WABCO ECU220 Users Manual
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 5
1.1 System structure 7
1.1.1 Example of installation in the bus 8
1.1.2 Example of installation in the trailer 8
2. Configuration 9
2.1 Components 10
2.1.1 Wheel module 10
2.1.2 Electronic control unit (ECU) 12
2.1.3 Display 13
2.2 Wiring 14
3. Installation instructions 17
3.1 General instructions 17
3.2 Overview 17
3.3 Additional mounting into vehicle/bus 18
3.3.1 Additional mounting into trailer 19
3.4 Inflation pressure 19
3.5 Installation of the control unit in vehicle 20
3.5.1 Installation of the wiring harness in vehicle 20
3.5.2 Installation of the wiring harness in trailer 22
4. Diagnostics 26
4.1 System configuration 26
4.2 Diagnostics structure 26
4.3 Instructions for use 27
4.3.1 Display instructi ons 27
4.4 Various information on display 27
4.4.1 Normal data 27
4.4.2 Pressure data 28
4.4.3 Error messages 29
4.4.4 Display reset 30
4.5 System error signalization 31
4.5.1 Interrupted connection to the wheel module 31
4.5.2 System failure 31
4.5.3 Interrupted connection between control unit and display 31
1
3
1. System functions
System functions
IVTM
1.
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 cab in and warns
driver about critical pressure drop. IVTM makes tr ansport
safer and more efficient, becau se mor e 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 tire s results in minimal fuel c onsumption
and extension of service life of tires.
Let us present some information:
Tire manufacturers estimate that total losses caus ed by
Main reasons for brakedowns at commercial vehicles are:
Service / information 3%
Structure 3%
Salvage operation 4%
Drive line 4%
Chassis 2%
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 e xception in e veryday life. This underinflation reduces service life of tires by 20 % and
unnecessarily incr eas es fu el co nsu mpt ion .
In order to minimize these costs WABCO company
designed new sy stem I VTM, which al so in crea ses t raffic
safety.
Operating
supplies 1%
Engine 36%
Brakes 4%
Electric 17%
The mileage of tyres significantly depends
on the tyre pressure...
tyre pressure
too low
tyre pressure
too high
Tire pressure
Source: Se rvice 24 GmbH & Co. KG
Tyres 26%
66000 brakedown missions
for trucks and busses in 1999
and fuel consumption also depends on the
tyre pressure.
Fuel consumption
tyre pressure
too low
tyre pressure
too high
Service life reduction
5
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.
Which types of pressure monitoring are
available?
Permanent tire press ure monitoring durin g 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 measureme nt 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 monitori ng during parking or before driving
start; diagnostics memory
2. able to distinguish uniform diffusion losses
• Additionally, properly maintained pressure in
tires ensures s afe driving properties of ve hicle
and short braking distance.
IVTM ensures travel efficiency:
• Prevents unnecessary delays and idle time.
• No backup vehicles/emergency actions needed
• Prevents loss of confidence from unsatisfied
customers and resulting drop of turnover.
records about tire pressure (rise)
Air pressure
in bar
3. fast detection of pres sur e d ro p, reac ti on t ime in order
of several seconds.
4. display of c urre nt ti re pres sure
5. higher precision
6. identification of leaking tire
7. measurement is not affecte d by driving on lo w qual ity
road
8. measurement is not affected by uneven vehicle
loading
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.
6
System functions
IVTM
1.
This requires using sophisticated evaluation algorithm,
instead of using simple identification of limit value.
Other requirements for tire pressure monitoring
systems of utility vehicles:
• 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
IVTM system
Vehicle
CAN bus
CAN bus or
HF wireless data transfer
from trailer control unit
to vehicle control unit
• Identification of tire pres sure fluctuation ba sed
on load and tire wear.
This function req uires complicated "eval uative
algorithm".
• Wheel modules must be m ounted flexible with
respect to different ty pes and locations of tire
valves on rims, different rim designs and
frequent wheel changes and mus t allow easy
exchange.
IVTM system
Trailer
Display:
« Standalone » or integrated
WABCO system is based on one el ectronic circuit 446
220 00x 0, so called control unit, which receives wireless
data transmitted by wheel modul es. Whe el modules 960
730 00x 0 are conn ected to the whee l valves by hoses .
Pressure informati on is processed by algorith ms stored
in control unit.
The information is sent through CAN bus to di splay unit
446 221 000 0. Di splay unit con sists of o ne disp lay, two
indicators, one buzzer and two buttons.
Warning massages of different levels are displayed;
indicator colour and type of audio signal shows
seriousness of the problem:
Control unit
Vehicle
Control unit
Trailer
• 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 min utes long audio signal
indicates smaller defec t; the vehicle shoul d be
slowed down and lower pressure adjusted.
Defects found by IVTM s ystem are stored in electronic
memory (EEPROM) for diagnostic purposes.
Wheel module
fro wheel
7
1.
1.1.1 Example of installation in the bus:
IVTM
System functions
wheel module
electronic control unit (ECU)
1.1.2 Example of installation in the trailer:
Driver display
Display
8
Control unit
Vehicle
Control unit
Trailer
wheel module
(one module per one tire)
2. Configuration
r
Configuration
IVTM
2.
In order to display tir e pressure and trailer warnings to
driver during driving it is in general case necessary to
install IVTM to both par ts of v ehicle, 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 availabl e after up to 15 mi nutes 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 vehicl es wi ll be able to display the d ata from CAN
System structure
bus on multifunction d isplay on the dashboard. If such
vehicles will not be ava ilable, data will be transfe rred to
the vehicle control IVTM unit wirelessly.
Certificates
Certificates for mounting and additional mounting of
IVTM are available, which significantly facilitate approval
of vehicle registr ati on pa pers . Ce rti ficat es ar e not part of
this booklet, how ever in case of need they cou ld 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
IVTM display
CAN bus
Wireless connection
IVTM ECU
Trailer
vehicle
data transfer
wireless
IVTM ECU
Vehicle
Wheel
modules
IVTM display
CAN bus
IVTM ECU
Vehicle
TCE/
EBS
Wireless connection
IVTM ECU
Trailer
vehicle
connection to TCE or EBS,
wireless data transfer
Integrated display Integrated display
CAN
J1939
IVTM ECU
Vehicle
EBS
ISO 11992
IVTM ECU
Trailer
vehicle
connection to TCE,
data transfer by CAN bus
Central
computer
Wheel
modules
TCE
Trailer
Central
Electronics
CAN
IVTM ECU
Vehicle
IVTM ECU
Trailer
vehicle
connection to EBS,
data transfer by CAN bus
J1939
ISO 11992
Central
compute
EBS
9
2.
IVTM
Configuration
Possible vehicle configuration:
Motor vehicle
4 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 4
Super-Single with with Super-Single
Steering-/ Steering-/lifting axle
Loading axle Super-Single
Trailer vehicles
1-axle 2-axles 3-axles 1-axle 2-axles 3-axles
trailer vehicle trailer vehicle trailer vehicle trailer vehicle trailer vehicle trailer vehicle
with double with double with double
tires tires tires
2.1 Parts
2.1.1 Wheel module
Wheel module is cast in plastic enclosure and is
composed 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 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 s ystem does not have to be newly
setup.
The wheel module must not disrupt wheel balance;
therefore the cou nter wei ght is moun ted on the o pposi te
side.
Evaluation and data transfer is provided by 433 MHz
signal. If the pressure is constant, measur ed value s are
transmitted every 15 minutes, if the pressure is changing,
frequency of data transfers is faster.
10
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