Installing communication systems to motorsport vehicles
Overview
This standard identifies the competences you need to install communication systems to motorsport vehicles, in accordance with approved procedures. You will be required to use appropriate installation drawings, specifications and documentation to install the various types of communication equipment which will include very high frequency (VHF), ultra high frequency (UHF) and high frequency (HF) radio, intercom headsets and voice recorders, digital data links and global position indicators. You will be required to select the appropriate tools, materials and equipment to use, based on the operations to be performed and the components to be installed You will be expected to correctly position, align and secure the components in the correct locations, using the specified or appropriate techniques and fastening devices. The components will include aerials, receiver units, transmitter units, intercom sets and global positioning system (GPS) units. In addition, you will be expected to make all necessary electrical connections to the equipment, and apply appropriate screening techniques as is appropriate to the equipment being installed. The installation activities will include making all necessary checks and adjustments to confirm the installation has been completed to the specification requirements.
Your responsibilities will require you to comply with organisational policy and procedures for the installation activities undertaken, and to report any problems with the activities, tools or equipment used that you cannot personally resolve, or that are outside your permitted authority, to the relevant people. You must ensure that all tools, equipment and materials used in the installation activities are removed from the vehicle on completion of the work, and that all necessary job/task documentation is completed accurately and legibly.
You will be expected to work with a minimum of supervision, taking personal responsibility for your own actions and for the quality and accuracy of the work that you carry out. The installation activity may be carried out as a team effort, but you must be able to demonstrate a significant personal contribution to the installation activities in order to satisfy the requirements of the standard. Competence in all the areas required by the standard must be demonstrated.
Your underpinning knowledge will provide a good understanding of your work, and will provide an informed approach to applying appropriate installation procedures for motorsport vehicle communication systems. You will know about the equipment being installed, its installation requirements, its correct function and any associated problems. You will also understand the installation methods and procedures used, and their application, in sufficient depth to be able to carry out the installation activities, to identify and correct any faults, and to ensure that the installed equipment is to specification.
You will understand the safety precautions required when carrying out the installation activities, especially those for ensuring safe isolation of equipment. You will also understand your responsibilities for safety, and the importance of taking the necessary safeguards to protect yourself and others in the workplace.
Note:
This standard does not involve maintenance/repair type activities, such as removal and replacement of existing equipment, or the installation of simple, self-contained items that have minimal installation requirements.
Performance criteria
You must be able to:
- work safely at all times, complying with health and safety and other relevant regulations, directives and guidelines
- follow all relevant drawings and specifications for the installation being carried out
- use the correct tools and equipment for the installation operations and check that they are in a safe, tested and usable condition
- install, position and secure the equipment and components in accordance with the specification
- check that all necessary connections to the equipment are complete
- deal promptly and effectively with problems within your control and report those that cannot be solved
- check that the installation is complete and that all components are free from damage
- ensure that work records are completed, stored securely and available to others, as per organisational requirements
- leave the work area in a safe condition on completion of the activities, as per organisational and legal requirements
Knowledge and Understanding
You need to know and understand:
- the specific safety precautions to be taken whilst carrying out the activities (including any specific legislation, regulations or codes of practice relating to the activities, equipment or materials)
- the health and safety requirements of the work area and the activities, and the responsibility these requirements place on you
- the hazards associated with the activities, and how to minimise them and reduce risks
- the personal protective equipment and clothing (PPE) to be worn during the activities
- the interpretation of drawings, wiring diagrams, standards, quality control procedures and specifications used for the installation of motorsport vehicle communication equipment (including current industry standard and code of practice schematics, wiring regulations, symbols and terminology)
- how to carry out currency/issue checks on the specifications you are working with
- how to identify the various motorsport vehicle communication equipment units and components to be installed
- the basic principles of operation of the motorsport vehicle communication system components and circuits being installed, and the purpose of individual modules/components, hardware and software
- how software can potentially affect hardware operations
- the importance of ground planes and their effect on radio transmission strength
- the assembly and installation techniques to be used, and the importance of adhering to these procedures
- how to mark out, drill and prepare holes for mounting and securing the components and cables including fitting cable protection devices
- the techniques used to position, align, adjust and secure the components to the motorsport vehicle without damage and according to their use
- the various mechanical fasteners that will be used and their method of installation (as open and blind rivets, threaded fasteners, adhesives and special securing devices)
- the use of anti-vibration mountings
- the use of seals/sealant, adhesives to avoid moisture ingress, and the precautions that need to be taken
- the different types of cabling and their application (uch multicore cables, single core cables, screened cables, co-axial and tri-axial cables, data/communications cables, fibre optics)
- the importance of correct routing and securing of the motorsport vehicle communication equipment components
- the techniques used to terminate electrical equipment and components (as free plugs and sockets, crimped cable end fittings, soldered fittings, screwed and clamped connections)
- the importance of applying electrostatic discharge (ESD) procedures when working on sensitive equipment or devices
- methods of attaching markers/labels to components or cables to assist with identification
- the tools and equipment used in the installation activities (the use of cable stripping tools, crimping tools, soldering irons)
- how to conduct any necessary checks to ensure the system integrity, functionality, accuracy and quality of the installation
- the quality control procedures to be followed during and after the installation operations
- how to check that tools and equipment are free from damage or defects, and are in a safe and usable condition
- the importance of ensuring that the completed installation is free from dirt, swarf and foreign object damage and of ensuring that any exposed components, looms and wiring are correctly covered/protected.
- why electrical bonding is critical, and why it must be both mechanically and electrically secure
- the tools and equipment used in the installation activities, and their calibration and care procedures
- how to recognise installation defects and the procedures to correct them
- the problems with assembly and installation of motorsport vehicle communication systems, and the importance of informing the appropriate people of non-conformances
- the procedure for the safe disposal of waste materials
- the recording documentation to be completed for the activities undertaken and, where appropriate, the importance of marking and identifying specific pieces of work in relation to the documentation
- the extent of your own responsibility and to whom you should report if you have problems that you cannot resolve
- how to access, use and maintain information to comply with organisational requirements and legislation
Scope/range
Scope Performance
Carry out all of the following activities during the installation:
- obtain clearance to work on the vehicle, and observe all relevant isolation and safety procedures
- obtain and use the appropriate documentation (such as job instructions, installation drawings, vehicle manuals, specifications, quality control documentation)
- adhere to procedures or systems in place for risk assessment, hazardous substances, personal protective equipment and other relevant safety regulations and procedures to realise a safe system of work
- provide safe access and working arrangements for the work area, and ensure that any appropriate environmental conditions can be met
- use approved installation techniques and procedures at all times
- where appropriate, apply electrostatic discharge protection procedures (ESD)
- ensure components and surrounding structures are maintained free from damage and foreign objects
- return all tools and equipment to the correct location on completion of the activities
- dispose of waste items in a safe and environmentally acceptable manner
- leave the vehicle communication system in a condition ready for testing
- leave the vehicle and work area in a safe and appropriate condition and free from foreign object debris
Install communication equipment on one of the following types of motorsport vehicle:
- single seater
- kart
- rallying
- historic
- sports car
- other specific approved competition vehicle
Install two of the following types of motorsport vehicle communication equipment :
- VHF radio
- intercom
- global positioning system
- HF radio
- visual recording systems (cameras)
- event position indicating system
- UHF radio
- digital data link
Install ten the following communication system components:
- aerials
- unit trays
- control units
- GPS units
- receiver units
- transmitter units
- intercom units
- cables
- headsets
- switches
- plugs and sockets
- power supply
- video units
- indicator units
- mounting devices
Apply appropriate installation methods and techniques to include ten of the following:
- marking out of location positions for components or modules
- making mechanical/screwed/clamped connections
- drilling and preparing holes for fasteners
- crimping terminations (such as tags and pins)
- preparing holes in bulkheads or panels for wires/cables
- terminating co-axial/tri-axial cables
- positioning and securing equipment and components using mechanical fixings
- soldering connections
- carrying out earth bonding
- routing and securing component wires and cables to avoid chafing and damage
- stripping cable insulation/protection
- adding cable end fittings
- terminating cables to installed components using free plugs and sockets
- attaching suitable cable identification
- carrying out appropriate adjustments to units and components
- sealing and protecting cable connections (such as heat shrinking, fitting protection devices and boots)
Carry out checks on the installed communication equipment, to include all of the following:
- visual checks for completeness and freedom from damage
- security of all installed components
- torque setting fasteners (where appropriate)
- all installed connectors are secure
- integrity of earth bonding
- correct polarity of all cables and connections
- continuity of cables and components
- cable routing is correct and secure
Check installations which comply with one of the following:
- race associations
- current legislation, industry standards, codes of practice and procedures
- vehicle manufacturers specification
- customer standards and requirements
- team/company standards and procedures
- specific vehicle requirements