Figure 1

The bags on the left and the top right of Figure 1 contain the parts required for various cable assemblies (see Table 3 for a bill of materials). The bag on bottom right contains a Printed Circuit Board (PCB) and electronic components to be soldered on the PCB (see Table 1 for bill of materials).

Dismounting the EMV unit from the car

For full instructions on how to dismount the EMV unit from the car please obtain and read a copy of “Modifications instructions for using Soarer TV in Australia, New Zealand, UK and Ireland” manual. At the time this document is written, a copy of the manual can be downloaded from here:

Saoarer TV conversion with two audio/video inputs 

Dismounting the tape unit

Undo the four screws holding the tape unit to the EMV unit. Figure 2 shows two of the screws circled in red.

Figure 2

Remove the two tape unit covers with the help of a screwdriver as shown on Figure 3.

Figure 3

Assembling the EMV interface PCB

Table 1 lists the EMV interface PCB bill of materials.

Table 1

Figure 4 shows all the components and the top view of the assembled PCB. The assembled PCB on the bottom of Figure 4 is for illustration purposes only and is not included in the kit.

Figure 4

Figure 5 and Figure 6 are showing the bare and the assembled PCB-s in a closer view. Note the three PCB standoffs lock orientation. This way will make it easier to unlock and detach the PCB if necessary.

Figure 5

Figure 6

Once the transistors are soldered, they must be checked for shorts with a multimeter, as their PCB pads are in a very close proximity of each other.

Figure 7 shows the bottom view of the PCB with the inserted adhesive standoffs.

Figure 7

Wiring the EMV interface PCB onto the EMV tape unit

Cut a 30cm strip off the provided 16-way rainbow ribbon cable and assemble the 16-way IDC socket exactly as shown on Figure 8.

Figure 8

Figure 9 shows how the cable is split and positioned in the EMV tape unit. Note that the three wires (grey, white and black) in the middle of the split are not used and are cut close to the IDC socket.

Figure 9

Figure 10 shows how the other end of the cable is soldered on the bottom of the EMV tape unit.

Figure 10

Figure 11 gives a closer view of the connections. Note the track cut circled in red.

Figure 11

Figure 12 shows a closer view of the track cut.

Figure 12

Cut a 30cm strip off the provided 16-way rainbow ribbon cable and assemble the 10-way IDC socket exactly as shown on Figure 13. Note the colours of the 10 wires that need to be used out of the original 16-way rainbow ribbon cable.

Figure 13

Insert and position the cable in the EMV tape unit as shown on Figure 14.

Figure 14

Crimp five blade connectors (Figure 15) on the brown, red, orange, yellow and green wires. Crimp five blade receptacles on the blue, purple, grey, white and black wires. Do not forget to insert the connector/receptacle covers over the wire before the crimp. Note that the receptacle cover is bigger than the connector one.

Figure 15

Disassemble and position the tape mechanism as shown on Figure 16 by:

-         Unlatching the connector marked in red by pulling out the top of it a few millimetres.

-         Pulling out the flexible cable marked in green.

-         Undoing the four screws marked in purple.

The flexible cable marked in blue does not need to be disconnected. It is also better if the cassette is removed from the tape unit before the EMV unit is taken out of the car. If it is not (as seen on the Figure 16), care should be taken when assembling back the tape unit to leave the cassette receptacle door open or the cassette can’t be ejected.

Figure 16

Peal the adhesive covers off the three PCB standoffs shown on Figure 7. Position and stick the PCB in the tape unit as shown on Figure 17. The three PCB standoffs are circled in red.

Figure 17

Plug the 16-way and 10-way IDC sockets to the PCB. The 10-way IDC socket is hidden under the 16-way one circled in yellow on Figure 18. Reassemble the cassette tape mechanism.

Figure 18

Figure 19 shows the assembled EMV tape unit after the EMV interface PCB has been embedded.

Figure 19

On the EMV connector, strip part of the insulation of three wires next to each other (orange, brown and white circled in red on Figure 20) and tin them.

Figure 20

Figure 21 shows a closer view of three wires.

Figure 21

Insert and solder a T-tap connector (crimp terminal) to each of the three wires as shown on Figure 21.

Figure 22

Close the terminal covers as shown on Figure 23

Figure 23

Figure 24 shows the tape unit assembled to the EMV and the three T-tap connectors joined with the corresponding blade connectors.

Figure 24

The connections are described in the Table 2:

Table 2

Figure 25 shows the three connections in a closer view.

Figure 25

Cables assembly and installation

Table 3 lists the EMV interface cables bill of materials.

Table 3

Figure 26 shows the EMV interface cable parts.

Figure 26

Infrared receiver cable assembly

The infrared receiver cable connects two infrared (IR) receivers to the EMV interface PCB. Both IR receivers are connected via a three-wire ribbon cable in parallel. A third IR receiver could be added in parallel if needed. The IR receivers can be placed anywhere in the car. At least one of them should be around the steering wheel dedicated to receive IR commands from a steering wheel IR remote. The second one can be used to receive IR commands from a voice operated IR remote. In this document the two receivers are placed on both sides of the steering wheel and the cable length is selected to suit this type of installation.

Each IR receiver requires a low pass filter on the power supply pins. The filter comprises a 4u7 surface mount capacitor connected in parallel and a 100R resistor in series. Figure 27 shows how the capacitor should be attached to the IR receiver. The IR receiver pins should be folded at a right angle near the plastic body. The IR receiver on the left shows the capacitor just inserted before it is soldered. The IR receiver on the right shows the capacitor after soldering.

Figure 27

Cut

-         nine 3cm pieces of heatshrink 1.5mm diameter

-         two 3.7cm pieces of heatshrink 6mm diameter

-         two 1.8cm pieces of heatshrink 3mm diameter

Peel off the blue, purple and grey wires (bunched up together) from the 16-way ribbon cable. The total length of this three-wire cable should be 140cm (60cm out of the provided 2m cable are used for the EMV interface PCB wiring in the EMV tape unit). Cut it in three pieces – 30cm, 40cm and 70cm. Solder one of the IR receivers to one end of the 40cm cable and the second IR receiver to one end of the 70cm cable as shown on Figure 28. Use six 3cm pieces of heatshrink to isolate the IR receiver pins. The colour order of the three wires should be exactly as shown on Figure 28.

Figure 28

Figure 29 shows an IR receiver after the heatshrink has been shrunk. 

Figure 29

Insert the 3.7cm piece of heatshrink (6mm diameter) around the three IR receiver pins and shrunk it as shown on Figure 30.

Figure 30

Cut the purple wire close to the IR receiver pins and solder the 100R resistor in series as shown on Figure 31. Use the 1.8cm piece of heatshrink (3mm diameter) to isolate the resistor.

Figure 31

Figure 32 shows the resistor covered with the heatshrink.

Figure 32

Solder together the other ends of the cables with the IR receivers as shown in Figure 33.

Figure 33

Solder the 30cm three-wire cable to the ones from Figure 33 as shown on Figure 34. Use three 3cm pieces of heatshrink of 1.5mm diameter for isolation.

Figure 34

Figure 35 shows the joints after shrinking the heatshrink.

Figure 35

Insert three blade covers and crimp three blade connectors to the unconnected end of the 30cm three-wire cable as shown on Figure 36.

Figure 36

The final IR receiver cable is shown on Figure 37.

Figure 37

Infrared emitter cable assembly

The infrared emitter cable connects two infrared (IR) emitters to the EMV interface PCB. Both IR emitters are connected via a two-wire ribbon cable in series. The IR emitters should be placed within a close distance to a device’s (DVD, Satellite navigation etc.) IR receiver eye. In this document one IR emitter is placed in the glove box and the other one is in the storage compartment between the two front seats. The cable length is selected to suit this type of installation.

Cut

-         four 3cm pieces of heatshrink 1.5mm diameter

-         two 1.5cm pieces of heatshrink 1.5mm diameter

Peel off the white and black wires (bunched up together) from the 16-way ribbon cable. The total length of this two-wire cable should be 140cm (60cm out of the provided 2m cable are used for the EMV interface PCB wiring in the EMV tape unit). Cut it in two pieces –40cm and 100cm. Solder the two IR emitters to one of the ends of the two cables as shown on Figure 38. Use the 3cm pieces of heatshrink to insulate the IR emitter pins. Note that the white wire is soldered to the shorter pin of the IR emitter.

Figure 38

Figure 39 shows the IR emitter after shrinking the heatshrink.

Figure 39

Cut the white wire of the 100cm cable at 60cm distance from the IR emitter. Solder the 40cm cable to the two ends of the cut and insulate them with two 1.5cm pieces of heatshrink. Insert two blade covers and crimp two blade connectors to the unconnected end of the 100cm two-wire cable. The final cable is shown on Figure 40.

Figure 40

Important: Note that the wires must be connected exactly in the way shown on Figure 40. Figure 41 shows a closer view of this connection.

Figure 41

Factory video terminal cable assembly

The factory video terminal cable connects one pin of the factory video terminal connector to the EMV interface PCB.

Peel off the brown wire from the 16-way ribbon cable. The total length of this wire should be 140cm (60cm out of the provided 2m cable are used for the EMV interface PCB wiring in the EMV tape unit). Insert one blade cover, one receptacle cover and crimp one blade connector and one blade receptacle to both ends of the wire. The final cable is shown on Figure 42.

Figure 42

Cable installation

Figure 43 shows the blade receptacles of three cables placed over the EMV loom distribution box.

-         Brown wire - factory video terminal cable.

-         Black and white wires – IR emitter cable.

-         Blue, purple and grey wires – IR receiver cable

Figure 43

Figure 44 shows how the IR transmitter cable is run towards the steering wheel.

Figure 44

Figure 45 and Figure 46 show one way of how the two IR receivers could be installed on the left and the right side of the steering wheel.

Figure 45

Figure 46

Figure 47 shows one of the IR emitters installed in the glove box next to a DVD IR eye.

Figure 47

Figure 48 shows the second IR emitter installed in the storage compartment between the two front seats.

Figure 48

Connecting the EMV unit to the EMV interface cables

Strip part of the insulation and tin the blue wire of the middle EMV connector (comes from the car loom). Insert and solder T-tap connectors as shown on Figure 49

Figure 49

Strip part of the insulation and tin the pink wire of the factory video terminal connector (situated under the cup holder). Insert and solder T-tap connectors as shown on Figure 50.

Figure 50

Insert the brown wire blade connector as shown on Figure 51

Figure 51

Position the EMV unit in the car and connect the EMV interface PCB cable blades to the IR receiver, IR emitter and factory video terminal cables by matching their colours. Six blade/receptacle pairs have to be connected to the ribbon cable wires with colours brown, black, white, blue, purple and grey. These six pairs are circled in yellow on Figure 52. The green wire blade is inserted in the T-tap connector (circled in red on Figure 52)

Figure 52

Touch screen operation and programming

Using the EMV touch screen with an in-car DVD player

Here is an example of how to program the EMV touch screen to control a DVD player with an IR remote control. While the DVD player is the most popular off-the-shelf device added by most Soarer owners to their cars, it is not the only one that can be controlled by the EMV interface kit. Any device having a standard IR remote control with 36KHz to 40KHz frequency carrier should be controllable by the kit. In practice most mass production devices with small exceptions are in this category. Contact your device manufacturer to check the details of its IR remote control.

The EMV touch screen normally does not function when the Soarer TV is viewed or listened to. The EMV interface makes the touch screen working when channel 19, channel 20 or the factory video terminal (FVT) inputs are selected. Note that channel 19 and 20 inputs are only available on a Soarer with converted TV. The FVT is available on all Soarer equipped with EMV and TV. The FVT connector is located under the cup holder as shown on Figure 50.  It allows video and mono audio to be used with the car TV. Toyota offers a simple AV cable as an option with one video, one audio and a mechanical switch to be plugged to the FVT connector. The mechanical switch is used to activate the FVT when the TV is selected. The EMV interface replaces the mechanical switch with an electronic switch that is activated by pressing and releasing the INFO (marked as FVT on Figure 55) EMV button. In other words the EMV interface changes the functionality of the INFO button to a FVT button.

 Figure 53 and Figure 54 show using a DVD player connected to the TV channel 20 input. Both screens allow the DVD to be controlled via the touch screen.

Figure 53

Figure 54

Figure 54 shows how the touch screen is virtually divided in eight areas

–        North-West (N-W)

–        North (N)

–        North-East (N-E)

–        West (W)

–        Centre (C)

–        East (E)

–        South-West (S-W)

–        South (S)

–        South-East (S-E)

Note that the red lines and text are just added on top of the photo and are not displayed on the EMV. When the screen is touched in the border of an area, a unique infrared command is sent to the DVD player. A short beep from the EMV feeds back the touch event. If the same area is touched and held for longer than 0.5 seconds a different infrared command is sent to the DVD player. A long beep from the EMV feeds back this type of touch event.

Assigning DVD control commands to an EMV touch screen area

A DVD control command is normally sent by the DVD IR remote. The EMV interface can learn the IR codes of the DVD remote and simulate them when the EMV touch screen is pressed. Each area from Figure 54 can learn and simulate two DVD IR commands, one for short touch and another one for long touch (touch and hold for longer than 0.5 seconds). Here is a procedure of how to assign DVD command PLAY to the South-East (S-E) touch screen area:

• 1. Select TV channel 20. The EMV screens on Figure 53 or Figure 54 should be displayed.

  2. Briefly touch (for less than 0.5 seconds) and release area S-E. A short beep should be heard.

  3. Press and hold the tape eject button (circled in yellow on Figure 54).

  4. Briefly press the DVD remote PLAY button. The DVD remote should be pointed towards one of the EMV interface IR receivers.

  5. Release the tape eject button.

To program another DVD function repeat steps 1 to 5 by using a different touch screen area or a long touch. This allows up to 16 different DVD functions to be programmed and activated via the EMV touch screen.

To test the programmed command, touch an EMV area and the DVD should respond to the programmed command. Note that the DVD IR eye should be placed close to one of the EMV interface IR emitters.

In addition to the 16 touch screen commands described above, there are two special commands which are activated on entering/exiting channel 20. For example PLAY/STOP DVD commands can be programmed when entering/exiting channel 20. To program the channel 20 ENTER command:

• 1. Select TV channel 20. The EMV screens on Figure 53 or Figure 54 should be displayed.

  2. Touch and hold area West until two long beeps are heard then release.

  3. Press and hold the tape eject button (circled in yellow on Figure 54).

  4. Briefly press the DVD remote PLAY button. The DVD remote should be pointed towards one of the EMV interface IR receivers.

  5. Release the tape eject button.

To test the ENTER command select an EMV function with a different than channel 20 audio source (e.g. FM radio). Switch the EMV back to TV channel 20. The DVD should respond to the ENTER command programmed above. To program EXIT command follow the same steps but substitute the West area with East area. The EXIT/ENTER commands can be also tested by touch and hold East/West areas until second long beep is heard.

Devices connected to channel 19 or the factory video terminal inputs will have their own independent 20 (18+2) touch screen commands. To program their commands, just select the input and perform the steps above for each command. The EMV interface will automatically switch to the correct set of commands when the video input sources are changed.

The EMV keeps the programmed codes in non-volatile memory. They will not be lost when the car battery is disconnected. The EMV touch areas can be reprogrammed as many times as needed. To erase all programmed codes:

-         Press and hold the tape eject button.

-         Briefly press the TV button.

-         Release the tape eject button.

Tip: The EMV interface learns an IR code by recording a DVD remote code for 0.5 seconds. Most remotes can send a single code for a much shorter time than 0.5 seconds. This way, the EMV interface can be made to record two different codes if two DVD buttons are pressed in sequence within 0.5 seconds during the learning process. This could be useful in some cases. For example the West area short press can be programmed with “chapter step back” and “move left menu control”. When browsing the DVD setup menus, the “move left menu control” is interpreted and “chapter step back” code is ignored. When playing DVD “chapter step back” selects the previous movie chapter and “move left menu control” is ignored.

Using Pioneer CD-SR100 steering remote to control and navigate the EMV

The EMV interface is designed to support a Pioneer CD-SR100 steering remote control. The remote is plug and play compatible with the EMV interface. No programming is required to get it working. It just needs to have one of the EMV interface IR receivers around the steering wheel to establish an IR connection.

The Pioneer CD-SR100 together with the EMV interface allow the following EMV function controls:

-         EMV user screens selection and navigation

-         Volume and mute control

-         FM, AM radio channels search and change.

-         FM, AM, TV preselected channels navigation

-         FM, AM auto scan of preselected channels

-         CD disk/track selection

-         CD track auto scan

-         TAPE forward/backward rewind, auto reverse

-         TAPE skip, APS and PROG functions

-         Switch between DSP surround settings

-         Switch between user preset equalizer settings

-         Air conditioning vents control and air flow control

-         EMV computer screen browsing and basic control

Figure 55, Figure 56 and Figure 57 show the mapping between the Pioneer CD-SR100 buttons and the EMV buttons.

Figure 56 shows the functions when a button is pressed and released for a short time (less than 0.5 second). Figure 57 shows the functions when a button is pressed, held and released for a longer than 0.5 second.

Figure 55

Figure 56

Figure 57

Figure 58 shows the volume up/down buttons on the Pioneer remote.

Figure 58

The Pioneer remote left/right buttons are used for EMV touch screen control and have different functions depending of the selected EMV user screen. Figure 59 and Table 4 show the mappings between the Pioneer remote left/right buttons and the EMV touch screen buttons.

Figure 59

Table 4

Using Pioneer CD-SR100 steering remote to control and navigate third party video/audio player connected to the EMV

The EMV interface allows the Pioneer CD-SR100 steering remote to control a video or audio player (for example DVD, satellite navigation system or iPod) connected to channel 19, channel 20 or the factory video terminal (FVT) inputs. The only requirement is the device to have a standard IR remote control with 36KHz to 40KHz frequency carrier.

The following procedure is an example of how to use CD-SR100 remote to control a DVD.

• 1. Program the EMV touch screen areas as described in “Touch screen operation and programming”.

  2. Switch the EMV to channel 19, channel 20 or FVT to view the DVD player (this can be done either via the Pioneer CD-SR100 remote or via the EMV buttons).

  3. Press and hold the UP key (see Figure 56) until a long beep is heard, then release the UP key. After this point, the Pioneer CD-SR100 keys will be mapped to the touch screen areas as shown on Figure 60 and Figure 61.

Figure 60

Figure 61

Once the EMV interface is in this mode of operation, pressing a Pioneer CD-SR100 key will be translated into an EMV touch screen event, which will send an IR remote command to the DVD player. Pressing and holding a Pioneer CD-SR100 key for a longer than 0.5 seconds will translate into a long touch screen event except in the following cases:

-         long press of North(N) key will return the Pioneer CD-SR100 remote to normal mode.

-         long press of Centre(C) key will be processed as volume mute – the same as in normal mode of operation.

When the Pioneer CD-SR100 is controlling the DVD, the volume control and the mute functions are not changed and still operate as per normal. To return the Pioneer remote to normal mode of operation, press and hold the UP (North) key until a long beep is heard and release it. Alternatively, return to normal operation can be achieved by changing from TV to FM, CD, TAPE, etc. user screens by using the EMV buttons.

Figure 62 and Figure 63 show an example of integrated Griffin iPod Media Center. For manufacture details please visit this link:

http://www.griffintechnology.com/products/tunecenter/

Figure 62

Figure 63

Using Sony TV/VCR IR remote to control and navigate the EMV and third party video/audio player connected to the EMV

The EMV interface supports a standard Sony TV IR remote in the same way as a Pioneer CD-SR100 steering wheel remote (see “Using Pioneer CD-SR100 steering remote to control and navigate a DVD” and “Using Pioneer CD-SR100 steering remote to control and navigate third party video/audio player connected to the EMV”).

The key mapping is shown on Figure 64 (short press), Figure 65 (long press) and Figure 66 (EMV touch screen).

Figure 64

Figure 65

The mute button, circled in yellow, and the volume control, circled in green on Figure 66, work as expected. The channel selection buttons, circled in blue, also work as UP/DOWN EMV buttons (see Figure 55 and Figure 57).

Figure 66

Pressing and holding a Sony key for longer than 0.5 second behaves in the same way as a Pioneer CD-SR100 key. Another way to simulate a press and hold event is to use a standard Sony VCR remote. A short button (1 to 9) press of a Sony VCR remote key is interpreted as long press and hold event on Sony TV remote key.

The Sony remote can also simulate any EMV button push and touch screen event by a special key sequence described below:

• 1. Press and release the power button circled in red on Figure 66.

  2. Dial a three-digit code by pressing and releasing buttons 0 to 9. The three-digit codes for different EMV buttons and touch screen events are shown on Figure 67.

Figure 67

The purpose of supporting a Sony TV/VCR remote is to enable voice control activation of EMV and DVD functions. Figure 68 shows a universal TV voice control remote. This remote was used to prove the concept of EMV and attached DVD voice control. Unfortunately, the voice recognition technology, at the time this document was written, was not mature enough for an in-car application. The noise level in a car environment is too high for reliable voice recognition.

Figure 68

Known limitations

1. Pioneer CD-SR100 steering remote suddenly ceases to operate.

   1. The CD-SR100 emits infrared light to the EMV IR receiver. If the EMV IR receiver is not in direct view of CD-SR100, the IR commands cannot be recognised. This may happen when the steering wheel is rotated at an angle, which makes the EMV IR receiver invisible to the CD-SR100. Installing two IR receivers on both sides of the steering wheel will eliminate this problem.

   2. Another scenario that will affect and even stop the CD-SR100 from working properly is when the EMV IR receiver is directly exposed to sunlight.

   3. And finally a low battery condition of CD-SR100 will affect the normal operation.

2. The Factory Video Terminal (FVT) cannot be selected when the TV is set on channel 19 or 20.

Appendix A: Pioneer CD-SR100 remote control installation

The Pioneer CD-SR100 remote can be attached to the steering wheel via the original strap provided with the remote or via the mechanical Do It Yourself kit provided as part of the EMV kit. Figure 69 shows how the remote fits on the steering wheel by the second option.

Figure 69

The kit includes the parts shown on Figure 70 and Figure 71.

Figure 70

Figure 71

Table 5 lists the bill of materials.

Table 5

Drill 8 x 3.5mm diameter holes in the metal plate. Use the template circled in yellow on Figure 71. Cut the metal plate in two. Figure 72 shows the drilled and cut metal plate together with the other parts. Enlarge the two holes circled in red on Figure 72 to 4.5 mm diameter.

Figure 72

Fold the small metal plate as shown on Figure 73.

Figure 73

Remove the plastic cover on the left side of the steering wheel as shown on Figure 74. This is easily achieved with the help of a screwdriver inserted in the small slot circled in yellow on Figure 79. The two holes circled in red on Figure 74 will be used with the two M4 x 10mm screws to attach the remote.

Figure 74

Drill 2 x 8mm holes (circled in red) in the plastic cover as shown on Figure 75. Use the provided template (circled in red on Figure 71) to centre the holes.

Figure 75

Assemble the small metal plate as shown on Figure 76 and Figure 77. The assembly consists:

• • two M4 x 10mm screws

  • four M4 flat washers

  • two M3 metal spacers - length 10mm

  • two M3 x 10mm screws

  • two M3 spring washers

  • the small metal plate

Figure 76

Figure 77 shows the other side of the assembly. The two M4 flat washers have to be inserted on the right M4 screw as shown on Figure 77.

Figure 77

Attach the assembly to the steering wheel with the two M4 screws as shown on Figure 78. The M4 screw with the three M4 washers is circled in red.

Figure 78

Insert back the plastic cover as shown on Figure 79.

Figure 79

Assemble the bigger metal plate as shown on Figure 80. The assembly consists:

• • two M3 metal spacers - length 15mm

  • four M3 x 10mm screws

  • four M3 spring washers

  • two M3 flat washers (circled in red on Figure 80)

  • the big metal plate 

Figure 80

Attach the assembly to the steering wheel as shown on Figure 81. The screw with the two M3 flat washers is circled in red.

Figure 81

Attach the plastic base of the remote with two M3 x 6mm screws and two M3 spring washers as shown on Figure 82. Note the lock orientation circled in red.

Figure 82

Finally attach the remote control as shown on Figure 83.

Figure 83