ABS VCS11.pdf

Vario Compact ABS

2 nd Generation

Part 1: System Description

818 000 426 3

8150004263

2 nd Edition

This publication is not subject to any update service.

New versions are available in INFORM at

www.wabco-auto.com

Vehicle Control Systems

An American Standard Company

The right of amendment is reserved

Version 002/06.04(en)

Wabcodruck 815 000 426 3

VCS II

Table of contents

1 The Vario Compact ABS Concept . . . . . . . . 3

4 Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

1.1

Scope of the System . . . . . . . . . . . . . . . . 4

4.1

Standard Version 400 500 070 0 . . . . . . . 18

2 System description and function . . . . . . . . . 5

4.2

Premium Version 400 500 081 0 . . . . . . 18

4.3

The Separate ECU 446 108 085 0 . . . . . 19

2.1 Design of the ABS . . . . . . . . . . . . . . . . . . 5

2.1.1 Modular System Structure . . . . . . . . . . . . 5

2.1.2 Description of an ABS Control Cycle . . . . 6

2.1.3 Voltage Supply . . . . . . . . . . . . . . . . . . . . . 7

2.1.4 ABS Modulators . . . . . . . . . . . . . . . . . . . . 7

2.1.5 Warning Lamp Control. . . . . . . . . . . . . . . . 8

2.1.6 Fault Monitoring . . . . . . . . . . . . . . . . . . . 10

2.1.7 Truck-Trailer Interface according to

ISO 11992 (CAN) . . . . . . . . . . . . . . . . . . 10

2.1.8 Diagnostic Interface . . . . . . . . . . . . . . . . 10

2.1.9 Recognition of Lift Axles . . . . . . . . . . . . . 10

2.1.10 Mileage Counter . . . . . . . . . . . . . . . . . . . 10

2.1.11 Allocation of the Pole Wheels to the

Tire Circumference . . . . . . . . . . . . . . . . . 11

4.4 ABS Solenoid Valves . . . . . . . . . . . . . . . 20

4.4.1 ABS Relay Valve 472 195 03 . 0 . . . . . . . 20

4.4.2 ABS Solenoid Control Valve . . . . . . . . . . 21

4.4.3 Silencer 432 407 . . . 0 . . . . . . . . . . . . . . 21

4.5 ABS Speed Sensors . . . . . . . . . . . . . . . . 22

4.5.1 Electrical Values of the

WABCO Sensors . . . . . . . . . . . . . . . . . . 22

4.5.2 Mounting Support 441 902 352 4 . . . . . . 22

4.6 Cabling Instructions . . . . . . . . . . . . . . . . 22

4.6.1 Cable Installation . . . . . . . . . . . . . . . . . . . 22

4.6.2 Extension of Voltage Supply Cables . . . . 23

4.6.3 Overview on the VCS II - Cables . . . . . . 23

2.2 GenericIO Functionality . . . . . . . . . . . . . 11

2.2.1 Brake Lining Wear . . . . . . . . . . . . . . . . . 12

2.2.2 Integrated Speed Switch (ISS) . . . . . . . . 13

2.2.3 Speed Signal . . . . . . . . . . . . . . . . . . . . . . 14

2.2.4 Voltage Supply. . . . . . . . . . . . . . . . . . . . . 14

2.2.5 ECAS Interface . . . . . . . . . . . . . . . . . . . . 15

2.2.6 ELM Interface . . . . . . . . . . . . . . . . . . . . . 15

2.2.7 Customer-Specific Functions . . . . . . . . . 16

4.7

Pneumatic Lines and Reservoirs . . . . . . 23

5 Diagnosis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

5.1

Access to the Diagnostic Program . . . . . 24

5.2

PC - Diagnosis . . . . . . . . . . . . . . . . . . . . 24

5.3

Flash Code . . . . . . . . . . . . . . . . . . . . . . . 24

6 Installation and System Startup . . . . . . . . . 26

2.3 Special Functions . . . . . . . . . . . . . . . . . . 16

3.3.1 Service Signal . . . . . . . . . . . . . . . . . . . . . 16

2.3.2 Integrated Notebook . . . . . . . . . . . . . . . . 16

7 Compatibility and Service . . . . . . . . . . . . . . 27

2.4 Further Electronic Control Units

in the Trailer . . . . . . . . . . . . . . . . . . . . . . 16

2.4.1 VCS II and ECAS . . . . . . . . . . . . . . . . . . 16

2.4.2 VCS II and ELM . . . . . . . . . . . . . . . . . . . 16

2.4.3 VCS II and Infomaster . . . . . . . . . . . . . . 16

7.1

Replacing VCS I by VCS II . . . . . . . . . . . 27

7.2

Replacing Vario C by VCS II . . . . . . . . . . 27

5.3

Flash Code . . . . . . . . . . . . . . . . . . . . . . . 24

8 Annex

3 Planning of an ABS System . . . . . . . . . . . . 17

1 Allocation of Pole Wheels -

Tire Circumference . . . . . . . . . . . . . . . . . . . . 28

2 Flash Code List . . . . . . . . . . . . . . . . . . . . . . . 29

3 Wiring of the Voltage Supply

of several VCS Systems . . . . . . . . . . . . . . . 30

4 Configuration of Lining Wear Indicator . . . . . 31

5 Replacing VCS I by VCS II . . . . . . . . . . . . . . 33

6 Overview of the VCS I-Diagnostic

Functions supported by VCS II . . . . . . . . . . . 35

3.1

General . . . . . . . . . . . . . . . . . . . . . . . . . . 17

3.2

Sensor Equipment . . . . . . . . . . . . . . . . . 17

3.3

Series Equipment / Retrofitting . . . . . . . . 17

3.4

VCS II in Vehicles for the Transport of

Hazardous Material . . . . . . . . . . . . . . . . 17

3.5

Fording Ability . . . . . . . . . . . . . . . . . . . . . 17

Introduction

VCS II

1 The Vario Compact ABS Concept

When in the early 80s commercial vehicles were

equipped with series-produced ABS for the first time,

this ABS system was a WABCO product. The applica-

tion in the towing vehicle was soon followed by the ap-

plication in the trailer. With regards to system versatility

and diagnosis, VARIO B and, starting in 1989, VARIO C

provided the customer with new opportunities. The trail-

er manufacturers defined increasingly high require-

ments with regards to simple assembly and testing. This

was the main reason for the development of WABCO’s

next ABS generation in 1993 - the V ARIO C ompact AB S

- VCS . Series production of this system was started in

1995. Due to its flexibility, reliability and high quality it

soon gained the market leader position.

trailer equipment. In order to maintain and extend this

position in a time of constantly rising degrees of autom-

atisation, WABCO developed the V ARIO C ompact AB S ,

2 nd Generation ( VCS II ). Here, once again the modular

principle is implemented because the VCS II technology

is based on the extremely robust ABS system for the

NAFTA market, TCS II. Moreover, an ISO 11992-inter-

face and the 8-pole connector principle for the TEBS

have been integrated.

Thus, the development of VCS II results in an even more

powerful system having, as compared with the previous

model, reduced installation dimensions and a consider-

ably reduced weight.

Today more than 1 million systems made the VCS one

of the most successful WABCO products in the range of

VCS II

Introduction

1.1

Scope of the System

VCS II is an ABS system for trailers, ready for installa-

tion. It meets all the statuatory requirements defined for

category A. The range of models reaches from the 2S/

2M system designed for semitrailers to the 4S/3M sys-

tem which is used for drawbar trailers or for a semitrailer

equipped with steering axle.

According to the specific requirements defined by the ve-

hicle manufacturers, VCS II is available as a compact

unit or in modular design (i.e., ECU and valves can be in-

stalled separately).

Standard variant 400 500 070 0:

• Voltage supply ISO 7638

• Additional 24 V supply

• Two speed sensor inputs

• Maximum configuration: 2S/2M

• GenericIO functionality D1 and D2

Premium variant 400 500 081 0:

• Voltage supply ISO 7638

• Additional 24 V supply

• Four speed sensor inputs

• Maximum configuration: 4S/3M

(with additional external 3 rd relay valve)

• ISO 11992-interface (CAN)

• GenericIO functionality D1, D2 and A1

• Battery charging output

Separate ECU 446 108 085 0:

• Voltage supply ISO 7638

• Four speed sensor inputs

• Maximum configuration: 4S/3M

• External ABS relay or solenoid control valves

• ISO 11992-interface (CAN)

• GenericIO functions D1

System description

VCS II

2 Description of the System and Function

2.1

Design of the ABS

The Vario Compact ABS (VCS) is applicable to all-pur-

pose air-braked trailers. The system range varies from

2S/2M to 4S/3M. The Anti-Lock-System (ABS) is a com-

plement to the conventional braking system and essen-

tially consists of:

of the ABS relay valves the normal building up of brake

pressure and its reducing requested by the driver will not

be influenced.

2.1.1 Modular System Structure

• two to four inductive speed sensors and toothed pole

wheels (for directly picking up the speed at the

wheels)

The Vario Compact ABS is a modular unit with the sys-

tem configurations 2S/2M, 4S/2M and 4S/3M. This

means, for each vehicle type there is a suitable variant.

At least one sensor and one modulator constitute a con-

trol channel.

• two or three electro-pneumatic modulators with the

following functions:

– building up brake pressure

– maintaining brake pressure

– reducing brake pressure

In the 2S/2M configuration each sensor and modulator

on one side of the semitrailer are integrated in a control

channel. All other wheels on one side are - if existing -

indirectly actuated. The braking forces are controlled ac-

cording to the principle of the so-called Individual

(Wheel) Control ( IR = I ndividual- R egelung). I.e., each

vehicle side is controlled by the brake pressure corre-

sponding to the road surface conditions and the brake

characteristic value. When unsensed wheels of a multi-

axle vehicle are controlled by this configuration, the sys-

tem is called “Indirect Individual Control” ( INIR = In di-

rekte I ndividual- R egelung). In some cases, an axle

control shall be realized by the 2S/2M configuration.

Therefore the 2S/2M Diagonal Axle Control ( DAR = D i-

agonale A chs- R egelung) was developed. Here all brake

cylinders of one axle are connected to one ABS modula-

tor (axle-by-axle control). The modulator of the first axle

is controlled by a sensor of the right vehicle side and the

modulator of the second axle by a sensor of the left ve-

hicle side (diagonal control). So, an individual brake

pressure can be controlled for each axle. However, on µ-

surfaces the not sensed wheel will lock on low coefficient

of friction.

• one E lectronic C ontrol U nit ( ECU ) with two or three

control channels and subdivided into functional

groups:

– input circuit

– main circuit

– safety circuit

– valve actuation

In the input circuit the signals generated by the respec-

tive inductive sensors are filtered and converted into dig-

ital information for determining period lengths.

The main circuit consists of a microcomputer. It contains

a complex program for the computation and logical oper-

ation of the control signals and for outputting the actuat-

ing variables to the valve control system. The safety

circuit monitors the ABS system, i.e. the sensors, sole-

noid control valves, ECU and wiring, before the vehicle

moves off and also while it is in motion, even if the

brakes are being actuated or not. It alerts the driver to

any errors or defects by through a warning lamp and cuts

off the whole system or parts of it. While the conventional

brake remains operational, it is only the anti-lock system

which is entirely or partially deactivated. The valve actu-

ation contains power transistors (output stages) which

are actuated by signals from the main circuit and which

switch the current for actuating the control valves.

In the 4S/2M configuration two sensors are located on

each vehicle side. The sensor signals of both wheels are

used by the ECU to control one modulator. Also in this

case the control happens sidewise. On one vehicle side

the brake pressure is equal on all wheels. The two

sensed wheels of this vehicle side are controlled accord-

ing to the Modified Sidewise Control ( MSR = M odifizierte

S eiten- R egelung) principle. This means the wheel of one

vehicle side, which locks first, is determinant for the ABS

control. However both modulators are individually con-

trolled. For both vehicle sides the individual control prin-

ciple is used. If unsensed wheels of a multi-axle vehicle

equipped with this configuration are controlled, the sys-

tem is called “Sidewise Indirect Control” ( INSR = In di-

rekte S eiten- R egelung).

ABS relay valves as well as ABS solenoid valves can be

used. The selection depends on the braking system and

especially on the time behavior. Consequently the corre-

sponding ECU will be used. Without electrical actuation

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