Compliance statement This procedure has been aligned to the Construction Plant-hire Association (CPA) / Construction Industry Plant Safety Group (CIPSG) Good Practice Guide for Machine-Mounted Human Form Recognition Systems (GPG HFRS, V1, July 2025), and to the manufacturer's adapted M4 installation checklist. HFRS is an aid to safety only. It forms part of — and does not replace — the site's risk assessment, method statement and existing people/plant interface controls (GPG HFRS 3.1, 3.14). |
1. Why it matters.
Plinx VisionKit is evolving. Now bringing a new dimension of visual intelligence to your machines. A powerful multi-camera system, with up to four seamlessly integrated viewpoints delivering a true 360° perspective.
Delivering a smarter, and more complete understanding of every moment on site. Non-invasive yet incredibly insightful, VisionKit now captures the full picture. With multiple angles around a machine, it provides live streaming when it matters most, while continuously generating meaningful data that builds a dynamic, long-term view of your operation.
Built with safety, sustainability and compliance at its core, 360 VisionKit acts as a vigilant set of ‘eyes-on’, now with enhanced context and awareness. The expanded field of view significantly improves human-form recognition and situational awareness around machinery, helping to identify risks earlier and respond faster.
From critical events to everyday operations, 360 VisionKit empowers teams with visual intelligence from every angle, protecting people, optimising performance, and creating a safer, smarter worksite.
Important: Human Form Recognition systems are a complementary aid to safety and must never be treated as the sole means of keeping people clear of machinery danger zones
(GPG HFRS 3.1, 3.14).
2. Required components and fixings
MachineSense device
Universal Power Adaptor (UPA)
Camera Switch
Up to 4 x HFR cameras
Camera extension cables (various, depending on machine)
1 x Driver display
Cable ties
1 x in-line fuse block (3 amp)
1 x Fuse tap (standard or mini blade), 5A fuse
1 x ‘Plinx READY’ sticker
Ring terminals and cable connectors (various)
Manufacturer evidence pack (technical file, declaration of conformity, calibration procedure, accuracy test records) — confirm this is available before starting
(GPG HFRS 3.9–3.10)
3. Pre-installation checks and Risk Assessment
Before any work begins, complete the following (GPG HFRS 3.9; checklist Section A):
Machine parked safely in a suitable working area; isolated where required; site safety procedures followed.
Point-of-Work Risk Assessment (POWRA) completed for the installation activity.
Machine switched off.
Roof type checked — plastic or metal.
Battery location, existing fuse board and suitable chassis grounding points identified.
Safe cable routes and camera mounting locations planned before securing anything.
All mounting areas cleared of debris and obstructions.
All required parts verified present and undamaged.
A competent, trained installer assigned to carry out the fitment.
Verify all parts required are present and undamaged
4. Fitting the Universal Power Adaptor (UPA)
The UPA is the staple for each machine and is supplied with a QR code which requires scanning to register the machine class and machine ID.
The Construction Site Camera & Evidence Platform will guide you through the registration process
See instructions below:
UPA registration instructions.
Scan QR code with smart phone
[this will prompt a registration screen]
Note the UPA ID number
[this will be pre-populated]
Fill in the Machine/Plant ID number
[for example EX25T***]
Fill in a brief description of machine
[for example Excavator 123GC]
From drop down list, select Machine Type
[for example Tracked Excavator]
Select SUBMIT to confirm
[A note will pop up to accept the machine registration]
Fit the UPA using the double-sided tape to the rear windscreen of the machine, avoiding any moving parts such as windscreen wipers. The screen should be free from dirt and other contaminants before affixing the unit. Once fitted, apply the ‘Plinx READY’ sticker supplied.
Route the UPA cable towards the battery compartment and retain spare length — do not trim any cable until testing is complete.
5. Locating the MachineSense control unit (Method 1 - Magnets)
The Plinx MachineSense comes fitted with 4 strong magnets under the body of the sensor. These will allow for easy placement on metallic roofs.
The magnets are sufficient to hold the unit firmly in place so a well selected location on the roof surface is preferred to allow reach to the Universal Power Adaptor (UPA) to the rear and Driver Display to the front.
Choose a location that protects the unit from mechanical damage, excessive vibration and accidental impact, while keeping connections accessible for future maintenance
(GPG HFRS 3.9, 3.11).
6. Locating the MachineSense control unit (Method 2 - Adhesive)
For machines with plastic roofs, there are a couple more steps to follow to place the sensor on the roof.
Plastic Roof Applications - Extra parts required:
Qty | Product | Image/URL |
2 | Oval Plates |
 |
1 | CTec - Grab and Bond |
Connect plates across the adjacent magnets (shown below):
WARNING: THE MAGNETS ARE STRONG SO AVOID TRAPPING FINGERS BETWEEN THE OVAL PLATES AND THE MAGNETIC FEET WHEN CONNECTING
Apply adhesive across the width of each oval plate:
Ensure the roof surface is completely dry and free from any debris.
Turn the MachineSense over and place it on the roof.
Press down firmly, moving the device from side to side to achieve maximum adhesion.
BE MINDFUL NOT TO TRAP ANY SECURITY OR POWER CABLES WHEN GLUING THE UNIT INTO PLACE. THE POWER CABLE MUST RUN TOWARDS THE FITTED UNIVERSAL POWER ADAPTOR (1M).
7. Securing the camera switch
The camera switch powers and manages up to four cameras installed on the machine. It should be mounted alongside the MachineSense unit on the roof, in a protected, weatherproof location with easy cable access, to ensure efficient connectivity and cable routing.
The switch features four dedicated camera ports. Cameras can be connected to any port, depending on their position and the most practical cable path.
Each connection uses a 6-pin male connector, which is keyed to ensure correct alignment and a watertight seal. When installing a camera, make sure the connector is properly aligned, the seal is seated correctly, and the locking nut is fully tightened.
Route camera cables to the switch clear of moving parts, sharp edges and hot surfaces, with adequate slack.
Secure all cables with zip ties at sensible intervals so routing is neat, protected and intentional, with no snagging, crushing or stretching risk
(GPG HFRS 3.9).
Power is supplied from the Universal Power Adaptor (UPA), which connects to the DVR port on the switch.
8. Position your cameras
The MachineSense unit should be securely installed on the roof, with the Camera Switch positioned adjacent to it for optimal connectivity. When mounting the cameras, each unit is designed with a specific orientation.
Cameras to face FORWARD, REAR, LEFT and RIGHT. The exact placement of these cameras will vary depending on the type of machine being fitted, so ensure their positioning is aligned with the specific configuration requirements of the equipment.
Cameras must be positioned to achieve the required coverage with zero unintended blind spots, mounted securely, protected from excessive vibration and accidental impact or loading/attachment damage, and with lenses left accessible for routine cleaning
(GPG HFRS 3.4(a), 3.9).
9. Add the Driver Interface
The Driver Interface is connected directly to the MachineSense unit - PORT 1. When positioning the MachineSense on the roof, ensure there is sufficient cable length to allow the display to be installed within the operator’s natural line of sight.
In most cases, the display is mounted on the left-hand side of the machine, either by securely clamping it to the grab rail (Bracketed) or by sticking it to the front window (Display Only - adhered).
Care should be taken to position the Driver Interface so that it does not interfere with any mechanical components, such as the windscreen wipers, while still remaining clearly visible to the driver during operation.
Apply the supplied QR sticker close to the Driver Interface so operators can access driver information.
10. Connection to the battery (12v system and 24v system)
The UPA is hardwired directly into the machines battery.
The UPA is fitted with a 4-core cable, with each core designed to be connected as follows:
RED Core: via in-line fuse block rated to 3-Amps directly to the +POS battery post.
BROWN Core: directly to the -NEG battery post BEFORE THE ISOLATOR.
Do not fit the 3A fuse into the in-line fuse holder yet — make it available, but leave it out until the final power-on step, so the circuit is not live while the remaining connections are made.
11. Connection to an ignition point - GREEN Core
Route the signal cable to the fuse board. Use extension core where required. Use a fuse tap or connect inline via a spare accessory fuse slot (e.g., ignition). Confirm fuse rating matches system specs (typically 2A–5A). The signal cable connection MUST be to an Ignition Powered Fuse only. The signal is sent to the MachineSense VisionKit on the roof each time the machine is turned on and off.
12. Connection to a ground point - WHITE Core
The white core needs to be attached to a chassis grounding bolt. Remove any paint or corrosion at the bolt to ensure a clean, low-resistance electrical contact. This enables monitoring of the energy used by the machine over time and also allows the correct signals to be sent when a machine is isolated, so the MachineSense does not think it has come back on after engine shut-down.
13. Configuring camera detection zones
Every camera must have its detection zones drawn, configured and saved before the machine can be commissioned
(GPG HFRS 3.4, 3.12; Annex B):
Camera | Red exclusion zone | Amber warning zone |
Front | < 2 m from machine circumference | < 5 m from machine circumference |
Rear | < 2 m from machine circumference | < 5 m from machine circumference |
Left | < 2 m from machine circumference | < 5 m from machine circumference |
Right | < 2 m from machine circumference | < 5 m from machine circumference |
These are the industry default settings for a 360° machine (GPG HFRS 3.4(a)). They are a starting point only. Zones must be reviewed and tailored to the specific site, environment and customer requirements under 3.12, with any change to default settings authorised by a competent person following a documented risk assessment (4.6).
Detection coverage must be validated using the Annex B accuracy protocol where practical:
• Minimum 95% detection accuracy achieved in each zone.
• No complete detection failures in the red (inner/exclusion) zone.
• No more than 3 consecutive failed detections in the amber (outer/warning) zone.
• Testing should reflect a representative range of PPE colours and body positions where practical.
• Confirm the visual indicator remains illuminated for as long as a person is present within a zone.
14. Final checks, fuse fitting and power-on
Once all connections have been secured and all cables routed and cable-tied, carry out the following:
• Final inspection: all cables secured, none hanging loose, none in contact with moving parts or under tension.
• All connectors fully seated; all mounting points secure.
• Fit the 3A fuse into the main in-line fuse holder and seal/protect it.
• Power on the machine and allow a minimum of 5 minutes for the MachineSense unit to establish location, upload UPA details, and initialise system communications.
Then complete the following checklist:
Component | Checks required |
UPA | Adhered to rear windscreen and registered |
MachineSense | On the roof and secure |
Switch unit / cameras | Camera positions selected and connected to the switch |
Driver display | Mounted and in ‘line of sight’ |
Battery connections | Fuse inserted, connections secure |
Ignition connection | Fuse inserted, connections secure |
All cabling | Routed and zip-tied. No obstruction to machine operation. |
15. Commissioning and functional verification
Before the machine is released for use, complete full commissioning (GPG HFRS 3.10; checklist Section F):
• Confirm Driver Interface display LEDs illuminate GREEN.
• Confirm all four camera connection LEDs on the switch are illuminated/flashing, and each camera is sending data correctly.
• Verify full system functionality end-to-end per manufacturer procedure, including the zone and alert testing from Section 13.
• Record commissioning results and sign off (see Section 16).
If a fault is found
Stop, secure the area and do not release the machine for use. Report sensor failure, system non-response or display failure to the supervisor and asset owner immediately, and arrange investigation by an authorised technician before returning the machine to service (GPG HFRS Annex A).
16. Handover, records and sign-off
• File all records — installation, connections, initialisation, commissioning and zone configuration, and installer training — retained for a minimum of 3 years.
• Only release the machine for use once all checks above are complete and signed off.
• Operators should receive a brief familiarisation on HFRS alerts, zone meanings and system limitations before use (GPG HFRS 3.14, Annex C).
Machine Type / ID | MachineSense ID | Date |
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Role | Name | Signature / Date |
Installer / commissioner |
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