Navigation System Manual

NAVIGATION SYSTEM
BEGAPT TECH SOLUTIONS

A-79, DDA Shed, Okhla Industrial Area, Ph-2,
New Delhi-110020, Telephone: +91-11-40817580
E-mail:[email protected]
BEGAPT@2012:PRIVACY POLICY
BEGAPT TECH. SOLUTIONS PVT. LTD. Navigation System Manual

IMPORTANT INFORMATION
Notes on Copyright©
Under the copyright laws, this publication may not be reproduced or transmitted in
any form, electronic or mechanical, including photocopying, recording, storing in
an information retrieval system, or translating, in whole or in part, without the
prior written consent of Begapt Tech. Solutions Pvt. Ltd.
LabVIEW National Instruments, NI, ni.com are trademarks of National Instruments.

Microsoft, Windows7 and microsoft.com are trademarks of Microsoft Corporation
Inc. U.S.A

CONTENTS:
 Chapter 1
- Company Overview
 Chapter 2
- Introduction to Navigation System
 Chapter 3
- Setup and Configuration
- Begapt Software
 Chapter 4
- Reinstallation of software
 Chapter 5
- Connection Overview
 Chapter 6
- Troubleshooting Steps
 Chapter 7
- Do’s & Don’t’s

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Company Overview
Begapt Tech Solutions
Begapt Tech Solutions Pvt. Ltd is a leader in automation and Control technologies
that enable utility and industry customers to improve their performance while
lowering environmental impact.
Begapt Solutions is a complete solution provider in the field of Control and

automation, Human Machine Interaction, Electromechanical systems, Mechatronics,
Artificial Intelligence and Machine vision to meet specific need of its customers.
We work with automotive R&D departments and OEMs to specify, prototype,

implement and test systems to bring reliable, feature rich, high quality products
and services with least development lead-time. We facilitate the development,
design, testing and trouble-shooting of various controllers along with the
consultancy services for impartial technology assessment and technical
endorsement.

Our Equipments carry a warranty of one year against any manufacturing defects. Our
customers have rarely used this in the past. All our equipments have been
working without any undue problems and require very little attention as far as
maintenance in concerned. Just in case your equipment needs attention, we are just
a phone call away in New Delhi. We have a well trained team of installation and
maintenance engineers on call round the clock.
Technology
Technology plays a key role for Begapt Solutions. We have activities throughout
India working to develop unique technologies that make our customers more
competitive, while minimizing environmental impact.
Sustainability
Sustainability is integral to all aspects of our business. We strive to balance

economic, environmental and social objectives and integrate the min to our daily
business decision.
Our expertise is in availability. Our strength is in delivering

the right solution for you.
We've worked with hundreds of small, medium and large companies, including
Fortune 500 companies - and they've all needed something unique to their
environment. We've combined over a decade of experience to offer you arrange of
availability solutions. Below you'll find a snapshot of our capabilities. Can't find
exactly what you're looking for? Call us anyway. Chances are we've done it before.
Development Services
We have extensive experience working with large OEM's to help them define,
develop and bring to market system management and availability solutions that

meet the needs of their customers. We also work with large companies, such as
Motherson Group, Delphi & many more, to customize high availability applications
to their environment.
Education Services
Begapt's education and training solutions range from the design, development and
delivery of an entire curriculum to public course offerings. We offer on-site private
workshops and courses that are customized to only the elements that you need to
know.
Contact us at:
Begapt Tech Solutions Pvt. Ltd
#A-79, DDA Shed,
Okhla industrial Area,
Phase-2, New Delhi (India)-110020
Phone no- +91-11-40817580, +91-987188063

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Introduction to Navigation System

Navigation system is such an important machine used in wiring harness industry.
It has a wide scope of application. It is also called process guiding machine. It guides
the process in making sub assembly of wiring harness. It also indicates the position
for pickup the wires and insertion point of the wire and checking the TBO. While doing
insertion of various wires it also checks the continuity of the both end of wire. It has
a wide range of features such as;
 LED Indication for wire insertion

 LED Indication for wire pickup
 Sensor feedback for wire pickup
 Continuity testing
 TBO testing
 Automatic Pneumatic Locking
 Diagnosis
 Report
This System includes 1 Minicomputer along with 1 Monitor, 1 Keyboard, 1 Mouse. It

consists of wiring plate designed for specific operation.

Why Navigation System needed?
In wiring harness industry there is a major quality concern about the wrong fitting,
wrong wire insertion and TBO defects. This is the very effective system to resolve this
type of quality concern. It guides the operator for wire insertion by indicating the
position of insertion on the monitor screen as well as there is an indication through
optical medium. There is a system to check the TBO of the holder. This system is user
friendly.
Application and Specification

Navigation system is used as a process guided system. This particular system is used to
detect the process as well as pull checking and continuity of the sub assembly of
harness. So, that it may check that the insertion of wire as well as correct colour of wire
is inserted in a correct place or not.
The specifications are as following:

1. PC based system.
2. Highly customized software.
3. User may decide that which points should be used in a connector or not.
4. User may decide that system is running with or without sensor.
5. User may decide the direction of process.
6. User may move the system from one place to another place easily.

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Setup & Configuration

This section describes each subsection of the Navigation System hardware as well as
how they interact with each other to perform the tests.
Computer System
The computer system has following configuration (system configuration may depend
from system to system as per requirement):
Intel(R) Pentium(R) Gold G5400 CPU@ 3.70GHz
4GB Installed Memory RAM
500GB Hard Drive
Windows 7/ Windows 10 Professional Operating System
19” Monitor
64-bit operating system, x64-based processor

Begapt Software
This section describes the system software.
Login Window
This is the login window screen. User has to login to perform the desired operations.
Here, user has to enter his/her User name and Password. Main window can only be
opened by correct entry of login User name and Password.

Main Window
This is the Main Window screen of the Navigation System. After successful login by
the user the Main Window screen will be appeared.
Model Window

This is the Model Window screen and its icon is available in the main window screen.
When the user has to Add, Edit, Delete and Copy the model, it has to select the
specific tab in the model window in order to perform the desired task.
For example, suppose user wants to add a model they may go into the “Add Model”
option.
Suppose user wants to delete a model first of all they may select a model and then
goes into the “Delete Model” option.

In similar way, suppose an user wants to edit name/part no./barcode of a model
first of all they may select the model first. After that they may clicks on to the
“Edit Model” option. After that the above screen will come. According to the
requirement of user they may change their name/part no./barcode and then click
on to the “ok” button.
In similar way, suppose an user wants to copy a model first of all they may select
a model and then clicks on to the “Copy-Model” option.
Connection Settings Window
When user clicks on to the “Connection Settings” the following window will appear.
In this window user may check his/her Input/output connections.

When user opens the connections they may see the above window as shown. Now
user can check his all connections. If user wants to check his/her Holder LED
connections user may open the holder led connections as well other also. If user
wants to add any new connection then they add by clicking the add button. If user
needs to delete the save data they can delete also by clicking the delete as well as
they can edit that also. The above figure shows that the connection of holder led
connections.

Teach Window
Teaching is the important part of the machine software. In this part you will teach
those point which you are using in your hardware part. When you click on the teach
button a window will open as shown in figure.
When user clicks on to the teach window following screen will appear. This window is
having two kinds of options.
 Production
 Connector/Wire
 Production
For that the user wants to clicks on to the production.

Now user needs to select a model.
Now you see five buttons to use. Add button is used to add that point which we need.
If you add any wrong string then you can delete that string by clicking the delete
button. First select the string which you want to delete and then click the delete
button.

If you need to edit any string you can edit it by clicking the edit button and then you
see a window is open as shown in figure.
So, this is all about the “production”.

 Connector/Wire
 In this section first of all user goes into the “select connector” section.
 After that he/she may goes into the “select file to load” section and then clicks
on to the “save connector image” option.
 After that clicks on to the “select holder pins to teach” option. Here the list of
pins which are teaching is come here.
 After that click on to the “select wire” option and select the name of wire
whatever you are written in “pickup led” section.
 If wire is having single colour then you select 1 in “No. of colours” section and
according to that colour option is come and you have to select the wire colour
according to your requirement. If number of colours is increasing according to
that you have to select the numbers in “No. of colours” section and also colours
of wire.

 After that goes into the “Teach point size”. In that section you may select the
size by scrolling the button and after selecting size you may select the pin
number of holder/connector where you wants to insert that colour combination
of wire.
 After that a popup screen will come. If you want to save these settings then
you click on to the “OK” option otherwise clicks on “cancel”.

 After that when all steps are done then you clicks on to the “Save” button.
you
 After clicking on to the save button then you may proceed all of these steps for
another holder/connector pins.
 If user wants to add wire code and circuit no. then they may goes into the “edit
select the wire and click on to the edit option.
wire details” option. Then select
 When user done his/her editing in the “edit wire details” then they clicks on to
the quit button and leave that window.
Production Window

The above figure shows the “production” window of Navigation machine.
 When user enters in that screen first of all they scan the barcode of that model, if
barcode is available, otherwise user may select model by manually clicking on to the
select model option.
 Then user clicks on to the “start test manua
manual”
l” option. After that operation will
be started.
 When production is running in “production” window “Wire” shows that which
wire user have to insert in the connector.
 According to that “Circuit no.” and “Wire code” is also display here.
 "Operator name” indicates that which operator/user is now working on that
system.
 “Production Count” indicates that “Total no.” of production of that model. Apart
from that it also shows that in “Total no.” of production how many productions
are “OK” and “NG”.
un the production at same time “cycle time” will also run. It may
 When user run
indicate that at what time it will takes to complete a production.
 Cycle time history shows that how much time the previous production may
production time in seconds.
take. It is basically a record of previous production
 When user completing one operation successfully the “Pass” message is
displaying in the system and “Green light” of tower light is also glowing.
 If operation is not successfully done or user/operator may leave the production
screen without
out completing the operation, it may counts the production of “NG”
and also the “Red light” of tower light is also glowing with buzzer.
 The below figure shows that the running production screen.

 This screen shows that where the user/operator has to insert the wire and
what’s the wire name or colour.
 The above screen will appear when production is done successfully and at the same
time “green light” of tower light will also glow.
 The above screen will appear when production is not done successfully or the
production is NG. At same time “red light” of tower light will also glow with buzzer.
This screen will only appear when system is login with operator ID and the same is

not happen when the system is login with administrator ID.
 In that case when user leaves the production window without completing/damage in
production
the production, this screen will appear and at a same time harness is also gets
locked.
 To leave this screen user may enters the administrator ID and password.
Admin Window
ove figure shows the “admin” window of Navigation machine.

The above
User Info Settings

The above figure shows the “User Info Settings” window of Navigation machine. In
this window there is an option of “Add User” and “Delete User”. In “Add user”
administrator may makes the login id and password for the different user. In that
section there is an option where administrator may decide that which window is
enable for the different user. Apart from that there is an option of “Delete user” due
to that administrator may delete the user.
When user clicks on to the setting option, then above window will appear. According
to requirement user may make changes in the system setting. For example, if user
does not want to display the “cycle time display”, they may click on it and off the
display. After that user may clicks on to the “Quit/Save” button. Then a pop-up
window will appear. If user wants to save those settings, then user may clicks on to
the “OK” otherwise click on “Cancel”. The below figure represent this.

In user info/settings there is an option of “Reset Production Count”.
If user wants to reset the production at any time, they may use this feature. When
user clicks on “Reset production count” the above window will appear.
If user clicks on to the “Reset Counts”, then the above window will appear. If user
clicks on to the “OK” then all counts may get reset and production count may start
from zero otherwise not. If user clicks on “OK”, then below window will appear. After
that user may click on to the “Back” button, so that user may leave that window.

 System
This window shows about the “System Information”.

Report Window
This window will appear when user clicks on the report button. User can see the
report time-wise along with date, type of worker, user type, part no., result. Figure
below shows that the “Production Report”.
User can also see the “Harness Report” by selecting the report and then click on to
the “view” button. Figure below shows that the “Harness Report”.

Diagnosis Window
Figure below shows that the “Diagnosis Window”. When user clicks on to the diagnosis
this window will appear.
Figure below shows that the “Diagnosis Window”. When user clicks on to the
diagnosis this window will appear. By using this window user may see that the all
pickup led, holder led and TBO is working fine or not. There is also a timer and the
range of that time is between 100-1500 ms (mille seconds).
User may check that all led’s are working fine or not by selecting one by one method
by clicks on to the “Run” button. Otherwise they may also check that all led’s working
fine or not at a time by clicks on to the “Run All” option.

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Re-Installation of System Components

This section will describe how re-installation of all the system components in future
can be done.
Warning
 Qualified personnel must complete all work.
 Do not apply power to the Navigation System until an Engineer is present and
has instructed you to do so.
 Window re Installation Procedure
 Insert the Window CD into DVD/CD writer.

 Setting up your Computer & BIOS changes (If required).
Now reboot your computer after popping in the all new Windows 7/10 DVD you just
created into the DVD Drive. In most cases if you do this you'll automatically boot into
the Windows 7/10 Installation DVD. But in some cases if the Boot device order is
changed in the BIOS it may boot into your older OS, instead of our DVD. In that case
you'll need to change the BIOS settings to get it done (More details in a different
tutorial).

Booting Up and First Installation Steps
Steps from here are pretty straight forward. Read the descriptions in each pages
before
ore clicking the Next button to avoid any disasters. IF there is an options to choose
in these steps you may find them with each image.
Figure a

You may choose your Language options by selecting the dropdowns 'Language to
install', 'Time and Currency format' and 'Keyboard or input method' here. I decided to
leave everything to 'US' but it would be better.
For selecting the correct settings here for non-English users.
Figure d Figure e
This screen is where the installation wizard begins. The install now options will leads to
the advanced install options. For repairing a corrupt installation the 'Repair your
computer' button located at the bottom-left can be used. For fresh installs just click
the Install now button.

Figure e
Tick the 'I accept the license terms 'check box and click 'Next' to proceed.

Which type of installation do you want?
This screen provides two options, Upgrade and Custom (advanced). The upgrade option
is for those who wish to upgrade an existing installation of older version of Windows to
Windows 7/10. It is confirmed that Windows Vista can be upgraded to Windows 7/10
without any issues, but Windows XP is still a problem. We will opt for the second option
here, the Custom install.
Where do you want to install Windows?
Clicking on the 'Custom' button brings the install location selection screen. In the test
machine we have an un-partitioned empty disk. But in the case of a normal installation
all your hard drive partitions (e.g. C:\D:\etc.) will be listed here. Choose the drive as
you like (a 15GB size is re-commended). Make sure the drive doesn’t have any
important data or the Windows 7/10 installation will wipe-out the contents of that
partition. You can back-up the data to another partition (e.g. for installing in D:\drive
move important files from there to say E:\ drive or to an external USB drive) for safe
keeping.

Partitioning/Creating or Modifying Partitions
Click the Drive options (advanced) for advanced partition management options like
'Delete', 'Format', 'New' and 'Extend'. To create a new partition clicks the new button.
But if you have list of partitions in the previous screen, choose the one where you are
planning to install windows 7/10 and click Format. Then click 'Next' to proceed.
The 'New' option provides a text box to enter the size of the partition you wish to
create in MBs. A 15GB (15*1024=15360MB) is recommended. In this case I opted for
the full size of my virtual drive, i.e. 9216 MB. Click the Apply button to continue. You
may be greeted with a message to ensure that all Windows features work correctly;
windows might create additional partitions for system files. This is a new feature in
Windows 7/10 to have a small boot partition for system files. Click Ok to continue.
So here we are, a new primary partition of 8.8 GB is created along with a System type
partition of 200 MB. Select the partition you just created and click Next to continue.

All right, we are all set. The Windows 7/10 installation begins. Time to grab a cup of
coffee for and wait for 15-30minutes for the all new OS!
 Navigation system software re-installation

procedure

LabView run-time Engine re-installation Procedure
Installation Steps:
Step 1 - Initialization
At first the installer initializes. It is recommended that the user exit all programs
before continuing the Setup. It also states that if virus scanning utilities are disabled
the installation speed may be improved. The LabView RTE has a License Agreement
which must be accepted to install the program. The License Agreement is displayed in
the fifth step. If the standard LabView RTE is the only program being installed there
is no activation required for the License Agreement. When the initialization is
complete you are able to proceed to the next step.

Step 2 – Destination directory
You are then given the option to select the primary installation directory. It is
recommended that you allow the installer to use the default directory.
Step 3 - Features
Then you are allowed to select the features to install. By default all options are
installed. If you desire to deselect a feature click on the icon to the left of the
feature and choose from the options in the left-click menu. When a feature is
selected the disk space required by that feature is displayed. If all features shown
here are installed the total disk space required is around 375 MB.
If a computer already has National Instrument software the icons may appear
differently indicating that they are already installed. If a custom installer has more
software than the RTE more items may appear here.

Step 4 - Product Notifications
The next step allows you to choose to allow the installer to contact National
Instruments to search for the latest notifications on the products you are installing.
By leaving the box checked (default) you acknowledge that your IP address will be
sent and collected in accordance with the National Instruments Privacy Policy. You
are able to review National Instruments Privacy Policy. If you are not connected to
the Internet you should deselect this box.

After the installer has contacted National Instruments any notifications will be
displayed. If there are notifications please review them before continuing the
installation. If there are no notifications the following window will be displayed.
Step 5 - License Agreement(s)
Next, the License Agreement is displayed for review. By default the I do not accept
the License Agreement radio button is selected and the installation cannot proceed.
This is so the user may review the agreement and choose to accept it once it is
reviewed. If there are other License Agreements for a custom installation they will be
accessible for review through tabs at the top of the Agreement section. Upon
acceptance the installation may proceed. The full license agreement is not displayed
in this image.
Step 6 - Installation Summary
The final step before installation is the installation summary. The summary may be
saved to a file if desired. If the summary is not accurate you may click the Back
button to change the installation settings. If it is correct click the Next button to
begin the installation.

Step 7 - Installation
If the installation includes only the features shown above with no previous National
Instrument software there are 28 parts to the installation. The installation time will
vary depending on the computer speed and number of applications running.
Once the installation is complete you may select the Finish button to close the
application. You must restart your computer to complete the installation. You will be
prompted to Restart, Shut Down or Restart Later. If the installation included other
drivers not shown in the walk-through you may need to install hardware. If this is the
case shut down the computer and installs the hardware before running the software.

NI Visa run-time re-installation Procedure
Installation Steps:
Step 1 - Initialization
At first the installer initializes. It is recommended that the user exit all programs
before continuing the Setup. It also states that if virus scanning utilities are disabled
the installation speed may be improved. The NI Visa run-time has a License
Agreement which must be accepted to install the program. The License Agreement is
displayed in the fifth step. If the standard NI Visa run-time is the only program being
installed there is no activation required for the License Agreement. When the
initialization is complete you are able to proceed to the next step.

Step 2 – Destination directory
You are then given the option to select the primary installation directory. It is
recommended that you allow the installer to use the default directory.
Step 3 - Features
Then you are allowed to select the features to install. By default all options are
installed. If you desire to deselect a feature click on the icon to the left of the
feature and choose from the options in the left-click menu. When a feature is
selected the disk space required by that feature is displayed. If all features shown
here are installed the total disk space required is around 375 MB.
If a computer already has National Instrument software the icons may appear
differently indicating that they are already installed. If a custom installer has more
software than the RTE more items may appear here.

Step 4 - Product Notifications
The next step allows you to choose to allow the installer to contact National
Instruments to search for the latest notifications on the products you are installing.
By leaving the box checked (default) you acknowledge that your IP address will be
sent and collected in accordance with the National Instruments Privacy Policy. You
are able to review National Instruments Privacy Policy. If you are not connected to
the Internet you should deselect this box.

After the installer has contacted National Instruments any notifications will be
displayed. If there are notifications please review them before continuing the
installation. If there are no notifications the following window will be displayed.
Step 5 - License Agreement(s)
Next, the License Agreement is displayed for review. By default the I do not accept
the License Agreement radio button is selected and the installation cannot proceed.
This is so the user may review the agreement and choose to accept it once it is
reviewed. If there are other License Agreements for a custom installation they will be
accessible for review through tabs at the top of the Agreement section. Upon
acceptance the installation may proceed. The full license agreement is not displayed
in this image.

Step 6 - Installation Summary
The final step before installation is the installation summary. The summary may be
saved to a file if desired. If the summary is not accurate you may click the Back
button to change the installation settings. If it is correct click the Next button to
begin the installation.

Step 7 - Installation
If the installation includes only the features shown above with no previous National
Instrument software there are 28 parts to the installation. The installation time will
vary depending on the computer speed and number of applications running.

Once the installation is complete you may select the Finish button to close the
application. You must restart your computer to complete the installation. You will be
prompted to Restart, Shut Down or Restart Later. If the installation included other
drivers not shown in the walk-through you may need to install hardware. If this is
the case shut down the computer and installs the hardware before running the
software.

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Connection Overview
This section describes all the wiring connection made in the sheet resistance measurement
setup.

BS-29 BS-26 BS-26 BS-05
BS-30
BS-29 BS-26 BS-27 BS-29

BS-06
Fig.: Demonstrative View of Wiring Plate
CONNECTION OF RELAY:
The internal connection of a relay is shown in the figure above. V1 and V2 are the voltages
applied on the terminals (+ & -) of the relay. Terminal Normally Closed (NC) is normally
connected to the Common terminal and when the coil is energized, the common terminal
switches to Normally Open (NO) terminal.

Connection of Relay Module:
Circuit diagrams are self explainable. Here 24v is supplied into the panel.
2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36
24V O1 P1 P2 C2 C3 O4 O5 P5 P6 C6 C7 - D1 D2 D5 D6
1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35
GND C1 O2 O3 P3 P4 C4 C5 O6 O7 P7 - - D3 D4 D7 -
J1 J2 J3 J4 J5 J6 J7 J8 J9
Fig: Relay Card (BS-06)

Connection details of pins with BS-06 with other boards or circuit:
CONNECT FROM CONNECT TO
BS-06
O1 NOT CONNECTED
C1 PC CONNECTOR
P1 PC CONNECTOR
O2 NOT CONNECTED
C2 24V SOLENOID
P2 24V MAIN
O3 GND TOWER LIGHT
C3 NOT CONNECTED
P3 GND MAIN
O4 GND TOWER LIGHT
C4 NOT CONNECTED
P4 GND MAIN
O5 GND TOWER LIGHT
C5 NOT CONNECTED
P5 GND MAIN
O6
C6
P6
O7
C7
P7
D1 PIN 7 BS-30
D2 PIN 8 BS-30
D3 PIN 9 BS-30
D4 PIN 10 BS-30
D5 PIN 11 BS-30
D6 PIN 12 BS-30
D7 PIN 13 BS-30
BEGAPT TECH. SOLUTIONS PVT. LTD. Navigation System

Manual
BS-05:
It is a Begapt board BS-05 which has 20 relay connections.
In the BS-05 board these terminals are connected to the green connector and the
terminals are assigned as:
V1= 24V and GND (assigned as required)
V2= D
NO=0
NC=C
COMMON= P
These relays are operated with 24V dc at one of the voltage terminal (D) and other terminal
be grounded. Relays are operated with NPN type sensors.
J1
2 4
24 VOLT
1 3
GND
J2 J3 J4 J5 J6 J7 J8 J9 J10 J11
6 8 10 12 14 16 18 20 22 24 26 28 30 32 34 36 38 40 42 44
D1 D11 O11 P11 P1 C1 P12 P2 D3 D13 O13 P13 P3 C3 P14 P4 D5 D15 O15 P15
5 7 9 11 13 15 17 19 21 23 25 27 29 31 33 35 37 39 41 43
D2 D12 C11 O1 O12 C12 O2 C2 D4 D14 C13 O3 O14 C14 O4 C4 D6 D16 C15 O5
J12 J13 J14 J15 J16 J17 J18 J19 J20 J21
46 48 50 52 54 56 58 60 62 64 66 68 70 72 74 76 78 80 82 84
P5 C5 P16 P6 D7 D17 O17 P17 P7 C7 P18 P8 D9 D19 O19 P19 P9 C9 P20 P10
29 31 33 35 5 7 9 11 13 15 17 19 5 7 9 11 13 15 17 19
O16 C16 O6 C6 D8 D18 C17 O7 O18 C18 O8 C8 D10 D20 C19 O9 O20 C20 O10 C10

Manual
Connection from each NO & Common of 1 Relay connected to the each channel of the I/P
Card as specified in the programming.
CONNECT CONNECT TO
FROM
BS-05
D1 O/P OF NPN SENSOR 1

Manual
Fig: Sensor Card (BS-05)
Fig: BS-30 (CONTROLLER CARD)

Manual
Fig: BS-27 (COMMUNICATION/EXPANSION CARD)
Fig: BS-26 (INPUT CARD)

Manual
Fig: BS-26 (MUX CARD)
Fig: BS-26 (OUTPUT CARD)

Manual
Fig: BS-29 (CONNECTOR BLOCK)
DESCRIPTION OF VARIOUS CARDS:
BS-30:
This is Begapt Board which is used to communicate with PC by serial communication.

It has 5 inputs and 7 outputs and one communicating IC.
The output connections are connected to BS-06 relay board and are used to operate
various outputs such as locking mechanism, tower lights etc.
BS-27:
This is Begapt Board which is used as communication/expander board connecting to

various cards for performing desired operations. It has 5 ports named PORT 0, PORT 1,

Manual
PORT2, PORT3, and PORT4. The connections are described below:
CONNECTOR NAME FROM TO

10 PIN WHITE CONNECTOR PORT 0 (BS-27) TOP SELECT BS-26
(INPUT CARD)
(OUTPUT CARD)
(MUX CARD)
(BOTTOM CARD)
BS-26:
This is Begapt Board which is used as Input, Output and MUX board. Each board has 48
points which is connected to the TBO & Sensor connections, Tray LEDs and Holder LEDs
respectively. It is connected through BS-29 board.
BS-29:
This is Begapt Board which is used as interfacing of each Input, Output and MUX board
to the TBO & Sensor connections, Tray LEDs and Holder LEDs respectively. It acts like
interfacing units. This board is connected to BS-26 board by Ribbon Cable.
Holder Pins and Holder LED Connections:
Each pin is directly connected to the each channel of the BS-29 board (MUX) as
specified in the programming. The LEDs representing the pin is connected parallel to
the wire connecting the pin. The positive pin of the LED is connected parallel to the
wire and the negative pin of the LED is shorted together and connected to the GND
terminal of the BS-29 board.

Manual
Tray LED Connections:
Each LED has 2 pins positive and negative (5v and GND) connected directly to the BS-
29 board (OUTPUT) through a 2 core wire at the specified channels in the
programming.
Selector Switch Connections:

Manual
The above image shows that the selector switch. This switch is having two points. One
is having input point and another is having output point. In input side there is a
connection of 24v and ground, which is coming from the supply end. In output side
there is a connection of 24v and ground and that is directly connected to BS-30 board.
This switch is used for providing power supply to the machine.
Push button Connections:
The above image shows that the Push Button. This is used for starting the PC as well
as starting the production.
If the PC is in off condition then first off all user may press on this button to on the
system. After that user may go into the production window and after selecting the
model, they may press this button to start the production.
These button having a connection of 5v and input connection, which is connecting to

the BS-30 board. Apart from that these button is having a connection of “PC ON” which
is connecting to the BS-06 board. In that case one point is connected to the Pi1 point
i.e. common point of the relay and second point is connected to the C1 point i.e.
normally closed point of the relay.
Common point Connections:
The below image shows that the common point of the system. This is used for
providing continuity to the wire which is used in the ECU/Connector. This point is
having a 2 pin connection. One is positive and second is negative i.e. 5v and ground
respectively, which is directly connected to the BS-29 board.

Manual
Sensor Connections:
Each sensor has 3 wires. In which one is goes on to the 24v, second is goes on to the
ground and third is goes on to the point D of the BS-05 board i.e. output of NPN sensor
is connected to point D of BS-05 board.
Tower Light Connections:
The below image shows that the tower light. It may indicate that the production is
completing in a good way or not. When “OK” product is making by user according to

Manual
the method in that case “green” light will glow. But if user makes “NG” or not good
product as per method in that case “red” light with “buzzer” will glow. It contains 4
connection, in which one is connected to the 24v (positive) and rest of the three
connection of respective colour of light is directly connected to “N.O.” point i.e.
normally closed point of BS-06 board.
LED Display Board:
The below image shows that the LED display board. This display board is used to
display document which is necessary to the system and production concern.

Manual
Holder LED & Solenoid Wiring Connection:
The above image shows that the connection or wiring diagram of “holder led and
solenoid”. Solenoid consists of two wiring point one is “24V” and another is “ground
(GND)”. 24V wire point is directly connected to “P2” point of “7 Relay Board” and
ground wire point is directly connected to the Solenoid ground (Solenoid GND)
terminal.
Holder having one switch pin which is shown in the above diagram. Switch pin consists
of two wires above and below position of the white ring. One wire point is directly
connected to the “GND” terminal and second wire point is connected to the “Solenoid
GND” terminal.

Manual
Holder has one micro or limit switch. Limit switch consists of two wire point, one is
connected to the “common point (P)” and another is connected to the “normally open
(N.O.)” point of limit switch and another end of both wire is directly connected to the
“connector block of Input or TBO card”.
Holder also consists led’s and pins. Led’s has two connection point, one is 5V and
another is ground. Ground of all led’s getting common and directly connected to the
“J1 point of MUX connector block”. 5V wire point of led’s and pin are joint and common
wire point of respective led’s and pins are directly connected to the J2, J3 etc. point of
“MUX connector block” respectively.
Filter Circuit:
The above image shows the “filter circuit” which is use for the protection of “controller
(BS-30) card”. Blue terminal of filter circuit having two points, one is 24V and another
is GND which is connected to the respective terminal of supply. Green terminal of filter
circuit having two point, one is 24V and another is GND which is directly connected to
the 24V and GND points of “controller (BS-30) card”.

Manual
------------------------------------------------------------
-----------------------------------------------------
Troubleshooting Steps
1. There is no proper power supply.
 Check the power cable is whether connected or not to main power supply.
 Check the proper AC voltage i.e. 220V.
 Check whether extension board in the panel is properly working.
2. There is no proper 24V power in the panel.
 Check whether power adaptor(24v) or SMPS(24v) is properly working (check

the led indicator present in adaptor or SMPS for indication of power).
 Ensure to turn ON the selector switch for 24V power in the panel.
 Ensure whether there is no any short circuit between the 24V, 9V, 5V and GND
respectively (ensure there is no any power in the panel while checking the short
circuit) with the help of multimeter.
 If selector switch is ON and adaptor or SMPS is working, then check the voltage
at terminal of 24V and GND with the help of multimeter.
3. There is an error while opening the navigation application which is shown below,
this is due to that there is no proper communication.
 Check whether 24V power is proper or not.
 Check the serial cable i.e. DB9 connector is properly connected to RS232 port of
CPU.

Manual
 Check the controller cable i.e. USB cable is properly connected to CPU.
4. Functionality of navigation system.
 Kindly ensure to diagnose all the parameters of diagnosis window at least once a
day.
 Diagnosis of Holder LED, Tray LED, TBO and Sensors that these are properly
working.
 If Holder LED is not working proper.

 Check the 10 pin connector is properly connected from Port 2 and Port 3 of BS-
27 card to Top Select and Bottom Select respectively of BS-26 (MUX Card) Card
as shown in figure below.
 Check the 2 pin connector is properly connected to J21 or J22 connector of BS-
26 (MUX Card) Card as shown in figure below.

Manual
 If Tray LED is not working proper.
 Check the 10 pin connector is properly connected from Port 1 of BS-27 card to
Top Select of BS-26 (Output Card) Card as shown in figure below.
26 (Output Card) Card as shown in figure below.

Manual
 If TBO or Sensor is not working proper.
 Check the 10 pin connector is properly connected from Port 0 of BS-27 card to
Top Select of BS-26 (Output Card) Card as shown in figure below.
26 (Output Card) Card as shown in figure below.

Manual
 If Sensor is not working proper.
 Check that 24v is proper in the BS-05 Card or not.
 Ensure the particular sensor output is connected to the corresponding D terminal

of each BS-05 Card.
 Yellow box shown in the figure indicates the 24v terminal of the BS-05 Card and
Black box indicates the D (1-20) terminal of the BS-05 Card.

Manual
 If Solenoid or any of the tower light is not working.
 Check that 24v and GND is proper in the BS-06 Card or not.
 Ensure the 8 pin connector connected from the BS-30 Card to the corresponding
D terminal of each BS-06 Card as shown below.
 Ensure the corresponding NO and P connections of BS-06 Card.

Manual
 Ensure some connections in the BS-30 Card which is indicated in the figure for
suitable and proper working.

Manual
Fig: Navigation System

Manual
--------------------------------------------------------
----------------------
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Do’s and Dont’s

The following items should be followed during use of this machine.
 Keep the machine away from flammable liquids, gases, and aerosols. A fire
or an electric shock might occur.
 Unplug the power cord from the wall outlet before you move the
machine.
 While moving the machine, you should take care that the power cord
will not be damaged under the machine.
 Do not turn off the power while the machine is in operation. Doing so
may damage the machine components.
ging the power cord or turning off the main power switch,
 Before unplugging
make sure remaining machine components are off.
 Do not touch areas on or around the probe unit.
 When you use this machine for a long time in a confined space without
good ventilation, you may detect an odd smell. To keep the workplace
comfortable, we recommend that you keep it well ventilated.
 If the machine is moved from a cold to a warm place, c

condensation
may form inside it.

Manual
 After moving the machine, do not use it for at least an hour. The
machine requires this time to adapt to its new environment.
 Do not open the covers of the machine when it is in operation.
 Do not move or tilt the machine when the machine is in operation.
 Do not allow small objects such as paperclips to fall into or become

stuck inside the machine.
 Do not knock the machine and place other thing on the fixture while it
is operating. Doing so may hamper the production or you will get error.
 Be sure to make a note of the registered machine settings in case they

are lost due to accident or malfunction.
 The supplier shall not be liable for any loss or damage resulting from a
failure of the machine, loss of settings, or use of the machine.

Manual
FAQ
Q1. Power not coming in panel?
Sol. Check the adaptor (power supply).
Q2. PC not getting ON?
Sol. a) Check power cable and measure the voltage and other end.
b) Check VGA cable.
c) Check monitor power supply.
Q3. Start test button, tower light not working?
Sol. Check connector cable at both the end.
Q4. Sensor not working?
Sol. a) Check power.
b) Check connecting cable at both end.
Q5. Continuity error?
Sol. a) Check pin.
b) Check connection at pin as well as in board side.
c) Check method.
Q6. Locking not working?
Sol. a) Check air pressure.
b) Check connecting cable at switch pin as well as in terminal side.
Q7. Holder LED and Pick-up LED not working?
Sol. a) Check connecting cable.
b) Check power supply.

Manual

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NAVIGATION SYSTEM

BEGAPT TECH SOLUTIONS

New Delhi-110020, Telephone: +91-11-40817580

BEGAPT TECH. SOLUTIONS PVT. LTD. Navigation System Manual

LabVIEW National Instruments, NI, ni.com are trademarks of National Instruments.

BEGAPT TECH. SOLUTIONS PVT. LTD. Navigation System Manual

- Introduction to Navigation System

- Setup and Configuration

- Do’s & Don’t’s

BEGAPT TECH. SOLUTIONS PVT. LTD. Navigation System Manual

Begapt Solutions is a complete solution provider in the field of Control and

We work with automotive R&D departments and OEMs to specify, prototype,

BEGAPT TECH. SOLUTIONS PVT. LTD. Navigation System Manual

Sustainability is integral to all aspects of our business. We strive to balance

Our expertise is in availability. Our strength is in delivering

BEGAPT TECH. SOLUTIONS PVT. LTD. Navigation System Manual

#A-79, DDA Shed,

Okhla industrial Area,

Phase-2, New Delhi (India)-110020

Phone no- +91-11-40817580, +91-987188063

BEGAPT TECH. SOLUTIONS PVT. LTD. Navigation System Manual

Introduction to Navigation System

 LED Indication for wire insertion

This System includes 1 Minicomputer along with 1 Monitor, 1 Keyboard, 1 Mouse. It

BEGAPT TECH. SOLUTIONS PVT. LTD. Navigation System Manual

Application and Specification

The specifications are as following:

BEGAPT TECH. SOLUTIONS PVT. LTD. Navigation System Manual

Setup & Configuration

Intel(R) Pentium(R) Gold G5400 CPU@ 3.70GHz

4GB Installed Memory RAM

500GB Hard Drive

Windows 7/ Windows 10 Professional Operating System

64-bit operating system, x64-based processor

BEGAPT TECH. SOLUTIONS PVT. LTD. Navigation System Manual

BEGAPT TECH. SOLUTIONS PVT. LTD. Navigation System Manual

BEGAPT TECH. SOLUTIONS PVT. LTD. Navigation System Manual

BEGAPT TECH. SOLUTIONS PVT. LTD. Navigation System Manual

Connection Settings Window

In this window user may check his/her Input/output connections.

BEGAPT TECH. SOLUTIONS PVT. LTD. Navigation System Manual

BEGAPT TECH. SOLUTIONS PVT. LTD. Navigation System Manual

For that the user wants to clicks on to the production.

BEGAPT TECH. SOLUTIONS PVT. LTD. Navigation System Manual

BEGAPT TECH. SOLUTIONS PVT. LTD. Navigation System Manual

So, this is all about the “production”.

BEGAPT TECH. SOLUTIONS PVT. LTD. Navigation System Manual

BEGAPT TECH. SOLUTIONS PVT. LTD. Navigation System Manual

BEGAPT TECH. SOLUTIONS PVT. LTD. Navigation System Manual

BEGAPT TECH. SOLUTIONS PVT. LTD. Navigation System Manual

BEGAPT TECH. SOLUTIONS PVT. LTD. Navigation System Manual

BEGAPT TECH. SOLUTIONS PVT. LTD. Navigation System Manual

ove figure shows the “admin” window of Navigation machine.

User Info Settings

BEGAPT TECH. SOLUTIONS PVT. LTD. Navigation System Manual

BEGAPT TECH. SOLUTIONS PVT. LTD. Navigation System Manual

BEGAPT TECH. SOLUTIONS PVT. LTD. Navigation System Manual

This window shows about the “System Information”.

BEGAPT TECH. SOLUTIONS PVT. LTD. Navigation System Manual