Modular Mining Systems 302395 Users Manual
Modular Mining Systems
302395 User’s Guide and Repeater
M/LC Repeaters
Network Design Guide
Part Number 201327
February 2004
RESTRICTIVE COVENANT
AND
DISCLAIMER
Copyright © 2004 by Modular Mining Systems, Inc.
Tucson, Arizona, U.S.A.
All rights reserved.
Modular Mining Systems, Inc., makes no representation regarding the fitness, quality, design, condition,
capacity, suitability, or performance of the equipment or of the material or workmanship thereof and/or compliance
of the system with the requirements of any law or regulations, and disclaims all warranties, either express or implied,
including but not limited to any implied warranty of merchantability or fitness for any particular purpose. Modular
Mining Systems, Inc., shall not be responsible for any loss or damage to property or injury or death to persons caused
by any defect or failure in the system hardware and/or software regardless of the form of action, whether in contract
or in tort, including negligence, strict liability, or otherwise. Modular Mining Systems, Inc., is not responsible for any
losses, financial or otherwise, that the customer, purchaser, or end user (hereafter, collectively, user) incurs nor shall
it be liable for any damages whatsoever (including, without limitation, damages for loss of business or investment
profits, business interruption, loss of business information or the like) arising out of the use, interruption in the use
of, or performance of the system hardware and/or software. User expressly agrees to indemnify and hold harmless
Modular Mining Systems, Inc., from and against all claims, damages, losses, and expenses, including but not limited
to: (i) any loss resulting from general or particular requirements of needs of user as defined in user’s originating
purchase order; (ii) any damages from loss of use, loss of data, loss of profits, or loss of business arising out of or in
connection with the performance of system hardware and/or software; (iii) any loss or damage to property or injury
or death to persons proximately resulting from system hardware and/or software, even if entirely due in whole or in
part to negligent acts or omissions of Modular Mining Systems, Inc.; and (iv) attorney’s fees and costs.
The information described in this document is furnished as proprietary information and may not be copied or sold
without the written permission of Modular Mining Systems, Inc.
Trademarks
The Modular distinctive font, PowerView, ProVision, and WebReports are trademarks of Modular Mining Systems,
Inc.
The Modular logo, DISPATCH, MasterLink, and IntelliMine are registered U.S. trademarks of Modular Mining
Systems, Inc.
All other brand names and product names used in this book are trademarks, registered trademarks, or trade names of
their respective holders.
Contents
1. Introduction.......................................................................................................1
2. Design Principles of a M/LC Repeater Network............................................3
2.1 General Hardware Selection Guidelines..........................................................................3
2.1.1 M/LC Infrastructure Hardware...............................................................................................3
2.1.2 Data Rates and Range.............................................................................................................4
2.1.3 M/LC Point-to-Point Links.....................................................................................................4
2.1.4 Temperature Related Decisions..............................................................................................4
2.1.5 Sizing a Solar Repeater ..........................................................................................................4
2.1.6 Lightning Protection...............................................................................................................5
2.2 General Coverage Guidelines.......................................................................................... 6
2.2.1 Locations, Repeater Quantities, and Antennas.......................................................................6
2.2.2 Location Considerations and Antenna Selection....................................................................6
2.2.3 Overall System Throughput Design Considerations ..............................................................7
2.2.4 Channel Selection...................................................................................................................7
2.3 The 302395 Repeater Electronics Unit............................................................................ 8
2.3.1 Approved Antennas................................................................................................................8
2.4 FCC Statements ...............................................................................................................9
3. Antenna Evaluation.........................................................................................11
3.1 Antenna Characteristics................................................................................................. 12
3.1.1 Antenna Coverage Patterns ..................................................................................................12
3.1.2 Antenna Gain........................................................................................................................13
3.1.2.1 dBi (Decibels Relative to Isotropic)....................................................................................... 13
3.2 Antenna Types............................................................................................................... 14
3.3 Antenna Patterns............................................................................................................15
3.3.1 Lobes....................................................................................................................................15
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302395 User’s Guide and Repeater Network Design Guide
3.3.2 Relative Gain........................................................................................................................16
3.3.2.1 dB (Decibels) .........................................................................................................................16
3.3.2.2 Half Power Points (—3 dB Points) ........................................................................................17
3.3.3 Tilt Angle (Down Tilt) .........................................................................................................19
3.3.3.1 Vertical Coverage by Antenna Type......................................................................................19
3.4 Signal Patterns and Gain Characteristics for Antenna Types........................................20
3.4.1 Omnidirectional Antennas....................................................................................................20
3.4.2 Sector Antennas....................................................................................................................21
3.4.3 Parabolic Antenna ................................................................................................................22
3.5 Adjusting, Changing, or Relocating an Antenna........................................................... 23
3.5.1 Understanding the Requirements of Your Network.............................................................23
3.5.2 Recording Antenna Characteristics......................................................................................24
3.6 Obtaining Additional Guidance.....................................................................................24
4. Moving an Access Point..................................................................................25
4.1 Selecting a New Access Point Site................................................................................ 25
4.2 Relocation Procedures ................................................................................................... 25
4.3 Verifying Radio Coverage.............................................................................................25
5. Cisco Wireless Access Point Support ............................................................27
5.1 Cisco Initial Setup .......................................................................................................... 27
5.1.1 Site First Steps......................................................................................................................27
5.1.2 WAP Monitor.......................................................................................................................27
5.1.3 MasterLink/OMS/Dispatch Integration................................................................................30
5.2 Troubleshooting.............................................................................................................31
5.2.1 The System Log....................................................................................................................31
5.2.2 Association Page ..................................................................................................................31
5.2.3 Link Test...............................................................................................................................32
5.2.4 Ping test................................................................................................................................33
5.3 Serial Port Configuration...............................................................................................34
5.3.1 Initial Configuration (Serial Port).........................................................................................34
5.3.1.1 Connect PC to MasterLink/Cicso Repeater Hub.................................................................... 34
5.3.1.2 Hyper Terminal Setup ............................................................................................................34
5.3.1.3 Express Setup.........................................................................................................................36
5.4 Standard Configuration via HTTP................................................................................. 37
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Contents—Continued
5.4.1.1 Ethernet connected.................................................................................................................38
5.4.1.2 Wireless..................................................................................................................................38
5.4.1.3 WEP ....................................................................................................................................40
5.4.1.4 Setting the Channel ................................................................................................................43
5.5 Password Recovery........................................................................................................ 43
6. Appendix A — 302395 Connection Diagram................................................45
Revision History ..............................................................................................47
List of Figures
Figure 1 Antenna Types..............................................................................................................................11
Figure 2 Antenna Patterns - Horizontal and Vertical Components.............................................................12
Figure 3 Typical Horizontal Patterns ..........................................................................................................14
Figure 4 Lobes in Antenna Pattern..............................................................................................................15
Figure 5 Antenna Pattern dB Scale .............................................................................................................16
Figure 6 Half Power Points.........................................................................................................................17
Figure 7 Horizontal and Vertical Lobes......................................................................................................18
Figure 8 Antenna Tilt Angle (Down Tilt) ...................................................................................................19
Figure 9 Omnidirectional Antennas............................................................................................................20
Figure 10 Sector Antennas..........................................................................................................................21
Figure 11 Parabolic Antenna.......................................................................................................................22
Revision A: February 2003 v
302395 User’s Guide and Repeater Network Design Guide
vi February 2004
1. Introduction
The Modular Mining Systems M/LC radio network provides high-quality, low-maintenance
communications to all mine operating areas. (M/LC stands for “MasterLink® Cisco” and is based on an
Ethernet Bridge from Cisco Systems.)
To keep the system working optimally, you can monitor performance reports and graphical displays.
Furthermore, equipment operators will inform you of any system degradation.
This document discusses the following topics:
• how to design an M/LC Repeater Network (i.e. infrastructure). Network design includes hardware
options, coverage issues, details on the 302395 Cisco electronics unit, and all FCC requirements
• how to select the appropriate antenna for each repeater location
• how to conduct a mobile access point relocation, and how to verify radio coverage at the new
location
• how to configure the 302395 Cisco electronics unit using configuration software
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2. Design Principles of a M/LC
Repeater Network
2.1 General Hardware Selection Guidelines
When selecting hardware components of a M/LC Repeater Network, there are several important issues
that must be addressed.
2.1.1 M/LC Infrastructure Hardware
Because Cisco bridges and access point have their own proprietary routing algorithms that dictate how to
make the “wireless” hops back to the hardline network, they can not be mixed with standard MasterLink
(M/L) repeaters.
IMPORTANT: ALL repeaters used in a mine must either be M/L or M/LC, but not a combination of the
two.
All of the mobile equipment in the mine should be standard M/L, and as such, will associate themselves
with one of the M/LC repeaters. As these mobile clients travel through the mine, they may change
associations often with the various M/LC repeaters.
M/LC Repeater Infrastructure includes the following:
• shovels
• base stations
• crusher bays
• mobile and fixed repeaters
Although it is possible for a shovel to be a M/L client instead of a M/LC repeater, it is highly
recommended that they be established as a M/LC repeater. This enables them to provide coverage to
surrounding haul trucks as the shovel digs itself into tights spots where coverage from a regular repeater
site is difficult. Remember, if the part number doesn’t contain an “M/LC” designation, it is not Ciscobased.
The GPS ground station need not be M/LC since its location is determined by other factors not related to
vehicle coverage (such as satellite constellation view, proximity to power, security, or even hardwired
Ethernet). A wireless M/L ground station needs only to associate itself with a M/LC repeater in order to
get its correction data through.
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302395 User’s Guide and Repeater Network Design Guide
2.1.2 Data Rates and Range
The M/LC repeater hardware is based on the 802.11b specification and as such supports data rates of
1.0 Mbps, 2.0 Mbps, 5.5 Mbps, and 11.0 Mbps. As the data rate increases, the range deceases. At ½ watt
of output power, the expected ranges are as follows:
DATA RATE ANTENNAS EXPECTED RANGE
2.0 Mbps Two 6 dBi Omnis 8 miles
11.0 Mbps Two 6 dBi Omnis 3 miles
The M/LC Repeater network will always transmit at the highest data rate possible provided there is a
good RF link between the two access points. Therefore, in practically all instances, intra-access point
traffic will be at 11.0 Mbps. However, M/L hardware transmits at 2.0 Mbps, so communications between
clients and the M/LC access points will be at 2.0 Mbps.
2.1.3 M/LC Point-to-Point Links
In a M/LC infrastructure, any point-to-point links must also be Cisco-based. Point-to-point links generally
use the 24.0 dBi dish antennas at each end in order to provide a link for distances up to 24 miles.
Although they could use the same channel as the rest of the mine, it is best if they are on a separate
channel. However, it is even better if they operate completely out of the 2.4 GHz Frequency range in
order to keep the 2.4 GHz 802.11b channels as traffic free as possible. 5.8 GHz point-to-point links are
available from Modular Mining Systems. These Cisco 1400 Aironet links are compatible with a M/LC
repeater infrastructure. They are listed on the MMS intranet site.
2.1.4 Temperature Related Decisions
M/LC mobile repeaters do not ship with batteries because in many instances batteries are obtained locally.
However, if a mine site will be operating from 0 to –20 C for extended periods of time (several days),
then SLA (Sealed Lead Acid) AGM (Absorbed Glass Matte) batteries must be used. These are available
from Modular as part number 105900 and are 12V Size 27 108AH. Repeaters will ship with foam
insulated battery boxes, and the foam must be placed over the vent in cold weather.
If temperatures will be below –20 C for extended periods of time, then NiCad batteries are recommended
in order to avoid “blackout” periods. NiCads are relatively expensive and heavy. 20 NiCad cells provide
205AH at 1.2V each for a total of 448 lbs and 24V. With the battery box they weight over 600 lbs.
M/LC shovel and crusher systems are all LT (Low Temp) already since the mobile hubs used have the
larger Vicor power supplies. All cables are now Xtra-guard 4. Therefore, with respect to a M/LC
infrastructure, the battery configuration is the decision point. Also, see “Sizing a Solar Repeater” below.
2.1.5 Sizing a Solar Repeater
Modular provides a 150 W and a 300 W M/LC mobile solar repeater. The amount of sunlight during the
worst month of the year is what dictates which one should be purchased. A solar analysis may be obtained
by Emailing the city (or Lat / Long) mine location information to Modular. This analysis will estimate the
performance of each system during each of the 12 months of the year, and will include the optimum angle
of solar panel tilt. It is very important that the panels be tilted at this angle during installation and facing
perfectly South (if in Northern Hemisphere) or perfectly North (if in Southern Hemisphere).
In the rare case of excellent sunlight but constant colder temperatures (0 to –20 C), such as at very high
elevations, four SLA AGM batteries should be used in a 150 W mobile repeater. By design, usually only
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Design Principles of a M/LC Repeater Network
two batteries are used with a 150 W repeater and four with a 300 W system, but you can always choose to
install four batteries in a 150 W system. (The battery box holds four.)
2.1.6 Lightning Protection
All M/LC repeaters come with some lightning protection. There are Polyphasors on the GPS and RADIO
RF inputs into the battery box. Also, power from the solar panels runs into a Delta lightning arrestor. All
chassis ground wires connect to one of the bolts at the base of the mast. However, the repeater uses no
lightning diverter at the top of the mast, nor does it use ground straps, or ground stake/rods.
If lightning is a concern at your installation, you can purchase the 302510 Lightning Protection Option
Kit from Modular for each mobile repeater. This kit includes the diverter at the top of the mast, ground
braids, copper straps, and a ground rod.
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302395 User’s Guide and Repeater Network Design Guide
2.2 General Coverage Guidelines
Before designing a M/LC infrastructure, review the following general rules.
2.2.1 Locations, Repeater Quantities, and Antennas
Location Description
PITS
HAUL
ROADS
REPEATERS
SHOVELS
It is always desirable to have triple coverage inside of deep pits. Three repeaters
positioned around the edge at geographically different locations is recommended
(roughly 120 degrees apart). However, they also must have a clear line-of-sight to
other repeaters so there is a trade-off to be made between visibility to other
repeaters, and view of the pit. The vertical beamwidth of the antenna must be enough
to cover into the pit from the edge. Although a omni (or sector) antenna can be tilted
downward up to 10 degrees into the pit to aid in this endeavor, the other line-of-sight
repeaters must remain in the coverage pattern of the antenna (which would be tilted
up off the backside).
It is desirable to have right side and left side coverage although this is not always
possible.
Ideally, each repeater would provide coverage over a selected area of the mine while
at the same time, having a view of at least two other “upstream” repeaters.
“Upstream” repeaters are access points that must be used in order to reach a hardwired bridge (or zero-hop) node. Minimizing the number of required “hops” is
important in order to maximize bandwidth (i.e. maximize the amount of traffic). The
more “zero-hop” (i.e. direct wired) repeaters that are available, the better the system
throughput will be.
Shovels are the most difficult area to cover. That is why M/LC shovel systems have
been provided in order to provide the repeater function. A point-to-point link can be
used to increase the number of effective zero-hop sites. This aids greatly in covering
haul trucks near the shovel. When a 6 dBi omni is mounted on the shovel above the
cab on the six-foot mast, a good view of other repeater site(s) should be obtained.
CRUSHERS,
OTHER
FIXED
LOCATIONS
Fixed buildings are usually good locations for repeaters since they provide AC
power so that a lower cost AC repeater may be used. Many times the top of the roof
provides a good high coverage location. If Ethernet is available at the building, then
a “wired” “zero-hop” is available.
2.2.2 Location Considerations and Antenna Selection
Section 3 in this manual provides details of the antenna patterns and gains. Each repeater location must
have an appropriate antenna selected in order to fulfill the coverage goals of that location. Typically
around the edges of the mine property, sectors are used in order to keep the RF energy on the mine
property (which also maximizes the range at that location). Sector antennas are also used against large
structures if an omni is not possible at the very top. Typically, omni antennas are used in the middle of the
mine, on rooftops, on shovels, and other high points. Dishes are only used for point-to-point links.
Always make sure that no solid reflective objects are close to an antenna and in its beam pattern. This will
result in high energy reflections which will cause null (i.e. dead areas) in you desired coverage area.
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Design Principles of a M/LC Repeater Network
2.2.3 Overall System Throughput Design Considerations
Even though intra-repeater (or intra-access point) traffic is at 11.0 Mbps, the “system” bandwidth or
throughput is reduced in direct proportion to the number of wireless access points (or “hops”) that a
message must be routed though in order to get to a bridge (an access point [AP] that is hardwired to the
LAN). Therefore, it is desirable to have as many “zero-hop” or “hardwired” APs as possible. Therefore,
always take advantage of all hardwired LAN locations as possible in order to install an AP. Good
examples of this are crushers, truck shops, and dispatch buildings with are often hardwired to the LAN
via fiber optics or even microwave links.
If a mine site is very large, and the hardwired Ethernet is only available at one location (which may not
even be a good site for an access point), then a point-to-point link should be used in order to construct
another “zero-hop” or “wired” equivalent access point. This is important to minimize bottlenecks and
avoid excessive “message hopping” though a repeater network. Although one of the 802.11b channels
may be used for this, often it is best to use a completely different frequency band in order to minimize 2.4
GHz traffic. The Cisco 1400 Aironet Bridges are highly recommended for this.
2.2.4 Channel Selection
802.11b LAN networks can use 11 channels of operation. These range from 1 (2412 MHz) to 11 (2462
MHz) and are separated by 5 MHz increments. However, because the occupied spectrum of each channel
is approximately 20 MHz, only three of these channels should ever be used at one time. Due to the RF
characteristics of the radio hardware, channel 1 almost always contains the most output power (and
slightly better performance). Assuming 0.3 dB per channel reduction, typically, channel 11 has 1.5 dB
less output power than channel 1. If good coverage and bandwidth can be achieved using only one
channel it should be channel 1. If two channels are decided on then it should be channel 1 and channel 11
since frequency separation is far more important than output power in this case. If three channels are to be
used, then channels 1, 6, and 11 would be used.
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302395 User’s Guide and Repeater Network Design Guide
2.3 The 302395 Repeater Electronics Unit
The common element to all M/LC repeater infrastructure installations is the 302395 M/LC Electronics
unit. This contains the Cisco BR350 Bridge, the ½ bi-directional power amp, the SKII GPS, and the
MMS power and interface circuit board. When using this unit always following these guidelines:
• Keep the unit out of direct sunlight.
• Always provide lightning protection on the GPS and RADIO RF connectors.
• Always follow the “System Config” diagrams when setting up an installation.
• Use only approved antennas and power settings listed below.
2.3.1 Approved Antennas
Only five antennas are approved by the FCC. No other antennas may be used with this system. These
antennas are the following:
MMS
PN
105831 Omni 2.5 dBi gain ½ wave stub 360 deg 60 deg 50 dBm
105342 Omni 6.0 dBi gain black foamed
105920 Sector 10 dBi gain 90 deg 35 deg 50 dBm
105708 Sector 13 dBi gain 120 deg 16 deg 50 dBm
105735 Dish 24 dBi high gain 9 deg 9 deg 5.0 dBm
The patterns and usage of these antennas is covered in the next section.
ANTENNA
DESCRIPTION
(hardened)
HORIZONTAL
BEAMWIDTH
360 deg 25 deg 50 dBm
VERTICAL
BEAMWIDTH
POWER
SETTING
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Design Principles of a M/LC Repeater Network
2.4 FCC Statements
MANDATORY SAFETY INSTRUCTIONS TO INSTALLERS AND USERS
1. Use only antennas supplied by Modular Mining Systems or dealer.
2. Antenna Minimum Safe Distance: 20 cm.
3. Antenna Gain: Zero dBd referenced to a dipole.
The Federal Communications Commission has adopted a safety standard for human exposure to RF
(radio frequency) energy which is below the OSHA (Occupational Safety and Health Act) limits.
Antenna Mounting
The antenna supplied by Modular Mining Systems or dealer must not be mounted at a location such that
during radio transmission, any person or persons can come closer than the above minimum safe distance
to the antenna, i.e. 20 cm.
To comply with current FCC RF exposure limits, the antenna must be installed at or exceeding the
minimum safe distance shown above, and in accordance with the requirements of Modular Mining
Systems.
Base Station
Installation
Mobile Repeater
Installation
Mine Vehicle
Installation
The antenna should be fixed-mounted on an outdoor permanent structure. RF
exposure compliance must be addressed at the time of installation.
The antenna must be mounted on a mast that is 12 feet or higher so that RF
exposure compliance is satisfied.
The antenna should be fixed-mounted on the vehicle facing away from the
vehicle such that a person is not able to move in front of the antenna. RF
exposure compliance must be addressed at the time of installation.
Antenna Substitution
Do not substitute any antenna for the one supplied or recommended by Modular Mining Systems. You
may be exposing person or persons to harmful radio frequency radiation. You may contact Modular
Mining Systems for further instructions.
WARNING: Maintain a separation distance from the antenna to person(s) of at least 20 cm.
You, as the qualified end-user of this radio device, must control the exposure conditions of bystanders to
ensure the minimum separation distance (above) is maintained between the antenna and nearby persons
for satisfying RF Exposure compliance. The operation of this transmitter must satisfy the requirements of
Occupational / Controlled Exposure Environment, for work-related use. Transmit only when person(s) are
a least the minimum distance from the properly installed, externally mounted antenna.
Changes or Modifications
CAUTION: changes or modifications not expressly approved by Modular Mining Systems could void
the user's authority to operate the equipment.
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302395 User’s Guide and Repeater Network Design Guide
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