned in a cold store or outdoors under cover. 10

11 Function description SpotMe IR sensor The infrared (IR) sensor is used to detect passing traffic (trucks people). Design The indoor unit has two sensors located in the front. See Figure 5 for an illustration of the unit. Centred in the front of the unit is an arrow that shows the active direction in which the sensor is triggered. To change the direction of detection, turn the sensor through 180 degrees and remount it. The IR sensor has a flexible bracket that makes it possible to mount the unit with screws or cable ties. The detection zone of the sensor is illustrated in Figures 7 and 8 on the next page. The IR sensor is also available in an outdoor design. See Figure 6. Figure 5. SpotMe indoor sensor The SpotMe indoor sensor has an adjustable bracket Figure 6. SpotMe outdoor sensor Power supply The unit is supplied power via an internal battery that has a service life of at least one year. The service life is completely dependent on extent of usage. Battery service life is calculated in relation to the traffic intensity. Battery replacement times are as follows: If the number of detections is below 6,000 per day (which corresponds to 12 per minute in single-shift operation or 6 per minute in double-shift operation), then the battery must be replaced after 3 years. If the number of detections exceeds this limit, then the battery must be replaced each year. Battery status is monitored by the sensor. A low battery level in indicated by a sensor message being sent to the warning unit. All warning lamps on the warning unit then begin to flash simultaneously each minute (see Troubleshooting ). The system will continue working normally for some time to allow time for battery replacement within 2 weeks. 11

12 Function description Function The sensor reacts to infrared radiation, i.e. thermal radiation. This technology makes it possible to detect both pedestrians and vehicles. When an object with a temperature that differs from the ambient temperature (hotter or colder) passes the unit, the movement of the object is analysed. If the object is moving in the active direction of the sensor, a detection command is transmitted wirelessly. This detection command is coded with the preset Figure 7. Sensor detection zone channel of the sensor. The sensor can detect passing objects within a range of approximately 5 metres. Objects that differ greatly from the ambient temperature can be detected from an even greater distance. The sensor reacts best to objects that are moving perpendicular to the centre point of the sensor. This means that objects moving in a circular path in front of the sensor can be detected within an angular area of 120. See Figure 8. The range of the radio signals from the unit is minimum 50 metres with free visibility. The actual distance varies Figure 8. Sensor viewed from above and is completely determined by where the unit is situated. The sensors can be ordered with 26 different channels, A-Z. The channels of the indoor sensor can be changed locally if needed using SpotMe Configuration Tool II. Note: Because channel setting requires removal of the battery, the battery monitor will be reset. It is therefore important to change the battery on old sensors. Otherwise, low battery level indication will not work properly. 12

13 Function description SpotMe OP sensor, Design and function The optical sensor communicates with the warning unit the same way as the IR sensor. The difference is the sensor technology. With an optical sensor, the sensing element transmits a thin beam of light, which strikes a reflector and returns to the sensor. Detection occurs when the light beam is broken by an object. The sensor can therefore react to all types of objects, regardless of internal temperature. The OP sensor reacts to all objects, regardless of direction of travel. The sensor and reflector create a sharp sensor barrier that can be up to 20 metres long. A typical application is in height warning systems for passage doors with low clearance. The OP sensor is powered via the accompanying battery eliminator. Figure 9. OP sensor The OP sensor can be ordered with 26 different channels, A-Z. The set channel can be changed locally if needed using SpotMe Configuration Tool II. SpotMe battery module The battery module is used to supply power to the warning unit. The module contains dry lead-acid battery cells, making it maintenance-free. Design The battery module has a connector that is used to both connect a warning unit and to charge the batteries. The top of the module houses a handle to make it easier to carry. The battery cable is ordered separately. It is available in lengths of 1 metre and 5 metres. Figure 10. Battery module Function The battery module can supply a SpotMe warning unit for up to 3 months. The length of time is greatly dependent on how much the unit flashes. The warning unit signals when the connected battery module is beginning to become discharged. The module is then disconnected and charged. It is a good idea to have a second battery module that can be connected while the other module is being charged. The unit is protected against short circuiting by an internal fuse. The battery module is not suitable for cold store applications and is only intended for use with warning units with amber warning lamps. The blue variant draws too much current. 13

14 Function description SpotMe battery charger The battery charger is used to charge SpotMe battery modules. Design Figure 11. Battery charger The battery charger comes with a cable that has a battery module connector at one end and a plug for connecting to a mains socket at the other. A lamp for indicating charging status is located on the front of the unit. Function When the unit is connected to the mains, the charging status lamp lights up. When a battery module is connected, the lamp will turn red if the battery is not fully charged. While the lamp is red, the battery is charged at full current strength. The lamp will turn orange when charging is almost complete and will then turn green when the battery is fully charged. A fully discharged SpotMe battery module takes approximately 19 hours to charge. 14

15 Design Function description SpotMe battery eliminator The battery eliminator is used to run SpotMe warning units without battery modules. Two versions of battery eliminator are available. The standard version is suitable for dry and warm environments. For cold applications, the temp. proof variant must be used. The unit comes with a cable that has a warning unit connector at one end and a plug for connecting to a mains socket at the other. The cable is 1.8 metres long. The eliminator is suitable for EU wall sockets. A UK adapter is also supplied. Figure 12. Standard battery eliminator Extension cables in lengths of 1 and 5 metres are also available for purchase. The cables can be connected in pairs so that the battery eliminator can be positioned up to 10 metres from the warning unit. This is a good solution if the customer does not permit installation of high-voltage cables in the racking. Figure 13. Temp. proof battery eliminator Function The battery eliminate converts the alternating current in the mains to 6 VDC, which is then supplied to the warning unit. Figure 14. Extension cable, 5 m 15

16 Function description SpotMe Configuration Tool II SpotMe Configuration Tool II is connected to a PC via a USB cable. It can then communicate wirelessly with system components. SpotMe Configuration Tool II has three application areas: 1. Configuration Figure 15. SpotMe Configuration Tool II The channel of the warning unit and sensor can be set wirelessly. The warning unit flash time can be changed if needed. 2. Statistics readout Over time, you can see how many warnings were issued by the system and how many detections each sensor made. 3. Status check The tool is also a good aid for checking the function and status of the system and components. You can also see radio traffic in progress and the signal strength of the systems, which corresponds to the distance to each component. Note: The earlier version of SpotMe Configuration Tool does not work on SpotMe units delivered starting from April The new SpotMe Configuration Tool II can also be used on older SpotMe units. Note: Before the configuration tool can be used on a new computer, the drivers must be installed from the USB memory provided. Refer to the last section in the Configuration chapter. Figure 16. SpotMe Configuration Tool II, start page 16

17 Maintenance The SpotMe warning system is normally maintenance-free. TMHE nonetheless recommends for the user to perform a daily functionality check and monitor the status of the units' power supply as described below. Warning unit battery replacement and charging When a warning unit indicates that the connected battery module is beginning to become discharged, then the battery module must be replaced or charged. The warning unit indicates this through 2 rapid flashes by all lamps every minute when battery capacity is down to approximately 20%. Unplug the cable from the battery module and plug it into a charged battery module. The lamps of the warning unit will flash alternately for 7 seconds. Battery module change is then complete. Figure 17. Battery module Charge the disconnected battery module as soon as possible. This is important as battery module capacity can be impaired if the module remains discharged for prolonged periods of time. To reduce the risk of accidents, charge the batteries over the weekend if there is no replacement battery. Cover the warning unit with a hood during charging to clearly indicate that the warning system is not active. The battery module is charged by connecting a battery charger into the socket. The level of charge is indicated via a red, orange or green light on the battery charger. The colours indicate poorly charged, partially charged and fully charged, respectively. A completely discharged battery module can take up to 19 hours to recharge completely. 17

18 Maintenance IR sensor battery replacement Battery status is monitored by the sensor. A low battery level in indicated by a sensor message being sent to the warning unit. All warning lamps on the warning unit then begin to flash simultaneously each minute (see Troubleshooting ). The system will continue working normally for some time to allow time for battery replacement within 2 weeks. Indoor variant When it is time to replace the battery on a sensor, remove the two screws on the sides and then remove the sensor. Undo the 4 screws on the back of the sensor unit; see Figure 18. Next, remove the mounting plate and lift off the cover from the sensor. The circuit board will now be visible in the plastic compartment; see Figure 19. Place your finger at the spot marked with a (1) in the figure to hold the circuit board in place. Then grasp the battery with two fingers at the spot marked with a (2). Pull the battery straight up from the circuit board. Carefully press a new battery into the empty battery holder. Ensure the battery poles face as indicated by the marking on the circuit board. Figure 18. Undo the 4 sensor screws Note: The spent battery cannot be charged. It must instead be turned in for recycling. Always use genuine SpotMe batteries for guaranteed operating time. Outdoor variant Figure 19. Sensor circuit board with battery Since the outdoor variant is encapsulated to withstand moist environments, battery replacement is a bit more complicated. Contact Technical Support for detailed instructions and to order a battery changing kit. Figure 20. Outdoor IR sensor 18

19 Recycling Recycling Battery disposal Spent batteries must be returned/sent to the battery manufacturer or its representatives (see the marking plate on the battery) for disposal/recycling. If you need help in returning the battery to the battery manufacturer, contact your local truck dealer. The symbol with the crossed out dustbin means that the battery must not be disposed of with household waste. The marking with chemical designation indicates which heavy metal is found in the battery. The substances that make up certain batteries and are most harmful to the environment (including animals and nature) and human health are the heavy metals mercury (Hg), cadmium (Cd) and lead (Pb). The sensor runs on a lithium battery. The warning unit battery module and the warning unit for outdoor use each contain a lead-acid battery. 19

20 Recycling 20

21 Features and benefits System for better warehouse safety SpotMe is a stationary and active warning system for all warehouse environment applications both indoors and outdoors. The system serves to warn truck operators and pedestrians in warehouse areas where the physical environment obstructs the view of possible dangers from moving fork lift trucks. Such areas are normally equipped with convex safety mirrors to help workers avoid accidents. The advantage of SpotMe is that the system alerts workers when a warning is really needed. The IR sensor detects objects in intersections in good time to illuminate the lamps on the warning unit and help the operator avoid an accident. SpotMe can be used as a free-standing solution or a supplement to the regular safety mirrors to improve safety in warehouse environments. Less damage, less injury and better efficiency SpotMe enables truck operators to plan their driving with less panic braking. This improved driving behaviour also saves energy and reduces the amount of lost and damaged items during transport. Over time, this will improve warehouse safety and reduce costs. When operator training alone is not enough A lot of money is spent on operator training each year to reduce the number of warehouse accidents. Despite these efforts, a large number of accidents are reported every year and the warehouse is considered an extremely dangerous place to work. Even though operators are aware of the risks and undergo rigorous training in safe driving, the stressful reality of the job can create dangerous situations each day. A technical solution like SpotMe is an effective way to improve safety by increasing workers' level of attention in dangerous areas. 21

22 Features and benefits Safety is valuable and uncompromising Companies work continually with measures to improve safety and prevent accidents. An accident with a fork lift truck is extremely costly in terms of personal injury, loss of manpower and damage to equipment. 60% of deaths related to fork lift trucks involve pedestrians. Reports show that an average accident with fork lift trucks cost the company 1,000. It is extremely common for our customers to monitor incidents and accidents and proudly present statistics such as number of days without an accident in company presentations. Customers are generally aware of the most hazardous areas of the warehouse since they likely require that all incidents and accidents be reported so that preventive action can be taken. We can offer a free demonstration of SpotMe to give the customer the chance to test the system in accident-prone areas and immediately improve safety. Visual warnings are effective Research shows that visual warnings are the most effective when drawing people's attention to a visual safety risk. SpotMe is a moving lamp system, which is easiest for the eye to see particularly for peripheral vision. In our peripheral vision, we cannot see colours or detect non-moving lamps as well. Visual warnings prepare people in an instinctive way for an expected, but also visual, safety risk. The normal method of honking the horn in each intersection is not as effective. 22

23 Features and benefits Scalable system design Modularity SpotMe is a modular system with full flexibility for scaling and adjusting to a number of applications and usage areas. By combining any number of sensors and warning units, the system is able to cover any need when it comes to detecting objects, people and vehicles. By using different detection channels, several systems can be installed in the same premises without interaction. All sensors and warning units communicate in the same manner, making it possible to combine components as you desire. Unique sensor technology The IR sensor reacts to changes in thermal emissions. It is not necessary to install any unit on trucks or people. The OP sensor is used for more focused detection, to limit an area or a specific height level. The IR sensors of the SpotMe system are wireless and the built-in lithium-ion battery ensures long and maintenance-free operation. During normal use, the battery has a life spanning several years. In cases where the objects that must be detected do not have a different temperature or if the detection field must be more focused, then OP sensors are a better choice. The sensors communicate with the warning module via licence-free radio communication (433 MHz). The unique sensors and software of the system make SpotMe the only stationary warning system on the market that can be installed in a matter of minutes thanks to its battery supply. Battery options The warning unit for indoor use can run on battery power as an alternative to the battery eliminator. Due to the power consumption, this battery option is only recommended for the amber variant. The battery version is perfect for demo installations and for applications where there is no access to the mains (230 V). The battery is sufficient for several months of operation without charging. The warning unit indicates low battery voltage (20%) through short flashes at a frequency of once per minute. Extra batteries can be purchased to avoid downtime for charging. 23

24 Features and benefits Suitable for many applications SpotMe works well regardless of the object, vehicle type or manufacturer the system is monitoring. The SpotMe system is intended for use indoors and in cold stores. The application guide indicates the most common applications and the components required. The warning unit can be programmed by a Toyota Service Technician with the SpotMe configuration tool. This tool can be used to set the warning flash time and the active radio channel. It is also possible to get a readout of statistics regarding the number of warnings and detections. If the application is complicated, make a sketch of the application and TMHE will help you to configure your SpotMe system. Low maintenance costs Once the SpotMe warning system has been installed, no maintenance is required beyond the regular functionality checks. These are required for various reasons: In industrial environments, there is always a risk of collisions and the components could be damaged or displaced during daily material handling. Sensors and warning units can be blocked by goods stored in the wrong location. Even though the battery supply is designed for a long service life, the user should check the battery status of the sensors and warning units regularly. The regular system checks are described in the user manual. 24

25 Application areas The application guide is a configuration manual that helps you specify the SpotMe warning system at the customer's workplace. The application guide contains layout examples and information to help you with the installation of a customer-tailored warning system. Description of symbols Programmed flashing warning time* Distance between sensor and risk zone* Detection channels for different SpotMe systems IR sensor with arrow indicating the activated direction OP sensor Warning unit in activated flashing mode Warning unit in standby mode Shaded objects trigger the sensors Line-drawn objects represent normal traffic Arrow indicates direction of travel * Comment: Warning flash time and sensor position must be adapted to the installation based on vehicle speeds, traffic intensity and visibility conditions. 25

26 Application areas 1. Passage doors and exits 1. One-way road with exit onto a main road An IR sensor detects objects in the exiting direction. The warning unit warns the traffic on the main road. 2. Exit with reverse warning Two IR sensors detect objects on the main road. The warning unit warns the incoming traffic way traffic with exit onto a main road Use of IR sensors on both sides is recommended for 2-way traffic or if the roadway is wider than 5 metres. 4. Open area with door to main road Two IR sensors are mounted with intersecting sensor fields and are angled towards the floor to limit sensor range. 26

27 Application areas 2. Blind corners 5. Application for blind corners Sensor a triggers warning unit a. The other direction is monitored by system b. Application with 2 channels. 6. Blind corners with intersecting traffic The aim is to warn workers of oncoming traffic. The position of the warning unit indicates where the danger comes from. Application with 3 channels. 3. Intersection 7a. 4-way intersection, basic This system warns of intersecting traffic in both directions. Application with 2 channels. 7b. 4-way intersection, advanced The aim is to warn workers of intersecting traffic. The position of the warning unit indicates where the danger comes from. Application with 4 channels. 27

28 Application areas 4. Intersection with pedestrians 8. Intersection with pedestrians Example of layout in combination with application 1. Application with 2 channels way intersection with pedestrians The aim is to warn truck operators of pedestrians approaching the intersection. The sensors should be mounted with a downward tilt to limit the sensor field to the walkway. 5. VNA applications 10. Warning for exit from narrow aisles The traffic outside of the aisles is warned about objects leaving the aisles. The number of channels required depends on the number of aisles. System with 1 channel per exit in the aisles. 11. Warning for entrance into narrow aisles The aim is to warn working order pickers of other workers about to enter the aisle. The warning units should be positioned at a height of 4 metres in operator-elevated applications. The individual sensors activate the warning units at both ends of the aisle. System with 1 channel per aisle. 28

29 Application areas 6. Height warning system 12. Height warning system A common accident with fork lift trucks is collisions with shelving and passage doors. With the OP sensor, operators can be given a warning to prevent an accident. 13. Walkway/hazardous area Areas intended for foot traffic are often adjacent to truck traffic. With the OP sensor, you can create a safety barrier that warns traffic when someone passes the safety zone. 14. Selective warning system By attaching reflectors only on the vehicles you want a warning for, the OP sensor can be used to create a selective warning system. In such cases, the aim is to minimise the number of warnings. The system therefore only reacts to certain vehicles. 29

30 Application areas 7. Statistics function 15. Study traffic flows and warning statistics With the help of SpotMe Configuration Tool II, you can check how many detections each sensor registered over time. You can also read how many times each warning unit has been triggered. It is possible to zero the statistics to measure traffic over a specific period. This makes it possible to study traffic flows and monitor how the SpotMe systems actively work to prevent accidents. For system installations where an optical protective ceiling was created using the OP sensor, the statistics function can be used to see how many accidents were potentially avoided thanks to SpotMe. 30

31 Installation Before starting installation, it is important to first plan out how the system will work and where each unit should be positioned. Examples of different types of installations can be found in the Application areas chapter. This guide only provides a description of how to mount the various units. We recommend that the installation technician discuss with warehouse personnel where the warning units should be positioned in order for SpotMe to gain acceptance and achieve maximum effect. The following tools may be required: ladder, drill, wall drill, screws, wall plugs, Allen keys and mounting strips. Mounting the indoor warning unit The warning unit can be mounted by screwing it directly into a structure, such as racking or a wall. The mounting arm mounting plate has flexible mounting holes (see figure). The hole pattern is suitable for most racking posts. The mounting arm is secured to the wall using mounting components suited to the wall type. The warning unit is then mounted to the other end with the supplied screw. The mounting height of the unit is completely dependent on the visibility conditions at the site. A general guideline is to mount the unit high enough to allow trucks to pass underneath. W = mm When the warning unit is in place, the desired power supply is connected (battery module or battery eliminator). The relevant cable is then secured to the mounting arm by routing a cable tie through the slots on the long side of the arm. The mounting arm is articulated at two spots, making it possible to position the warning unit close to the wall. When fully extended, the warning unit protrudes 30 cm from the wall. After the unit is positioned as required, tighten the screws in the mounting arm joints to lock the unit in this position. H = mm Mounting the battery holder The battery holder has the same hole pattern as the mounting arm and can therefore be positioned between the wall and the mounting arm. This makes it possible to position the battery close to the warning unit. If the battery version has been chosen as a permanent solution, the holder must be positioned at a height that makes it easy to change the battery. 63 mm 138 mm 261 mm 31

32 Installation Mounting the indoor IR sensor Mounting of the sensor is the most important part of SpotMe installation. The IR sensor is screwed into a wall or racking post at a spot with free visibility so that all objects passing in the right direction can be detected. The sensor mounting plate has the same appearance and dimensions as the one for the warning unit mounting arm. Check that the maximum distance to the objects is 5 metres and that the sensor is set to the right channel. Generally, the sensor should be positioned at a height of 150 cm, but this installation height must be adjusted to the conditions of the site. If there is no suitable wall for mounting the sensor on, it can be mounted in the ceiling above the traffic at a maximum height for 6 metres above the floor. It is critical that the sensor can only see traffic passing across the sensor eye and not any traffic moving straight towards or straight away from the sensor eye. See Figure 1. If the sensor must be installed at a spot where there is a lot of traffic that could interfere or if the sensor range must be limited, the sensor must be angled downwards to screen off the other traffic. See Figure 2. Adjust the sensor field to the required angle. Lock the sensor with the side screws and, if necessary, lock the angle by inserting a screw in one of the holes on the bracket. After a sensor has been mounted, it should be tested by repeatedly passing by it and checking the warning unit to see that it starts to flash and that it reacts early enough. A suitable distance between the IR sensor and the warning unit (D) is determined by the average velocity (V) of the object to be detected. See the table below: V D 1 m/s (3.6 km/h) > 3 m 2 m/s (7.2 km/h) > 6 m 3 m/s (10.8 km/h) > 9 m 4 m/s (14.4 km/h) > 12 m 32

33 Installation Mounting the outdoor warning unit The SpotMe warning unit for outdoor use is encapsulated with a plexiglas hood to withstand rain. The unit must therefore always be positioned horizontally. The warning unit is battery powered and is charged automatically via solar cells. With its need for solar recharging, the unit must be not be positioned in an area with constant shadow. A small number of in-sun hours per week is sufficient to charge the batteries. The warning unit can be mounted on a pole with the accompanying pole bracket. The bracket fits a vertical pole with a diameter of 50 mm or a square pole with a profile dimension of 50x50 mm. Mounting the outdoor IR sensor The SpotMe IR sensor for outdoor use is cylindrical in shape and encapsulated to withstand cold and rain. The sensor detection direction is marked with a coloured decal on one side. The decal indicates what direction the object must have in order to be detected. The sensor is supplied with a bracket suitable for a pole with a 50 mm diameter. The bracket can also be used to mount the sensor on a wall. In other respects, the instructions are the same as for the indoor sensor. The outdoor variant is available with 26 different channels in fields. The channels are fixed and cannot be reset. 33

34 Installation Mounting the OP sensor System with fixed reflector The OP sensor is delivered complete with flexible bracket, 230 V current adapter and reflector. The OP sensor is mounted on a wall with the accompanying bracket. The bracket allows the sensor to be rotated laterally so it can be aimed straight at the reflector. See Figure 1 (from above). The battery eliminator is plugged into a nearby wall socket. The reflector is mounted on the other side of the roadway at the same height and perpendicular to the sensor. The maximum distance between the sensor and the reflector is 20 metres. The OP sensor must be aimed towards the reflector until the yellow lamp comes on to indicate that the light beam is hitting the reflector. Activate the OP sensor following the instructions (see the section Setting mode ). In this mode, the OP sensor reacts when the light beam is broken. The warning unit will be triggered for the amount of time that the beam is broken plus the time set as the warning flash time. Mounting 1. Position the fork lift truck under the obstacle and lift the mast to the maximum permitted height for the obstacle (door, etc.). The recommended safety distance is ~ 50 mm. 2. Determine where the OP sensor should be positioned. The normal position is 8-12 metres in front of the obstacle. 3. Move the fork lift truck in line with the point where the OP sensor will be installed. The upper part of the truck mast must be in line with the optical light beam from the OP sensor. 4. Position a 2-way laser level on the top of the mast. The two laser points on the walls indicate where you need to install the OP sensor and the reflector. Figure 1. OP sensor from above 5. After installation, check the highest machine height that the vehicle can have without being detected and make sure that the safety distance between the machine and the obstacle is more than 50 mm. If not, lower the height of the OP sensor slightly. 34

35 Installation Mounting with mobile reflector (selective detection) Same as above, except the reflector is mounted on the vehicle to be detected. Make sure that the reflector is mounted on a fixed part of the vehicle and at the same height as the OP sensor. With this principle, the OP sensor will react in the reverse manner and activate the warning unit when it sees the reflector. The maximum distance to the vehicle to be detected is 16 metres. Several vehicles can be fitted with reflectors at the same height. Upon delivery, the OP sensor is set for detection with fixed reflector. Change to selective detection as described in section 5 below before performing the setting in section 3. Control panel 1. Control panel overview The control panel is protected by a transparent plastic cover. Open the cover by undoing the screw located on one of the short sides of the plastic cover. The control panel has a button marked TEACH plus three LEDs. The first LED is green and is marked RUN or GR. The second LED is red and is marked STAB or RD. The third LED is yellow and is marked OUT or YW. There is also a sliding button with the positions PNP and NPN. This should always be in the PNP position. A drawing of the control panel is shown below. The right-hand section shows the symbol that will be used through the rest of the manual. 2. Operating mode During normal operation, the sensor will be in operating mode. This is indicated by the green LED being lit with a steady light. The yellow LED comes on during detection. Refer to Setting mode for information on how to set the unit to operating mode. 35

36 Installation 3. Setting mode The sensor is delivered zeroed in a so-called setting mode. This is indicated by the sensor's green LED flashing when power is supplied to the unit. No detection occurs while the sensor is in setting mode. Note: Even if the sensor will not be used with a fixed reflector, a reflector must be in front of the sensor's detection surface when this setting is performed. Aim the sensor towards the reflector so that the yellow LED lights up. Then secure the sensor bracket. Verify that the yellow LED is still lit. If not, re-aim the sensor. If the yellow LED is not lit, the sensor is not aligned or the distance to the reflector is too great. Using an object with a blunt tip, press and hold the button depressed for 3 seconds. Release the button as soon as the green LED comes on. If the green LED remains lit, setting was successful and the sensor is now in operating mode. If instead the red LED begins flashing rapidly, setting failed and the sensor must be reset before the procedure can be repeated. If the sensor will be used with a reflector mounted on an object, refer to the section Setting reverse detection. 36

37 Installation 4. Resetting The sensor can be easily reset to setting mode. Using an object with a blunt tip, press and hold the button depressed. The green LED will go out and then light up again after 3 seconds. After another 3 seconds, the yellow LED will light and then 3 seconds later the green, yellow and red LEDs will flash. Release the button and make sure that the green LED is flashing. The sensor has now been reset. 5. Setting reverse detection There are cases where it is impractical to mount a reflector on the opposite side of the sensor and cases where you only want to detect select objects. It is possible to put reflectors on the objects to be detected instead, but this requires resetting of the sensor. The sensor must first be in operating mode. Using an object with a blunt tip, press and hold the button depressed. The green LED goes out and then lights up again after 3 seconds. Three seconds later, the yellow LED comes on. Release the button and make sure that the green LED flashes and then lights with a steady glow. The sensor is now set to selective detection. Repeat the procedure to restore normal detection. It is easy to test what mode the sensor is in. Simply hold a reflector right in front of the detection surface. If the yellow LED lights up, reverse detection is set. Otherwise, the sensor is in normal detection mode. 37

38 Installation Warning unit flash time Once all system components have been installed and sensor positions have been adjusted, the flash time of the warning units must be checked. Flash time must be long enough to give the detected object time to pass by before the warning units stop flashing. However, it is also possible to adjust flash time so that it does not continue longer than necessary. If the system flashes too long, it reduces the warning effect if there is a lot of traffic. The default flash time is 5 seconds, but this can be changed with the SpotMe Configuration Tool. 38

39 Installation Installation of several SpotMe systems 400 metres If installing several SpotMe systems in the same area, it is important to use different channels so that the sensors do not trigger the wrong warning units. There must be a distance of at least 400 metres between two SpotMe systems to be sure that they do not interfere with each other. If the systems are installed closer to each other than 400 metres, different channels must be used. New warning units are installed on channel A. The sensors are normally delivered with preset channels, but the channels of the indoor variant can be changed on site if necessary. Note: Because channel setting requires removal of the battery, the battery monitor will be reset. It is therefore important to change the battery on old sensors. Otherwise, low battery level indication will not work properly. SpotMe Configuration Tool II is used to set the warning unit channel. 39

40 Installation 40

41 Troubleshooting This section describes troubleshooting that cannot be performed though simple visual inspection of the system and its units. An initial visual inspection can often quickly and easily indicate whether a warning unit or sensor is working properly. This troubleshooting guide picks up at this stage. Several stages of the guide require use of a SpotMe Configuration Tool and a laptop. Note: Before the configuration tool can be used on a new computer, the drivers must be installed from the USB memory provided. Refer to the last section in the Configuration chapter. Testing SpotMe functionality with the configuration tool Position yourself within 5 metres of a functioning warning unit and select the Test command. Connect the configuration tool to your laptop and start the SpotMe program. On the start page, the warning unit's response should appear in the Map window. Is there a response? Yes: The configuration unit is working properly. No: Go closer to the unit and test again.»» Still no response: Restart the configuration tool. Then repeat step one.»» Still no response: Test with another warning unit. If it does not work, this indicates that the unit is defective. Testing warning unit functionality with the configuration tool General communication test Position yourself within 5 metres of the warning unit and use a SpotMe Configuration Tool to read out which channel the warning unit is set to. Is there a response? Yes: The warning unit is working properly. No: Test up to 3 times as other radio traffic my interfere with the functionality test.»» Still no response: Restart the warning unit by disconnecting the power supply cable, waiting a few seconds and then reconnecting it. Does the unit start to flash? * No: Switch to a power source that you are sure is working properly and start from the beginning again. * No: If the power source is OK, this indicates that the warning unit is defective. 41

42 Troubleshooting Detection test Using a SpotMe Configuration Tool, send a sensor message on the channel the unit is set to. Does the unit start to flash? Yes: The warning unit is working properly. No: Go closer to the unit and test again. Does the unit start to flash?»» Yes: The warning unit is working properly.»» No: Switch to a power source that you are sure is working properly and start from the beginning again.»» No: If the power source is OK, this indicates that the unit is defective. IR sensor does not detect passing traffic Does the person/vehicle pass the sensor in the direction indicated by the arrow on the sensor? No: Turn the sensor 180 degrees so that the arrow faces the right direction. Yes: Continue with the next troubleshooting point. Does the person/vehicle pass the sensor at a distance greater than 5 metres? Yes: Move the sensor or mount another sensor across from the existing sensor. No: Continue with the next troubleshooting point. Is the distance to the warning unit 50 metres or more? Yes: Move the sensor closer to the warning unit. No: Continue with the next troubleshooting point. Use a SpotMe Configuration Tool. Are messages from the sensor visible in the Live Traffic field when traffic passes in the active direction? Yes: Move the sensor closer to the warning unit.»» If this does not help, refer to the section Testing warning unit functionality. No: Replace the sensor battery.»» If battery replacement does not help, the sensor is defective. 42

43 Troubleshooting The warning unit does not flash when someone passes Is a functioning power source connected to the warning unit? No: Connect a functioning power source. Yes: Continue with the next troubleshooting point. Are the sensor and the warning unit set to the same channel? (Check the channel marking on the sensor and read out the active channel of the warning unit using the SpotMe Configuration Tool) No: Reset the channel of the warning unit or replace the sensor with one that uses the right channel. Yes: Continue with the next troubleshooting point. Does the person/vehicle pass the sensor in the direction indicated by the arrow on the sensor? No: Turn the sensor 180 degrees so that the arrow faces the right direction. Yes: Continue with the next troubleshooting point. Does the person/vehicle pass the sensor at a distance greater than 5 metres? Yes: Move the sensor or mount another sensor across from the existing sensor. No: Continue with the next troubleshooting point. Is the distance to the warning unit 50 metres or more? Yes: Move the sensor closer to the warning unit. No: Continue with the next troubleshooting point. Position yourself 5 metres from the sensor. Using a SpotMe Configuration Tool, check whether radio messages from the sensor are visible in the Live Traffic window when someone passes by in the active direction of the sensor. Yes: Go to the section Testing warning unit functionality. No: No messages visible replace the sensor battery. If battery replacement does not help, the sensor is defective. If none of the above has remedied the problem, refer to the section Testing warning unit functionality. Note: If the sensor is used in a cold store application, it should be positioned slightly below eye level. Warm clothing insulates thermal radiation and can hinder detection. 43

44 Troubleshooting IR sensor is triggered for no apparent reason Is there traffic in front of the sensor that does not move across the sensor eye? Yes: Adjust or move the sensor so that it only sees traffic that goes across the sensor eye. No: Continue with the next troubleshooting point. Does traffic pass in front of the sensor at a distance greater than 5 metres? Yes: This traffic may be triggering the sensor if its heat differs greatly from the ambient temperature. If the sensor should not be detecting such vehicles, the sensor should be angled down towards the ground to screen it off. No: Continue with the next troubleshooting point. Does the sensor have a permanent heat or cold source in its detection zone? Yes: Adjust or move the sensor so that it does not see this source. No: Continue with the next troubleshooting point. Replace the sensor. Is the new sensor also triggered without apparent reason? Yes: Try to determine the reason by going back to step 1. No: The first sensor is defective. Warning unit flashes for no apparent reason Do all lamps on the unit flash twice per minute? Yes: This indicates: 1. Low power supply level, or 2. An IR sensor has a low battery level.»» 1. Switch to a fully charged battery module. If a battery eliminator is used, then the cable between the battery eliminator and the warning unit is too long. Use an extension cable with a length of 10 metres or less.»» 2. If the problem persists, an IR sensor has a discharged battery that must be replaced. NOTE: Only replace the battery with an original SpotMe battery. Otherwise, low battery level indication will not work. No: Continue with the next troubleshooting point. If several sensors are used in the same system, SpotMe Configuration Tool II can be used to determine which sensor is discharged. The Live Traffic window will indicate which sensor is indicating a low battery level. Compare the serial number of the sensor message with the marking on the sensors. If the warning unit flashes normally, use the Live Traffic window of the SpotMe Configuration Tool to determine which sensor is sending the detection messages. No messages can be seen on the affected channel: Go around the vicinity with the configuration tool and continue searching for radio traffic. Radio messages are found: Find the sensor sending the message and refer to the section Sensor is triggered for no apparent reason. In the Map window on the start page, you can use the RSSI value to see how far away in the premises the sensor is located. 44

45 Troubleshooting OP sensor troubleshooting Sensor does not detect Is the green LED lit? No, it is flashing -> The sensor is in setting mode. See the chapter Setting mode. No, not at all -> Check the power supply to the sensor. Does the warning unit fail to flash even though the yellow LED is lit? No -> Is the sliding button on the control panel in the PNP position? No -> Move it to the PNP position Yes -> The warning sensor does not hear the sensor. Check the distance to the warning unit and that the right channel is being used. Sensor detects continuously (fixed reflector). Is the sensor correctly aimed towards the reflector? No -> Adjust the sensor mechanically until the yellow LED goes out. Yes -> Clean the detection surface and the reflector. Does the sensor stop detecting if you block the reflector? Yes -> Wrong mode set; see the section Setting reverse detection. Sensor detects continuously (reflector on object) Is there any reflective object in front of the sensor? Yes -> Move the object or move the sensor. Does the sensor stop detecting if you hold a reflector in front of the sensor? Yes -> Wrong mode set; see the section Setting reverse detection. If the above troubleshooting did not resolve the problem, then the sensor is probably incorrectly calibrated. Perform a reset and then follow the instructions in the section Setting mode. 45

46 Troubleshooting 46

47 List of components Component overview The components can be ordered from BT Parts. Contact TMHE AB Logistic Solutions and Development for product support. Pos Included in starter kit Part number A 20 B 1 Door 1S 230 V Door 1S battery Door 2S 230 V Door 2S battery Blind corner 230 V Blind corner battery Intersection B 230 V Intersection B battery Pos Component list Part number Info 9 Warning unit orange WU with holder 10 Warning unit blue WU with holder 11 Outdoor warning unit With solar cells and battery 12 Pole bracket, WU outdoor For mounting on metal pole 13 Battery module V for WU orange 14 Battery holder Battery cable, 1 m Extension cable, 5 m Battery charger EU+UK plug V converter EU+UK plug V converter, temp. proof EU+UK plug 20 IR sensor XXX* 21 Outdoor IR sensor XXX* 22 OP sensor XXX* 23 Configuration Tool II Configuration tool ver. -002, USB cable and software 24 User manual XXX All languages 25 LED circuit board, orange Spare part 26 Battery, indoor IR sensor Spare part 27 Bracket, indoor IR sensor Spare part 28 Bracket, indoor WU Spare part * Suffix determines channel. A=001, B=002, C=003, Z=026 Application areas Component Indoor 0-40 C Cold store -30 C Outdoors dry Outdoors damp Warning unit orange X X X Warning unit blue X X Warning unit solar cell X 230 V converter X X 230 V converter, temp. proof X X X Battery module X IR sensor X X X X Outdoor IR sensor X OP sensor X X Configuration Tool II X X X X X X 47

48 List of components Important information when ordering components When the customer is ordering his first SpotMe system, we recommend one of the starter kits found in the list of components. Each kit comes with a user manual. When the same customer wants to order another SpotMe system for the same site, a kit is not required for the following reasons: In order for several SpotMe systems to work in the same premises, they must not disturb each other's radio communication. The sensors must therefore be ordered with channels not already in use at the site. The channel is marked on each sensor. The IR sensor channel can be changed if necessary using SpotMe Configuration Tool II. Note: Because channel setting requires removal of the battery, the battery monitor will be reset. It is therefore important to change the battery on old sensors. Otherwise, low battery level indication will not work properly. The warning units are always delivered set to channel A and must be reprogrammed using SpotMe Configuration Tool II during installation to pair the warning unit with the respective sensor. At the same time, a suitable flash time is set based on factors such as vehicle speed and visibility. Examples: The customer purchased the Door 2S kit solution with 2 doors for a passage door and later wants to purchase a solution for a four-way intersection. Before placing an order, the salesperson must find out what sensor channels are already being used by the customer. Starter kit Door 2S uses 2 sensors with channel A. For an intersection, you need two pairs of sensors with two different channels. It is therefore best to order two sensors with channel B and two with channel C so as not to cause disturbance in the existing passage door solution. The configuration tool is then used to program the warning units to channels B and C during installation. 48

49 Configuration 1. Equipment required Laptop with USB port SpotMe configuration unit (SpotMe Configuration Tool II, ). USB A/mini B cable. SpotMe warning units and sensors Note: Before the configuration tool can be used on a new computer, the SpotMe program must be installed on the computer from the USB memory provided. See section Getting started Start the application using the SpotMe icon on the computer desktop. Connect the configuration unit to the computer's USB port. The program then automatically searches for the configuration unit's port and the correct port is shown in the pop-up window. -Click OK. The program's start page then opens and you are ready to configure your SpotMe equipment. Components requiring an external power supply must be activated in order to be configured. 49

50 Configuration 3. Start page As soon as the start page opens, it begins to present SpotMe activities and radio messages in progress. The start page has two function fields: Map (A) and Live Traffic (B). Map (A) The Map field shows a search list of all SpotMe units that are active in the radio range and that can be reconfigured. The following information is presented:»» Actual time the unit was identified, type of component, serial number, set channel and any error messages.»» RSSI shows the signal strength of the radio message, which varies in proportion to the distance from the actual position. Live Traffic (B) The Live Traffic field continually shows all radio traffic happening in the room. The following information is presented:»» Message time, type of component, serial number and radio message content.»» If Show All Traffic is deselected, then only the sensor messages are shown. Either field can be cleared by clicking on Clear. The Home button takes you back to the main menu, while the gear is used for port settings. If a red error message appears at the bottom of the page, then there is a problem with the configuration tool connected to the USB port. 50

51 Configuration 4. Warning unit configuration If you double-click on a warning unit listed in the Map field on the start page, a page opens to enable you to configure that unit. Check the serial number on the warning unit label to ensure you are working with the right unit. Configuration field (C) This field shows the current radio channel and flash time. It also shows battery status (for warning units with battery module) and any error messages. The current settings for channel and flash time are shown in the Channel and Time fields. Change the settings as follows: 1. Select a new channel (A-Z) and/or flash time (0-999 s) using the relevant drop-down list. 2. Confirm the reprogramming in the pop-up window by clicking Yes or cancel it by clicking No. 51

52 Configuration 5. Sensor configuration If you double-click on a sensor listed in the Map field on the start page, a field (D) opens to enable you to configure that sensor. Check the serial number on the sensor label to ensure you are working with the right sensor. The following steps must be carried out to change the radio channel of an indoor sensor: IR sensor: Dismantle the unit, remove the battery and then refit it. The IR sensor is now in programming mode and the channel can be changed as described above. OP sensor: Unplug the power connector briefly. Reconnect the power supply to the unit. The OP sensor is now in programming mode and the channel can be changed as described above. If no reprogramming is done, previous settings resume after the programming mode time has elapsed (~3 minutes). The sensors are only selectable in the Map window while programming mode is running. 1. Set the sensor to programming mode as described above. 2. Double-click on the sensor in the Map field. 3. To change the radio channel, select a channel (A-Z) from the drop-down list. 4. Confirm the reprogramming in the pop-up window. Note: -The outdoor sensor cannot be configured. -For information on removing the battery on the IR sensor, see the Maintenance chapter. -Battery replacement is required on a used IR sensor being reprogrammed. Otherwise, the sensor's battery monitor will not work properly. -After switching a sensor's channel, the new channel must be marked on sensor label. 52

53 Configuration 6. Statistics If you double-click on a warning unit listed in the Map field on the start page, a page opens with activation statistics for the system. Check the serial number on the warning unit label to ensure you are reading from the right unit. Statistics field (E) If you click on the Refresh button, the warning unit will show the total number of warnings it has issued. The list also shows the number of detections made by SpotMe system sensors. All sensors with the same channel as the warning unit are shown. If you click on the Reset button, the counter is reset (factory reset), enabling you to measure statistics over a specific period of time. The Export button enables you to save the statistics as a text file. 53

54 Configuration 7. Testing the warning unit At the bottom of every page, there is a field (F) where you can test warning unit functionality. With this command, the computer sends out a detection message of the same type as when a sensor detects an object. This enables you to confirm that a warning unit is operating and that it is listening to the right channel. 1. Select the sensor channel you want use from the drop-down list. 2. Click on Test to send the message. The warning unit should react immediately and flash for the set amount of time. If this does not happen, check the channel setting on the unit. Refer to the Troubleshooting chapter for further problem solving. 54