BENDIX VORAD VS-400 Installation Manual
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BENDIX VORAD VS-400 Installation Manual

BENDIX VORAD VS-400 Installation Manual

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

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Summary of Contents for BENDIX VORAD VS-400

  • Page 1 Bendix VORAD VS-400 ™ ® Installation Guide Bendix VORAD VS-400 System ™ ® BW2772 (Formerly VOIG0100) September 2010...

  • Page 2: Table Of Contents

    Table of Contents Introduction Warnings....................2 Federal Communications Commission.

  • Page 3: Warnings

    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.

  • Page 4: Federal Communications Commission

    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.

  • Page 5: Application Information

    Driver Interface Unit (DIU) and Side Object Forward Looking Radar (FLR) Detection System Function S/C Only CWS Only S/C & CWS S/C, CWS & SOD SOD Only S/C = Bendix SmartCruise adaptive cruise control ™ ® CWS = Collision Warning System...

  • Page 6: Installation Tools

    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 Tools Reference Literature • Installation Guide - BW2772 • Troubleshooting Guide - BW2771 •...

  • Page 7: Space Claim

    Space Claim Space Claim Forward Looking Radar Dimensions 3.85" (98.0mm) 2.49" (63.4mm) 3.87" 3.30" (98.5mm) (84.0mm) 1.60" (40.6mm) 3.30" (84.0mm)

  • Page 8: Side Object Detection Dimensions

    Space Claim Side Object Detection Dimensions Side Sensor 5.36" (136.1mm) 0.82" (20.8mm) 5.60" (142.2mm) 1.38" (35.1mm) 0.9" (22.9mm) 2.04" 2.04" (51.8mm) (51.8mm) 3.24" 3.53" (82.3mm)
  • Page 9 Space Claim Side Sensor Display 1.20" (30.5mm) 1.60" (40.6mm) 1.00" (25.4mm) 2.30" 2.00" (58.4mm) (50.8mm) 0.70" (17.8mm) 2.10" (53.3mm) 2.80" 39.00” ± 3.00" (71.1mm) (990.6mm ± 76.2mm) 2.00" (50.8mm)

  • Page 10: Driver Interface Unit Dimensions

    Space Claim Driver Interface Unit Dimensions 1.97" (50mm) 3.70" (93.90mm) 4.07" (103.39mm) 3.67" (93.18mm) 3.16” (80.2) 4X R.207 (5.25) 1.58” (40.1) 2X 2.5˚ .20” (5.2) Panel Cut Out 2X 1.56” (39.5) 1.97” (50.0) (Without bezel) 2X .63” (15.9) 1.61” (40.9) 2X 2.5˚...

  • Page 11: Mounting Requirements

    Mounting Requirements 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.
  • Page 12 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 ™...
  • Page 13 Mounting Requirements Installation Bumper Mounting (Optional) Bracket 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...
  • Page 14 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...
  • Page 15 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.
  • Page 16 Mounting Requirements Options in white boxes are considered good options. Options in grey boxes are considered possible options. Material Recommended Recommended Material Number Commercial Reference* Material Thickness (mm) Thickness with Cover @ 80° (mm) Polyloy B69L62 PA6 2.25 2.22 TUC1228/93 CYCOLAC XMA 2.36 2.32...
  • Page 17 Mounting Requirements Vibration Specifi cations Mounting mechanisms shall be designed to be compliant with the radar vibration spectrum illustrated below. These vibration constraints are based on radio-frequency considerations in order to be compliant with the radar functional specifi cation. There are no specifi c mechanical requirements along the Y- and Z-axis from a radio-frequency point of view. The mechanical movements measured at the FLR center along the X-axis shall be less than the peak-to-peak displacement shown below.
  • Page 18 Mounting Requirements Painting A wide variety of colors and textures can be applied to the Forward Looking Radar housing using commercially available organic paints and conventional application processes. Painting the component may assist with color degradation over time. The following guidelines apply: •...
  • Page 19 Mounting Requirements Alignment ▲ WARNING The alignment of the Forward Looking Radar is critical to the correct operation of the Bendix ™ VORAD ® VS-400 system. Improper alignment can cause the system to improperly detect objects in the vehicle’s path. Every precaution should be taken to ensure the VS-400 alignment (both horizontal and vertical), is correct.
  • Page 20 Mounting Requirements Horizontal Alignment The Forward Looking Radar must be facing straight ahead (azimuth) of the vehicle in order to optimally detect objects in the vehicle path. Select two truck reference points that are identical and symmetrical about the truck centerline. Ensure the reference points are equally aligned.

  • Page 21: Side Object Detection (Sod)

    Mounting Requirements Mounting Requirements - Side Object Detection (SOD) Side Sensor The Side Sensor should be mounted on the side of the vehicle, between 22" (558.8mm) and 36" (914.4mm) from the ground and at least 18" (457.2mm) rear of the side view mirror (see diagram below). Typically, the Side Sensor is located on the passenger side of the vehicle, however, it can also be installed on the driver side of the vehicle.
  • Page 22 Mounting Requirements Sensor Orientation The Side Sensor should be orientated so the embossed logo is parallel to the ground. Orientation is crucial for proper operation due to the radar's polarized beam profi le. Mounting the Sensor The sensor should be mounted to the vehicle using 10-24 (6mm) stainless steel hardware. Bolts should be installed from the sensor side, with fl...
  • Page 23 Mounting Requirements Mounting Requirements - Driver Interface Unit (DIU) The Driver Interface Unit (DIU) serves as the Bendix VORAD Collision Warning System's central information center. The DIU provides ™ ® the driver with visual and audible alerts, as well as system confi guration, status, and diagnostic information. The DIU uses the vehicle's SAE J1939 data link to communicate with the FLR, and other vehicle system devices.
  • Page 24 Mounting Requirements Installation The DIU should be located where the driver can easily view and adjust the controls. This can be located on top of, or integrated into, the dashboard fl ush with the front edge of the dashboard. Ease of operation and visibility of the DIU front panel are the primary considerations. The method chosen for routing the wiring harness to the DIU should also be taken into consideration when determining the optimal location.

  • Page 25: Electrical Requirements

    Electrical Requirements Electrical Requirements - Forward Looking Radar (FLR) Power Requirements • Operating Voltage: +9-16Vdc • Power Current: < 2 amps (average 1 amp) • Recommended Fuse: 5 amp delayed fuse Wiring Schematic All electrical connections can be made in the engine compartment. Front Looking Radar Mating Connector: Connector Body:...

  • Page 26: Wiring Harness

    Electrical Requirements Wiring Harness Notes: All wires to be cross link TXL or equivalent unless otherwise specifi ed. Use approved J1939 cable. Interconnection Table From Code Gauge From Code Gauge J1-1 Plug – – J1-7 Plug – – J1-2 Plug –...

  • Page 27: Ignition And Ground

    Electrical Requirements Ignition and Ground Ignition power (switched power) run to main power lead that feeds the ignition bus Pin # Description J1-9 Chassis Ground J1-10 +9-16VDC Switched...

  • Page 28: J1939

    Electrical Requirements J1939 Note: The J1939 data bus uses two (2) 120-ohm resistors to terminate each end of the data bus on the vehicle. These resistors must remain in place for proper data bus communication. Due to the mounting location of the Forward Looking Radar, the closest of the vehicle's J1939 terminators may have to be relocated nearer the radar as shown in the diagram below.

  • Page 29: Side Object Detection (Sod)

    Electrical Requirements Electrical Requirements - Side Object Detection (SOD) The Side Object Detection (SOD) system consists of two components: a Side Sensor (SS) and a Side Sensor Display (SSD). Power Requirements • Operating Voltage: +9-32Vdc • Power Current: Not to exceed 0.25 amps •...

  • Page 30: Ignition And Ground

    Electrical Requirements Ignition and Ground fuse Ignition power (switched power) run to main power lead that feeds the ignition bus fuse Ignition power (switched power) run to main power lead that feeds the ignition bus...

  • Page 31: Driver Interface Unit (Diu)

    Electrical Requirements Electrical Requirements - Driver Interface Unit (DIU) Power Requirements • Operating Voltage: +9-32Vdc • Power Current: Not to exceed 2 amps • Recommended Fuse: 4 amp Wiring Schematics Driver Interface Unit Mating Connector: Molex Connector Body: 30700-1081 Terminal: Amp / Tyco Terminal (18/20 AWG): 1393366-1...

  • Page 32: Wiring Harness

    Electrical Requirements Wiring Harness Quantity Mating Connector: Molex Connector Body: 30700-1081 Terminal: Amp / Tyco Terminal (18/20 AWG): 1393366-1 Mating Connector: Packard Connector Body: 12092449 Cover: 12033731 Terminal: 12020156 4 Amp Fuse: 12004004 Mating Connector: Deutsch Connector Body: DTM06-2S Wedge: WM-2S Socket: 0462-201-20141...

  • Page 33: Ignition And Ground

    Electrical Requirements Ignition and Ground Driver Interface Unit 8-pin Connector FRONT VIEW DIU (8-pin Connnector) Pin # Description J1-4 +9-32VDC Switched J1-5 Chassis Ground...

  • Page 34: J1939

    Electrical Requirements J1939 Terminating J-1939/15 data link resistor (OEM supplied) Terminating resistor Note: The illustration above shows J1939/11, however J1939/15 (2-wire) can be used. Pin # Description J1-6 J1939- J1-7 J1939+...

  • Page 35: Optional I/O

    Electrical Requirements Optional I/O Driver Interface Unit 8-pin Connector FRONT VIEW DIU (8-pin Connnector) WIRE SOFTWARE PIN # DESCRIPTION FUNCTION INPUT / OUTPUT REQUIRED R-SPK Right Speaker Output - 4 ohm 1 watt L-SPK Left Speaker Output - 4 ohm 1 watt Blackout Blackout_Input Input - Tri-state...

  • Page 36: Final Test

    Final Test Final Test Bendix VORAD VS-400 SmartCruise Adaptive Cruise OEM: ™ ® ® Control and Collision Warning Chassis S/N: Trans Model: Trans S/N: Functionality Testing Clutch Size/Type: Shift Control S/N: Description Corrected Validate SmartCruise Adaptive Cruise Control Operation and CWS Operation (dyno environment preferred).

  • Page 37: Appendix

    Appendix Retrofi t Information Retrofi t Recommended Practices Body builder electrical systems that are to be interconnected with the VS-400 electrical system should adhere to the latest recommendations of SAE J1292. In addition to SAE J1292, the following recommendations should be followed: All wiring terminals should be properly insulated to prevent "short circuits".
  • Page 38 Appendix Maximum Current Capacity Wire Gauge (Crosslink Polythlene Copper Wire) 14 Amps 18 Amps 24 Amps 34 Amps 42 Amps 58 Amps 80 Amps 110 Amps...

  • Page 39: J1939/11 Data Link Detail

    Appendix J1939/11 Data Link Detail Recommended Cable J1939 (+) J1939 (-) J1939 Cable Part (PIN "A") (PIN "B") (PIN "C") Round Manufacturer Number Color Color Shield Champlain 23-00013-001 Yellow Green Champlain 23-00028-001 Yellow Green Raychem 2021D0311 Yellow Green Raychem 2021D0001 Yellow Green Raychem...

  • Page 40: Sae J1939/11 Recommended Cable Termination Procedure

    Appendix SAE J1939/11 Recommended Cable Termination Procedure Remove cable outer jacket approximately 1" (25mm). Remove foil from exposed wires to within 1/16" (2mm) from cable jacket. Strip insulation from data wires .25" (7mm). Attach extended wire barrel socket contact to the drain wire or attach adhesive fi ller solder sleeve and wire to drain wire per manufacturer's recommendations.

  • Page 41: Sae J1939/11 Recommended Cable Splice Procedure

    Appendix SAE J1939/11 Recommended Cable Splice Procedure Remove cable outer jacket approximately 1-1/2" to 4" (40 to 100mm). Remove foil shield from exposed wires to within 1/16" (2mm) from cable jacket. Strip insulation from data wires .25" (7mm). Attach X-link wire to drain wire with crimp slice per manufacturer's recommendation. Slide adhesive fi...

  • Page 42: J1939/15 (Lite) Data Link Detail

    Appendix J1939/15 (lite) Data Link Detail Maximum 131 feet (40 meters) length. Maximum 10 feet (3 meters) stub length. Maximum 10 modules on segment. Twisted pair (18 or 20 AWG) with 1 twist per inch. 120 Ohm terminating resistors must be used. Connector at ECU is not defi...

  • Page 43: Wiring Schematics

    Appendix Wiring Schematics ™ ® Bendix SmartCruise Adaptive Cruise Control and/or Collision Warning System Using the OEM Integrated Dash as Display...

  • Page 44: Smartcruise And/Or Collision Warning System

    Appendix ™ ® Bendix SmartCruise Adaptive Cruise Control and/or Collision Warning System Using the Driver Interface Unit as Display...

  • Page 45: Collision Warning System With Side Object Detection

    Appendix Collision Warning System with Side Object Detection Terminating Resistor...

  • Page 46: Connector Pin Descriptions

    Appendix Connector Pin Descriptions Forward Looking Radar 10-pin TRW Connector PIN # SIGNAL NAME TYPE INTERFACE LEVEL NO_CONNECTION – – NO_CONNECTION – – J1939_SHIELD TRUCK J1939 LINK CAN_HI – TRUCK J1939 LINK CAN_LO – TRUCK J1939 LINK NO_CONNECTION – – NO_CONNECTION –...
  • Page 47 Appendix Side Sensor Display Unit 4-pin Deutsch Connector PIN # SIGNAL NAME TYPE INTERFACE LEVEL POWER +12V FROM SENSOR GROUND POWER CHASSIS GROUND COMMUNICATION TURN_SIGNAL +12V Side Sensor 6-pin Deutsch Connector PIN # SIGNAL NAME TYPE INTERFACE LEVEL IGNITION POWER +12V SWITCHED GROUND POWER...

  • Page 48: Vendor Contact Information

    Appendix Vendor Contact Information AMP/Tyco Littelfuse World Headquarters Harrisburg, PA 800 E. Northwest Highway Tel: 800.522.6752 Des Plains, IL 60016 http://www.tycoelectronics.com/ Tel: 847.824.1188 Fax: 847.391.0894 http://www.littelfuse.com Champlain Cable Corporation Molex 175 Hercules Drive 2222 Wellington Court Colchester, Vermont 05446 Lisle, IL 60532-1682 Tel: 800.451.5162 Tel: 800.78MOLEX http://www.champcable.com/...
  • Page 49 The Roadranger System features ® Bendix brand foundation brakes. ® 901 Cleveland Street • Elyria, OH 44035 • 1-800-AIR-BRAKE • www.bendix.com BW2772 ©2010 Bendix Commercial Vehicle Systems LLC, a member of the Knorr-Bremse Group • All Rights Reserved • 09/10...

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