vehicle ignition interlock

vehicle ignition interlock
VEHICLE IGNITION INTERLOCK
MODEL SM107 (software release 3.0)
INSTALLATION & MAINTENANCE GUIDE
Document ver. 4
Manufactured in Australia by Alian Electronics Pty Ltd
408 Old Sale Rd. Drouin West 3818 Ph. (03) 5625 2545
CONTENTS
Installation & Maintenance
Australian Standards for forklift operators
3
General Description……………………………..3
Safety Information…………………………….…4
Features in detail.…………………….………….4
Mounting Procedure…………………….……….6
Electrical Connections …..…………………… ..7
Optional handbrake wiring…………………...…7
Neutral gear shift interlock……………………...8
Electronic seatbelt sensors..……………………8
Specifications ..……..……………………………8
Warranty Information.……………………………9
Appendix 1…Vehicle label…………………..…10
2
ISO 3691.8 – Australian Standards on Forklift Driver restraint – Sept 2013
This extract describes the requirements that forklift vehicles in Australia must adhere to.
….Where seatbelts are fitted, they shall be interlocked to prevent the truck
from travel motion unless the seatbelt is buckled. In addition, the seatbelt
interlock shall include the sequencing/logic of the seatbelt switch with a
seat pressure switch. The weight of the operator on the seat shall be
detected prior to the seatbelt switch being engaged.
In addition to the seatbelt interlock sequencing, it shall be linked to the
neutral switch and the handbrake to ensure that it is applied before the
truck can be started. The system shall be tamper-proof.
The SM107 can be fitted to non-compliant vehicles to allow them to meet these requirements
GENERAL DESCRIPTION
The SM107 unit will prevent a vehicle from being operated until the
Driver is safely seated, Handbrake ON & the seatbelt is correctly attached.
It will work on both electric and internal combustion vehicles where the vehicle battery
voltage is anywhere between 8v and 48v dc.
Only when the Handbrake sensor, seat sensor and the seatbelt buckle sensor have been
operated in the correct sequence, will the vehicle ignition be enabled.
Anti – tamper circuits will trigger an alarm lamp if any of the sensors or the ignition circuit
is bypassed. (Resetable only by a key) A second output relay activates when the vehicle
is armed that is not connected to the Anti-tamper circuit. This can be used to enable other
non-critical equipment up to 10 amps such as lift controls or reversing camera if required.
LED indicators track the progress of the start sequence, a single ‘Beep’ is generated by
the unit whenever the ignition is enabled. (described in this document as ‘Armed’)
A multi-stage power spike filtering system on the power supply provides protection against
high voltage transients that are often present in electric vehicles, forklifts etc.
The enclosure is water resistant rated to IP65, with un-pluggable screw terminal blocks for
easy testing & service.
Input sensors may be simple switch contacts, hall effect sensors, or opto-interrupter
devices. Seat, buckle and ignition circuit sensors are continuously tested by the unit for
‘interference’ by unauthorised persons, and may trip the TAMPER alarm lamp to a steady
glow.
If three consecutive ignition attempts are made without the vehicle being used within the
first minute of operation, the unit will deem that the unit was ‘Hot-wired’ and the TAMPER
lamp will slowly flash. The Tamper lamp can only be reset with a key switch after the
vehicle battery has been briefly disconnected. Simple disconnection of power will not
reset a tamper event.
3
UNIT ENCLOSURE
The SM107 unit is mounted in a sealed die-cast aluminium enclosure with rubberised gaskets to
ensure water ingress protection to the IP65 standard.
SAFETY INFORMATION
This equipment must be installed and maintained by electrical staff conversant with
electrical installations within the automotive and industrial equipment industry.
Do not install this equipment if the enclosure or any internal components appear damaged.
The vehicles power system (battery) should be isolated before commencing an
installation.
Before drilling holes behind the control unit for mounting purposes or cable access, ensure
that no active cables are present in the cavity behind the unit that will be damaged by drill
bits or mounting screws.
Do not remove the cover of the control unit enclosure during inclement weather or where
water spray is present.
Do not operate this equipment until all outgoing cables to sensors are correctly terminated.
The SM107 vehicle interlock unit is designed for petrol/gas vehicles operating of 12V or for
electric vehicles with a battery in the 17 to 48V range. (higher voltage electric vehicles will need
either a lower voltage tapping to extract power from, or a suitable voltage converter with a 12V or
24V output.)
Special spike and transient filters are present within the unit enabling it to operate in the harsh
electrical environments present in 48V electric vehicles where voltage spikes frequently reach
hundreds of volts.
The unit has a green POWER lamp to indicate that a DC supply has been correctly connected.
4
UNIT OPERATION
Description of Inputs & outputs
Essentially the SM107 is a device with three inputs and two outputs.
The three inputs monitor the state of the Handbrake switch, the Seat switch and the
Seatbelt Buckle.
o
These three switch inputs relate to a ‘common’ negative battery connection. Each switch
must assume the ‘closed’ condition when it is in use. All switch inputs must be open or
closed for a full one second period before the system will respond to it.
The two outputs operate simultaneously. One output is an internal relay contact that will
enable the vehicle’s ignition system. This output has anti-tamper detection and has a 3
Amp maximum rating. The second output does not monitor for Tamper conditions, but it
has a 10Amp switched output.
Startup delay
When the unit is first powered up, there is a 2 second delay before the HANDBRAKE input is
monitored and a 3 second delay before the SEAT SWITCH is monitored. This ensures that if the
unit is powered up by the ignition key going to the Accessory position, then the operator does not
need to re-activate the handbrake and seat switch for these inputs to be monitored successfully.
Input sequence
The three inputs must be operated in the sequence of: HANDBRAKE – anytime, then SEAT and
SEATBELT BUCKLE in that order, no faster than one second apart. The progress of the three
inputs can be seen by the three LED indicators on the front panel. If they are operated in any
other sequence, the vehicle ignition will remain disabled. This prevents the seatbelt from being
left permanently plugged into the seatbelt buckle as a method of bypassing the safety harness.
Once the three inputs have been operated in the correct order, the green IGNITION indicator will
activate and the alert beeper will sound for approximately one second. This means that the
vehicle ignition has been armed and the vehicle should start when the operator turns the key.
Rules of operation in detail
If the handbrake is OFF at the start of a sequence, the vehicle ignition will be disarmed
The SEAT SWITCH must be closed BEFORE the seatbelt buckle goes to the latched
position or the vehicle ignition will be disarmed
Once the ignition has been successfully armed (engine ready to run) then the handbrake
can be turned off without the engine from being stopped or disarmed.
Once the ignition is enabled (engine running) and the handbrake is ON, then unbuckling
the seatbelt or getting out of the seat is possible without the engine stopping.
Once the ignition is enabled (engine running) and the handbrake is OFF, then unbuckling
the seatbelt or getting out of the seat for more than 2 seconds will kill the ignition.
(if there is no Neutral gearshift interlock already fitted to the vehicle, then, a Neutral
position switch should be wired in series with the Handbrake circuit. Hence the handbrake
ON condition will only be measured when the vehicle is also in Neutral.)
These are the conditions that must be met for forklift safety compliance in Australia.
5
NORMAL VEHICLE
CIRCUIT
VEHICLE CIRCUIT
WITH SM107 FITTED
+ BATT
+ BATT
Ignition
key
Ignition
key
Other
equip.
Other
equip.
Vehicle
Ignition
Current
sensor
Vehicle
Ignition
GND
Logic
SEAT &
SEATBELT
SENSORS
GND
Break ignition loop at any
point, regardless of polarity
3 amps Maximum)
Ignition circuit detection
The SM107 monitors the current flowing through the vehicle ignition system so it will be aware
when the vehicle has been started (three amps maximum). Once the vehicle ignition has been
activated by the operator, the IGN lamp on the SM107 will change from flashing to a steady glow.
The current sensing circuit inside the SM107 is isolated from all other circuitry, so that the ignition
switching loop can be electrically wired either side of the vehicle ignition key, independent of D.C.
polarity.
Anti-tamper
A small 10K ohm resistor should be connected directly across the rear of the SEAT and Buckle
switch contacts. So when the switches are ‘Open’ the SM107 will read the presence of the 10K
ohm resistor. If the resistor is not present, the wiring is deemed to have been compromised and
the red TAMPER lamp will latch ON. It will continue to stay ON until reset by a brief operation of
the key switch.
Additional anti-tamper protection on the ignition system ensures that the SM107 has not been
bypassed or ‘hot-wired’. If the unit fails to see power being drawn by the ignition less than a
minute from the seatbelt being plugged in on three successive occasions, the unit will deem that
it has been bypassed and the tamper lamp will flash slowly. The count of three is present to stop
false tripping of the tamper lamp by operators turning the ignition key ‘off’ to talk to staff or
operate a cell phone for extended periods without leaving the vehicle.
Once a Tamper event has been detected it can only be reset by brief disconnection of the vehicle
battery from the unit and application of the reset key. Internal memory within the SM107 will
ensure that the tamper event will continue to be displayed even if the battery is removed from the
vehicle for some weeks.
MOUNTING PROCEDURE
The unit is contained within an aluminium die-cast enclosure with mounting flange at each end. It
can be mounted in any position convenient to the vehicle wiring, though it may be advantageous
to mount it where the operator can see the display that monitors the progress of the ignition
sequence.
When drilling holes within the vehicle to mount the SM107 unit, care must be taken that no
vehicle wiring is on the other side of the metal being drilled.
6
ELECTRICAL CONNECTIONS
Because of inherent variations in wiring between vehicles there may need to be some creative
adaptation to ensure that the input connections can be achieved correctly. For example, some
vehicles may need to have a separate seat switch to one already on the vehicle that is
performing other tasks
Should the unit need to be removed for service, the wires can remain in the terminal strip and the
entire 12-way green connector can be unplugged from the front panel as a unit.
AUX 10A RELAY ARMING
CONTACT FOR ENABLING
OTHER CIRCUITS
REAR VIEW OF SM107 UNIT
WIRE IN SERIES
WITH VEHICLE
IGNITION SWITCH
+12V AUX TO
POWER SENSORS
(IF REQUIRED)
Supply
+17-50V
+12v
SELECT
INPUT TO
MATCH
VEHICLE
BATTERY
VEHICLE IGNITION
SWITCH in
ACC POSITION
Note the 10K
ohm resistor
wired across
each switch
contact
VEHICLE
BATTERY
SEAT BELT
BUCKLE
SWITCH
SEAT
SWITCH
HANDBRAKE
SWITCH
(& NEUT GEAR
SWITCH IF REQ.)
HANDBRAKE SWITCH CONNECTION
If the existing handbrake switch is wired to the existing vehicle electronics, it may be possible to
piggy-back onto this circuit without the need to provide a separate switch. To be compatible, it
must have a vehicle ground potential on the common terminal and a +5V signal on the Normally
Open terminal when the switch is released.
(To check compatibility place a volt meter across the switch. See if one side is at a vehicle
ground potential and observe that the other Normally Open terminal rises to 5V when the
handbrake is OFF)
7
If the above switching arrangements are present, then it is ok to connect the N/O terminal of the
switch to the Handbrake input of the SM107 controller.
If these conditions are not in evidence then a separate handbrake switch may need to be fitted to
the handbrake that CLOSES a contact when the handbrake is ON.
NEUTRAL GEAR SHIFT REQUIREMENT
Many vehicles with a manual gear-shift lever already have an interlock that prevents the engine
from starting unless it has been placed in the Neutral position. This is a mandated requirement.
If the feature is already in place, then no additional gear-shift switch connection is needed.
If this feature is NOT in place, it should be added to the system to achieve full compliance.
A microswitch needs to me mounted in such a way that a contact CLOSES when the gear shift is
in Neutral. This contact can then be wired in series with the Handbrake input, ensuring both a
Neutral and Handbrake condition before the vehicle ignition may be armed.
ELECTRONIC SEATBELT SENSORS
Some vehicles may be equipped with sensors that require a small DC voltage to support an LED
Photo-interrupter or magnetic Hall Effect device. This voltage is available on the +12V AUX
terminal on the front of the SM107 unit. It is a filtered DC potential fed via a small current limiting
resistor inside, which makes it appropriate for directly powering LED devices with no further
components needed.
To +12VAUX
To ‘COMMON’
INPUT
To SWITCH
INPUT
SEATBELT
FITTING
SPECIFICATIONS
Supply Voltage (low)
8 to 15V DC, Low voltage input
Supply Voltage (high)
17V to 50V DC, High voltage input
Supply Current
40ma, (or 80ma with all LED’s lit)
Ignition Switching current
3 Amps Maximum
Aux Start Relay contact
10A Maximum
Enclosure Height/Width/Depth
39 x 117 x 217mm
8
WARANTY INFORMATION
A warranty period of 12 months applies to the unit from the date of installation. This
warranty becomes void where: (A) The unit has been damaged by excessive and
unreasonable impacts, or (B) Water damage has resulted by exposure to weather where the
enclosure has not been fully sealed by the installer, or (C) The unit has been used for an
application other than that specified in the installation document.
The warranty implies that a repair or replacement will be given when the defective unit
is returned to the supplier. The warranty does not cover delivery and handling charges,
compensation for time lost, damage caused by incorrect wiring during installation, or damage
to other plant and equipment at the installation site.
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APPENDIX 1
OPERATOR INSTRUCTION LABEL
Vehicles that have been fitted with the seatbelt interlock should have a label fitted to the
operator console to inform the driver about the correct way of using this system
The text below is a sample of the label provided for this purpose.
DRIVER PLEASE NOTE
This vehicle has been fitted with the mandatory seat belt
detection system that will prevent engine operation if it is
not started in the correct sequence.
To start the vehicle, the driver must:
1. Be seated in the driver seat with the ignition OFF and with the
handbrake ON and the gear shift in the Neutral position.
2. Turn the ignition switch position to the Accessory position
3. Wait 3 seconds and plug the seatbelt into the buckle
4. A brief tone will sound and NOW the vehicle may be started
with the ignition key.
Also note:
If the engine is running with the handbrake OFF and the seatbelt is
unbuckled by the driver, or the driver rises from the seat, then the
engine will stop.
If the engine is running with the handbrake ON and the vehicle is in
Neutral, the driver may safely leave the seat for a short period
without the engine stopping.
When the driver returns, it is necessary to re-fasten the seatbelt
BEFORE releasing the handbrake or the engine will stop.
Anti-tamper technology ensures that these steps cannot be bypassed
without tripping an alarm that can only be reset by service staff.
For more information on this control product (model SM107) visit:
www.alianelectronics.com.au/sm107.
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