WABCO WM730-0 Integrated Vehicle Tire Monitoring Wheel Module User Manual IVTM Integrated Vehicle Tire Pressure Monitoring
WABCO GmbH Integrated Vehicle Tire Monitoring Wheel Module IVTM Integrated Vehicle Tire Pressure Monitoring
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Users Manual
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| Document ID | 472209 |
| Application ID | Uh6jkDv2p+if2wLWJNvZZg== |
| Document Description | Users Manual |
| Short Term Confidential | No |
| Permanent Confidential | No |
| Supercede | No |
| Document Type | User Manual |
| Display Format | Adobe Acrobat PDF - pdf |
| Filesize | 71.94kB (899253 bits) |
| Date Submitted | 2004-09-24 00:00:00 |
| Date Available | 2004-09-24 00:00:00 |
| Creation Date | 2004-04-29 07:29:55 |
| Producing Software | Acrobat Distiller 5.0 (Windows) |
| Document Lastmod | 2004-09-24 08:36:30 |
| Document Title | IVTM Integrated Vehicle Tire Pressure Monitoring |
| Document Creator | AdobePS5.dll Version 5.2.2 |
| Document Author: | WABCO |
Integrated Vehicle Tire Pressure Monitoring Vehicle tire pressure monitoring system System functions System configuration Instructions for installation and diagnostics 1st. edition 815 000 452 3 8150004523 Revisions of this document are not set up. New versions could be found in INFORM website www.wabco-auto.com Ó Copyright WABCO 2004 Vehicle Control Systems An American Standard Company 8150003993 Changes are reserved Version 001/04.03(en) Wabcodruck 815 000 452 3 FCC Notice This 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 is subject to the following two conditions: (1) this device may not cause harmful interference, and (2) this device must accept any interference received, including interference that may cause undesired operation. Changes or modifications not expressly approved by the party responsible for the compliance could void the user's authority to operate the equipment. Contents 1. System functions 1.1 System structure 1.1.1 Example of installation in the bus 1.1.2 Example of installation in the trailer 2. Configuration 2.1 Components 2.1.1 Wheel module 2.1.2 Electronic control unit (ECU) 2.1.3 Display 2.2 Wiring 10 10 12 13 14 3. Installation instructions 3.1 General instructions 3.2 Overview 3.3 Additional mounting into vehicle/bus 3.3.1 Additional mounting into trailer 3.4 Inflation pressure 3.5 Installation of the control unit in vehicle 3.5.1 Installation of the wiring harness in vehicle 3.5.2 Installation of the wiring harness in trailer 17 17 17 18 19 19 20 20 22 4. Diagnostics 4.1 System configuration 4.2 Diagnostics structure 4.3 Instructions for use 4.3.1 Display instructions 4.4 Various information on display 4.4.1 Normal data 4.4.2 Pressure data 4.4.3 Error messages 4.4.4 Display reset 4.5 System error signalization 4.5.1 Interrupted connection to the wheel module 4.5.2 System failure 4.5.3 Interrupted connection between control unit and display 26 26 26 27 27 27 27 28 29 30 31 31 31 31 System functions 1. 1. IVTM System functions IVTMstands for Integrated Vehicle Tire Pressure Monitoring. It is the tire pressure monitoring system, which is installed in the vehicle. IVTM continuously monitors the pressure in all tires. This monitoring is performed by the pressure sensors in all tires, which relays information to the display in the cabin and warns driver about critical pressure drop. IVTM makes transport safer and more efficient, because more than 80 % of tire damage could be recognized before serious damage occurs, which requires repair. IVTM thus cuts down operational costs, as continually maintained optimized pressure in all tires results in minimal fuel consumption and extension of service life of tires. Let us present some information: improper maintenance of tires of commercial vehicles are more than 10 millions of Euro in Germany. Lot of vehicle users unfortunately tend to overlook this important factor of operational costs. By selecting correct tires and proper maintenance it is possible to save up to 2500.- €per vehicle for one year. The unnecessary expanses are further increased by widely spread carelessness of driving with under-inflated tires. Tires with 20 % lower pressure are no exception in everyday life. This underinflation reduces service life of tires by 20 % and unnecessarily increases fuel consumption. In order to minimize these costs WABCO company designed new system IVTM, which also increases traffic safety. Tire manufacturers estimate that total losses caused by Main reasons for brakedowns at commercial vehicles are: Service / information 3% Structure 3% Chassis 2% Operating supplies 1% Salvage operation 4% Drive line 4% Engine 36% Brakes 4% Electric 17% Tyres 26% The mileage of tyres significantly depends on the tyre pressure... Source: Service 24 GmbH & Co. KG 66000 brakedown missions for trucks and busses in 1999 and fuel consumption also depends on the tyre pressure. tyre pressure too low tyre pressure too high Fuel consumption Service life reduction Tire pressure tyre pressure too low tyre pressure too high 1. IVTM System functions 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 rolling resistance • smaller tire wear owing to lower deformation losses => 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 of rupture => higher vehicle load. tyre pressure too low IVTM warns driver about sneak pressure drop early, i.e. before the tire could burst. IVTM enhances safety of passengers, driver, vehicle and traffic : • • The driver may react to sneak pressure drop early and prevent up to 85 % of tire bursts. Additionally, properly maintained pressure in tires ensures safe driving properties of vehicle and short braking distance. IVTM ensures travel efficiency: Which types available? of pressure monitoring Permanent tire pressure monitoring during driving could be performed in several ways: – direct tire pressure measurement permanent on-line pressure monitoring is possible. Extremely precise and effective, very expensive. – direct tire pressure measurement with limit value monitoring not so precise. – indirect tire pressure measurement moderately expansive, not nearly as precise and reliable. The pressure is calculated from drive slip, measured by ABS turning sensors. WABCO IVTM uses direct pressure measurement and in comparison with systems using ABS presents these advantages: 1. pressure monitoring during parking or before driving start; diagnostics memory 2. able to distinguish uniform diffusion losses 3. fast detection of pressure drop, reaction time in order of several seconds. 4. display of current tire pressure 5. higher precision • Prevents unnecessary delays and idle time. 6. identification of leaking tire • No backup vehicles/emergency actions needed • Prevents loss of confidence from unsatisfied customers and resulting drop of turnover. 7. measurement is not affected by driving on low quality road 8. measurement is not affected by uneven vehicle loading records about tire pressure (rise) Air pressure in bar VEHICLE rear axle inside TRAILER 3 axles VEHICLE front axle The range of tire pressure oscillation for utility vehicles is far higher then for passenger car. are System functions This requires using sophisticated evaluation algorithm, instead of using simple identification of limit value. exact wheel identification for vehicles with more than 10 wheels or with double wheels • high efficiency of wireless data transport • pressure range 2 - 14 bars 1.1 System architecture 1. • Identification of tire pressure fluctuation based on load and tire wear. This function requires complicated "evaluative algorithm". • Wheel modules must be mounted flexible with respect to different types and locations of tire valves on rims, different rim designs and frequent wheel changes and must allow easy exchange. Other requirements for tire pressure monitoring systems of utility vehicles: • IVTM IVTM system Trailer IVTM system Vehicle CAN bus CAN bus or HF wireless data transfer from trailer control unit to vehicle control unit Display: « Standalone » or integrated Control unit Vehicle WABCO system is based on one electronic circuit 446 220 00x 0, so called control unit, which receives wireless data transmitted by wheel modules. Wheel modules 960 730 00x 0 are connected to the wheel valves by hoses. Pressure information is processed by algorithms stored in control unit. The information is sent through CAN bus to display unit 446 221 000 0. Display unit consists of one display, two indicators, one buzzer and two buttons. Control unit Trailer Wheel module fro wheel • Red light and 1 minute long audio signal indicates serious defect; the vehicle must be stopped immediately (possible threat to lives and vehicle). • Yellow light and 10 minutes long audio signal indicates smaller defect; the vehicle should be slowed down and lower pressure adjusted. Defects found by IVTM system are stored in electronic memory (EEPROM) for diagnostic purposes. Warning massages of different levels are displayed; indicator colour and type of audio signal shows seriousness of the problem: 1. IVTM System functions 1.1.1 Example of installation in the bus: wheel module Driver display electronic control unit (ECU) 1.1.2 Example of installation in the trailer: Display Control unit Vehicle Control unit Trailer wheel module (one module per one tire) Configuration 2. 2. IVTM Configuration In order to display tire pressure and trailer warnings to driver during driving it is in general case necessary to install IVTM to both parts of vehicle, i.e. one control unit to trailer and one unit to motor vehicle. Any vehicle equipped with IVTM could be connected to any trailer equipped with IVTM. Control unit of vehicle identifies control unit of trailer automatically: Synchronization is ensured through the break lights wiring, data are transported wirelessly. As trailers are usually not permanently powered, it is possible that due to the frequency of wheel modules transmission the tire pressure data for all the wheels could be available after up to 15 minutes after the drive start. In combination with WABCO-TCE (Trailer Central Electronics) or EBS systems the information about the pressure could be transmitted into control unit through standardized bus connection CAN according to 11992. Future vehicles will be able to display the data from CAN bus on multifunction display on the dashboard. If such vehicles will not be available, data will be transferred to the vehicle control IVTM unit wirelessly. Certificates Certificates for mounting and additional mounting of IVTM are available, which significantly facilitate approval of vehicle registration papers. Certificates are not part of this booklet, however in case of need they could be ordered in WABCO or by Internet at www.wabco-auto.com Ordering number 815 000 414 3 (D) / 815 000 415 3 (GB) Contents: Expertise TÜH ATC - TB 2002-108.00 and Certificate part of TÜH ATC - TB 2003-023.00 Ordering number 815 000 441 3 (D) Contents: Model verification 94/9/EG CE 0032, TÜV03 ATEXxxxx Aplication range ex II 2G EEx ib IIC T4 System structure Central computer IVTM ECU Vehicle EBS TCE/ EBS IVTM ECU Trailer vehicle connection to TCE or EBS, wireless data transfer ISO 11992 Wheel modules Wireless connection Wireless connection data transfer wireless Central computer IVTM ECU Vehicle Wheel modules IVTM ECU Trailer vehicle CAN J1939 CAN J1939 IVTM ECU Vehicle Integrated display TCE Trailer Central Electronics IVTM ECU Trailer vehicle connection to TCE, data transfer by CAN bus ISO 11992 IVTM ECU Vehicle CAN bus CAN bus Integrated display IVTM display IVTM display EBS IVTM ECU Trailer vehicle connection to EBS, data transfer by CAN bus 2. IVTM Configuration Possible vehicle configuration: Motor vehicle 4x2 4x2 Super-Single 6x2 with Steering-/ Loading axle 6x2 with Steering-/lifting axle Super-Single 6x2/6x4 6x2/6x4 Super-Single 8x4 Trailer vehicles 1-axle trailer vehicle 2.1 2-axles trailer vehicle 3-axles trailer vehicle Parts 2.1.1 Wheel module 1-axle trailer vehicle with double tires 2-axles trailer vehicle with double tires 3-axles trailer vehicle with double tires Life cycle of the battery > is five years under normal operating conditions. Wheel module is mounted by the standard nuts from outside 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 tire change, i.e. the system does not have to be newly setup. Wheel module is cast in plastic enclosure and is composed of: • • • • • 10 pressure sensor 2-14 bars electronic circuits for data procession electronic circuits for data transmission lithium-battery 24 bit identification code The wheel module must not disrupt wheel balance; therefore the counter weight is mounted on the opposite side. Evaluation and data transfer is provided by 433 MHz signal. If the pressure is constant, measured values are transmitted every 15 minutes, if the pressure is changing, frequency of data transfers is faster. Configuration IVTM 2. Special identification code of each wheel allows unique assignment of modules to particular wheels. Possibility of receptions of signals from another vehicle is excluded. Wheel module mounting on front and lifting axle Installation instructions: For wheels 22.5 x 7.5, 22.5 x 8.25, 22.5 x 9 10 holes, pitch circle diameter 335 mm, ET 160 – Single tires (front axle, lifting axle, trailer axle, Super-Single): 1 wheel module + 1 weight – Double tires (rear axle): Wheel with protective nut circle: L-Shape wheel module 960 730 001 0 with hose 960 730 056 4. Install counter weight on opposite side. Wheel with axle cap: Wheel module 960 730 001 0 with module 960 730 057 4. Counter weight 960 730 820 4 on opposite side. Wheel module installation on rear axle with double tires 2 standard wheel modules for outer wheel. Please do not use plastic valve extensions, as these parts are not designed for permanent pressure load. Use instead brass extensions (i.e. Alligator V 153-MS-R, length 177 mm, type 332 903) or flexible valve extensions with clamps. For wheels 22.5 x 7.5, 22.5 x 8.25, 22.5 x 9 10 holes, pitch circle diameter 335 mm, ET 160 Remark: During hose installation ensure that wheel module connection is not exposed to excessive mechanical load or excessive pressure. Do not use excessive force when tightening cup nut of tire inflation valve. Check connection seal with test spray. Replace damaged O rings of wheel module connection: 4.47 x 1.78 EPDM 70 2 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. 11 2. IVTM Configuration Wheel module installation on axle of trailer with single tires and Super-Single 2.1.2 Electronic control unit (ECU) For trailer wheels 22.5 x 11.75 ET 0 and 120; SuperSingle wheels 22.5 x 11.75, 22.5 x 15, 22.5 x 17, 10 holes pitch circle diameter 335 mm Three different types of electronic control unit (ECU) are used: ET 0 1. Motor vehicle (truck) 446 220 000 0 2. Attached vehicle (trailer) 446 220 001 0 3. Attached vehicle with TCE (trailer with TCE) 446 220 002 0 Electronic units differ by HF signal structure and connection to CAN bus (ID). Externally could be recognized by type label. Technical parameters Operational temperature range: - 40°C to + 80°C Storage temperature range: - 40°C to + 90°C max +100°C for 2h Voltage: 24V ± 8V DC Protection: IP 69K DIN 40050/IEC 529 Torque: 15 Nm ± 10% ET 120 Wheel module 960 730 001 0 Hose for trailer wheel 22.5 x 11.75 ET 0: 960 730 055 4 Hose for trailer wheel 22.5 x 11.75 ET 120: 960 730 053 4 Hose for Super-Single wheel 22.5 x 11.75 and 22.5 x 15: 960 730 055 4 Hose for Super-Single wheel 22.5 x 17: 960 730 052 4 Install counter weight 960 730 820 4 on opposite side. Electronic control unit is mounted in central part of vehicle to chassis, so that perfect HF connection with all wheel modules and connection between vehicle control unit and trailer control unit is ensured. For control units preferentially use mounting system 960 730 350 4. Wireless connection is provided by aerial inside control unit housing, which guarantees pressure signal reception from all wheels even for most difficult operating conditions. All changes from pre-programmed required values of tire pressure are immediately recognized by comparison with limit pressure values and pressure changes. Incorrect values of tire pressures are displayed immediately during start of the drive (if the unit is permanently powered). 12 Configuration 2. IVTM The system may be extended up to 12 wheel modules for one control unit. All necessary information of IVTM system is shown on display. Connected to particular control unit by CAN bus. Performance of the system may be checked by internal diagnostics memory. These data are among others shown on the display: – All tire pressures could be displayed by pressing the button (Manometer). Manual tire pressure checks are not necessary. 2.1.3 Display – The driver is informed by pilot lights and audio signals: • Yellow light indicates slightly lower pressure or sneaking pressure drop: In such case the maximum speed of vehicle should be decreased and the tire pressure should be checked on first occasion. • Red light indicates critical pressure drop: The vehicle should be stopped immediately. – Pressing button “?” displays additional information about position of defect tire and current pressure. red indicator light STOP button Manometer symbol button yellow indicator light „?“ Turtle symbol Diagnosestecker Diagnostic plug DIN-BajonettDIN bayonet Stecker plug (7 pin) (7polig) Adaptor in the Zwischenstecker vehicle im Fahrzeug 2 3 5 4 Diagnostic cable Diagnosekabel 446 300 348 0 CAN-H CAN-H CAN-L CAN-L ground Masse 7 + 24 V +24 V 5 brake light Bremslicht SUB-DStecker plug SUB-D diagnostic Diagnoseinterface interface ignition Zündung external außen inside innen brake light trailers only) Bremslicht (nur (on bei Anhängefahrzeug) Elektr. Anschlüsse +24 V, Masse, Zündung electrical connectors +24V, gnd, ignition offene Enden stripped ends 5A-Sicherung vorgeschrieben! 5A fuse required 13 2. 2.2 14 IVTM Configuration Motor vehicle: Cable set 894 607 295 0 Cabling Configuration Trailer: Cable set 449 674 051 0 IVTM 2. 15 2. 16 IVTM Configuration Trailer with TCE: Cable set 449 302 000 0 Installation instructions 3. 3.1 3. IVTM Installation instructions General instructions These installation instructions are for experts, who have knowledge about installation of electronic and electropneumatic equipment in vehicles. It describes on examples mounting of IVTM equipment in motor vehicle and trailer. Respect general and special laws and regulations. Further respect drawings in appendix and particular technical parameters. Warning: Work on insufficiently secured vehicle may result in spontaneous movement of the vehicle. Safety instructions Respect valid regulations for work safety and instructions of vehicle manufacturer. Before mounting make all necessary safety precautions, for example secure the car against spontaneous movement. Do not clean working clothes, workplace and tools by pressure air. Additional 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 the control unit and display. 5. Finally: IVTM system configuration with PC diagnostics. socket Overview Pin15, 15, Kl. 30,30, 31 31 3.2 brake light Bremslicht Diagnosediagnostic steckdose Wheel nuts must be tightened with torque specified by vehicle manufacturer. Check tightness of wheel nuts after 500 km. Display Elektronik control unit (ECU) (ECU) 11wheel module Radmodul per protyre Reifen Additional mounting in trailer 1. Wheel modules are installed first. 2. Installation of the control unit to vehicle chassis. On three axles trailer preferentially in front of the first axle 17 Installation instructions 3. Mounting and connection of cable harness to the control unit. 4. Finally: IVTM system configuration with PC diagnostics. light IVTM +24V GND brake Bremslicht 3. diagnostic Diagnosesocket steckdose 3.3 Additional mounting in motor vehicle/ bus Wheel modules are installed first. Elektronik control unit (ECU) (ECU) For the front wheels always one module with connecting hose and counter weight is necessary. The vehicle needs not to be lifted as only four wheel nuts are dismounted. First connect module hose to wheel module by inserting connecting segment to wheel module opening. Secure the connection by turning the connecting segment. After mounting to wheel it could not be removed. Unscrew four nuts and remove protecting ring. Then mount the wheel module and counter weight on opposite side. Return protection ring and tighten wheel nuts. Connect hose to tire valve. 18 For installation to rear axle of vehicle (in this example) two modules for double tires for each side with one connecting hose are needed. Warning: Do not use plastic valve extension Requirements of this connection are fulfilled only by metal valve extension! First remove four wheel nuts depending on mounting position of module (on opposite sides) as well. Installation instructions Connect hoses to modules and mount modules on prepared location (removed nuts). Then mount back wheel nuts. Connect hoses to valves. 3.4 3. IVTM Inflation pressure Actual tire pressures and pressures stored in diagnostics should correspond with values given by vehicle or tire manufacturer. Inflation pressure in tires should ideally be set up in ambient drive temperature, i.e. strictly before drive on ”cold” tires. In this manner you will be operating your tires with optimum inflation pressure and achieve optimum life cycle with minimum fuel consumption. It is common that for example during longer drive on highway the tires are heated and their pressure rises. Such higher pressure should under no circumstances be lowered to standard value. Inflation pressure of ”cold” tires would then be significantly lower. 3.3.1 Additional mounting in trailer. For additional mounting in trailer follow installation instructions for motor vehicle/bus. Proceed according to the same instructions. In accordance with mounting instructions for vehicle, first connect proper hose to the module. Further in accordance with mounting instructions for motor vehicle, in case of single front vehicle tires install counter weight. In following situations the inflation pressure set on cold tires is not correct: 1. Inflation pressure was adjusted in very cold night and during drive in day the tires are heating up. In this case the tire pressure during day is too high. Example: Required inflation pressure: 8 bars Ambient temperature during tire inflation: Ambient temperature during day drive: -10°C +20°C ☞ Effective tire pressure during day rises above 9 bars. ☞ Inflation pressure during could night should therefore After removing of four nuts install both parts and return back the nuts. be 7.1 bar. The tire pressure before day drive would in this example be 8 bars. 2. Inflation pressure in cold weather is adjusted in heated workshop. In this example the tire inflation pressure is too low during drive. Finally connect hoses to tire valves. Example: Required inflation pressure: 8 bars Ambient temperature during tire inflation: Ambient temperature during drive: +20°C -10°C ☞ Effective tire pressure drops to approximately 7.1 bar. ☞ Inflation pressure for heated workshop should be set to 9 bars. Tire pressure would reach correct values outside before the start of the drive. 8 bars. 19 3. 3.5 IVTM Installation instructions Installation of electronic control unit to motor vehicle The control unit should be installed on such place, which is in same distance from all wheels. It is usually installed in the centre of vehicle. For trailer the control unit should be installed ahead of front axle. Install electronic control unit in such position, that longitudinal axis of unit is parallel with longitudinal axis of vehicle. Apart from that only installation ”terminals up” is allowed. This mounting position is necessary for optimum reception of signal. Use body shell clams for mounting of control unit 960 730 350 4, because welding is not allowed on chassis of vehicle. Body shell clamp Control unit 3.5.1 Cable harness installation Motor vehicle For installation of electronic units into motor vehicle use prepared cable harnesses WABCO. IVTM parts are connected by installed plug-in modules. Adjust location of cables to individual vehicle situation. Respect relevant law regulations. connecting wiring-plug Connection to battery (permanent, plus) and ignition must be fused 5A. Connection to brake lights Wire to brake light Diagnostics plug Connection to terminals 15, 30 and 31 20 wire from IVTM-ECU Example of motor vehicle wiring with connectors to brake lights, plus terminal of Batt, chassis and ignition. Installation instructions 3. IVTM Display Chassis Driver cabin DiagnosticsPlug WABCO Diagnostics Interface 446 301 021 0 Diagnostics Wire 446 300 348 0 connection for PC: COM Connection to IVTM-ECU red: +24 grey: ignition (with fuse 5A!) blue: ground yellow: brake light Break lights wiring should be connected only in case of vehicles with trailers, i.e. for example not for buses. Connection provides synchronisation of signals from trailer to motor vehicle. Install display on favourable position on dashboard. Due to audio signals it is not necessary to install display directly in front of driver. Break lights cable could be connected for example through the connector for brake pedal. Conditions of particular vehicle may and must be taken into account. 21 3. IVTM Installation instructions If possible install IVTM diagnostics plug close to other diagnostics terminals of vehicle. 3.5.2 Cable harness installation Trailer For installation of electronic units into motor vehicle use prepared cable harnesses WABCO. IVTM parts are connected by installed plug-in modules. Adjust location of cables to individual vehicle situation. Respect relevant law regulations. Wiring + 24V must be fused 5A. Install electronic control unit in such position, that longitudinal axis of unit is parallel with longitudinal axis of vehicle. Apart from that only installation ”terminals up” is allowed. This mounting position is necessary for optimum reception of signal. Use body shell clams for mounting of control unit 960 730 350 4, because welding is not allowed on chassis of vehicle. 22 Installation instructions IVTM 3. Examples of Vario C wiring: **) + 24 Volt Masse Vario C wiring without additional electronics For connection in Vario C housing are needed auxiliary thread connections : brake light **) + 24 Volt Vario C wiring with auxiliary electronics ECAS Masse brake light with power module 446 107 530 0 **) Remark: For installation of connecting cable IVTM in trailer WABCO is recommending cable socket AK 192 from: Apparatebau Kirchheim-Teck GmbH & Co. Alleenstraße 36 D 73230 Kirchheim-Teck 23 24 960 730 820 4 960 730 056 4 960 730 054 4 960 730 058 4 960 730 052 4 960 730 053 4 960 730 055 4 L-shape hose External hose for rear axle Internal hose for rear axle Single tire hose ET 120 trailer hose ET 0 trailer hose external hose for bus rear axle Super Single for bus 884 014 985 0 960 730 007 0 wheel module L-Shape (front axle) Counter weight 884 623 605 0 960 730 001 0 wheel module Standard 449 674 051 0 Trailer cable 884 650 161 0 446 221 000 0 Display 894 607 295 0 884 906 940 0 446 220 001 0 Trailer ECU truck bus for 4x2- Necessary parts truck bus for 6x2- Necessary parts double tires ET 0 Necessary Parts for 3 axles trailer Super ET 120 Single Necessary Parts for 6x2Swivel bus ET 120 ET 0 Necessary Parts for 2 axles Trailer truck bus 4x2 Super Single IVTM Truck cable 884 906 939 0 446 220 000 0 Series Truck ECU Prototypes Situation in the beginning of 2003 3. Installation instructions Installation instructions IVTM 3. Review of connecting hoses: Super Single 22.5 x 17 960 730 052 4 Trailer 22.5 x 11.75 ET 120 960 730 053 4 Double tires – external 22.5 x 7.5 ET 160 22.5 x 8.25 ET 160 22.5 x 9 ET 160 Trailer Double tires – internal 22.5 x 11.75 ET 0 22.5 x 7.5 ET 160 Super Single 22.5 x 11.75 22.5 x 15 960 730 054 4 960 730 055 4 Independent L-shape wheel 22.5 x 7.5 with protecting ring 22.5 x 8.25 ET 160 22.5 x 9 960 730 056 4 Independent wheel with axle cap 22.5 x 7.5 22.5 x 8.25 ET 160 22.5 x 9 960 730 057 4 Double tires – internal 22.5 x 8.25 ET 160 22.5 x 9 960 730 058 4 25 4. IVTM 4. Diagnostics 4.1 System configuration Diagnostics Newly installed IVTM system is configured, i.e. set up, by PC diagnostics of IVTM system. Parts necessary for configuration: Diagnostics connecting cable: 446 300 348 0 Diagnostics interface with cable: 446 301 021 0 Diagnostics software: 446 301 730 0 Remark: Diagnostic could be done only with special diagnostics cable for IVTM, other diagnostics cables WABCO (i.e. cables for EBS, ECAS etc.) could not be used. 4.2 26 Diagnostic structure Diagnostics 4.3 OPERATING INSTRUCTIONS IVTM 4. If the tire pressures are not exceeding specified values, following data are displayed after initialisation: The system consists of one electronic unit, so called electronic control unit, which receives wireless information from wheel modules. Wheel modules are permanently connected by hoses to tire valves. Pressure information is processed by algorithms stored in control unit. Data are relayed by CAN bus to display. Display unit consists of one display, two indicators, one buzzer and two buttons. Warnings of different levels are signalised; importance could be recognised by colour of indicator light and audio signal: – Red light (STOP) and 1 minute long audio signal indicates serious defect; the vehicle must be stopped immediately (possible threat to lives and vehicle). – Yellow light (turtle) and 10 minutes long audio signal indicates smaller defect; the vehicle should be slowed down and lower pressure adjusted. Defects found by IVTM are stored in electronic memory for diagnostic purposes. Two buttons on front panel are used to control different functions. Left button with symbol of manometer displays vehicle tire pressure. Right button with question mark symbol shows detected defects. If pressed longer, the error messages are deleted (after correction of tire pressure). 4.4 DIFFERENT VALUES ON DISPLAY 4.4.1. Normal values After initialisation the top view of vehicle is displayed (driving direction upward) for 12 seconds. For example 4x2 truck is shown like: 4.3.1 Display operation Cable harness is connected to display by 4-pole plug. It is powered only if the ignition is on. After the ignition is switched on, internal check procedure is performed, when all internal functions are tested: all symbols are displayed for one second, all pilot lights and audio signals are switched on; this procedure is repeated twice. IVTM Fig. 3 psi bar IVTM If the trailer with IVTM system is connected to motor vehicle, both vehicles are shown alternatively in one second intervals for 12 seconds. psi bar mn km psi bar Fig. 1 27 4. IVTM Diagnostics Example: If the three axles trailer is connected to shown vehicle, Fig. 3 is changed to: 4.4.2 Pressure display This manometer function shows the tire pressures measured by IVTM system, and completely replaces manual pressure measurement through tire valves. The values are displayed after pressing left button ”manometer” in normal mode. IVTM The axle, whose pressures are displayed, is marked. Fig. 4 The display shows IVTM logo (Fig. 2) and stays without change till the button is pressed or the defect is found. bar bar IVTM If the defect is found on one of the vehicle wheels, symbol of 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 vehicle or trailer, symbols of all defect wheels are blinking. Fig. 7 Tire pressures on following axle could be displayed by repeatedly pressing button ”manometer”. If one of the axles is equipped with double tires, individual pressures are displayed in sequence. Display of pressure in outer tires of double tires: IVTM bar Fig. 5 bar IVTM 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. Fig. 8 The pressure of inner tires could be displayed by repeatedly pressing button ”manometer”: IVTM bar IVTM Fig. 6 Fig. 9 In all cases the indicator light and audio signal corresponding with the worst defect is switched on. If the defect is found on one tire of double tires, the system activates error message for both tires. bar If the trailer is connected the pressure in the tires of trailer is displayed in the same way. After display of tire pressure in last axle and pressing the button ”manometer” the display switches to normal mode. 28 Diagnostics If the button ”manometer” is not pressed for 20 seconds, the display also switches to normal display mode. 4. IVTM 4.4.3.2 Extremely high pressure 4.4.3 Error messages All defects found by system could be displayed in order of their importance. bar IVTM 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 detected defect and particular indicator are lighted. By successive pressing the button ”?” it is possible to display all defects. After another press of button the user is asked to reset data (see 4.4.2). If button ”pump” is not pressed for 20 seconds, display switches to normal mode. If no defect is found the system does not react to pressing button ”?”. Fig. 11 Display informs about position and current pressure of defect tire. Yellow indicator is on. Action: Driver should slow down the vehicle to prevent bursting of tire. The cause of high pressure should be found out (for example heated brake). 4.4.3.3 Sneaking pressure drop Different types of defects, which could be found by IVTM system, are described below. Let us start with the most dangerous. bar IVTM 4.4.3.1 Extremely low pressure Fig. 12 Display informs about position and current pressure of tire, where the drop was detected. The symbols of wrench and soft tire are displayed. Yellow indicator is on. bar IVTM Action: Fig. 10 Display informs about position and current pressure of defect tire. The symbols of wrench and red light are displayed. Driver should slow down the vehicle and on first occasion find out the cause of pressure drop, or change the tire. 4.4.3.4 Low pressure Action: Drive should immediately stop the vehicle and check the pressure drop. Generally, it is necessary to change the tire because of the damage. bar IVTM Fig. 13 Display informs about position and current pressure of defect tire. Symbol ”pump” is displayed. Yellow indicator is on. 29 4. IVTM Diagnostics Action: Drive should slow down the vehicle and on first occasion adjust the tire pressure. If the image of vehicle is displayed and you press the button ”pump” for 5 seconds, the control unit of this vehicle is reset. 4.4.3.5 High pressure Switching off of the display confirms successful reset. If the unit is not reset, the display changes to normal operating mode. As all data about defects and tire pressures of particular vehicle are deleted, new information about tire pressure may be displayed after up to 15 minutes. bar IVTM Fig. 14 This defect could be found only for cold tires, i.e. if the vehicle stand for more than four hours with ignition switched off. In this case the defect is displayed two minutes after the ignition is switched on. 4.5 SYSTEM ERROR DISPLAY 4.5.1 Connection of the wheel module is interrupted Display informs about position and current pressure of defect tire. Symbol ”pump” is displayed. Yellow indicator is on. IVTM Action: The pressure in tires should be adjusted before starting the engine. 4.4.4 Reset This function allows resetting all information about tire pressure and possible defects of IVTM system. Reset is necessary for example after adjustment of the tire pressure, because otherwise the system may report false defect. Repeatedly press right button ”?”, until all defects of vehicle are displayed. All wheels are lighted. This image of vehicle is displayed for five seconds. After that, if IVTM system recognizes trailer, it displays image of trailer for another five seconds. Fig. 16 This error message is shown when there are no data received from one of the wheel modules for more than one hour. Display shows position of wheel, which is not transmitting data. 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 of wheel module, it is likely, that the module battery is discharged. Change the wheel module (it is necessary to perform new setup using system diagnostics). 30 Diagnostics 4.5.2 System error IVTM 4. 4.5.3 Interrupted connection between control unit and display If the connection between IVTM and display is interrupted, following information is shown and white line on IVTM logo is flashing. IVTM Fig. 17 IVTM This error message is displayed when IVTM functions or regular tire pressure monitoring fails. All wheels are blinking on display. IVTM logo is crossed. In certain cases the type of vehicle equipped with IVTM is not recognized. In this case following data are displayed: Fig. 19 Action: – Check plugs: ECU, connecting plug – Check connection to harness 30 – Plugs from harnesses 15 and 30 could have been interchanged (display is on even after ignition is switched off) IVTM – Check cable connections Fig. 18 – Diagnostics Action: System diagnostics, check of the control unit wiring 31
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