RALLYSAFE RALLY CAR FITTING KIT MANUAL
Rallysafe® Fitting Kit Manual – RALLY CAR
**Product Disclaimer**
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Rallysafe,isforthepurposeofinformationonly.Duetocontinuousongoingdevelopment;informationand
specificationsmaychangeatanytimewithoutnotice.Rallysafeandthecompaniesthathavecontributedtoit,
shallnotbeliableforanyuseofthemanualorinformationsupplied.
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ThecommercialexploitationofthematerialcontainedinthisspecificationrequiresalicensetosuchIntellectual
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informationalpurposesonly.Foranyotherpurpose,nopartofthespecificationmaybeutilizedorreproduced,
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Rallysafe® Fitting Kit Components
The Rallysafe Fitting Kit includes:
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RallysafeInstallationandFittingKitInstructionSheet;
2in1AntennawithLeads(optionsforstickonorboltonandleadlengthtobeselectedwhen
ordering),withtheboltontypebeingthepreferredmethod.
InternalWi-FiAntennawithlead(optionsofleadlengthtobeselectedwhenordered)
6–24vhardwiringloomwithplug(lengthselectedwhenorderingtoinclude300mmsparecableat
mountingpoint.)
1RollCageMountor1flatmountwith25mmballjoint(tobeboltedthroughdash)
1adjustablemountconnector/knuckle(shortoflongtobeselectedwhenordering).
(Contentsmaynotbeidenticaltothepictureshown)
(TheRallysafeDisplayUnitisnotapartofthefittingkitandwillbeavailableatdocumentationorscrutiny)
12 Volt Power Supply(Please read this carefully)
Rallysaferequiresacontinualreliablepowersupplyfrom9to28voltsDC,foryoursafetyandcontinuityof
service,itisimperativethattheunitisconnectedtoanun-switchedsupplyonthebatterypositiveterminalor
thebatterypositivesideoftheisolationswitch,insurethatpowerissuppliedtotheunitatalltimes.Donot
useanignitionswitchedpowersupply.
Werecommendthata5amp(Max)bladetypeorsimilarqualityfuseisusedatthebatterysupplyendofthe
Rallysafepowerlead.
0voltsorBatterynegativecanbepickedupatanysuitableearthingpointprovidingtheisolationswitchdoes
notswitchthenegativesideofthebattery.
TheRallysafeunithasaninternalbatterythatiskeptchargedviathecarspowersupply,itisonlythereasa
reservesupplytopowertheunitinanaccidentsituationwherethecarspowersupplyisinterrupted.ie:car
batterysmashedordislodged.
AstheRallysafeunitisawareofmovementanditslocation;itwillautomaticallygointopowersave/sleep
mode5minutesafternomovementisdetected,however,theunitwillcontinuetofunctioniswhenitis
sendingHazardtypesignalswhileonstage.Theunitwillbe"woken"upbypressinganybuttonorby
movementofthecar.
Intheyellowpowerloomthereare5wiresredandblackareusedasfollowes,whiteblueandgreymustbe
staggercutandheatshrinkedortapedbacksotheycantshorttogroundortoeachother.
Connection Diagram.
Mounting and Antenna Leads
Hereiswhatastandardinstallationwould
looklike.Notetheunitandaerialplacedin
clearandunobstructedview.
Therearpaneloftheunit,withallaerial
andpowerleadsconnected.
Aminimumof300mmofRallysafePowerSupplyCableandAntennaLeadsshouldbeleftattheunit
mountingbracketlocationforconnectiontotheunit
TheAntennaleadsareconnectedasfollows.(Theremaybevariationswiththetypeandnumberofleads)
1:TheWiFileadlabelledbythecolour"Blue"isconnectedtotheterminallabelled"Wi-Fi"ontheRallysafe
unit,(itisRightHandThread),terminalsmaybeonthesideorrearoftheunitandorcolourcodedBlue.
2:TheSatellitecommunicationAntennaleadisconnectedtothecentreorrearterminallabelled"IRI".Itmay
alsobecolourcodedYellow;(thismaybenotmarkedonthe2in1antenna)andisLeftHandThread.
3:TheGPSAntennaleadlabelled"GPS",isconnectedtotheterminallabelled"GPS"ontheRallysafeunit,(itis
RightHandThread),terminalsmaybeonthesideorrearoftheunitandorcolourcodedGreen.
4:GSM,ifoptionedwillhaveasmallstickantennasuppliedwiththeRallysafeunit,andisconnectedto
correspondingterminallabelled"GSM"ontheRallysafeunit,(itisLeftHandThread),theterminalmaybeon
thesideorrearoftheunitandorcolourcodedRed.
(Note:InternalWi-Fiisonlymarkedbythecolour"Blue",itistobeconnectedtotheuppermostorrearterminal
labelled"Wi-Fi"ontheRallySafeUnit)
.
Unit Mounting & Dimensions
ThepreferredmountingmethodfortheRallySafeunitisonaRamstyle50mmx75mmflatbasewithball,
boltedthroughthedash(witha3mmaluminumbackingplate),inaprotectedcentrallocation,easilyseenand
accessiblebyboththedriverandco-driver/nav.Photographsofthebestmountingoptionsandpositioningare
below.
AnalternativemountingmethodfortheRallysafeunitisontherollcageforwardlegontheCo-Driver'ssideon
aRightAngleRollcageBracketwithballandConnectorClamp(alsoshowninphotosaboveandbelow).
TheRallysafeunitshouldbemountedinavertical(preferred)positionwhereperipheralvisionwillcatchscreen
warningsetc.SomeDriversprefertohavevisualcontactwiththeunitothersprefertolettheCo-Driverview
thescreenandcallthewarningsasrequired.
Herethe25mmrubberballmountissecurely
attachedtotheAPillarbaroftheRollCage
TheRallySafeunitthenmountstothe25mm
RubberBallmount.(Thisisconnected
throughtheRallySafeconnector)
UNIT DIMENSIONS
Antenna installation
Allleadsonbothexternalandinternalantennasmustrunontheinsideofallrollcagebars.Thisistostopcable
crushingonanimpact.Thepreferredrouteistogofromantennaunderthenacrossthemainhooptorollcage
frontleg,thenfollowdowntheinsideofthefrontlegdowntheapillarontheinsidetotheunit.Anyexcess
cablemustberaninawaythatthecableisnotbentanytighterthata100mmradiuswerecommendrunningit
acrosstheundersideofthedashandback(donotcoilintightloops)Cablesmustbetiedneatlyalongthe
wholeinstallationrighttotheunitssodamagefromhookinggearorbodypartswillnotcausedamagetothe
installation,allthiswillbecheckedatscrutineeringandyoumayberequiredtofixitbeforeyourcarwillpass.
Bolt on Antenna: (Preferred)
Theantennaismountedthrougha12mmholeinacentral
locationontheROOFofthevehicle,preferably50mm
forwardofthemainRollbarhoopallowingthecablingto
passthroughtheroofandfollowthecagebarsbacktothe
RallySafeunitlocation.Incertaincircumstances,an
alternativestyleofantennacanbeorderedthatdoesnot
requireaholetobemadethroughtheroof.Itishighly
recommendedthatthenormal2in1antennabeused,asit
significantlyimprovescommunications.Theantennaisafully
watertightunitwhichsealsagainsttheroofsurface
Step By Step Process for the Bolt on Antenna
Stick on Antenna: (Alternative)
TheantennaistobemountedinalocationontheROOFofthevehiclepreferablywithineasycablereachof
thefinalRSunitmountingpositionallowingthecablingtothenpassthroughthedoorsealandfollowthecage
barsbacktotheRSunitlocation.Theantennaisafullywatertightunitwhichsealsagainsttheroofsurface.
Cablingwillneedtobesuitablytapedandprotectedtotheoutsideofthecar.
Internal Wi-Fi:
TheInternalWi-FishouldbeplacedontheinsideoftheROOFwitha200mmradiusclearofanybarworkor
solidmetalobjectinaclearunclutteredarea.TheinternalWi-FiAntennahasamagneticbasewithadouble
sidedtapeforadhesion,thecableisthentoberuntotheRallysafeunit.*(Pleasekeepcableinsiderollcageso
nottobecrushedintheeventofanaccident.)Poorpositioningormountingofthisantennawillresultin
decreasedrangeofCartoCarfunctionsi.e.pushtoPassHazardwarningsetc.Itisalsoimportantforrelaying
yoursafetystatusoutviaothervehiclestoracecontrolifdamageisdonetoyourexternalantenna.
PleasenotetheInternalAntennais200mmAWAY
fromanyrollcagecomponents
Heretheantennaisstuckinsidetheroofinthe
middleofthevehicle(Preferred)
Unit Power Consumption Figures & Specifications
Power Cable Conductor Specifications
Unit Power Consumption at 12 Volts
NumberofConductors
5
PoweronTransitMode
.200A
ExternalDiameter
2.5mm
PoweronTransitMode-Charging
.300A
Material
Copper
PowerDown–SleepMode
.002A
CurrentRating
5A
TransmittingIncidentonStage
.250A
Contact Us
RallySafeNederland
Witmoesdijk24
7461PMRijssenTheNetherlands
Phone:0031653641315
Email:contact@rallysafe.nl