Bendix Commercial Vehicle Systems VS-400 User Manual

Bendix™ VORAD® VS-400

Installation Guide

Bendix™ VORAD® VS-400 System BW2772 (Formerly VOIG0100) September 2010

Table of Contents

Introduction

Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Federal Communications Commission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3

Application Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4

Installation Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Space Claim

Forward Looking Radar Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Side Object Detection Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Driver Interface Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Mounting Requirements

Forward Looking Radar (FLR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-19

Side Object Detection (SOD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20-21

Driver Interface Unit (DIU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22-23

Electrical Requirements

Forward Looking Radar (FLR) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Wiring Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

Wiring Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Ignition and Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

J1939 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .27

Side Object Detection (SOD) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .28

Ignition and Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .29

Driver Interface Unit (DIU) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Power Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .30

Wiring Harness. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Ignition and Ground . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

J1939 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Optional I/O. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .34

Final Test

Final Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

Appendix

Retroﬁ t Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .36

J1939/11 Data Link Detail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

SAE J1939/11 Recommended Cable Termination Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

SAE J1939/11 Recommended Cable Splice Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

J1939/15 (lite) Data Link Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Wiring Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .42

SmartCruise and/or Collision Warning System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .43

Collision Warning System with Side Object Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .44

Connector Pin Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Vendor Contact Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

General Information

Warnings and Cautions

WARNING

▲

™

Improper use of this system could lead to a serious accident. Read this entire Installation Guide before operating the Bendix VORAD® VS-400 system. Pay particular attention to the safety messages below. This manual should be used in conjunction with proper training.

Limitations of Collision Warning Systems

The Bendix™ VORAD® VS-400 collision warning system is intended solely as an aid for an alert and conscientious professional driver. It is not to be used or relied upon to operate a vehicle. The system should be used in conjunction with rear view mirrors and other instrumentation to maintain safe operation of the vehicle, ground personnel, and adjacent property. A vehicle equipped with the Bendix VORAD® VS-400 system should be operated in the same safe manner as if the system were not installed. The system is not a substitute for normal safe driving procedures. It will not compensate for any driver impairment, such as drugs, alcohol, or fatigue. Should the system become inoperative, it could jeopardize the safety or lives of those who depend on the system for safety.

™

WARNING

▲

The system will not sense objects if the sensor view is obstructed. Therefore, do not place objects in front of the system sensor. Remove heavy buildups of mud, dirt, ice, and other materials.

Proper alignment is critical to correct operation of the system.

Testing and inspection of the system in accordance with these instructions and record of the results should be listed on the daily maintenance report. The units on operating vehicles must be tested each day (see the “Testing and Maintenance” section) prior to the vehicle’s operation. Results of this test must be recorded in the maintenance log.

People operating this equipment MUST check for proper operation at the beginning of every shift or safety inspection period.

WARNING

▲

People’s lives depend on the proper installation of this product in conformance with these instructions. It is necessary to read, understand, and follow all instructions shipped with the product.

Failure to follow all safety precautions and instructions may result in property damage, serious injury, or death.

™

The Bendix understanding of truck electrical systems and procedures, along with proﬁ ciency in the installation.

VORAD® VS-400 system is intended for commercial use. Proper installation of a backup aid requires a good

Store these instructions in a safe place and refer to them when maintaining and/or reinstalling the product.

General Information

FCC Compliance Statement

Federal Communications Commission

This device complies with Part 15 of the FCC (Federal Communications Commission) rules. Operation is subject to the following two conditions: (1) This device may not cause harmful interference and (2) this device must be able to accept any interference received, including interference that may cause undesired operation. Any interference that may be caused should be reported to the local FCC ﬁ eld ofﬁ ce or to the Federal Communications Commission; Enforcement Bureau; 445 12th Street S.W.; Room 7-C485; Washington, DC 20054.

Any changes or modiﬁ cations made by the user to this equipment that are not expressly approved by Bendix Commercial Vehicle Systems LLC could void the user’s authority to operate the equipment.

Every effort has been made to ensure the accuracy of all information in this brochure. However, Bendix Commercial Vehicle Systems LLC makes no expressed or implied warranty or representation based on the enclosed information. Errors or omissions should be reported to: Bendix Commercial Vehicle Systems LLC, 901 Cleveland Street, Elyria, OH 44035 or 1-800-AIR-BRAKE (1-800-247-2725).

Application Information

Driver Interface Unit (DIU) and Side Object Forward Looking Radar (FLR) Detection System

Function FLR DIU SOD

S/C Only X X CWS Only X X S/C & CWS X X S/C, CWS & SOD X X X SOD Only X

S/C = Bendix™ SmartCruise® adaptive cruise control CWS = Collision Warning System

Introduction

Installation Tools

Recommended Tools

• Forward Looking Radar Alignment Tools - Digital Level and 4’-6’ Straight Edge

• PC-Based Service Tool - ServiceRanger - TCMT-0070B

• Basic Hand T ools

Reference Literature

• Installation Guide - BW2772

• Troubleshooting Guide - BW2771

• Driver Instructions - BW2769

Reference Drawings

• Side Object Detection System Display - 15670-001 Installation Drawing

• Side Object Detection System Sensor - 15671-001 Installation Drawing

• Side Object Detection System Harness - 15672-001 Installation Drawing

• Forward Looking Radar - VSFR-001 Installation Drawing

• Driver Interface Unit - VSDI-001 Installation Drawing

For more information within the U.S., Canada, and Mexico call 1-800-AIR-BRAKE (1-800-247-2725), or contact a local OEM dealer.

Space Claim

Forward Looking Radar Dimensions

3.85"

(98.0mm)

Space Claim

2.49"

(63.4mm)

3.87"

(98.5mm)

3.30"

(84.0mm)

1.60"

(40.6mm)

3.30"

(84.0mm)

Side Object Detection Dimensions

Side Sensor

5.36"

(136.1mm)

Space Claim

0.82"

(20.8mm)

5.60"

(142.2mm)

3.53"

1.38"

(35.1mm)

0.9" (22.9mm)

2.04"

(51.8mm)

2.04"

(51.8mm)

3.24"

(82.3mm)

Side Sensor Display

Space Claim

1.20" (30.5mm)

1.60" (40.6mm)

1.00"

(25.4mm)

2.10"

(53.3mm)

2.30"

(58.4mm)

39.00” ± 3.00"

(990.6mm ± 76.2mm)

2.00"

(50.8mm)

0.70" (17.8mm)

2.80"

(71.1mm)

2.00"

(50.8mm)

Driver Interface Unit Dimensions

Space Claim

1.97"

(50mm)

4X R.207 (5.25)

.20” (5.2)

2X 1.56” (39.5)

1.58” (40.1)

1.61” (40.9)

3.67"

(93.18mm)

3.16” (80.2)

3.22” (81.8)

3.67” (93.18mm)

3.70"

(93.90mm)

2X 2.5˚

2X .63” (15.9)

2X 2.5˚

.22” (5.7)

4.07"

(103.39mm)

1.97” (50.0)

Panel Cut Out (Without bezel)

Mounting Requirements

Overview

The installation of the Bendix™ VORAD® VS-400 System is intended to cover a wide range of commercial vehicle applications. This publication is intended to be a reference for commercial vehicle installations using the vehicle’s SAE J1939 data link interface. For vehicles without a SAE J1939 data link, some installation procedures may vary for a proper system installation and operation.

Typical Component Locations

Note: Not all components are required for every application.

Forward Looking

Radar (FLR)

Side Sensor

Display (SSD)

Driver Interface

Unit (DIU)

Side Sensor

(SS)

Mounting Requirements

Mounting Requirements - Forward Looking Radar (FLR)

The Forward Looking Radar (FLR) determines the distance, lane position (azimuth), relative speed (velocity), and direction of vehicles in front of the host vehicle. The FLR is a Doppler radar that transmits at a 77 GHz frequency. A built-in yaw rate sensor (gyro) provides relative azimuth for lane positioning in turns. The SAE J1939 interface allows the FLR to be installed as a Bendix™ SmartCruise™ adaptive cruise control only stand-alone unit, or as a component of the complete Bendix™ VORAD® VS-400 System.

The FLR can track multiple objects simultaneously in relative motion within the radar’s effective range of view. Relative motion is deﬁ ned as an object’s movement towards, or away from, the radar transceiver.

Note: The Forward Looking Radar is only activated while the vehicle is in motion.

Mounting Orientation

snoitacoL eloH gnitnuoMweiV tnorF

Mirror Must

Mounting Requirements

Installation

Bumper

(Optional)

Forward Looking

Radar

Note: The design of the Mounting Bracket may vary. This is a typical representation.

Located on the forward most position of the vehicle, the FLR transmits and receives low power, high frequency electromagnetic energy. Transmitted energy that is reﬂ ected off objects in front of the vehicle is received and processed by the radar’s internal microprocessor to determine the object(s) relative distance, position (azimuth), speed (velocity), and direction of travel.

Mounting

Bracket

For proper operation, the 77GHz forward looking radar unit shall be installed on the vehicle with the following constraints:

• The radar unit must be rigidly attached to the forward most position of the vehicle chassis, perpendicular with the vehicle’s forward thrust axis.

• The lateral position of the radar should be located as close to the vehicle’s center as possible (+/- 50mm).

• The vertical position of the radar must be at a minimum of 12” (304.8mm) and a maximum of 28” (711.2mm) from the ground.

• The radar must be installed in a manner that protects it from minor frontal impacts, as well as protecting the radar’s harness connector from road debris.

• The mounting hardware must allow for a minimum of ±3° mechanical adjustment of the radar’s horizontal and vertical axis.

• The radar must be orientated so the harness connector is pointing in the downward position.

The mounting location must provide a clear view in front of the radar. Ideally, the radar will be recessed behind the proﬁ le of the vehicle’s front bumper or grill, but not to interfere with the radar’s sight proﬁ le. See “No Radar Obstruction Zone” on next page.

Mounting Requirements

Requirements

The Forward Looking Radar can be mounted on the front of the vehicle, or integrated behind a non-metallic body panel as long as the mounting, alignment, and material requirements are met in the following sections.

Field of View Deﬁ nition

The Forward Looking Radar (FLR) ﬁ eld of view in elevation and azimuth is illustrated below. The grey area represents a cross-cut view of the three-dimensional “No Radar Obstruction Zone”.

Using the illustration below, the diameter of the hole in front of the Forward Looking Radar can de determined. For materials within 30mm of the FLR, the hole diameter must be greater than 70mm. For materials 40mm from the front of the FLR, the hole diameter must be greater than 90mm.

WARNING

▲

Any hole diameter less than the required size, will effect a clear line of sight for the FLR unit.

1.18"

(30mm)

1.57"

(40mm)

2.76"

(70mm)

4.72"

(120mm)

3.54"

(90mm)

Mounting Requirements

Cover Material Requirements

Any material that may be located in the Forward Looking Radar’s ﬁ eld of view (including bumpers, spoilers, etc.) can not be made out of any metallic material or have any carbon content. It is recommended that any material that will be located in the FLR ﬁ eld of view be approved by Bendix Commercial Vehicle Systems prior to use.

If the radar has a cover perpendicular to the radar beam, even a very slight vibration of the cover can cause the reﬂ ected radar signal to be seen as a very strong false target at close range. If the radar cover is not perpendicular by more than 5° then the returned reﬂ ection does not enter the receiver channel and hence is not detected. The recommended angle of the beam to the cover is 50° to 80°. There have been applications that have the cover perpendicular, but the forward radar and the cover were directly mounted to each other to minimize the cover’s movement to the radar module. This may be a difﬁ cult condition to maintain.

The cover must not contain any metal or high carbon concentrations, as this reduces the radar range. The electrical characteristics of the cover material (on microwave RF) and its thickness can effect the range as well. Polymeric or ceramic material is recommended. Recommended thickness are based on the cover’s angle. The table on the following page lists material thicknesses for a perpendicular or 80° angle cover. The ideal thickness also depends on the angle of incidence of the cover relative to the radar beam axis. The materials in this table do not represent the only possible make up for a cover.

The recommendation scoring system has been applied as follows:

• Losses shall be less than 0.7dB.

• Thickness for rigidity reasons shall be greater than 2mm.

Thickness accuracy: +/- 0.15mm

Thickness recommendation is based on cover being a ﬂ at unpainted surface that extends beyond the “No Radar Obstruction Zone” (see previous page). Since paints can impact the losses, they need to be evaluated separately. As with the cover, the paint must not contain metal or carbon.

• The thickness depends on the angle of incidence of the bumper shield located in the radar ﬁ eld view relative to the radar beam axis; it should be updated with the real angle.

• The angle of incidence is recommended to be between 50° to 80°; 90° is prohibited so as to avoid any spurious reﬂ ection of the radar beam back into the Forward Looking Radar.

Reflected

Beam

Radar Beam

Radar

Beam

• Painting can induce extra losses that depend heavily on the painting thickness itself and on its painting process. These paints need to be tested individually to assess their impact on the recommendations made in this document. For more information, see the “Painting” section of this publication.

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