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BPW ECO Tronic EBS Operating And Installation Instructions

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BPW · THE QUALITY FACTOR
ECO Tronic EBS.
Operating and Installation Instructions
Version 1.4

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Summary of Contents for BPW ECO Tronic EBS

  • Page 1 BPW · THE QUALITY FACTOR ECO Tronic EBS. Operating and Installation Instructions Version 1.4...
  • Page 2 BPW Operating and Installation Instructions...

  • Page 3: Table Of Contents

    5.2.7 3/2-ways magnetic valve 3.1.2 Position with Trailer Roll Stability (TRS) 5.2.8 Steering axle lock application function 3.1.3 Identifi cation of ECO Tronic EBS ports 5.3 Soft Docking and fi xing - Main Modulator - Additional Modulator 6 Hazardous Goods / ADR Installations 3.1.4 Painting - protected areas...

  • Page 4: Introduction

    This publication provides assistance essential nowadays. This is because EBS offers a whole for fi rst installation of an ECO Tronic EBS in a semi trailer, range of advantages compared to conventional pneumatic centre axle drawbar trailer or drawbar trailer (full trailer). It deals brake systems: It increases safety due to shorter response with the confi...
  • Page 5 The ECO Tronic EBS can be used in a wide range of applications between the vehicles, thereby allowing for convenient through- with its fi...
  • Page 6 The special feature of ECO Tronic EBS: BPW not only offers you numerous standard EBS functions but also additional With the new ECO Tronic EBS, BPW is for the first time trailer-specifi c functions that help you to optimise your fl eet...

  • Page 7: Abbreviations

    1.2 Abbreviations Abbreviations Explanation Description 2S/2M 2 Sensors / 2 Modulators ABS system with 2 rotational speed sensors and 2 modulators Anti-Lock Braking System Prevents the locking of braked wheels to maintain lateral grip Assembly Data Management Software function for storing all important vehicle data Accord européen relatif au transport European agreement on international transport of dangerous goods by international des marchandises...

  • Page 8: Safety Information

    • Tighten screws and nuts with the prescribed tightening torque. • BPW can only guarantee the safety, reliability and performance of systems, in particular those of ECO Tronic EBS, if all instructions are complied with.

  • Page 9: System Layout

    - the full EBS function is guaranteed Fig. 1. (pin 5 of ISO 7638 connector). The power supply of the ECO Tronic EBS with a 5 pin ISO 7638 The warning lamp has two functions: connection is also possible. In this case the response time (time •...

  • Page 10: General Components

    Introduction 1.5 General components 1.5.1 Location of components in the trailer Modulator Sensor and Exciter ISO7638 - 7 pin connector Trailer Monitor Driver’s information plate Trailer Control Module (TrCM) (modifi ed 01.01.2011) Fig. 4 - Overview of the main components and their location in the trailer...

  • Page 11: Primary Features Of The Modulator

    1.5 General components 1.5.2 Primary features of the Modulator Integrated quick release valve An integrated quick release valve provides a rapid installation and reduces the need for separate pipe fi ttings and connections. In addition the spring brake air, once exhausted, is silenced using the silencing mechanism.
  • Page 12 24 V DC (min. 19 V to max. 32 V) Current consumption: max. 3.2 A Operating temperature: - 40° C to +70° C Operating medium: Exciter ring: 60 to 120 teeth BPW EBS Modulator (5 AUX, stability, with integrated quick release valve and double check valve).

  • Page 13: Ecu Connector Identifi Cation

    1.5 General components 1.5.3 ECU connector identifi cation - 2S/2M, 4S/2M system 24 V Switched Output, 24 V Switched Output, Analogue Input, Analogue Input, ISO 1185 power supply, Speed indicator Input for switching signal 5 V Power supply 5 V Power supply three digital inputs, 24 V power supply AUX 1...

  • Page 14: Overview Of Electrical Connections

    AUX 1, 2 or 3 Lining wear system (LWS) AUX 4 only External roll stability sensor AUX 5 only (as an option for the ECO Tronic EBS of the basic kit) N.B. AUX to be confi gured accordingly with Trailer Manager...

  • Page 15: Wiring Diagram - 2M

    Availability of auxiliaries and pressure sensor function depend on ECU variant and confi guration. N 8 If the solenoid is not approved by BPW, fi t a 1 A, 100 V minimum, diode as shown. N 2 “Right” is viewed sitting in the driver seat facing forward.

  • Page 16: Wiring Diagram - 3M

    (0 V to 24 V) Availability of auxiliaries and pressure sensor function N 7 If the solenoid is not approved by BPW, fi t a 1 A, 100 V depend on ECU variant and confi guration. minimum, diode as shown.

  • Page 17: Overview Of Pneumatic Connections

    1.5 General components 1.5.7 Overview of pneumatic connections Emergency 11 12 Service AUX1 11 12 = Item = Port Fig. 19 : 3-axle semi trailer - 2S/2M side by side confi guration - 2-line air brake system with Trailer Control Module and spring brake chambers Item Description...

  • Page 18: Installation Options (Confi Gurations)

    Installation options (Confi gurations) 2.1 Semi and centre axle drawbar trailers 2.1.1 2S/2M and 4S/2M, side by side Fig. 20 • Either (but only one) directly controlled axle may be lifted - 4S/2M • Any axle without directly controlled wheels may be a lift axle Modulator - 2S/2M ECU power connectors...
  • Page 19 2.1 Semi and centre axle drawbar trailers 2.1.2 4S/3M (recommended for self-steering axle) Fig. 21 • Any axle without directly controlled wheels may be lifted. • Any axle can be a steered axle. Modulators • Master ECU is mounted to EPRV’s. All sensors must be ECU power connectors connected to this Master ECU.

  • Page 20: 2M + Sl, Side By Side

    Installation options (Confi gurations) 2.1 Semi and centre axle drawbar trailers 2.1.3 2S/2M + SL, side by side (not recommended for self-steered axle) Fig. 22 • Any axle without directly controlled wheels may be a lift axle. Modulators ECU power connectors Select low valve (SL)

  • Page 21: Drawbar Trailers (Full Trailers)

    2.2 Drawbar trailers (full trailers) 4S/3M Fig. 23 • Sensed axles cannot be lifted. • Any axle without directly controlled wheels (unsensed) may be a lift axle. Modulators ECU power connectors • Master ECU is mounted to EPRV’s 21/22. All Sensors must be connected to this Master ECU.

  • Page 22: Chassis Installation

    Chassis installation 3.1 Mounting of the Modulator 3.1.1 Position without Trailer Roll Stability (TRS) function 360º Note: The following is applicable to installations and confi gurations without TRS function. The unit should be orientated and positioned so that the Power Cable connections face towards the required installation option (confi...

  • Page 23: Position With Trailer Roll Stability (Trs) Function

    (RH) chassis members of the vehicle (Fig. 29). Tandem axle For any other applications please refer to Within BPW Bergische Achsen KG. LH and RH chassis members The unit should not be in direct spray or splash water area and should be protected against high pressure cleaning.

  • Page 24: Identifi Cation Of Eco Tronic Ebs Ports

    Chassis installation 3.1 Mounting of the Modulator 3.1.3 Identifi cation of ECO Tronic EBS ports and fi xing - Main Modulator 283.5 mm Studs x 3 M 10 x 1.5 mm, 22 mm long 30.5 mm Delivery test port (22) 190.4 mm...

  • Page 25: Additional Modulator

    3.1 Mounting of the Modulator 3.1.3 Identifi cation of ECO Tronic EBS ports and fi xings - Additional Modulator 161.5 mm Fixing bolts x 4 M 8 x 1.25 mm, Tightening torque: 34 Nm (32 - 35 Nm) 58 mm...

  • Page 26: Painting - Protected Areas

    Chassis installation 3.1 Mounting of the Modulator 3.1.4 Painting - protected areas Mounting face When painting/coating all non-used electrical connections, pneumatic and exhaust ports must be protected. These are indicated by the shaded areas marked in Fig. 32. Adequate protection should be used to avoid penetration of the paint/coating.

  • Page 27: Mounting

    3.1 Mounting of the Modulator 3.1.5 Mounting Additional bracket design has to be as rigid as possible Mounting bracket (Fig. 33). The mounting fi xing must provide an electrical connection between the Modulator bracket and the trailer chassis. The installation angle must be  0.5 mm out of level. Fixing holes 0 ...

  • Page 28: Electrical Wiring

    Chassis installation 3.2 Electrical wiring 3.2.1 Wiring schematic ISO 7638 Safety back-up Sensor 7 Core 2 Core 2 Core 5 x 1.5 mm² 2 x 1.5 mm² 2 x 0.75 mm² 2 x 4.0 mm² ISO 7638 max. 4 m ISO 1185 (24N) Junction box...

  • Page 29: Wiring Diagram

    3.2 Electrical wiring 3.2.2 Wiring diagram B Sensors A Sensors ISO 1185 ISO 7638 Pin4 Pin1 Sensor S1B Sensor S1A Interface Trailer Monitor Fig. 38 - 2 Sensors - ISO7638 & ISO1185 with Trailer Monitor (3 AUX‘s fi tted) ISO7638 ISO1185 DIAG AUX 1...

  • Page 30: Auxiliary Equipment Wiring

    Chassis installation 3.2 Wiring diagram 3.2.3 Auxiliary equipment wiring Brake pad wear sensing B Sensors A Sensors External stability sensor (option for basic kit) ISO 1185 ISO 7638 Pin4 Pin1 Sensor S1B Sensor S1A Interface Sensor S2B Sensor S2A Trailer Monitor Fig.

  • Page 31: General Installation Recommendations - Cabling

    3.2 Electrical wiring 3.2.4 General installation recom- mendations - cabling Anti-vibration support Excess cable must not be allowed to hang free, but must be attached to the chassis (Fig. 40/1) to prevent damage due to vibration and abrasion. Ø max. 150 mm Fig.
  • Page 32 Chassis installation 3.2 Electrical wiring 3.2.5 General installation recom- mendations - ISO 7638 ISO 7638 Connector Should be positioned/grouped with other electrical connections (Fig. 43). Pin detail and identifi cation key location. Pin No. Designation ISO 1185 ISO 7638 Red (RD) 4 mm Plus electro valve (24 N) Black (BK) 1.5 mm...

  • Page 33: General Installation Recommendations - Junction Box

    3.2 Electrical wiring 3.2.6 General installation recom- Junction box mendations - Junction box The junction box should be mounted on a fl at surface (Fig. 47). Mounting holes to be drilled min. 6.25 mm diameter to avoid stress at the box from incorrect location. On mounting ensure cable runs are up to the junction box Cable (Fig.

  • Page 34: Power / Diag /Sensor / Aux Cabling

    Chassis installation 3.2 Electrical wiring 3.2.7 Power / DIAG / Sensor / 24 V AUX cabling Deck of trailer Sensor cable route should follow the centre line or outer radius of pipe or hose (Fig. 49). max. 400 mm Tie wraps not to be overtightened because on brake application rubber hose expands, i.e.

  • Page 35: Power (Iso 7638) Connections

    3.2 Electrical wiring 3.2.8 Power (ISO 7638) connections Electric wiring power connection From the slide lock housing (Fig. 52/1) (top horizontal connector housing). Remove transit cover from „PWR-A” position. Unlock the housing by sliding down lever (Fig. 52/2). Make sure slider is in the unlock position (Fig. 52/3). Ensure contact pins and seal are kept clean and free of any contamination prior to installation.

  • Page 36: Power (Iso 1185)

    Chassis installation 3.2 Electrical wiring 3.2.9 Power (ISO 1185) Super AUX connections „PWR-B“ (ISO 1185, 24 N) connection Remove blanking plug from position „PWR-B” (Fig. 55). Fig. 55 Identify orientation of the ISO 1185 orange coloured connector or the black SAUX connector (Fig. 56). Ensure contact pins and seal are clean and free of any contamination prior to installation.

  • Page 37: Diag Connections

    3.2 Electrical wiring 3.2.10 „DIAG” connections Diagnostic „DIAG” connection - Option 1 If no diagnostic units are to be installed retain blanking plug in position marked „DIAG” (Fig. 57). Fig. 57 Diagnostic „DIAG” connection - Option 2 If a remote mounted Trailer Monitor is installed remove blanking plug (Fig.

  • Page 38: Diag / Side Of Vehicle Connection

    Chassis installation 3.2 Electrical wiring 3.2.11 „DIAG” / Side of vehicle connection Diagnostic „DIAG” - side of vehicle connection - Option 3 Fig. 60 Mount the diagnostic connector on the outside of the main chassis rail. The position must be in an accessible area but not in the direct spray of the wheels (Fig.

  • Page 39: Connectors / Blanking Plugs

    3.2 Electrical wiring 3.2.12 Connectors / Blanking plugs Make sure that all connectors/blanking plugs are fully inserted into the ECU slide lock housing (Fig. 63). Fig. 63 Push in lock slider (Fig. 64/1) to secure in place all plugs/ connectors. Note: Do not use extreme force to push in slider.

  • Page 40: Sensor / Aux Plugs

    Chassis installation 3.2 Electrical wiring 3.2.13 Sensor / AUX plugs Example: Sensor 1B Sensor Plug Identification tags are incorporated on either side of the BLACK sensor / ECU connector (Fig. 66). front case These must be removed to identify the appropriate sensor before connecting into the ECU (Fig.

  • Page 41: Sensor / Aux Connections

    3.2 Electrical wiring 3.2.14 Sensor / AUX connections The ECU is supplied with blanking plugs in positions indicated (Fig. 68). These require to be removed to allow fi tment of additional sensors or permitted ancillary equipment. Fig. 68 Example - „AUX 1” connection Identify the „AUX 1”...

  • Page 42: Sensor Connections/ Cabling

    Chassis installation 3.2 Electrical wiring 3.2.15 Sensor connections/ Extension cable plug Sensor cable socket cabling Sensor Connection Sensor extension cable plug must be pushed fully into sensor cable socket till they clip into place to prevent falling out with axle vibration (Fig. 72). Clip to ‘click’...

  • Page 43: Colas Ilas

    3.2 Electrical wiring ® 3.2.16 COLAS 0.5 - 0.6 Nm 4 - 6 Nm ® ILAS -E connections (0.4 - 0.5 lbft) (3 - 4.4 lbft) DIN connector COLAS ® + / ILAS ® -E cable should be secured down the chassis rail on piping and should be secured at not more than 400 mm intervals.

  • Page 44: Auxiliary Equipment Wiring

    Chassis installation 3.2 Electrical wiring 3.2.17 Auxiliary equipment wiring ® ® COLAS ILAS Fig. 76 Fig. 77 Warning lamp Red (+) Black (-) Fig. 78 Steer axle lock (incl. reversing axle lock) Red (+) Lock Lock Sol. Sol. Black (-) Relay 1 Relay 2 Reverse lamp...
  • Page 45 3.2 Electrical wiring 3.2.17 Auxiliary equipment wiring ® Traction assist using ILAS -E, option 1 Junction box 24 V from Truck Traction Assist from switch AUX 2 or 3 ISO 12098 (15 Pin) ILAS ® Fig. 80 Traction assist is made operative by a 24 V (constant or Function: On request for traction assist, front axle lifts.

  • Page 46: Multimeter Measurements

    1.0 k < R < 2.4 k Sensor 1A, 1B or 2A, 2B Sensor disconnected 0  < R < 5  Earth continuity ECO Tronic EBS bracket and chassis 79  < R < 96  ® COLAS + Solenoid...

  • Page 48: Piping

    Piping 4.1 Pipe recommendation Brake and suspension piping layout Emergency 11 12 Service AUX1 = Item = Port Fig. 86 : 2M- 3-axle semi trailer with Trailer Control Module, spring brake chambers and suspension air bags (bellows)
  • Page 49 Item Description Material Size Remarks Emergency pipe Plastic 8 x 1 Pref 10 x 1 / 1.25 Alt 10 x 1.5 Alt Service pipe Plastic 8 x 1 Pref 2a to be 1/3 total trailer length 10 x 1 Alt 10 x 1.5 Alt Service pipe Plastic...

  • Page 50: Brake Piping Layout

    Piping 4.2 Brake piping layout 4.2.1 2M, 3-axle semi trailer, side by side 11 12 11 12 Emergency Service 11 12 11 12 = Item = Port Fig. 87 : 2M - 3-axle semi trailer with Trailer Control Module and spring brake chambers Item Description Notes...

  • Page 51: 3-Axle Semi Trailer

    4.2 Brake piping layout 4.2.2 3M, 3-axle semi trailer 11 12 11 12 Emergency Service 11 12 11 12 = Item = Port Fig. 88 : 3M - 3-axle semi trailer with Trailer Control Module and spring brake chambers Item Description Notes Emergency coupling with integrated fi...

  • Page 52: 2-Axle Drawbar Trailer (Full Trailer)

    Piping 4.2 Brake piping layout 4.2.3 3M, 2-axle drawbar trailer (full trailer) 11 12 Emergency Service 11 12 = Item = Port Fig. 89 3M - 2-axle drawbar trailer (full trailer) with Trailer Control Module and spring brake chambers Item Description Notes Emergency coupling with integrated fi...

  • Page 53: Air Suspension System Piping Layout

    4.3 Air suspension system piping layout ® + and ILAS ® Air suspension leveling valve, COLAS AUX2 AUX1 = Item = Port ® ® Fig. 90 : 3-axle semi trailer, COLAS + with auto reset to ride (RtR), ILAS -E, air suspension levelling valve Item Description Notes...

  • Page 54: Brake System

    Installation and Operating Instructions 5.1 Brake system Trailer air braking system When the brake is released, the yellow brake line is exhausted via the exhaust on the trailer control valve in the tractor unit. Twin-circuit braking system as per Directive The EBS vents the service brake cylinder of the braked axles 71/320/EEC via its ventilation outlets for the left and right side.

  • Page 55: Coupling Heads

    5.1 Brake system 5.1.1 Coupling heads Coupling head emergency Applications The coupling heads of the two line brake system, red for “supply” and yellow for “brake”, are installed to connect the supply and brake lines between the vehicle or the tractor unit and trailer vehicles.

  • Page 56: Trailer Control Module Trcm

    Installation and Operating Instructions 5.1 Brake system 5.1.2 Trailer Control Module TrCM Trailer Control Module TrCM Applications The Trailer Controle Module TrCM is a trailer brake valve with emergency brake, combined actuation valves (release and parking valve) and a charging valve without backfl ow. The release valve deactivates the „emergency brake“...
  • Page 57 5.1 Brake system 5.1.2 Trailer Control Module TrCM Connection Designations Pressure loss in the supply line. Effect on the service brake system (BBA): When pressure in the emergency line decreases by at least 1 bar per second, the automatic braking of the towing vehicle is activated before the pressure in the supply line drops to 2 bar.
  • Page 58 Installation and Operating Instructions 5.1 Brake system 5.1.2 Trailer Control Module TrCM 24.5 2 point 6 x M16x1.5 12 deep 5x M8 12 deep fixing Charging valve 3 point max. permissible fixing connecting piece 12 32.8 Fig. 98 Installation Guidelines Functional diagrams Install the valve with its attachment fl...

  • Page 59: Trailer Control Module Trcm

    5.1 Brake system 5.1.3 Trailer Control Module TrCM + Trailer Control Module TrCM + Applications TrCM + is a parking and shunting valve with with an integrated emergency brake valve for the service brake system and an overfl ow valve for auxiliary equipment (e.g. air suspension) which is used in two-line air brake systems in trailers The TrCM a fl...
  • Page 60 Installation and Operating Instructions 5.1 Brake system 5.1.3 Trailer Control Module TrCM + Initial charging Mode of Operation 24 23 1-2 4 21 Supply line coupled (Fig. 103 + 104): When the supply line is connected, the supply pressure provided by the tractor is available to the braking system in full, the service brake is released and the spring brakes are operating.
  • Page 61 5.1 Brake system 5.1.3 Trailer Control Module TrCM + Manoeuvring when uncoupled Pressure loss in the supply line. Effect on the service braking system (Fig. 105): 24 23 1-2 4 21 If the pressure in the supply line falls by at least 1 bar per second, the automatic brakes of the trailer vehicle will come on before the pressure in the supply line falls to 2 bar.
  • Page 62 Installation and Operating Instructions 5.1 Brake system 5.1.3 Trailer Control Module TrCM + 24.5 2 point 5x M8 12 deep M22x1.5 12 deep fixing 6 x M16x1.5 12 deep Charging valve 3 point fixing max. permissible connecting piece 12 32.8 73.5 Fig.

  • Page 63: Brake Lining Wear Sensoring

    The system is connected to special indicators of the brake linings. If corresponding wear of the linings occurs, a signal is transmitted to the ECU of the ECO Tronic EBS, which then results in the warning lights coming on. The brake lining wear sensoring helps to provide early recognition of worn brake linings.

  • Page 64: Air Suspension

    5.2 Air suspension Fig. 113 BPW Air Suspension A running gear system is only ever good as its suspension. BPW air suspension systems are individually designed to cope with where and for what they‘re going to be used, and what load they‘re going to carry.

  • Page 65: Standard Air Suspension Valve

    5.2 Air suspension 5.2.1 Standard air spring valve – dimensions and connections Identification mark for the lever mounting position, lever swivel angle 360° Charging Discharging Ø 6 min. 80 max. 320 Linkage assembled without tension (valve axle) Fig. 115 Application Air suspension valve The levelling valve is installed as a level control valve for load depended control using the air bellows of vehicles with air...
  • Page 66 Installation and Operating Instructions 5.2 Air suspension 5.2.1 Standard air suspension valve Technical Data When the vehicle is being loaded, the body (frame) approaches Operating pressure, dyn.: pe max. 13 bar the axle, causing the leverage and the control lever to rise and Permitted dyn.
  • Page 67 (d=4h8) on housing and on bore of the spindle. Statutorily prescribed max. heights must be adhered to. Please see the BPW documentation for air suspension systems for further information. The actual length of the connecting rod between the linkage to axle and the linkage at the control lever can now be determined, and the connecting rod can be fastened.

  • Page 68: Level Adjustable Air Suspension Valve

    Installation and Operating Instructions 5.2 Air suspension 5.2.2 Air suspension valve with height limitation – dimensions and connections max. 320 min. 80 SW 27 Identification mark for the lever mounting position Charging Discharging Ø 3.3 Adjusting screw Exhaust valve SW 13 Ø...
  • Page 69 5.2 Air suspension 5.2.2 Air suspension valve with height limitation Piping diagram Adjustment of Height Limitation The height limitation can be set over a range of α = 15° to 40°. If the factory-set height limitation of α = 45° ±2° needs to be changed, the dump valve must be removed (using SW 13) and the adjuster screw turned with a suitable tool.
  • Page 70 Installation and Operating Instructions 5.2 Air suspension 5.2.3 Air suspension valve with zero point adjustment – dimensions and connections max. 320 min. 80 Identification mark for the lever mounting position, lever swivel angle 360° Charging 1. Ride height Discharging Ø6 Linkage assembled without tension (valve axle) Fig.

  • Page 71: Air Suspension Valve With Zero Point Adjustment

    5.2 Air suspension 5.2.3 Air suspension valve with zero point Piping diagram adjustment Inspection Check function and leak. The pressure should neither rise nor fall at the delivery ports 21, 22 in the neutral position. Check the linkage moves freely and is in good condition, replace if bent or welded.

  • Page 72: Colas

    Installation and Operating Instructions 5.2 Air suspension ® 5.2.4 COLAS ® COLAS Applications The „COLAS ® +“ raising/lowering valve has a broad range of functions. The following features are integrated: deadman function, RoRo position and “Reset to Ride“ (RtR) function. Mode of Operation “Drive“...
  • Page 73 An electrical connection to the solenoid valve is permissible only via the ECO Tronic EBS-ECU, which provides a signal „Reset Fig. 130 to ride height“. BPW Bergische Achsen is not liable for other...
  • Page 74 To ensure the permitted spring defl ections are not exceeded during the raising process, it is advisable to use a height limitation device (e.g.: BPW air suspension valve with height limitation). Any exceeding of permitted spring defl ections can lead to individual components being damaged.

  • Page 75: Ilas -E

    5.2 Air suspension ® 5.2.5 ILAS ® ILAS Application ® „ILAS -E“ is used for electrically controlled lifting and lowering of one or several lift - axles with conventional air suspension systems. With electronically controlled air brake systems, e.g. EBS, ILAS- E are controlled by the load depended output signal.
  • Page 76 Installation and Operating Instructions 5.2 Air suspension ® 5.2.5 ILAS - Identifi cation of ports and fi xings Bayonet connection according to DIN 72585 All ports Push-in fi ttings for tube DIN 7424 - 8x1 - 23 mm deep 204. mm 49.5 mm 65 mm 67 mm...

  • Page 77: Shut-Off Cock

    5.2 Air suspension 5.2.6 Shut-off cock Fig. 135 Application The shut-off cock is used for fi lling and exhausting compressed air lines, e.g. lift axle valves, combined chambers or steering axles. The shut-off cock is used, for example, for manually activating the steering axle lock when reversing (see example of application p.

  • Page 78: 3/2-Ways Magnetic Valve

    Installation and Operating Instructions 5.2 Air suspension 5.2.7 3/2-Ways magnetic valves M 12 x 1.5 Bayonet connection according to DIN 72585 Fig. 137 Application 3/2-ways magnetic valves are used to control ventilation and breathing procedures in pneumatic installations. These valves are operated electrically and used in connection with the ECO Tronic EBS, for example for controlling steering axle blocks or for zero point adjustment in the case of air suspension valves...

  • Page 79: Steering Axle Lock Application

    5.2 Air suspension 5.2.8 Example of an application of a steering axle block (with 3/2-ways magnetic valve and manual shut-off cock) AUX1 AUX2 = Item = Prot Fig. 139: 3-axle semi trailer, COLAS ® + with auto reset to ride (RtR), air suspension levelling valve, 3/2-ways magnetic valve for installation with a steering axle lock as well as manual shut-off cock Item Description...

  • Page 80: Soft Docking

    BPW offers added security with Soft Docking, when linked to the ECO Tronic EBS which can apply the brakes automatically when reversing into a loading bay. Benefi ts: •...
  • Page 81 5.3 Soft Docking Preparation Soft Docking Junction Box - Determine a suitable mounting point for: - Soft Docking junction box 116 mm - Ø 6 mm - Reversing alarm Installation 72.5 mm Ø 6 mm All cables must be installed where suitably protected by the trailer chassis.
  • Page 82 Plug the adapter for the power supply between these two connectors (main cable and rear junction cable) (Fig. 146). Fig. 146 Connection to ECO Tronic EBS Connection to the Modulator Plug the Auxiliary Cable into the AUX ports 4 or 5 in the EBS Modulator (Fig.
  • Page 83 Reverse alarm: returns to slow beep frequency Principle of operation The braking command is delivered from the ECO Tronic EBS The controlled automatic braking commences at 1 meter via an auxiliary port. The braking at 1 meter distance lasts for 2 distance from the dock.
  • Page 84 Installation and Operating Instructions 5.3 Soft Docking Adjusting the sensors: Adjusting the sensors If you cannot position the sensor assembly on the outermost area of the rear panel, you can adjust the detection of the sensors with a special tool (DIN 546). The available adjustable area of the sensor is 10°...
  • Page 85 5.3 Soft Docking Night Silent Mode Technical Data If the reverse gear is engaged twice (within 2 seconds) the Nominal voltage 24 V acoustic warning installation (buzzer) will be ‘’night silent’’. The Operating voltage 19 bis 32 V outline marker is however active. The ‘’night silent’’ option is to Operating temperature -30 bis +65°...
  • Page 86 Liability Exclusion The system is not totally accurate under all circumstances. The driver must manoeuvre with care up to the dock. BPW cannot be held responsible for any damage that may occur when using the system. It is the driver’s responsibility to reverse safely.

  • Page 87: Hazardous Goods / Adr Installations

    Hazardous goods / ADR installations Vehicles equipped to transport hazardous goods or explosive substances are required to have electrical systems with ADR/GGVS: ---/----/-- specifi ed levels of safety and protection. These requirements are defi ned in the European Agreement on International Transport of Dangerous Goods by Road (ADR 2007).
  • Page 88 Hazardous goods / ADR installations Junction box Any wiring required to a junction box (for brake lamp power supply) must be fully approved for use on an ADR vehicle (Fig. 157). Fig. 157 Auxilliary connections It is the installers responsibility to ensure that the auxiliary component fi...

  • Page 89: Programming

    Programming To complete the ECO Tronic EBS installation the ECU must be programmed by using the Trailer Manager software. Refer to Trailer Manager Operator’s Guide BPW-BA-TM 37071102e for further information.

  • Page 91: System Diagnostics

    System diagnostics 8.1 System diagnostics An important feature of the ECO Tronic EBS is that it provides an extensive on board diagnostic capability. The system displays a range of codes, which allow rapid diagnosis of the problem should one occur. BPW offers a diagnostic case containing the Alternative positions necessary software and connectors.

  • Page 92: Warning Lamp

    A warning lamp located on the driver’s console of the towing vehicle is operated from the ISO 7638 power cable only when the ECO Tronic EBS is powered by the ignition switch (Fig. 162). As an option in addition to the cab warning lamp a trailer Fig.

  • Page 93: Power Up Eco Tronic Ebs

    8.1 System diagnostics 8.1.3 Power up ECO Tronic EBS The ECO Tronic EBS system has two power up modes. When switching the ignition on (24 V on B+) the following occurs: With no yellow line pneumatic pressure (i.e. Brakes OFF) The system adopts automatic load sensing mode when the brakes are applied.

  • Page 94: Diagnostic Trouble Codes (Dtc)

    System diagnostics 8.2 Diagnostic Trouble Codes (DTC) If a Diagnostic Trouble Code displayed is not listed here, check for intermittent sensor and wiring faults. DTC Displayed Description DTC Displayed Description ECU TIME OUT No supply on ignition Brake Apply Solenoid Group switched line.
  • Page 95 8.2 Diagnostic Trouble Codes (DTC) DTC Displayed Description DTC Displayed Description Demand Pressure Transducer Group Air Suspension Pressure Transducer Group PRESSURE DEMAND Service line pressure SUSPENSION SENSOR Suspension pressure SENSOR SHORT CIRCUIT transducer short circuit SHORT CIRCUIT transducer short circuit PRESSURE DEMAND Service line pressure SUSPENSION SENSOR...
  • Page 96 System diagnostics 8.2 Diagnostic Trouble Codes (DTC) DTC Displayed Description DTC Displayed Description UNKNOWN The ECU has generated a Lining Wear Group DTC that is not recognised Lining wear wiring open by this version of Trailer BRAKE PADS circuit Manager or Trailer Monitor and so cannot be decoded TRAILER ROLL STABILITY Lateral accelerometer wiring...

  • Page 97: Recommended Maintenance Schedule

    Recommended maintenance schedule Time or Mileage Component Operation (whichever occurs fi rst) Every 3 months or 40,000 km Complete system Perform system check out and air leakage check. Annually or every 160,000 km Complete system Perform system check out and air leakage check. Check wiring and piping security and integrity.
  • Page 98 Notice...
  • Page 100 BPW Bergische Achsen Kommanditgesellschaft . P.O. Box 12 80 . D-51656 Wiehl . Phone: +49 2262 78-0 . info@bpw.de . www.bpw.de...

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