WABCO OPTITIRE User Manual
OptiTire
Tire Pressure Monitoring
for Commercial Vehicles
OptiTire
Tire Pressure Monitoring
for Commercial Vehicles
System Description
This publication is not subject to any update service.
© 2013/2015 WABCO Europe BVBA – All rights reserved.
Edition 7
You will find the current version at
http://www.wabco.info/xxxxxxxxxx
The right of amendment is reserved.
Draft Version 1.2015(en)
Xxx xxx xxx x
OPTITIRE
Table of Contents
1 Important instructions ............................................................................................................ 6
1.1 Information and Disclaimer ........................................................................................... 6
1.2 Symbols used ............................................................................................................... 6
1.3 General information ...................................................................................................... 7
1.4 General safety instructions ........................................................................................... 7
2 Introduction ............................................................................................................................. 8
2.1 OPTITIRE prevents tire blow-outs ................................................................................ 8
2.2 OPTITIRE reduces cost ............................................................................................... 8
3 System Description .............................................................................................................. 10
3.1 OPTITIRE Basic Functions ........................................................................................ 10
3.2 OPTITIRE at trailer-towing operation ......................................................................... 11
3.3 Configuration for bus and towing vehicle ................................................................... 11
3.4 Configuration for trailers ............................................................................................. 13
3.5 Certificates .................................................................................................................. 16
4 Components .......................................................................................................................... 18
4.1 Wheel module WM2 ................................................................................................... 18
4.2 Wheel Internal Sensor (WIS) ...................................................................................... 21
4.3 Electronic Control Unit (ECU) ..................................................................................... 22
4.4 The display ................................................................................................................. 23
4.5 Connecting cable ........................................................................................................ 24
4.6 Connecting tube ......................................................................................................... 27
5 Operation ............................................................................................................................... 28
5.1 Warning signals .......................................................................................................... 28
5.2 Switch on of ignition.................................................................................................... 28
5.3 Checking pressure values .......................................................................................... 29
5.4 Display of faults .......................................................................................................... 30
5.5 Adjusting tire pressures .............................................................................................. 31
5.6 Display of System Errors ............................................................................................ 31
5.7 Operation via SmartBoard .......................................................................................... 33
6 Installation ............................................................................................................................. 34
6.1 Mounting the wheel modules – WM2 ......................................................................... 35
6.2 Mounting the wheel modules – WIS ........................................................................... 37
9.3 Mounting the ECU in bus / towing vehicle .................................................................. 39
6.3 Wiring in towing vehicle/bus ....................................................................................... 40
6.4 Mounting the ECU in the trailer .................................................................................. 41
6.5 Wiring in trailer ............................................................................................................ 41
6.6 Start-up ....................................................................................................................... 42
7 Workshop instructions ......................................................................................................... 44
7.1 Diagnosis .................................................................................................................... 45
7.2 Wheel Changes .......................................................................................................... 46
7.3 Replacing PA tubes .................................................................................................... 47
7.4 Replacing hose connections ...................................................................................... 47
7.5 Replacing wheel module I with wheel module II ........................................................ 48
7.6 Creeping pressure loss .............................................................................................. 48
7.7 No reception of the wheel module .............................................................................. 49
4
Table of Contents
7.8 Disposal ...................................................................................................................... 51
OPTITIRE
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1
OPTITIRE
Important instructions
1 Important instructions
1.1 Information and Disclaimer
We assume no liability for the correctness, completeness or actuality of the information in this document. All technical information, descriptions and images are applicable for the day of printing this document or respective supplements. We retain
the right to any changes as a result of continuous further development.
The content of this document provides no guarantees nor warranted characteristics
nor can it be construed as such. Liability for damages is strictly excluded, as long
as there has been no respective intention or gross negligence on our part or any
forced legal provisions in opposition.
Text and graphics are subjected to our utilisation rights, copying or distribution in
any form require our approval.
Any brand markings, even if not indicated as such, are subject to the rules of the
labelling rights. If legal disputes arise from the utilisation of the information in this
document, these are exclusively to be handled under the regulations of national
law.
In so far as components or individual formulations of this applicable legal status
documentation are no longer or not fully relevant, the remaining parts of the documentation remain unaffected thereby in their content and validity.
1.2 Symbols used
DANGER
WARNING
CAUTION
Imminent hazard situation which can cause serious personal injury or death if the
safety instruction is not observed.
Potential hazard situation which can cause death or serious personal injury if the
safety instruction is not observed.
Potential hazard situations that can cause minor or moderate to severe injury, or
material loss, if the safety instruction is not observed.
Important instructions, information, or tips that you should always observe.
Reference to information and publications on the Internet
6
• List
– Step
Consequence of an action
1
1.3 General information
This publication is directed at trained service technicians employed at workshops
for commercial vehicles.
Proper use
The OPTITIRE system is designed exclusively for monitoring the tire pressure in
commercial vehicles.
Carefully read all the safety instructions as well as all the repair and maintenance
instructions in this document before you start maintenance work, repairs or replacing parts.
These instructions must be observed to avoid personal injury or material damage.
WABCO only guarantees the reliability and performance of its products and sys-
tems if all instructions, notes and safety instructions are observed.
1.4 General safety instructions
Important instructions
OPTITIRE
WARNING
Before you perform any work on the vehicle (repair, maintenance, replacing parts,
etc.), you must ensure the following:
Severe damage to property and injuries to health may result due to improper
assembly or repair work.
– Only trained and qualified personnel may perform repairs on the vehicle.
– Always follow the specifications and instructions of the vehicle manufacturer.
– Always comply with the Company and national accident prevention guidelines
and Health and Safety regulations.
– Wear suitable protective clothing as the situation requires.
– Ensure that the workplace is dry and provided with sufficient lighting.
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2
OPTITIRE
Introduction
2 Introduction
This chapter gives you an overview of the benefits OPTITIRE provides.
2.1 OPTITIRE prevents tire blow-outs
OPTITIRE stands for Integrated Vehicle Tire Pressure Monitoring. The system is
continuously monitoring tire pressure on all wheels by means of sensors. In the
event of a critical pressure drop, a display in the driver cabin of the towing vehicle
warns the driver in time. Since around 85% of all punctures are caused by driving
with wrong air pressure or creeping pressure loss while in motion, risk of tire burst
can be reduced down to 15% thanks to OPTITIRE.
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fig. 2-1: Root causes for roadside emergencies (source: ADAC 2011)
A
Tires 31.6%
B
Electrics 29.2%
C
Engine 20.7%
D
Others 18.5%
2.2 OPTITIRE reduces cost
By selecting the correct tires and having them properly maintained, substantial savings can be achieved per vehicle and year. Maintaining correct inflation pressure
for instance: In practice, about every second tire is run at an air pressure falling below 10 percent of the specified one. Also 20% under nominal pressure is not rarely
observed and this will reduce tire mileage by as much as 20%. This will push up
fuel consumption in each case.
Full tire pressure checks usually take around 30 minutes per vehicle, OPTITIRE
can help reduce or even eliminate this extra work.
So OPTITIRE minimises cost and makes a great contribution to safety on our
roads.
OPTITIRE allows employment of Super Singles instead of twin wheels.
OPTITIRE can be easily retrofitted.
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2
within a few stages.
Return of Investment Calculator
Using our Return of Investment Calculator on our website http://www.OptiTire.com
or http://www.wabco-auto.com, you are able to calculate use your OPTITIRE offers
You can either enter your individual application data or use standard profiles for
determining which savings you are able to achieve using the OPTITIRE.
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Introduction
OPTITIRE
fig. 2-2: Dependence of tire service life from air pressure
A
Tire pressure
B
Service life reduction
C
Tire pressure too low
D
Tire pressure too high
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fig. 2-3: Consumption vs. air pressure dependency
A
Tire pressure
B
Fuel consumption
C
Tire pressure too low
D
Tire pressure too high
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3
OPTITIRE
System Description
3 System Description
This chapter describes the mode of operation of the OPTITIRE system. Furthermore, you will also obtain information concerning technical reports for installing and
retrofitting.
3.1 OPTITIRE Basic Functions
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Measuring
Evaluating
fig. 3-1: Solo system
A
Electronic Control Unit (ECU)
B
Wheel module
C
Display
Each wheel continuously transmits actual tire pressure to a central electronic control unit (ECU). The signals of all wheels are evaluated there and the information is
conveyed to a display in the driver's cab.
Wheel modules measure the air pressures on the conventional valves every 15
minutes (WM2) or 1 min (WIS) and transmit them to the ECU. If the pressure
changes critically then the wheel module would sent the values in shorter periods.
Evaluation is far more than just comparing a current pressure value with an allowed one and sending a warning message on falling below. The ECU discriminates a real problem situation from usual pressure fluctuations during vehicle operation also on bad road conditions or uneven load.
In the event that an irregularity occurs then this fact would not only be reported on
the display but the wheel in question would be exactly indicated too.
An OPTITIRE ECU can receive and process data from up to 20 wheel modules
each and further ECUs. Dual tires will each be fitted with individual sensors. Sensor pressure range is between 2 and 14 bar corresponding to nominal pressure
values from 3 to 10.5 bar.
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3
System Description
Displays
WABCO is offers a driver's display for indicating warning messages and tire pressure checking.
For certain vehicles the data can also be transmitted to an integrated display as an
alternative. Detailed description of display functionality is given in chapter "Operation"(see chapter 5, page 28).
OPTITIRE, and therefore TPI, cannot announce sudden, extreme tire damage
caused by external effects.
3.2 OPTITIRE at trailer-towing operation
Operating mode
Initially, the OPTITIRE system on the trailers will work self-sufficiently if there is a
power supply. In order to display tire pressure and trailer warnings to the driver
during driving, however, it is necessary to install OPTITIRE to both parts of vehicle,
which means one control unit to the trailer and one unit to the towing vehicle.
Any towing vehicle equipped with OPTITIRE could be connected to any trailer
equipped with OPTITIRE.
OPTITIRE
Variants
The OPTITIRE for trailer vehicles can be operated using the WABCO SmartBoard
as well as for stand-alone versions.
Tire pressure values, in connection with WABCO TCE or EBS, can be transferred
to the towing vehicle's CAN bus via standard CAN data connection according to
ISO 11992 (only in connection with appropriately prepared towing vehicle).
Automatic trailer recognition
Control unit of towing vehicle identifies control unit of trailer automatically: The stop
light is enabled on towing vehicle and trailer when hitting the brake. The trailer
ECU radios a signal with this voltage pulse that is expected by the towing vehicle's
ECU that instant. The towing vehicle thus clearly detects that the trailer belongs to
the tractor/trailer combination and subsequently transmits trailer ECU messages to
the display.
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 of
the trailer is not available in the display for up to 15 minutes after starting the drive.
3.3 Configuration for bus and towing vehicle
In this chapter, you will learn which components you require for your vehicle.
Selection of OPTITIRE components depends on vehicle type, type and number of
wheels and type of systems connected to OPTITIRE but not on the vehicle system
voltage.
ECU
Display
Trucks, buses or articulated buses are equipped with the ECU 446 220 100 0.
IVTM display 446 221 000 0 is used for the retrofitting of the display and operation
devices. Original equipment, however, will often address a central computer via
CAN with the latter controlling indication of the integrated dashboard-mounted display.
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3
OPTITIRE
2 2 4
Wheel modules
System Description
Select wheel modules and counterweights according to their axle configuration.
The table contains components for three vehicle type examples. Further information in chapter "Components", see chapter 4, page 18.
Order
Number
446 220 100 0 ECU Communication with trailer
446 221 000 0 Display
894 607 390 0 Wiring harness Cable set, 7-pin
960 731 051 0 L shape wheel
960 731 031 0 Wheel module for rear axle, rim 22.5", 10
960 730 822 2 Counterweight Balance weight for front
960 731 802 0 PA tube for front axle wheel module,
960 731 822 2 PA tube for rear axle wheel module,
Component Comment 4x2 6x2 Articulated
ECU / warning lamps
optional 894 607 295 0
(5-pin, no trailer-towing
operation)
for the front axle, rim 22.5",
module
10 holes
holes
axle wheel module
L-shape
outside
bus 6x2
1 1 1
1 1 1
1 1 1
2 4 2
4 4 8
2 4 2
2 4 2
2 2 4
Operation via CAN bus
Circuit diagrams
960 731 804 0 PA tube for rear axle wheel module,
inside
960 731 801 0 PA tube
Table: 3-1: Components for bus / towing vehicle
Super Single
2 2 4
Provided the trailer is equipped appropriately, data exchange can also be made via
CAN bus besides wireless connection between towing vehicle and trailer. Towing
vehicle ECU needs to be connected to vehicular CAN Bus for this purpose too.
Detailed circuit diagrams are – as are the outline drawings of the components –
available on the Online Product Catalogue INFORM at http://www.wabco-auto.com.
Enter wiring diagram product number for opening the file:
• 841 801 970 0: Solobus
• 841 801 971 0: Articulated bus
• 841 801 972 0: Articulated truck / truck
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3.4 Configuration for trailers
Transmission types
Trailer and towing vehicle must be equipped with OPTITIRE for displaying trailer
OPTITIRE data in the diver's cab.
Alternatively, trailer data can display in towing vehicle only then when it is equipped
with an integrated display. When the trailer is also equipped with TCE or TEBS
then data transfer can be made to the towing vehicle central computer via CAN.
The following illustration compares both transmission types, wireless connection
and CAN bus, with each other.
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System Description
OPTITIRE
fig. 3-2: Data transfer wireless connection (top) and CAN
A
IVTM display
B
Wheel modules
C
OPTITIRE-ECU
D
Wireless connection
E
OPTITIRE Trailer ECU
F
Integrated display
G
Central computer
H
TEBS/TCE
Stand-alone trailer towing operation
If the trailer should be independently equipped with OPTITIRE, then the pressure
release can be carried out via telemetry or the vehicles own display. When using
the OPTITIRE display, it requires a special box for splash protection or another
protected attachment location. The WABCO SmartBoard can be installed as an alternative.
The driver cannot receive fault messages without OPTITIRE support while the towing vehicle is in motion.
OPTITIRE with several trailers
Equipment of tractor/trailer combinations with more than one trailer is possible.
Tractor/trailer combinations with two trailers can still be made with wireless connections; roadtrains need CAN bus connection with special ECUs.
Please contact your WABCO partner for more information.
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3
OPTITIRE
System Description
OPTITIRE with TEBS D, TEBS E or TCE
Installation in a vehicle with TEBS D, TEBS E or TCE is simple because this merely has to be plugged into pre-assembled cables. Other systems would require open
wiring that needs to be enclosed by protective housing.
Observe the current installation instructions for the control unit of the ABS / EBS in
the WABCO product database INFORM http://www.wabco-auto.com and / or those
of the vehicle manufacturer.
The circuit diagrams illustrated in the following table in excerpt form can be retrieved from INFORM.
Wiring diagrams for trailers
The circuit diagrams shown in excerpt form below can be retrieved from the WAB-
CO online product database NFORM at http://www.wabco-auto.com. To retrieve
them, enter the desired circuit diagram number in the "Product number" input field.
Wiring diagram 841 801 943 0:
Trailer ABS VCS
Cable position 8 (449 314 ... .) is opened and con-
nected to cable position 3 (449 674 273 0) and a
line to the stop light in a wiring box.
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Wiring diagram 841 801 946 0:
Trailer ABS VCS II
Cable position 8 (449 336 ... .) is opened and con-
nected to cable position 3 (449 674 273 0), cable
position 11 (449 621 ... .) and a line to the stop light
in a wiring box.
Wiring diagram 841 801 941 0:
Trailer EBS with CAN connection
Cable position 8 (449 614 ... .) is opened and con-
nected to cable position 3 (449 674 273 0) and a
line to the stop light in a wiring box. The ISS output
must not be used and needs to be set to 0 km/h.
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3
System Description
OPTITIRE
Wiring diagram 841 801 945 0:
Trailer EBS D with CAN
Connection is made with cable position 3
(449 377 ... 0 / 449 378 ... 0). The ISS output must
not be used and needs to be set to 0 km/h.
OPTITIRE diagnosis through diagnostic cable
446 300 329 2 via TEBS diagnostic port.
Trailer TCE
Connection like on Trailer EBS D with CAN but with
cable 449 302 ... 0.
Wiring diagram 841 801 940 0:
Trailer ECAS
Cable position 3 (449 674 273 0) is introduced into
bottom box of ECAS-ECU and connected there.
One cable to stop light (position 7) is installed additionally. You need screwed cable glands (PG 11:
894 130 312 2) for two cables.
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Wiring like 841 801 945 0
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Wiring diagram 841 801 944 0:
Vario-C
Cable position 3 (449 674 273 0) is introduced into
bottom box of ABS-ECU and connected there. One
cable to stop light (position 7) is installed additionally. You need screwed cable glands (PG 11:
894 130 312 2) for two cables.
Wiring diagram 841 801 942 0:
Trailer EBS and ELM
Cable position 8 (449 344 ... .) is opened and con-
nected to cable position 3 (449 674 273 0) and a
line to the stop light in a wiring box.
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3
OPTITIRE
The certificates are not part of this document but can be retrieved from the WABCO
System Description
Wiring diagram 841 801 913 0:
Trailer EBS D and SmartBoard
(from year of manufacture 2004)
The SmartBoard and OPTITIRE are connected to
the Trailer EBS D modulator on port IN/OUT2. CAN
2 must be activated (activation via diagnostic software).
1 Trailer EBS D Modulator 480 102 014 0
2 Cable family 449 377 ... 0
3 SmartBoard 446 192 110. 0
4 OPTITIRE
5 Distributor housing
Wiring diagram 841 802 155 0
Trailer EBS-E
OPTITIRE is connected to sub-systems using cable
(449 911 ... .).
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Wiring diagram 841 802 155 0
TEBS E with SmartBoard
OPTITIRE and SmartBoard are connected to sub-
systems using cable (449 916 ... .).
Table: 3-2: Components for trailers
3.5 Certificates
Certificates for mounting and additional mounting of OPTITIRE are available, which
significantly facilitate approval of vehicle registration papers.
online product database INFORM at http://www.wabco-auto.com. To retrieve them,
enter the search term in the "Index" input field.
Following certificates are stored there:
• Expertise TÜH ATC TB 2002-108.00
• Part certificate of TÜH ATC - TB 2003-023.00
• Type approval 94/9/EG CE 0032, TÜV03 ATEXxxxx
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