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* Discovery Device with wiring harness
* Discovery Device with wiring harness
* Active SIM card (data enabled)
* Active SIM card (data enabled)
* Wire tap connectors / crimp terminals
* Multimeter – Voltage & continuity checks
* Multimeter (for voltage checks)
* Wire tap connectors / Crimp terminals – Electrical connections
* Automotive insulation tape
* Side cutter / Wire stripper – Cutting & stripping wires 
* Cable ties
* Automotive insulation tape / Heat-shrink sleeves – Joint insulation
 
* Cable ties – Securing wiring & device
* Trim removal tools – Dashboard & panel removal
* Screwdriver set – Opening panels & fixing
* Fuse tap with blade fuse – Protected battery power
==== Safety Instructions ====
==== Safety Instructions ====
* Turn vehicle '''OFF''' before wiring
<pre> &#9888;&#65039; Before starting any work: </pre>
* Avoid Airbag, ECU, ABS and CAN bus wiring routes
* Turn vehicle ignition OFF  
* Ensure wiring does not interfere with moving/heat sources
* Disconnect battery if required by OEM practice
* Open dashboard using trim removal tools and screwdrivers
*Avoid routing near:
**Airbags
**ECU / ABS lines
**Steering column & pedals
* Avoid sharp edges, moving parts, and hot zones
*Always use a fuse tap with blade fuse for battery connection


=== 2. SIM Installation ===
=== 2. SIM Installation ===
* Insert SIM card properly into device slot
*Open SIM slot .
* Ensure data plan active
*Insert SIM in correct orientation.
* Confirm SIM is properly seated and locked
*Ensure:
* Press the Restart button on the PCB
**SIM is activated
**Data plan enabled
**SIM PIN lock disabled
*Lock SIM properly.
*Press Restart / Reset button on PCB.


=== 3. Device Mounting Guidelines ===
=== 3. Device Mounting Guidelines ===
Device must be placed with its top surface facing the sky.
Important Rule:<br>
 
➡ Device top surface must face the sky for proper GPS reception.
'''Recommended Zones'''
<div style="border:2px solid #1a7f00; padding:10px; background:#e9ffe9;">
* Inside dashboard near windshield
<b>&#9989; Recommended Locations</b><br><br>
* Under plastic trims with sky visibility
<ul>
* Away from electronics that cause interference
<li>Inside dashboard near windshield</li>
 
<li>Under plastic trims near A-pillar</li>
'''Avoid'''
<li>Under dashboard with sky visibility</li>
* Engine compartment
</ul>
* Enclosed metal cavities
</div>
* Areas exposed to high temperature or vibration
<div style="border:2px solid #cc0000; padding:10px; background:#fff4f4;">
 
<b>&#10060; Avoid Locations</b><br><br>
Secure using cable ties / OEM tape to avoid loose fitting.
<ul>
<li>Engine compartment</li>
<li>Enclosed metal cavities</li>
<li>Near amplifiers / high-current wiring</li>
<li>Areas exposed to:
    <ul>
        <li>High heat</li>
        <li>Water</li>
        <li>Continuous vibration</li>
    </ul>
</li>
<li>Secure the device using cable ties or OEM tape</li>
</ul>
<b>Ensure no free movement after fixing.</b>
</div>


=== 4. Wiring Instructions ===
=== 4. Wiring Instructions ===
'''Before Wiring'''<br>
*Strip wires using wire stripper / side cutter.
*Prepare terminals using a crimping tool.
*Use wire tap connectors where required.
{| class="wikitable" style="width:100%"  
{| class="wikitable" style="width:100%"  
!style="background-color:#680022; color:white;" | Wire Color
!style="background-color:#680022; color:white;" | Wire Color
Line 43: Line 75:
!style="background-color:#680022; color:white;" | Notes
!style="background-color:#680022; color:white;" | Notes
|-
|-
| <div style="color: Red; font-weight: bold;"> RED </div>|| 1 || Vehicle Battery + (9–90V DC) || Main power || Always powered — ensures continuous tracking even after the engine is off
| <div style="color: Red; font-weight: bold;"> RED </div>|| 1 || Vehicle Battery + (9–90V DC) || Main power || Must be connected to a constant battery supply (24/7 power). Verify voltage using a multimeter before final fixing. .
|-
|-
| <div style="color: Black; font-weight: bold;"> BLACK </div>|| 7 || Vehicle chassis ground || Ground reference || Ensure clean metal contact
| <div style="color: Black; font-weight: bold;"> BLACK </div>|| 7 || Vehicle chassis ground || Ground reference || Ensure clean, paint-free metal contact. Verify ground continuity using a multimeter.
|-
|-
| <div style="color: Green; font-weight: bold;"> GREEN</div>|| 2 || Vehicle ignition line (12V) || Detects ignition state || Must give 12V when key ON and 0V when ignition OFF
| <div style="color: Green; font-weight: bold;"> GREEN</div>|| 2 || Vehicle ignition line (12V) || Detects ignition state || Confirm 12V only when key is ON and 0V when OFF using a multimeter.
|}
|}
 
<div style="border:2px solid #cc0000; padding:10px; background:#fff4f4;">
:''Important:'' If Ignition (Green) wire not connected correctly → Device stays in sleep mode → sends old location, no movement/speed detection. Always confirm power continuity and ignition behavior before finishing.
<b>&#9888;&#65039; Critical Ignition Warning</b><br><br>
If the <span style="color:green; font-weight:bold;">GREEN ignition wire</span> is wrongly connected:
<ul>
<li>Device may remain in sleep mode</li>
<li>Old / stale location may appear</li>
<li>Speed & movement detection may fail</li>
</ul>
</div>
<div style="border:2px solid #1a7f00; padding:10px; background:#f3fff3;">
<b>&#9989; Mandatory Multimeter Verification</b><br><br>
Using a multimeter, confirm:
<ul>
<li><b>RED (Power):</b> Continuous voltage even when engine is OFF</li>
<li><b>GREEN (Ignition):</b> 12V only when key is ON, 0V when OFF</li>
<li><b>BLACK (Ground):</b> Near-zero resistance and noise-free</li>
</ul>
After wiring:
<ul>
<li>Crimp joints using a crimping tool</li>
<li>Insulate all joints using insulation tape / heat-shrink sleeves</li>
</ul>
</div>


=== 5. LED Status — Normal Operation ===
=== 5. LED Status — Normal Operation ===
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|<div style="color: Red; font-weight: bold;"> Power </div>|| Red || Solid || Power OK
|<div style="color: Red; font-weight: bold;"> Power </div>|| Red || Solid || Power OK
|-
|-
|<div style="color: Red; font-weight: bold;"> User </div>|| Red || Blinking || Processor functioning
|<div style="color: Red; font-weight: bold;"> User </div>|| Red || Blinking || Processor working
|-
|-
|<div style="color: Orange; font-weight: bold;"> GNSS </div> || Orange || Blink every ~2 sec || GPS fix OK
|<div style="color: Orange; font-weight: bold;"> GNSS </div> || Orange || Blink every ~2 sec || GPS fix OK
Line 67: Line 120:
|<div style="color: Green; font-weight: bold;"> Network</div> || Green || Blink every ~2 sec || Network registered
|<div style="color: Green; font-weight: bold;"> Network</div> || Green || Blink every ~2 sec || Network registered
|}
|}
 
<pre> &#9989;If all LEDs match → Device is working properly </pre>
=== 6. LED Status — Troubleshooting Guide ===
=== 6. LED Status — Troubleshooting Guide ===
{| class="wikitable" style="width:100%"  
{| class="wikitable" style="width:100%"  
Line 75: Line 128:
!style="background-color:#680022; color:white;" | Corrective Action
!style="background-color:#680022; color:white;" | Corrective Action
|-
|-
|<div style="color: Red; font-weight: bold;"> Power </div> || OFF || No power || Check VCC & GND wiring
|<div style="color: Red; font-weight: bold;"> Power </div> || OFF || No power || Check RED & BLACK using multimeter, verify fuse tap
|-
|-
| <div style="color: Red; font-weight: bold;"> User </div> || OFF || Modem not initialized || Reboot device / wiring recheck
| <div style="color: Red; font-weight: bold;"> User </div> || OFF || Modem not initialized || Reboot using reset button
|-
|-
| <div style="color: Orange; font-weight: bold;"> GNSS </div> || OFF || No GPS fix || Re-mount device facing sky
| <div style="color: Orange; font-weight: bold;"> GNSS </div> || OFF || No GPS fix || Re-mount device facing sky
Line 83: Line 136:
|<div style="color: Green; font-weight: bold;"> Network</div> || Fast blinking || Searching for network || Move vehicle to open area, check SIM
|<div style="color: Green; font-weight: bold;"> Network</div> || Fast blinking || Searching for network || Move vehicle to open area, check SIM
|-
|-
| <div style="color: Green; font-weight: bold;"> Network</div>|| Double blinking || SIM not registered || Verify data pack & signal
| <div style="color: Green; font-weight: bold;"> Network</div>|| Double blinking || SIM not registered || Remove & reinsert SIM
|}
|}


=== 7. Commissioning & Validation ===
=== 7. Commissioning & Validation ===
Perform 2 km road test:
* Perform 2 km road test:
* Live movement visible on portal
* Verify on portal using mobile phone or laptop:
* Speed & location updates correctly
**Live movement  
* Ignition ON/OFF events visible
**Speed updates  
 
**Ignition ON / OFF events  
If any parameter fails → check wiring & LEDs again.
<pre> ❗ If any point fails → Recheck wiring using multimeter and verify LED status again.</pre>


=== 8. Finalization ===
=== 8. Finalization ===
* Secure all wiring with cable ties
* Secure wiring using cable ties.
* Ensure no loose parts behind dashboard
* Insulate joints using insulation tape / heat-shrink sleeves.
* Refit trims and panels properly
* Ensure:
* Record installation date & vehicle details
**No loose wires
* Take Photos of connections and device placement and save it, later it can be used for troubleshooting
**No rattling noise
* Take a 10 sec video for  LED status and save it , later it can be used for troubleshooting
Record:
 
* Installation date  
* Vehicle Number
* IMEI 
Capture:
* Photos of power, ground, and ignition connections  
* Photo of device mounting
* 10-second LED status video using mobile phone
Save all media for future troubleshooting. 
=== Quick Troubleshooting Summary ===
=== Quick Troubleshooting Summary ===
{| class="wikitable" style="width:100%"  
{| class="wikitable" style="width:100%"  
Line 108: Line 168:
!style="background-color:#680022; color:white;" | Fix
!style="background-color:#680022; color:white;" | Fix
|-
|-
| No power || RED wire or GND issue || Re-check wiring points
| No power || RED wire or GND issue || Check using multimeter, verify fuse tap
|-
|-
| Shows old location data || Ignition (Green) wire error || Confirm ignition 12V signal when ignition is ON
| Shows old location data || Ignition (Green) wire error || Recheck GREEN wire using multimeter
|-
|-
| No GPS || Blocked sky view || Change mounting position
| No GPS || Blocked sky view || Change mounting position

Latest revision as of 07:28, 8 December 2025

Discovery Device — Installation & Commissioning

1. Pre-Installation Requirements

Tools & Materials

  • Discovery Device with wiring harness
  • Active SIM card (data enabled)
  • Multimeter – Voltage & continuity checks
  • Wire tap connectors / Crimp terminals – Electrical connections
  • Side cutter / Wire stripper – Cutting & stripping wires
  • Automotive insulation tape / Heat-shrink sleeves – Joint insulation
  • Cable ties – Securing wiring & device
  • Trim removal tools – Dashboard & panel removal
  • Screwdriver set – Opening panels & fixing
  • Fuse tap with blade fuse – Protected battery power

Safety Instructions

 ⚠️ Before starting any work:
  • Turn vehicle ignition OFF
  • Disconnect battery if required by OEM practice
  • Open dashboard using trim removal tools and screwdrivers
  • Avoid routing near:
    • Airbags
    • ECU / ABS lines
    • Steering column & pedals
  • Avoid sharp edges, moving parts, and hot zones
  • Always use a fuse tap with blade fuse for battery connection

2. SIM Installation

  • Open SIM slot .
  • Insert SIM in correct orientation.
  • Ensure:
    • SIM is activated
    • Data plan enabled
    • SIM PIN lock disabled
  • Lock SIM properly.
  • Press Restart / Reset button on PCB.

3. Device Mounting Guidelines

Important Rule:

➡ Device top surface must face the sky for proper GPS reception.

✅ Recommended Locations

  • Inside dashboard near windshield
  • Under plastic trims near A-pillar
  • Under dashboard with sky visibility

❌ Avoid Locations

  • Engine compartment
  • Enclosed metal cavities
  • Near amplifiers / high-current wiring
  • Areas exposed to:
    • High heat
    • Water
    • Continuous vibration
  • Secure the device using cable ties or OEM tape

Ensure no free movement after fixing.

4. Wiring Instructions

Before Wiring

  • Strip wires using wire stripper / side cutter.
  • Prepare terminals using a crimping tool.
  • Use wire tap connectors where required.
Wire Color Pin No. Connect To Purpose Notes
RED
1 Vehicle Battery + (9–90V DC) Main power Must be connected to a constant battery supply (24/7 power). Verify voltage using a multimeter before final fixing. .
BLACK
7 Vehicle chassis ground Ground reference Ensure clean, paint-free metal contact. Verify ground continuity using a multimeter.
GREEN
 2 Vehicle ignition line (12V) Detects ignition state Confirm 12V only when key is ON and 0V when OFF using a multimeter.

⚠️ Critical Ignition Warning

If the GREEN ignition wire is wrongly connected:

  • Device may remain in sleep mode
  • Old / stale location may appear
  • Speed & movement detection may fail

✅ Mandatory Multimeter Verification

Using a multimeter, confirm:

  • RED (Power): Continuous voltage even when engine is OFF
  • GREEN (Ignition): 12V only when key is ON, 0V when OFF
  • BLACK (Ground): Near-zero resistance and noise-free

After wiring:

  • Crimp joints using a crimping tool
  • Insulate all joints using insulation tape / heat-shrink sleeves

5. LED Status — Normal Operation

LED Color Pattern Meaning
Power
Red Solid Power OK
User
Red Blinking Processor working
GNSS
Orange Blink every ~2 sec GPS fix OK
Network
 Green Blink every ~2 sec Network registered 
 ✅If all LEDs match → Device is working properly

6. LED Status — Troubleshooting Guide

LED Behavior Condition Corrective Action
Power
OFF No power Check RED & BLACK using multimeter, verify fuse tap
User
OFF Modem not initialized Reboot using reset button
GNSS
OFF No GPS fix Re-mount device facing sky
Network
 Fast blinking Searching for network Move vehicle to open area, check SIM
Network
 Double blinking SIM not registered Remove & reinsert SIM

7. Commissioning & Validation

  • Perform 2 km road test:
  • Verify on portal using mobile phone or laptop:
    • Live movement
    • Speed updates
    • Ignition ON / OFF events
 ❗ If any point fails → Recheck wiring using multimeter and verify LED status again.

8. Finalization

  • Secure wiring using cable ties.
  • Insulate joints using insulation tape / heat-shrink sleeves.
  • Ensure:
    • No loose wires
    • No rattling noise

Record:

  • Installation date
  • Vehicle Number
  • IMEI

Capture:

  • Photos of power, ground, and ignition connections
  • Photo of device mounting
  • 10-second LED status video using mobile phone

Save all media for future troubleshooting.

Quick Troubleshooting Summary

Issue Likely Cause Fix
No power RED wire or GND issue Check using multimeter, verify fuse tap
Shows old location data Ignition (Green) wire error Recheck GREEN wire using multimeter
No GPS Blocked sky view Change mounting position
No network SIM / signal issue Replace or reinsert SIM
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