WABCO ECU220 IVTM Electronic Control Unit User Manual IVTM Integrated Vehicle Tire Pressure Monitoring

WABCO GmbH IVTM Electronic Control Unit IVTM Integrated Vehicle Tire Pressure Monitoring

Users Manual

Integrated Vehicle Tire Pressure MonitoringVehicle tire pressure monitoring systemSystem functionsSystem configurationInstructions for installationand diagnostics1st. edition815 000 452 38150004523Revisions of this document are not set up.New versions could be found in INFORM websitewww.wabco-auto.com Ó Copyright WABCO 2004Vehicle Control SystemsAn American Standard Company8150003993Changes are reservedVersion 001/04.03(en)Wabcodruck 815 000 452 3
FCC NoticeThis device consists of Wheelmodul 960 730 XXX X (SA4-WM730)and Electronic Control Unit 446 220 XXX X (SA4-ECU220)This device complies with Part 15 of the FCC Rules. Operation issubject to the following two conditions:(1) this device may not cause harmful interference, and(2) this device must accept any interference received, includinginterference that may cause undesired operation.Changes or modifications not expressly approved by the partyresponsible for the compliance could void the user's authority tooperate the equipment.
31Contents1. System functions 51.1 System structure 71.1.1 Example of installation in the bus 81.1.2 Example of installation in the trailer 82. Configuration 92.1 Components 102.1.1 Wheel module 102.1.2 Electronic control unit (ECU) 122.1.3 Display 132.2 Wiring 143. Installation instructions 173.1 General instructions 173.2 Overview 173.3 Additional mounting into vehicle/bus 183.3.1 Additional mounting into trailer 193.4 Inflation pressure 193.5 Installation of the control unit in vehicle 203.5.1 Installation of the wiring harness in vehicle 203.5.2 Installation of the wiring harness in trailer 224. Diagnostics 264.1 System configuration 264.2 Diagnostics structure 264.3 Instructions for use 274.3.1 Display instructions 274.4 Various information on display 274.4.1 Normal data 274.4.2 Pressure data 284.4.3 Error messages 294.4.4 Display reset 304.5 System error signalization 314.5.1 Interrupted connection to the wheel module 314.5.2 System failure 314.5.3 Interrupted connection between control unit and display 31
51. System functionsIVTMstands for Integrated Vehicle Tire PressureMonitoring. It is the tire pressure monitoring system,which is installed in the vehicle. IVTM continuouslymonitors the pressure in all tires. This monitoring isperformed by the pressure sensors in all tires, whichrelays information to the display in the cabin and warnsdriver about critical pressure drop. IVTM makes transportsafer and more efficient, because more than 80 % of tiredamage could be recognized before serious damageoccurs, which requires repair. IVTM thus cuts downoperational costs, as continually maintained optimizedpressure in all tires results in minimal fuel consumptionand extension of service life of tires.Let us present some information:Tire manufacturers estimate that total losses caused byimproper maintenance of tires of commercial vehicles aremore than 10 millions of Euro in Germany. Lot of vehicleusers unfortunately tend to overlook this important factorof operational costs. By selecting correct tires and propermaintenance it is possible to save up to 2500.- €pervehicle for one year. The unnecessary expanses arefurther increased by widely spread carelessness ofdriving with under-inflated tires. Tires with 20 % lowerpressure are no exception in everyday life. This under-inflation reduces service life of tires by 20 % andunnecessarily increases fuel consumption.In order to minimize these costs WABCO companydesigned new system IVTM, which also increases trafficsafety.System functions 1.IVTMMain reasons for brakedowns at commercial vehicles are:Brakes 4%Electric 17%Tyres 26%Engine 36%Operating supplies 1%Chassis 2%Service / information 3%Structure 3%Salvage operation 4%Drive line 4%Source: Service 24 GmbH & Co. KG66000 brakedown missionsfor trucks and busses in 1999Fuel consumption Tire pressureService life reduction The mileage of tyres significantly depends on the tyre pressure...and fuel consumption also depends on thetyre pressure.tyre pressure too lowtyre pressure too lowtyre pressure too hightyre pressure too high
6System functionsIVTM1.Checks of the car fleets show:Every second tire is under-inflated by more than 10 %.Using of new IVTM system increases profitability :• reduced fuel consumption due to lower rollingresistance• smaller tire wear owing to lower deformationlosses => longer tire life cycle• Saving costs of manual tire pressure check(up to 30 minutes for one vehicle)• spare tire is not needed due to low probability ofrupture => higher vehicle load.tyre pressure too lowIVTM warns driver about sneak pressure dropearly, i.e. before the tire could burst. IVTM enhances safety of passengers, driver, vehicle andtraffic :• The driver may react to sneak pressure dropearly and prevent up to 85 % of tire bursts. • Additionally, properly maintained pressure intires ensures safe driving properties of vehicleand short braking distance.IVTM ensures travel efficiency:• Prevents unnecessary delays and idle time.• No backup vehicles/emergency actions needed• Prevents loss of confidence from unsatisfiedcustomers and resulting drop of turnover.Which types of pressure monitoring areavailable? Permanent tire pressure monitoring during driving couldbe performed in several ways: – direct tire pressure measurementpermanent on-line pressure monitoring is possible.Extremely precise and effective, very expensive.– direct tire pressure measurement with limit valuemonitoring not so precise.– indirect tire pressure measurement moderately expansive, not nearly as precise andreliable. The pressure is calculated from drive slip,measured by ABS turning sensors. WABCO IVTM uses direct pressuremeasurement and in comparison with systemsusing ABS presents these advantages:1. pressure monitoring during parking or before drivingstart; diagnostics memory2. able to distinguish uniform diffusion losses3. fast detection of pressure drop, reaction time in orderof several seconds. 4. display of current tire pressure5. higher precision6. identification of leaking tire7. measurement is not affected by driving on low qualityroad 8. measurement is not affected by uneven vehicleloadingAir pressurein barrecords about tire pressure (rise)VEHICLErear axle insideTRAILER3 axlesVEHICLEfront axleThe range of tire pressure oscillation for utility vehicles is far higher then for passenger car.
7This requires using sophisticated evaluation algorithm,instead of using simple identification of limit value.Other requirements for tire pressure monitoringsystems of utility vehicles:• exact wheel identification for vehicles with morethan 10 wheels or with double wheels• high efficiency of wireless data transport• pressure range 2 - 14 bars• Identification of tire pressure fluctuation basedon load and tire wear. This function requires complicated "evaluativealgorithm". • Wheel modules must be mounted flexible withrespect to different types and locations of tirevalves on rims, different rim designs andfrequent wheel changes and must allow easyexchange. 1.1 System architectureWABCO system is based on one electronic circuit 446220 00x 0, so called control unit, which receives wirelessdata transmitted by wheel modules. Wheel modules 960730 00x 0 are connected to the wheel valves by hoses.Pressure information is processed by algorithms storedin control unit.The information is sent through CAN bus to display unit446 221 000 0. Display unit consists of one display, twoindicators, one buzzer and two buttons.Warning massages of different levels are displayed; indicator colour and type of audio signal showsseriousness of the problem:• Red light and 1 minute long audio signalindicates serious defect; the vehicle must bestopped immediately (possible threat to livesand vehicle).• Yellow light and 10 minutes long audio signalindicates smaller defect; the vehicle should beslowed down and lower pressure adjusted.Defects found by IVTM system are stored in electronicmemory (EEPROM) for diagnostic purposes.System functions IVTM 1.Wheel modulefro wheelControl unitTrailerVehicleControl unitDisplay:« Standalone » or integratedIVTM systemVehicleCAN busIVTM systemTrailerCAN bus or HF wireless data transferfrom trailer control unit to vehicle control unit
8System functionsIVTM1.1.1.1 Example of installation in the bus:1.1.2 Example of installation in the trailer:Driver displaywheel moduleelectronic control unit (ECU)Display Control unitVehicle Control unitTrailer wheel module(one module per one tire)
9Configuration IVTM 2.2. ConfigurationIn order to display tire pressure and trailer warnings todriver during driving it is in general case necessary toinstall IVTM to both parts of vehicle, i.e. one control unitto trailer and one unit to motor vehicle. Any vehicleequipped with IVTM could be connected to any trailerequipped with IVTM. Control unit of vehicle identifiescontrol unit of trailer automatically: Synchronization isensured through the break lights wiring, data aretransported wirelessly. As trailers are usually not permanently powered, it ispossible that due to the frequency of wheel modulestransmission the tire pressure data for all the wheelscould be available after up to 15 minutes after the drivestart.In combination with WABCO-TCE (Trailer CentralElectronics) or EBS systems the information about thepressure could be transmitted into control unit throughstandardized bus connection CAN according to 11992.Future vehicles will be able to display the data from CANbus on multifunction display on the dashboard. If suchvehicles will not be available, data will be transferred tothe vehicle control IVTM unit wirelessly.Certificates Certificates for mounting and additional mounting ofIVTM are available, which significantly facilitate approvalof vehicle registration papers. Certificates are not part ofthis booklet, however in case of need they could be or-dered in WABCO or by Internet at www.wabco-auto.com:Ordering number 815 000 414 3 (D) / 815 000 415 3 (GB)Contents: ExpertiseTÜH ATC - TB 2002-108.00 andCertificate part of TÜH ATC - TB 2003-023.00 Ordering number 815 000 441 3 (D)Contents: Model verification 94/9/EGCE 0032, TÜV03 ATEXxxxxAplication range ex II 2G EEx ib IIC T4CAN busCAN busWheel modulesWireless connectionWireless connectionTCE/EBSIVTM ECUTrailer vehicleIVTM ECUVehicleIVTM displayIVTM ECUVehicleIVTM displayIVTM ECUTrailer vehicledata transfer wirelessconnection to TCE or EBS, wireless data transferIntegrated display Integrated displayIVTM ECUVehicle IVTM ECUVehicleCAN J1939CAN J1939Centralcomputer CentralcomputerWheel modulesISO 11992EBSISO 11992EBSconnection to TCE, data transfer by CAN busTCETrailerCentralElectronicsIVTM ECUTrailer vehicleIVTM ECUTrailer vehicleconnection to EBS,data transfer by CAN busSystem structure
10ConfigurationIVTM2.Possible vehicle configuration:Motor vehicle4 x 2 4 x 2 6 x 2 6 x 2 6 x 2 / 6 x 4 6 x 2 / 6 x 4 8 x 4Super-Single with with Super-SingleSteering-/ Steering-/lifting axleLoading axle Super-SingleTrailer vehicles1-axle 2-axles 3-axles 1-axle 2-axles 3-axlestrailer vehicle trailer vehicle trailer vehicle trailer vehicle trailer vehicle trailer vehiclewith double with double with doubletires tires tires2.1 Parts2.1.1 Wheel moduleWheel module is cast in plastic enclosure and iscomposed of: • pressure sensor 2-14 bars• electronic circuits for data procession• electronic circuits for data transmission• lithium-battery• 24 bit identification code Life cycle of the battery > is five years under normaloperating conditions.Wheel module is mounted by the standard nuts fromoutside to the shank to rim and is connected to valve.Result is:+easy installation, tire dismounting is not necessary+high quality of wireless data transfer+Modules remain in their place even during tirechange, i.e. the system does not have to be newlysetup.The wheel module must not disrupt wheel balance;therefore the counter weight is mounted on the oppositeside.Evaluation and data transfer is provided by 433 MHzsignal. If the pressure is constant, measured values aretransmitted every 15 minutes, if the pressure is changing,frequency of data transfers is faster.
11Special identification code of each wheel allows uniqueassignment of modules to particular wheels. Possibility ofreceptions of signals from another vehicle is excluded.Installation instructions:–Single tires (front axle, lifting axle, trailer axle, Super-Single): 1 wheel module + 1 weight–Double tires (rear axle):2 standard wheel modules for outer wheel.Please do not use plastic valve extensions, as theseparts are not designed for permanent pressure load. Useinstead brass extensions (i.e. Alligator V 153-MS-R,length 177 mm, type 332 903) or flexible valve extensionswith clamps.Remark:During hose installation ensure that wheel moduleconnection is not exposed to excessive mechanical loador excessive pressure.Do not use excessive force when tightening cup nut of tireinflation valve. Check connection seal with test spray.Replace damaged O rings of wheel module connection:4.47 x 1.78 EPDM 70Wheel module mounting on front and liftingaxleFor wheels 22.5 x 7.5, 22.5 x 8.25, 22.5 x 9 10 holes,pitch circle diameter 335 mm, ET 160Wheel with protective nut circle:L-Shape wheel module 960 730 001 0 with hose 960 730056 4. Install counter weight on opposite side.Wheel with axle cap:Wheel module 960 730 001 0 with module 960 730 0574. Counter weight 960 730 820 4 on opposite side.Wheel module installation on rear axle withdouble tiresFor wheels 22.5 x 7.5, 22.5 x 8.25, 22.5 x 9 10 holes,pitch circle diameter 335 mm, ET 1602 wheel modules 960 730 001 0 Hose for outer wheel: 960 730 054 4 (22.5 x 7.5, 22.5 x 8.25 und 22.5 x 9)Hose for inner wheel: 960 730 055 4 (22.5 x 7.5)respectively 960 730 058 4 (22.5 x 8.25 and 22.5 x 9)Counter weight is not needed.Configuration IVTM 2.
12ConfigurationIVTM2.Wheel module installation on axleof trailer with single tires and Super-SingleFor trailer wheels 22.5 x 11.75 ET 0 and 120; Super-Single wheels 22.5 x 11.75, 22.5 x 15, 22.5 x 17, 10 holespitch circle diameter 335 mmET 0ET 120Wheel module 960 730 001 0Hose for trailer wheel 22.5 x 11.75 ET 0: 960 730 055 4Hose for trailer wheel 22.5 x 11.75 ET 120: 960 730 053 4Hose for Super-Single wheel 22.5 x 11.75 and 22.5 x 15: 960 730 055 4Hose for Super-Single wheel 22.5 x 17: 960 730 052 4Install counter weight 960 730 820 4 on opposite side.2.1.2 Electronic control unit (ECU) Three different types of electronic control unit (ECU) areused:1. Motor vehicle (truck) 446 220 000 02. Attached vehicle (trailer) 446 220 001 03. Attached vehicle with TCE (trailer with TCE) 446 220 002 0Electronic units differ by HF signal structure andconnection to CAN bus (ID). Externally could berecognized by type label. Technical parametersOperational temperature range: - 40°C to + 80°CStorage temperature range: - 40°C to + 90°C max +100°C for 2hVoltage: 24V ± 8V DCProtection: IP 69K DIN 40050/IEC 529Torque: 15 Nm ± 10%Electronic control unit is mounted in central part of vehicleto chassis, so that perfect HF connection with all wheelmodules and connection between vehicle control unit andtrailer control unit is ensured. For control unitspreferentially use mounting system 960 730 350 4.Wireless connection is provided by aerial inside controlunit housing, which guarantees pressure signal receptionfrom all wheels even for most difficult operatingconditions.All changes from pre-programmed required values of tirepressure are immediately recognized by comparison withlimit pressure values and pressure changes.Incorrect values of tire pressures are displayedimmediately during start of the drive (if the unit ispermanently powered).
13The system may be extended up to 12 wheel modules forone control unit.Performance of the system may be checked by internaldiagnostics memory.2.1.3 DisplayAll necessary information of IVTM system is shown ondisplay. Connected to particular control unit by CAN bus. These data are among others shown on the display:–All tire pressures could be displayed by pressing thebutton (Manometer). Manual tire pressure checks arenot necessary.–The driver is informed by pilot lights and audio signals:• Yellow light indicates slightly lower pressure orsneaking pressure drop: In such case themaximum speed of vehicle should bedecreased and the tire pressure should bechecked on first occasion. • Red light indicates critical pressure drop: The vehicle should be stopped immediately.–Pressing button “?” displays additional informationabout position of defect tire and current pressure.red indicator lightSTOPbuttonManometer symbolbutton„?“yellow indicator lightTurtle symbolConfiguration IVTM 2.DiagnosesteckerCAN-HCAN-LMasse+24 VBremslichtZündungBremslicht (nur bei Anhängefahrzeug)außen innen61375Zwischensteckerim FahrzeugDIN-Bajonett-Stecker(7polig)Elektr. Anschlüsse +24 V, Masse, Zündungoffene Enden5A-Sicherung vorgeschrieben!4571Diagnosekabel446 300 348 05421SUB-D SteckerDiagnose-interface2354DIN bayonet plug (7 pin)Adaptor in the vehicleexternal insideCAN-HCAN-Lground+ 24 Vbrake light ignitionDiagnostic plugDiagnostic cable SUB-D plug diagnostic interfacebrake light (on trailers only)electrical connectors +24V, gnd, ignitionstripped ends5A fuse required
14ConfigurationMotor vehicle: Cable set 894 607 295 0IVTM2.12.2 Cabling
15ConfigurationTrailer: Cable set 449 674 051 0 IVTM 2.1
16ConfigurationTrailer with TCE: Cable set 449 302 000 0IVTM2.
173. Installation instructions3.1 General instructionsThese installation instructions are for experts, who haveknowledge about installation of electronic and electro-pneumatic equipment in vehicles.It describes on examples mounting of IVTM equipment inmotor vehicle and trailer.Respect general and special laws and regulations.Further respect drawings in appendix and particulartechnical parameters.Warning: Work on insufficiently secured vehicle mayresult in spontaneous movement of the vehicle. Safety instructionsRespect valid regulations for worksafety and instructions of vehiclemanufacturer.Before mounting make all necessarysafety precautions, for example securethe car against spontaneousmovement.Do not clean working clothes,workplace and tools by pressure air.Wheel nuts must be tightened withtorque specified by vehiclemanufacturer. Check tightness ofwheel nuts after 500 km.Installation instructions IVTM 3.3.2 OverviewAdditional mounting in motor vehicle/bus.1. Wheel modules are installed first.2. Installation of the control unit to vehicle chassis.3. Display installation.4. Mounting and connection of cable harness to thecontrol unit and display.5. Finally: IVTM system configuration with PC diagnostics.Additional mounting in trailer1. Wheel modules are installed first.2. Installation of the control unit to vehicle chassis. On three axles trailer preferentially in front of the first axleDiagnose-steckdoseKl. 15, 30, 31Bremslicht1 Radmodulpro ReifenElektronik(ECU)Displaybrake lightdiagnostic socketPin 15, 30, 31 control unit(ECU) 1 wheel module per tyre
18Installation instructionsIVTM3.3. Mounting and connection of cable harness to thecontrol unit.4. Finally: IVTM system configuration with PC diagnostics.3.3 Additional mounting in motor vehicle/busWheel modules are installed first.For the front wheelsalways one module withconnecting hose andcounter weight isnecessary.The vehicle needs not tobe lifted as only four wheelnuts are dismounted.First connect module hose to wheel module by insertingconnecting segment to wheel module opening. Securethe connection by turning the connecting segment. Aftermounting to wheel it could not be removed.Unscrew four nuts andremove protecting ring.Then mount the wheelmodule and counter weighton opposite side.Return protection ring andtighten wheel nuts.Connect hose to tire valve.For installation to rear axle of vehicle (in this example)two modules for double tires for each side with oneconnecting hose are needed.Warning:Do not use plastic valveextensionRequirements of thisconnection are fulfilled onlyby metal valve extension!First remove four wheelnuts depending onmounting position ofmodule (on opposite sides)as well.Diagnose-steckdose+24VGNDBremslichtElektronik(ECU)control unit(ECU)brake diagnostic socketlight
19Connect hoses to modulesand mount modules onprepared location (removednuts). Then mount backwheel nuts.Connect hoses to valves.3.3.1 Additional mounting in trailer.For additional mounting in trailer follow installationinstructions for motor vehicle/bus. Proceed according tothe same instructions.In accordance withmounting instructions forvehicle, first connect properhose to the module. Furtherin accordance withmounting instructions formotor vehicle, in case ofsingle front vehicle tiresinstall counter weight.After removing of four nutsinstall both parts and returnback the nuts.Finally connect hoses to tirevalves.3.4 Inflation pressureActual tire pressures and pressures stored in diagnosticsshould correspond with values given by vehicle or tiremanufacturer.Inflation pressure in tires should ideally be set up inambient drive temperature, i.e. strictly before drive on”cold” tires. In this manner you will be operating yourtires with optimum inflation pressure and achieveoptimum life cycle with minimum fuel consumption.It is common that for example during longer drive onhighway the tires are heated and their pressure rises.Such higher pressure should under no circumstances belowered to standard value. Inflation pressure of ”cold”tires would then be significantly lower.In following situations the inflation pressure set on coldtires is not correct:1. Inflation pressure was adjusted in very cold night andduring drive in day the tires are heating up. In this casethe tire pressure during day is too high.Example:Required inflation pressure: 8 barsAmbient temperatureduring tire inflation: -10°CAmbient temperatureduring day drive: +20°C☞Effective tire pressure during day rises above 9 bars.☞Inflation pressure during could night should thereforebe 7.1 bar.The tire pressure before day drive would in thisexample be 8 bars.2. Inflation pressure in cold weather is adjusted inheated workshop. In this example the tire inflationpressure is too low during drive.Example:Required inflation pressure: 8 barsAmbient temperatureduring tire inflation: +20°CAmbient temperature during drive: -10°C☞Effective tire pressure drops to approximately 7.1 bar.☞Inflation pressure for heated workshop should be setto 9 bars.Tire pressure would reach correct values outsidebefore the start of the drive.8 bars.Installation instructions IVTM 3.
20Installation instructionsIVTM3.3.5 Installation of electronic control unitto motor vehicleThe control unit should be installed on such place, whichis in same distance from all wheels. It is usually installedin the centre of vehicle. For trailer the control unit shouldbe installed ahead of front axle.Install electronic control unit in such position, thatlongitudinal axis of unit is parallel with longitudinal axis ofvehicle. Apart from that only installation ”terminals up” isallowed. This mounting position is necessary for optimumreception of signal.Use body shell clams for mounting of control unit 960 730350 4, because welding is not allowed on chassis ofvehicle.Body shell clamp 3.5.1 Cable harness installationMotor vehicleFor installation of electronic units into motor vehicle useprepared cable harnesses WABCO. IVTM parts areconnected by installed plug-in modules. Adjust location ofcables to individual vehicle situation. Respect relevantlaw regulations.Connection to battery (permanent, plus) and ignitionmust be fused 5A.Example of motor vehicle wiring withconnectors to brake lights, plus terminal ofBatt, chassis and ignition.connecting wiring-plugDiagnostics plugConnection to brake lightsWire tobrake lightConnection to terminals 15, 30 and 31 wire fromIVTM-ECUControl unit
21Break lights wiring should be connected only in case ofvehicles with trailers, i.e. for example not for buses.Connection provides synchronisation of signals fromtrailer to motor vehicle.Break lights cable could be connected for examplethrough the connector for brake pedal. Conditions ofparticular vehicle may and must be taken into account.Install display on favourable position on dashboard. Dueto audio signals it is not necessary to install displaydirectly in front of driver..Installation instructions IVTM 3.Chassis Driver cabinConnection to IVTM-ECUDiagnostics-PlugDiagnosticsWire446 300 348 0 DisplayWABCODiagnosticsInterface446 301 021 0 connectionfor PC: COMred: +24grey: ignition (with fuse 5A!)blue: groundyellow: brake light
22Installation instructionsIVTM3.If possible install IVTM diagnostics plug close to otherdiagnostics terminals of vehicle. 3.5.2 Cable harness installationTrailerFor installation of electronic units into motor vehicle useprepared cable harnesses WABCO. IVTM parts areconnected by installed plug-in modules. Adjust location ofcables to individual vehicle situation. Respect relevantlaw regulations.Wiring + 24V must be fused 5A.Install electronic control unit in such position, thatlongitudinal axis of unit is parallel with longitudinal axis ofvehicle. Apart from that only installation ”terminals up” isallowed. This mounting position is necessary for optimumreception of signal.Use body shell clams for mounting of control unit 960 730350 4, because welding is not allowed on chassis ofvehicle.
23Examples of Vario C wiring:Installation instructions IVTM 3.+ 24 VoltMasseVario C wiringwithout additionalelectronicsFor connection in Vario C housingare needed auxiliary threadconnections :brake light**)+ 24 VoltMasseVario C wiringwith auxiliary electronicsECASbrake lightwith power module 446 107 530 0**)**) Remark:For installation of connecting cable IVTM in trailerWABCO is recommending cable socket AK 192from:Apparatebau Kirchheim-Teck GmbH & Co.Alleenstraße 36D 73230 Kirchheim-Teck
24Installation instructionsIVTM3.Situation in the beginning of 2003Prototypes SeriesNecessarypartsfor 4x2-Necessarypartsfor 6x2-NecessaryPartsfor 6x2-Swivel busNecessaryPartsfor 3 axlestrailerNecessaryPartsfor 2 axlesTrailer4x2Super Singletruck bus truck bus double tires SuperSingle ET 120 ET 0 ET 120 ET 0 truck busTruck ECU 884 906 939 0 446 220 000 0 1 1 1 1 1 1 1 1Trailer ECU 884 906 940 0 446 220 001 0 1 1 1Display 884 650 161 0 446 221 000 0 1 1 1 1 1 1 1 1Truck cable 894 607 295 0 1 1 1 1 1 1 1Trailer cable 449 674 051 0 1 1 1 1wheel moduleStandard 884 623 605 0 960 730 001 0 4 4 4 4 8 4 6 6 4 4 2 2wheel moduleL-Shape (front axle) 884 014 985 0 960 730 007 0 2 2 4 4 2 2 2 2Counter weight 960 730 820 4 2 2 4 4 2 6 6 6 4 4 4 4L-shape hose 960 730 056 4 2 2 4 4 2 2 2 2External hose for rear axle 960 730 054 4 2222 4Internal hose for rear axle 960 730 058 4 2 2Single tire hose 960 730 052 4 2ET 120 trailer hose 960 730 053 4 6 4ET 0 trailer hose external hose for bus rear axleSuper Single for bus 960 730 055 4 2 2 4 4 6 4 2
25Review of connecting hoses:Super Single 22.5 x 17 960 730 052 4Trailer 22.5 x 11.75 ET 120 960 730 053 4Double tires – external 22.5 x 7.5 ET 16022.5 x 8.25 ET 16022.5 x 9 ET 160 960 730 054 4Trailer 22.5 x 11.75 ET 0Double tires – internal 22.5 x 7.5 ET 160Super Single 22.5 x 11.7522.5 x 15960 730 055 4Independent L-shape wheel 22.5 x 7.5with protecting ring 22.5 x 8.25 ET 16022.5 x 9 960 730 056 4Independent wheel 22.5 x 7.5 with axle cap 22.5 x 8.25 ET 16022.5 x 9 960 730 057 4Double tires – internal 22.5 x 8.25 ET 16022.5 x 9 960 730 058 4Installation instructions IVTM 3.
264. Diagnostics4.1 System configurationNewly installed IVTM system is configured, i.e. set up, byPC diagnostics of IVTM system.Parts necessary for configuration:DiagnosticsIVTM4.Diagnostics connecting cable: 446 300 348 0Diagnostics interface with cable: 446 301 021 0Diagnostics software: 446 301 730 0Remark: Diagnostic could be done only with special diagnostics cable for IVTM, other diagnostics cablesWABCO (i.e. cables for EBS, ECAS etc.) could not be used.4.2 Diagnostic structure
274.3 OPERATING INSTRUCTIONSThe system consists of one electronic unit, so calledelectronic control unit, which receives wirelessinformation from wheel modules. Wheel modules arepermanently connected by hoses to tire valves. Pressureinformation is processed by algorithms stored in controlunit.Data are relayed by CAN bus to display. Display unitconsists of one display, two indicators, one buzzer andtwo buttons.Warnings of different levels are signalised; importancecould be recognised by colour of indicator light and audiosignal:–Red light (STOP) and 1 minute long audio signalindicates serious defect; the vehicle must be stoppedimmediately (possible threat to lives and vehicle).–Yellow light (turtle) and 10 minutes long audio signalindicates smaller defect; the vehicle should be sloweddown and lower pressure adjusted.Defects found by IVTM are stored in electronic memoryfor diagnostic purposes.4.3.1 Display operationCable harness is connected to display by 4-pole plug. Itis powered only if the ignition is on.After the ignition is switched on, internal check procedureis performed, when all internal functions are tested: allsymbols are displayed for one second, all pilot lights andaudio signals are switched on; this procedure is repeatedtwice.If the tire pressures are not exceeding specified values,following data are displayed after initialisation:Two buttons on front panel are used to control differentfunctions.Left button with symbol of manometer displays vehicletire pressure.Right button with question mark symbol shows detecteddefects. If pressed longer, the error messages aredeleted (after correction of tire pressure).4.4 DIFFERENT VALUES ON DISPLAY4.4.1. Normal valuesAfter initialisation the top view of vehicle is displayed(driving direction upward) for 12 seconds. For example4x2 truck is shown like:If the trailer with IVTM system is connected to motorvehicle, both vehicles are shown alternatively in onesecond intervals for 12 seconds.Fig. 1hmnkmpsibarpsibar psibarIVTM+Fig. 3IVTMDiagnostics IVTM 4.
28Example: If the three axles trailer is connected to shownvehicle, Fig. 3 is changed to:The display shows IVTM logo (Fig. 2) and stays withoutchange till the button is pressed or the defect is found.If the defect is found on one of the vehicle wheels, symbolof particular wheel is blinking in corresponding image(vehicle or trailer). Depending on seriousness of defect,control lights and audio signals are switched on.If the defect is found on more than one wheel of vehicleor trailer, symbols of all defect wheels are blinking.If the defects are found in both vehicle and trailer wheels,images of both vehicles are changing each ten seconds,and all defect wheels are blinking.In all cases the indicator light and audio signalcorresponding with the worst defect is switched on.If the defect is found on one tire of double tires, thesystem activates error message for both tires.4.4.2 Pressure displayThis manometer function shows the tire pressuresmeasured by IVTM system, and completely replacesmanual pressure measurement through tire valves.The values are displayed after pressing left button”manometer” in normal mode.The axle, whose pressures are displayed, is marked.Tire pressures on following axle could be displayed byrepeatedly pressing button ”manometer”.If one of the axles is equipped with double tires, individualpressures are displayed in sequence. Display of pressure in outer tires of double tires:The pressure of inner tires could be displayed byrepeatedly pressing button ”manometer”:If the trailer is connected the pressure in the tires of traileris displayed in the same way.After display of tire pressure in last axle and pressing thebutton ”manometer” the display switches to normalmode.Fig. 4IVTMFig. 5IVTMFig. 6IVTMFig. 7bar barIVTMFig. 8bar barIVTMFig. 9barIVTMbarDiagnosticsIVTM4.1
29Diagnostics IVTM 4.If the button ”manometer” is not pressed for 20 seconds,the display also switches to normal display mode.4.4.3 Error messagesAll defects found by system could be displayed in order oftheir importance.This function could be activated by pressing button”question mark - ?”.Symbol of defect wheel blinks in particular vehicle image(both tires in case of double tires), symbol of detecteddefect and particular indicator are lighted.By successive pressing the button ”?” it is possible todisplay all defects. After another press of button the useris asked to reset data (see 4.4.2).If button ”pump” is not pressed for 20 seconds, displayswitches to normal mode.If no defect is found the system does not react to pressingbutton ”?”.Different types of defects, which could be found by IVTMsystem, are described below. Let us start with the mostdangerous.4.4.3.1 Extremely low pressureDisplay informs about position and current pressure ofdefect tire. The symbols of wrench and red light aredisplayed.Action:Drive should immediately stop the vehicle and check thepressure drop. Generally, it is necessary to change thetire because of the damage.4.4.3.2 Extremely high pressureDisplay informs about position and current pressure ofdefect tire. Yellow indicator is on.Action:Driver should slow down the vehicle to prevent burstingof tire. The cause of high pressure should be found out(for example heated brake).4.4.3.3 Sneaking pressure dropDisplay informs about position and current pressure oftire, where the drop was detected. The symbols ofwrench and soft tire are displayed. Yellow indicator is on.Action:Driver should slow down the vehicle and on first occasionfind out the cause of pressure drop, or change the tire.4.4.3.4 Low pressureDisplay informs about position and current pressure ofdefect tire. Symbol ”pump” is displayed. Yellow indicatoris on.Fig. 10IVTMbarFig. 11IVTMbarFig. 12IVTMbarFig. 13IVTMbar
30Action:Drive should slow down the vehicle and on first occasionadjust the tire pressure.4.4.3.5 High pressureThis defect could be found only for cold tires, i.e. if thevehicle stand for more than four hours with ignitionswitched off.In this case the defect is displayed two minutes after theignition is switched on.Display informs about position and current pressure ofdefect tire. Symbol ”pump” is displayed. Yellow indicatoris on.Action:The pressure in tires should be adjusted before startingthe engine.4.4.4 Reset This function allows resetting all information about tirepressure and possible defects of IVTM system. Reset is necessary for example after adjustment of thetire pressure, because otherwise the system may reportfalse defect. Repeatedly press right button ”?”, until alldefects of vehicle are displayed. All wheels are lighted.This image of vehicle is displayed for five seconds. Afterthat, if IVTM system recognizes trailer, it displays imageof trailer for another five seconds.If the image of vehicle is displayed and you press thebutton ”pump” for 5 seconds, the control unit of thisvehicle is reset.Switching off of the display confirms successful reset.If the unit is not reset, the display changes to normaloperating mode.As all data about defects and tire pressures of particularvehicle are deleted, new information about tire pressuremay be displayed after up to 15 minutes.4.5 SYSTEM ERROR DISPLAY4.5.1 Connection of the wheel module is interruptedThis error message is shown when there are no datareceived from one of the wheel modules for more thanone hour.Display shows position of wheel, which is not transmittingdata. Two lines are displayed instead of pressure value.IVTM logo is crossed.Action:–Optimize mounting position of control unit–ECU and/or wheel module is excessively dirty If this error shows after several years of operation ofwheel module, it is likely, that the module battery isdischarged. Change the wheel module (it is necessary toperform new setup using system diagnostics).Fig. 14IVTMbarFig. 16IVTMDiagnosticsIVTM4.
31Diagnostics IVTM 4.4.5.2 System errorThis error message is displayed when IVTM functions orregular tire pressure monitoring fails.All wheels are blinking on display. IVTM logo is crossed.In certain cases the type of vehicle equipped with IVTM isnot recognized. In this case following data are displayed:Action:System diagnostics, check of the control unit wiring4.5.3 Interrupted connection between controlunit and displayIf the connection between IVTM and display isinterrupted, following information is shown and white lineon IVTM logo is flashing.Action:–Check plugs: ECU, connecting plug–Check connection to harness 30–Plugs from harnesses 15 and 30 could have beeninterchanged (display is on even after ignition is switched off)–Check cable connections–DiagnosticsFig. 17IVTMFig. 18IVTMFig. 19IVTM

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