Bendix™ VORAD® VS-400 Installation Guide Bendix™ VORAD® VS-400 System BW2772 (Formerly VOIG0100) September 2010
Table of Contents Introduction Warnings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Federal Communications Commission. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 Application Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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. Limitations of Collision Warning Systems The Bendix™ VORAD® VS-400 collision warning system is intended solely as an aid for an alert and conscientious professional driver.
FCCGeneral Compliance Information Statement Federal Communications Commission This device complies with Part 15 of the FCC (Federal Communications Commission) rules. Operation is subject to the following two conditions: (1) This device may not cause harmful interference and (2) this device must be able to accept any interference received, including interference that may cause undesired operation.
Application Information Application Information Function S/C Only CWS Only S/C & CWS S/C, CWS & SOD SOD Only Driver Interface Unit (DIU) and Forward Looking Radar (FLR) FLR DIU X X X X X X X X S/C = Bendix™ SmartCruise® adaptive cruise control CWS = Collision Warning System 4 Side Object Detection System SOD X X
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 • Driver Instructions - BW2769 Reference Drawings • Side Object Detection System Display - 15670-001 Installation Drawing • Side Object Detection System Sensor - 15671-001 Installation Drawing • Side Object D
Space Claim Space Claim Forward Looking Radar Dimensions 3.85" (98.0mm) 3.87" (98.5mm) 3.30" (84.0mm) 1.60" (40.6mm) 3.30" (84.0mm) 6 2.49" (63.
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" (51.8mm) 3.53" 2.04" (51.8mm) 3.24" (82.
Space Claim Side Sensor Display 1.20" (30.5mm) 1.60" (40.6mm) 1.00" (25.4mm) 2.30" (58.4mm) 2.00" (50.8mm) 0.70" (17.8mm) 2.10" (53.3mm) 39.00” ± 3.00" (990.6mm ± 76.2mm) 2.80" (71.1mm) 2.00" (50.
Space Claim Driver Interface Unit Dimensions 1.97" (50mm) 3.70" (93.90mm) 4.07" (103.39mm) 3.67" (93.18mm) 4X R.207 (5.25) .20” (5.2) 3.16” (80.2) 1.58” (40.1) 2X 1.56” (39.5) 2X 2.5˚ 1.97” (50.0) Panel Cut Out (Without bezel) 2X .63” (15.9) 1.61” (40.9) 3.22” (81.8) 2X 2.5˚ .22” (5.7) 3.67” (93.
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.
Mounting Requirements Mounting Requirements - Forward Looking Radar (FLR) The Forward Looking Radar (FLR) determines the distance, lane position (azimuth), relative speed (velocity), and direction of vehicles in front of the host vehicle. 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.
Mounting Requirements Installation Bumper (Optional) Mounting 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.
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 Definition The Forward Looking Radar (FLR) field of view in elevation and azimuth is illustrated below. The grey area represents a cross-cut view of the three-dimensional “No Radar Obstruction Zone”.
Mounting Requirements Cover Material Requirements Any material that may be located in the Forward Looking Radar’s field of view (including bumpers, spoilers, etc.) can not be made out of any metallic material or have any carbon content. It is recommended that any material that will be located in the FLR field of view be approved by Bendix Commercial Vehicle Systems prior to use.
Mounting Requirements Options in white boxes are considered good options. Options in grey boxes are considered possible options. Material Number 9 Commercial Reference* Polyloy B69L62 PA6 TUC1228/93 CYCOLAC XMA TUC1137/94 B70GFE30 TUC308/92 Hostacom PPX678/2 TUC1617/89 NORYL PX1112 TUC648/86 Hostaform C9021 TUC2559/83 Hostalen GDPE7255 TUC310/92 Hostacom PPR1042 TUC2641/86 PP-Kienb 10 11 ABS-Kienb PPN 1080 1 2 3 4 5 6 7 8 12 Recommended Material Thickness (mm) 2.
Mounting Requirements Vibration Specifications 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 specification. There are no specific mechanical requirements along the Y- and Z-axis from a radio-frequency point of view.
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: • Paints must not contain metal or carbon particles. • Carbon content of paint could be a factor as high concentrations could reduce transparency.
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. Alignment of the Forward Looking Radar is a repetitive process of adjusting the vertical and horizontal axis using the bracket screws.
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. 1. Select two truck reference points that are identical and symmetrical about the truck centerline. Ensure the reference points are equally aligned. Items such as fenders and headlights should not be damaged or distorted, otherwise, the alignment will be inaccurate. 2.
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.
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 profile. 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 flat washers and nylock nuts on the backside. Torque hardware to a maximum of 22 lbs. in. (2.5 Nm). Do not over torque.
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 configuration, status, and diagnostic information. The DIU uses the vehicle's SAE J1939 data link to communicate with the FLR, and other vehicle system devices. Mounting Orientation 0.91" 1.97" (50mm) 1.65" 3.67" (93.18mm) 0.38" (9.
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 flush 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.
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.
Electrical Requirements Wiring Harness Notes: All wires to be cross link TXL or equivalent unless otherwise specified. Use approved J1939 cable.
Electrical Requirements Ignition and Ground Ignition power (switched power) run to main power lead that feeds the ignition bus Pin # J1-9 J1-10 26 Description Chassis Ground +9-16VDC Switched
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. Check the resistance of the data bus using an ohmmeter before and after adding any device to the bus.
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 Recommended Fuse: 1 amp Wiring Schematics Side Sensor 6 1 5 2 4 3 Connector Rear P2 SOD 4 1 3 2 Connector Rear ODU P1 Notes: All wires to be cross link GXL or equivalent unless otherwise specified.
Electrical Requirements Ignition and Ground P2 SOD 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 6 1 5 2 4 3 29
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 J1 Mating Connector: Connector Body: Terminal: Terminal (18/20 AWG): Molex 30700-1081 Amp / Tyco 1393366-1 DIU 8-pin Connnector DIU 8-pin Connector 1 2 3 J3 T3 J1939 Data 6 7 30
Electrical Requirements Wiring Harness T3 T4 T5 J3 J1 Quantity J1 Mating Connector: Connector Body: Terminal: Terminal (18/20 AWG): Molex 30700-1081 Amp / Tyco 1393366-1 1 4 4 J2 Mating Connector: Connector Body: Cover: Terminal: 4 Amp Fuse: Packard 12092449 12033731 12020156 12004004 1 1 2 1 J3 Mating Connector: Connector Body: Wedge: Socket: Deutsch DTM06-2S WM-2S 0462-201-20141 1 1 2 T1 T2 J2 Notes: All wires to be cross link GXL or equivalent unless otherwise specified.
Electrical Requirements Ignition and Ground Driver Interface Unit DIU 8-pin Connector FRONT VIEW DIU (8-pin Connnector) Pin # J1-4 J1-5 32 Description +9-32VDC Switched Chassis Ground 4 3 2 1 8 7 6 5
Electrical Requirements J1939 Terminating resistor J-1939/15 data link (OEM supplied) Terminating resistor 4 8 3 7 2 1 6 5 Note: The illustration above shows J1939/11, however J1939/15 (2-wire) can be used.
Electrical Requirements Optional I/O Driver Interface Unit DIU 8-pin Connector FRONT VIEW DIU (8-pin Connnector) PIN # 1 2 3 34 WIRE DESCRIPTION R-SPK L-SPK Blackout FUNCTION Right Speaker Left Speaker Blackout_Input INPUT / OUTPUT Output - 4 ohm 1 watt Output - 4 ohm 1 watt Input - Tri-state SOFTWARE REQUIRED Yes Yes Yes
Final Test Final Test Bendix™ VORAD® VS-400 SmartCruise® Adaptive Cruise Control and Collision Warning Functionality Testing OEM: Chassis S/N: Trans Model: Clutch Size/Type: Shift Control S/N: Description Yes Validate SmartCruise® Adaptive Cruise Control Operation and CWS Operation (dyno environment preferred). 1. Start truck and verify VS-400 system powers-up (goes through bulb check with no faults indicated). 2. Bring truck up to road speed (50-60 MPH suggested). 3.
Appendix Retrofit Information Retrofit 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: 1. All wiring terminals should be properly insulated to prevent "short circuits". All terminals should be of insulation grip design to provide a reliable connection and to prevent terminal fatigue. 2.
Appendix Wire Gauge 20 18 16 14 12 10 8 6 Maximum Current Capacity (Crosslink Polythlene Copper Wire) 14 Amps 18 Amps 24 Amps 34 Amps 42 Amps 58 Amps 80 Amps 110 Amps 37
Appendix J1939/11 Data Link Detail Recommended Cable Manufacturer Cable Part Number J1939 (+) (PIN "A") Color J1939 (-) (PIN "B") Color J1939 (PIN "C") Shield Champlain 23-00013-001 Champlain 23-00028-001 Yes Yellow Green N/A No Yellow Green Raychem N/A 2021D0311 No Yellow Green N/A Raychem 2021D0001 No Yellow Green N/A Raychem 2021D0301 Yes Yellow Green N/A BICC Brand-Rex T-14945 Yes Yellow Green N/A Round Shield Termination J1939 (+) J1939 (-) J1939 Shield Ref.
Appendix SAE J1939/11 Recommended Cable Termination Procedure 1. Remove cable outer jacket approximately 1" (25mm). 2. Remove foil from exposed wires to within 1/16" (2mm) from cable jacket. 3. Strip insulation from data wires .25" (7mm). 4. Attach extended wire barrel socket contact to the drain wire or attach adhesive filler solder sleeve and wire to drain wire per manufacturer's recommendations.
Appendix SAE J1939/11 Recommended Cable Splice Procedure 1. Remove cable outer jacket approximately 1-1/2" to 4" (40 to 100mm). 2. Remove foil shield from exposed wires to within 1/16" (2mm) from cable jacket. 3. Strip insulation from data wires .25" (7mm). 4. Attach X-link wire to drain wire with crimp slice per manufacturer's recommendation. 5. Slide adhesive filled shrink tube over crimp splice. 6. Slide adhesive filled shrink tube over cable end.
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 defined. The third pin for sheild is not used in 'in-line' the T-connectors. Recommended Cable Manufacturer Cable Part Number Champlain J1939/15 Twisted Pair J1939 (-) J1939 (+) J1939 (+) J1939 (-) Ref.
Appendix Wiring Schematics Bendix™ SmartCruise® Adaptive Cruise Control and/or Collision Warning System Using the OEM Integrated Dash as Display 42
Appendix Bendix™ SmartCruise® Adaptive Cruise Control and/or Collision Warning System Using the Driver Interface Unit as Display 43
Appendix Collision Warning System with Side Object Detection Terminating Resistor 44
Appendix Connector Pin Descriptions Forward Looking Radar 10-pin TRW Connector PIN # 1 2 3 4 5 6 7 8 9 10 SIGNAL NAME NO_CONNECTION NO_CONNECTION J1939_SHIELD CAN_HI CAN_LO NO_CONNECTION NO_CONNECTION NO_CONNECTION GROUND IGNITION TYPE – – – – – – – POWER POWER INTERFACE LEVEL – – TRUCK J1939 LINK TRUCK J1939 LINK TRUCK J1939 LINK – – – CHASSIS GROUND +12V SWITCHED Driver Interface Unit 8-Pin Molex Connector PIN # 1 2 3 4 5 6 7 8 SIGNAL NAME RIGHT_SPEAKER LEFT_SPEAKER BLACKOUT_INPUT / SPARE BATTERY GR
Appendix Side Sensor Display Unit 4-pin Deutsch Connector PIN # 1 2 3 4 SIGNAL NAME POWER GROUND COMMUNICATION TURN_SIGNAL TYPE I POWER I I INTERFACE LEVEL +12V FROM SENSOR CHASSIS GROUND +12V Side Sensor 6-pin Deutsch Connector PIN # 1 2 3 4 5 6 46 SIGNAL NAME IGNITION GROUND COMMUNICATION POWER SODDU-GROUND NO CONNECTION TYPE POWER POWER O O POWER – INTERFACE LEVEL +12V SWITCHED CHASSIS GROUND +12V GROUND –
Appendix Vendor Contact Information AMP/Tyco Littelfuse World Headquarters Harrisburg, PA Tel: 800.522.6752 http://www.tycoelectronics.com/ 800 E. Northwest Highway Des Plains, IL 60016 Tel: 847.824.1188 Fax: 847.391.0894 http://www.littelfuse.com Champlain Cable Corporation Molex 175 Hercules Drive Colchester, Vermont 05446 Tel: 800.451.5162 http://www.champcable.com/ 2222 Wellington Court Lisle, IL 60532-1682 Tel: 800.78MOLEX http://www.molex.
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