Ein Unternehmensbereich der BESAN141.DOC 1/36 WABCO Standard GmbH. Directive 98/12/EC. Annex XIV

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1 BESAN141.DOC 1/36 Standard GmbH Directive 98/12/EC Annex XIV Alternative Test Procedure for Trailer Anti-Lock Braking Systems Information Document for Vario Compact Trailer ABS Trailer ABS Information Document

2 BESAN141.DOC 2/36 Standard GmbH Contents: GENERAL Name of manufacturer System name System variations System configurations Explanation of the basic function and philosophy of the system APPLICATIONS List of trailer types and ABS configurations Schematic diagrams of the system configurations Relationship of tyre circumference to the resolution of the exciter Tolerance on tyre circumference between one axle and another fitted with the same exciter Scope of application with respect to suspension type Recommendations on differential brake input torque in relation to the ABS configuration and trailer bogie Test data of energy consumption Additional information to the application of the anti-lock braking system COMPONENT DESCRIPTION Sensors Controllers Modulators Electrical Equipment Pneumatic circuits ELECTROMAGNETIC COMPATIBILTY (EMC) APPENDICES 11 Appendix 1: configurations of sensors and modulators for different trailer types 12 Appendix 2: relationship between tyre circumference and number of polewheel teeth 15 Appendix 3: modulator types 16 Appendix 4: VCS wiring diagram 17 Appendix 5: brake diagrams 18 Appendix 6: EMC approval report 34 Appendix 7: Approved Suspension Types 36 Trailer ABS Information Document

3 BESAN141.DOC 3/36 Standard GmbH General Name of manufacturer Am Lindener Hafen 21 D Hannover Germany System name Vario Compact Trailer ABS System variations The Vario Compact ABS ECU and modulator components can be mounted seperately on the vehicle frame. Alternatively integrated units are available, where ECU and modulator are combined to one compact unit. Standard power supply is 24 Volts, but also 12 Volt versions are available System configurations 2S/2M: two sensors and two modulators 4S/2M: four sensors and two modulators 4S/3M: four sensors and three modulators Explanation of the basic function and philosophy of the system The Vario Compact ABS is installed as an add-on -system in line with the service braking system. The sensors fitted to the wheels are inductive wheel speed sensors generating an electrical signal proportional to its wheel s speed. The electronic control unit processes these signals into logical quantities for controlling the braking pressure via the modulators according to load and road conditions. In case of a locking tendency the brake cylinder pressure of the corresponding wheel will be released, kept constant during expected or measured wheel re-acceleration and is increased stepwise after re-acceleration to start the ABS-cycle again if the brakeforce is still too high for actual friction. The electrical system monitors itself. In the event of a fault, any parts found to be defective are selectively switched off, and the warning facility is actuated. Even in Trailer ABS Information Document

4 BESAN141.DOC 4/36 Standard GmbH the event of the whole system is being switched off, the function of the braking system covered by the ABS is maintained (although without ABS control). Correct electrical/electronic functioning of the ABS is indicated by a warning facility in the driver s cab of the towing vehicle, or a warning light on the headboard of the trailer Applications List of trailer types and ABS configurations The Vario Compact ABS applies semitrailers, central axle trailers or drawbar trailers of categorie O 3 and O 4 with air braking systems according to 98/12/EG. No. of 2S/2M 4S/2M 4S/3M axles 1 x - - semi-trailer 2 x x x 3 x x x 1 x - - central-axle trailer 2 x x x 3 x x x full trailer x x The running gear can have mechanical or air suspension. Depending on the specific requirements of the respective trailer special equipment may be fitted upstream of the modulator, e. g. automatic load sensing valve, reducing, pressure limiting or adapting valves. The braking system may be equipped with drum brakes or disc brakes. For sample diagrams see Schematic diagrams of the system configurations Appendix 1 shows possible configurations of sensors and modulators for the different trailers defined in item Relationship of tyre circumference to the resolution of the exciter Trailer ABS Information Document

5 BESAN141.DOC 5/36 Standard GmbH The sensor frequency must be in the range of 7,05 Hz/(km/h) to 10,14 Hz/(km/h). When sensing an exciter with 100 teeth, this frequency range corresponds to a wheel circumference of mm to mm. This represents a tolerance range of - 20 % % using a standard circumference of mm. For other tyre dimensions out of this range corresponding exciters must be used as shown in appendix Tolerance on tyre circumference between one axle and another fitted with the same exciter The sum of rolling circumference tolerances for the permissible tyre combinations for the vehicle must not exceed a value of 6,5 %. Otherwise the number of teeth on the pole wheels must be adjusted to the respective tyre circumferences as shown in appendix Scope of application with respect to suspension type The Vario Compact ABS is applicable to trailers with mechanical or air suspension. Appendix 7 defines specific suspension types by manufacturer for use Recommendations on differential brake input torque in relation to the ABS configuration and trailer bogie For multiple-axle applications an almost identical utilization of friction of these axles is required. If all of the wheels are not fitted with sensors, the axle(s) which usually lock(s) first must be equipped with sensors. Multiple-axle applications having only static axle load proportioning must be equipped in that way that the wheels of all axles reach their locking point simultaniously and that one wheel directly controlled - does not control more than two other wheels or - in the case of central axle trailers does not indirectly control more than one wheel or one axle Test data of energy consumption The energy consumption has been tested according to paragraph 6.1 of annex 10 of 98/12/EG and annex 13 of ECE R 13, series 09, respectively. To determine the worst case a variation of axle load has been made. Within a range of ± N of the worst case the energy consumption for different ABS configurations have been determined. During all energy consumption tests the load sensing valve was in a fully laden position. Automatic slack adjusters (if installed) were out of operation, unless the vehicle with disc brakes (due to the design of this brake type). Trailer ABS Information Document

6 BESAN141.DOC 6/36 Standard GmbH The following table represents the data of the energy consumption tests. It shows the supply pressure after ABS control of 15 sec and five additional applications. The results are different for O 3 - and O 4 -vehicles. Energy Consumption O3-vehicles O4-vehicles ,5 2,0 2,5 3,0 3,5 4,0 4,5 Axle load in kg* Additional information to the application of the anti-lock braking system Each electronic control unit has a standard parameter setting depending on the part number and identification. Any defect can therefore be displayed for any specific system. The connection of an ECU, with its parameters set correspondingly, to a system arrangement is indicated by the warning facility staying on, and a specific error message. Trailer ABS Information Document

7 BESAN141.DOC 7/36 Standard GmbH Component description Sensors Inductive wheel speed sensors are mounted opposite to a toothed wheel and generate an AC voltage with variable frequency depending on the wheel speed. The sensors transmit the information from the rotating toothed wheels to the ECU. Based on this information the ECU calculates the wheel and vehicle speeds. Special care must be taken to ensure accurate speed information. Identification: Wheel speed sensors: part number Sensors are mounted in clamp bushings, part number or Controllers The Electronic Control Unit (ECU) controls and supervises the connected components. Main features are: ABS control in case of locking tendency of the wheels fault detection diagnostic communication The ECU is designed in a microprocessor-controlled digital technology with system recognition and adjustable parameters. Main inputs and outputs are: power supply accoding to ISO 7638 alternative power supply according ISO 1185 or ISO 3731 up to four inputs for wheel speed signals up to three outputs for activating the modulators Failure modes: The electrical system monitors itself. In the event of a fault, any parts found to be defective (ECU, sensors, modulator(s)) are selectively switched off, and the warning facility is actuated. Even in the event of the whole system being switched off the function of the braking system covered by ABS is maintained (although with ABS control). Correct electrical/electronic function of the ABS is indicated by a warning facility in the drivers cab in the towing vehicle (via pin 5 of the electrical connector conforming to ISO 7638) or a warning light on the headboard of the trailer. Identification: Trailer ABS Information Document

8 BESAN141.DOC 8/36 Standard GmbH Electronic Control Unit: part numbers to (further versions are possible) Additional features: retarder control integrated speed switch speed output diagnostic interface according to ISO 9141 internal and external blinkcode automatic recognition of lift axles Modulators The ABS modulator valve serves the purpose of holding the pressure or venting the brake chambers, this is being done independently of the pressure that is transmitted by the brake valve of the trailer. Several types of modulators can be used (please also refer to appendix 3): ABS Relay Valve Electrically driven relay valves -both single or horizontally opposed relay valves- with the functions of: holding pressure (solenoid EV activated) reducing pressure (solenoid AV activated) increasing pressure (no solenoid active) During a brake application without ABS active due to high friction surface, the device operates as a relay valve; pressure that is put in the relay valve, is not influenced by the valve. part numbers: to (further versions are possible) For limitations of application regarding volume of brake chamber etc. see the product specification of the valve. ABS Solenoid Control Valve Electrically controlled modulators with the functions of: holding pressure (solenoid EV activated) reducing pressure (solenoid EV and AV activated) increasing pressure (no solenoid active) Trailer ABS Information Document

9 BESAN141.DOC 9/36 Standard GmbH During a brake application without ABS active due to high friction surface, the device has no function; pressure that is put in the valve, is not influenced by the valve. part numbers: to to (further versions are possible) For limitations of application regarding volume of brake chamber etc. see the product specification of the valve Electrical Equipment The circuit diagram in appendix 4 shows the connection of all external components (power supply, sensors, modulators). All components are connected via external connectors, which are moulded and coded to avoid mismatching. All cables and connectors fullfil GGVS resp. ADR requirements. Powering methods standard powering of the ECU and modulators via power connector according to ISO (24V) or ISO (12V) alternative powering is possible according to: - ISO 1185 (24N, port 1 and 4 of the 7-pole plug-in connection) or - ISO 3731 (24S, port 2 and 6 of the 7-pole plug-in connection) Warning lamp sequence The ECU can perform two different warning lamp sequences. The sequence can be changed by parameter setting. 1st Option: When the vehicle is stationary: warning facility comes on after the power supply is switched on if no current error is detected, the warning facility is switched off after app. 3 seconds. if during prior driving a sensor or air gap fault was detected, the warning facility is not turned off until v 7 k.p.h. (provided there is no current error present) When the vehicle is moving at v 7 k.p.h.: Warning facility comes on or stays on if an error is detected 2nd Option: When the vehicle is stationary: warning facility comes on after the power supply is switched on Trailer ABS Information Document

10 BESAN141.DOC 10/36 Standard GmbH if no current error is detected the warning facility will go off after app. 3 seconds and come on again after further 2 seconds. The warning facility is switched off after v 7 k.p.h. if, however, a current error has been detected, e.g. of the sensor/air gap fault, the warning facility will stay on permanently after power supply has been switched on Pneumatic circuits Sample brake diagrams for different trailers with standard air brakes are represented in appendix 5 (page 1 to 16): Page 1: Page 2: Page 3: Page 4: Page 5: Page 6: Page 7: Page 8: Page 9: Page 10: Page 11: Page 12: Page 13: Page 14: Page 15: Page 16: 1-axle central axle trailer with 2S/2M 2-axle central axle trailer with 2S/2M 2-axle central axle trailer with 2S/2M (diagonal axle regulation, DAR) 2-axle central axle trailer with 2S/2M or 4S/2M 2-axle central axle trailer with 4S/3M 3-axle central axle trailer with 2S/2M 3-axle central axle trailer with 4S/2M 3-axle central axle trailer with 4S/3M 1-axle semi-trailer with 2S/2M 2-axle semi-trailer with 2S/2M or 4S/2M 2-axle semi-trailer with 4S/3M 3-axle semi-trailer with 2S/2M 3-axle semi-trailer with 4S/2M 3-axle semi-trailer with 4S/3M 2-axle trailer with 4S/3M 3-axle trailer with 4S/3M Limitation on pipe/tube size and associated lengths: The length of the hoses between modulator valve and brake chambers should be as short as possible. If the cross section of the hose from the modulator valve to the brake cylinder is 9 mm the maximum length is 2.5 m. If the cross section of the hose from the modulator valve to the brake cylinder is 11 mm the maximum length is 3.0 m. All brake chambers actuated by the modulator valve should be connected with the same pipe length and cross section to the device. In any case the gradient of pressure decrease in the brake chamber should be 20 bar/s at least (between 5 and 2 bar) to assure sufficient performance. The size of brake chambers should not exceed 3 x type 30 per relay modulator resp. 2 x type 30 per solenoid control valve. The cross section for the air supply hose to the relay modulator valve (fitted to port 1) should be choosen as wide as possible; recommended is a minimum of 9 mm. Trailer ABS Information Document

11 BESAN141.DOC 11/36 Standard GmbH Electromagnetic Compatibilty (EMC) The Vario Compact ECU has been certified according to 72/245/EEC (last amended by Directive 95/54/EC). The type approval number is e1*72/245*95/54*1058. The EMC approval report is enclosed in appendix 6. Further EMC tests have been carried out to verify sufficient immunity level equivalent to 100 V/m. Emission tests have been made to check out that there is no disturbance in radio frequency communication on vehicles Appendices Trailer ABS Information Document

12 BESAN141.DOC Standard GmbH Appendix 1: configurations of sensors and modulators for different trailer types (page 1/3) Trailer ABS Information Document

13 BESAN141.DOC Standard GmbH Appendix 1 (page 2/3) Trailer ABS Information Document

14 BESAN141.DOC Standard GmbH Appendix 1 (page 3/3) Trailer ABS Information Document

15 BESAN141.DOC Standard GmbH Appendix 2: relationship between tyre circumference and number of polewheel teeth (page 1/1) Trailer ABS Information Document

16 BESAN141.DOC Standard GmbH Appendix 3: modulator types (page 1/1) Trailer ABS Information Document

17 BESAN141.DOC Standard GmbH Appendix 4: VCS wiring diagram (page 1/1) Trailer ABS Information Document

18 Appendix 5: brake diagrams (page 1/16) page 18/36

19 Appendix 5 (page 2/16) page 19/36

34 BESAN141.DOC 34/36 Standard GmbH Appendix 6: EMC approval report (page 1/2) Trailer ABS Information Document

35 BESAN141.DOC 35/36 Standard GmbH Appendix 6 (page 2/2) Trailer ABS Information Document

36 BESAN141.DOC 36/36 Standard GmbH Appendix 7: Approved Suspension Types Manufacturer Model Type Acerbi AV Air suspension, balanced Bartoletti Bartoletti Air suspension, balanced Bartoletti Mechanical BPW SLU. SLO, SLM, VA Air suspension, balanced VB, GW, BW, VG, VB Mechanical Cardi PR, PR Air suspension, balanced MR Mechanical Cometto SP1, SP2 Air suspension, balanced MA3 + G1 Mechanical Gigant / SAE LG, TLG, LR, TLR, NLR,TO Air suspension, balanced LK Mechanical Granning PTS, PTL Air suspension, balanced Hendrikson HTE, HT 250 Air suspension, balanced HST Mechanical Meritor Flexair, Indair Air suspension, balanced SMT Mechanical Piazenza U2, N2, P1, R2, S2,V1, V2, Air suspension, balanced R2, N2, S2 Mechanical Rolfo 7T, 10T, 16T Air suspension, balanced SAF Intraax, Intradisk, Intradisk plus, IWST, Modul Air suspension, balanced SMB NA, SA, ZA Air suspension, balanced FA Mechanical Weweler Euro, Heavy Duty, Mega Lite: Specials; Ultra Lite Air suspension, balanced Viberti AV Air suspension, balanced Zorzi B4P, R4P, R6P, R10P, S6P, S10P, S12P S6M, S10M, R10M Air suspension, balanced Mechanical Trailer ABS Information Document