VCS II Installation Instructions

VCS II Installation Instructions
Vario Compact ABS
2nd generation
Part 2: Installation
instructions
3rd edition
This publication is not subject to any update service.
New versions can be found in INFORM under
www.wabco-auto.com
 2007 WABCO
The right of amendment is reserved
Version 004/09.07(en)
815 010 009 3
VCS II
Table of contents
1 Introduction
1.1 General information
1.2 Diagnosis and commissioning
6 Braking system diagrams
3
3
2 System proposals
2.1 Sensor allocation
2.2 Overview of the VCS II generation
4
8
3 Outline drawings
3.1 Separate electronic control unit
3.2 Premium version
3.3 VCS II cabling diagrams
9
10
12
4 Cable overview
4.1 Power supply cables
5-wire power supply cable
5-wire Y-power supply cable
7-wire power supply cable
7-wire Y-power supply cable
7-wire Y-power supply cable + diagnosis
4.2 Connecting cables
Diagnostic cable
Triple cable
Y-diagnostic cable
Cable for ECAS connection
Y-cable for ECAS connection
Triple cable for ECAS connection
Y-cable for ELM connection
Cable for modulator
16
16
17
18
19
20
20
20
22
21
22
22
23
23
23
5 Installation instructions
5
5.1
5.2
5.3
5.4
2
Vario installation
Compact ABS 2nd generation
General information
Installation of the Premium version
Installation of the Standard version
Installation of the separate electronic control
unit
25
25
25
26
27
1-axle
ZA 2S2M
ZA 2S2M
SA 2S2M
SA 2S2M
SA 2S2M
Standard ECU
Separate ECU
Standard ECU
Separate ECU
Standard ECU
841 601 100 0
841 601 101 0
841 700 991 0
841 700 993 0
841 700 994 0
28
29
30
31
32
2-axle
ZA 2S2M
ZA 2S2M
ZA 2S2M
ZA 4S2M
ZA 4S3M
ZA 4S3M
ZA 4S3M
DA 4S3M
DA 4S3M
DA 4S3M
SA 4S2M
SA 4S2M
SA 4S3M
Separate ECU
Separate ECU
Premium ECU
Premium ECU
Separate ECU
Premium ECU
Premium ECU
Premium ECU
Separate ECU
Premium ECU
Premium ECU
Premium ECU
Premium ECU
841 601 114 0
841 601 116 0
841 601 177 0
841 601 110 0
841 601 112 0
841 601 113 0
841 601 118 0
841 601 121 0
841 601 123 0
841 601 124 0
841 700 981 0
841 701 120 0
841 700 983 0
33
34
35
36
37
38
39
40
41
42
43
44
45
3-axle
DA 4S3M
DA 4S3M
SA 2S2M
SA 2S2M
SA 2S2M 12 V
SA 4S3M
SA 4S2M
Premium ECU
Premium ECU
Premium ECU
Premium ECU
Premium ECU
Premium ECU
Premium ECU
841 601 130 0
841 601 131 0
841 701 060 0
841 701 062 0
841 701 151 0
841 700 971 0
841 700 973 0
46
47
48
49
50
51
52
4-axle
DA 4S3M
DA 4S3M
DA 4S3M 12 V
SA 4S3M
Premium ECU
Premium ECU
Premium ECU
Premium ECU
841 601 140 0
841 601 141 0
841 601 143 0
841 701 002 0
53
54
55
56
5-axle
SA 4S3M
Premium ECU 841 701 080 0
SA 4S3M 12 V Premium ECU 841 701 081 0
57
58
VCS II
Introduction
1.1
General information
1
formed on the vehicle and that the brake must not be
applied.
This publication is meant for commercial vehicle workshop personnel with knowledge of automotive electronics. It provides assistance in the installation and
commissioning of a VCS II trailer ABS system.
1.2
Diagnosis and commissioning
of the VCS II
Further detailed information about this system can also
be found in the publication "VCS II system description"
under the WABCO number 815 010 008 3.
The diagnosis is carried out using a PC or notebook connected to the vehicle electronics. WABCO diagnostic
software must be installed on the notebook.
VCS II is a vehicle safety system. Installation, retrofitting,
repairs and modification of the system settings may only
be performed by trained and qualified specialist personnel.
You can find out the current status on the Internet
(www.wabco-auto.com) via the "Download" menu.
WABCO offers the training required for installation and
commissioning of the VCS II system both directly on-site
at our premises and on the Internet at http://wbt.wabco.info.
Before you perform any work on the vehicle (installation, repairs, parts replacement, diagnosis, etc.) you
must ensure the following:
– Always follow the specifications and instructions of
the vehicle manufacturer.
– Always comply with the company and national accident prevention/health and safety regulations.
– Wear suitable protective clothing as the situation requires.
– The workplace has to be dry and sufficiently lit and
ventilated.
– The gearbox of the towing vehicle, if present, must be
in the "neutral" position and the hand brake must be
activated.
– Secure the vehicle against rolling away using brake
wedges.
– Attach a clearly marked note on the steering wheel of
the towing vehicle, stating that work is being per-
All available language versions of the WABCO diagnostic programme are shown on the diagnostic software
subscription pages.
The diagnostic memory and current measuring data can
be obtained through the diagnostic programme. Errors
are described when malfunctions occur.
Commissioning of the VCS II system is also performed
via this diagnostic programme. The programme guides
users through the menu. After successful commissioning, the ABS system is ready for operation.
Note: The connection between the diagnostic connection socket (with blue protection cover) on the trailer and
the diagnostic PC requires a diagnostic interface allowing for use of both the serial interface and the USB version.
VCS II allows for straightforward fault indication in the
towing vehicle via a warning lamp on the instrument panel and, if present, via a green warning lamp on the exterior of the towing vehicle.
The system is available in 2S/2M, 4S/2M and 4S/3M configurations with integrated or separate ECU.
Trailer ABS warning lamp
ISO 7638
VCS II
Modulator
(Standard)
(2S/2M)
w a bco
Sensor extension cable
w a bco
ISO 1185 (24N)
ISO 7638/24N power
supply cable
Diagnostic cable
Fig. 1: 3-axle semitrailer
with 2S/2M
Diagnostic socket
3
2
2.1
VCS II
System proposals
Sensor allocation
ABS configurations for semitrailer vehicles, central-axletrailers
and drawbar trailers
Lifting axles
2S/2M system:
Lifting axles are not allowed to have sensors fitted
All other systems:
Lifting axles may be fitted with ABS sensors e and f.
Steering axles
Forced steering axles can be treated like beam axles. WABCO prescribes ABS configurations
4S/3M or 2S/2M+SLV for vehicles with self-steering axles.
If 2S/2M or 4S/2M ABS systems are to be used in vehicles with self-steering axles, tests performed
during the type test must establish that there are no abnormal axle vibrations or course deviations.
It is not possible to investigate all axles on the market to check how they respond when ABS is
triggered.
*
These types of vehicle (see p. 6 and p. 7) are not listed in the "Type approval report no.
EB 140.0" and require separate acceptance.
Modulator versions
ABS solenoid modulator valves are not permitted with 2S/2M and 4S/2M systemsin 3-axle semitrailers and central-axle trailers.
Installation recommendation for unit types:
= Driving direction
B
C
Allocation of control channels:
(Acc. to WABCO cabling diagram 841 801 930 0 to
841 801 933 0)
= ABS modulator main axle (B/C)
Sensors
A
= ABS modulator valve A
Modulator
WITH SENSORS
(DIRECTLY CONTROLLED)
WITHOUT SENSORS
(INDIRECTLY CONTROLLED)
= Double cut-off valve (SLV)
Tested ABS modulators:
- ABS double relay valve (integrated)
- Separate ABS relay valves (not integrated)
- ABS solenoid modulator valves (not integrated)
4
B/C
c,d
A
e,f
B/C
e,f
B/C
d,f
SYSTEM AXLE CONTROL LOGIC:
Main axle
IR / MSR
(not lifting)
Steering axle
MAR
(lifting)
Auxiliary axle
MSR
(lifting)
Main axle
IR
(not lifting)
STANDARD VERSION
400 500 070 0
VEHICLE TYPE
2S / 2M 1)
2
VCS II
System proposals
4S / 2M
4S / 3M
d
B
C
c
d
f
d
B
C
B
C
c
+
d
f
d
B
C
c
e
c
e
f
d
f
d
B
C
B
C
c
A
e
B
C
A
e
c
c
CENTRAL-AXLE TRAILER + SEMITRAILER
d
C
B
c
2S/2M + DAR
d
d
B
C
+
f
B
C
c
B
C
c
d
e
f
d
c
d
c
f
d
e
d
A
c
e
f
d
B
C
c
e
B
C
f
B
C
A
c
B
C
B
C
f
d
B
C
A
c
e
c
e
2S/2M + SLV
B
C
c
f
d
f
d
B
C
e
d
B
C
A
c
e
f
d
e
c
c
B
C
1) For the Standard version 400 500 070 0, the allocation is "Modulator B / Sensor f and Modulator C / Sensor d".
5
2
VCS II
VEHICLE TYPE
System proposals
2S / 2M
4S / 2M
4S / 3M
f
d
B
C
A
e
c
d
f
DRAWBAR TRAILER
B
C
A
c
e
f
d
B
C
A
c
e
f
d
B
C
A
c
e
f
d
*
B
C
A
c
e
SEMITRAILER+ DRAWBAR TRAILER
f
*
d
B
C
A
c
e
f
d
B
C
A
e
f
c
d
B
C
A
c
e
f
d
A
e
6
B
C
c
System proposals
VEHICLE TYPE
2S / 2M
*
4S / 2M
4S / 3M
f
d
B
C
A
c
DRAWBAR TRAILER
e
f
d
B
C
A
c
e
f
d
B
C
A
c
SEMITRAILER
e
*
2
VCS II
*
f
A
e
d
B
C
c
These types of vehicle are not listed in the "Type approval report no. EB 140.0" and require separate
acceptance.
7
2
2.2
VCS II
System proposals
Overview of the VCS II generation
Separate ECU
4S/3M
STANDARD
2S/2M
PREMIUM
4S/2M (3M)
PREMIUM
4S/2M (3M) painted
PREMIUM
4S/2M (3M) 12 V
WABCO part number
System
400 010 203 0
Tabular drawing
400 500 090 0
Complete device
400 500 070 0
400 500 081 0
400 500 082 0
400 500 083 0
Separate ECU
446 108 085 0
Installation diagram
841 801 932 0
841 801 930 0
841 801 933 0
841 801 933 0
841 801 935 0
corresponds to VCS I
446 108 030 0
400 500 045 0
400 500 035 0
400 500 063 0
400 500 050 0
24 V
24 V
24 V
24 V
12 V
X
X
X
Functions
Power supply
ISO 7638-1
ISO 1185 (24N)
ISO 1724 (12N)
X
Possible systems
2S/2M
X
4S/2M
4S/3M
X
X
X
X
X
X
X
X
X
X
X
X
External ABS-RV 1)
X
X
X
X
ABS-MRV 2)
X
Modulators
Paint 3)
X
GenericIOs & special functions
GIO D1 / D2 / A1
X/-/-
X/X/-
X/X/X
X/X/X
X/X/X
X
X
Diagnostic plug
Diagnostic plug
Diagnostic plug
Diagnostic plug
X
X
X
X
Communication
ISO 11992 interface
(CAN)
Diagnosis at:
X
Supply plug
Various
ECAS / ELM interface
4)
Preferred vehicle use
O3 vehicles and
special-purpose
vehicles
Semitrailers
Semitrailers/draw- Semitrailers & draw- Semitrailers & drawbar trailers (incl. with bar trailers in Scan- bar trailers in Auselectr. air suspendinavia
tralia and Israel
sion)
1)
(X): External relay valve for 4S/3M - configuration required
2)
Change of parameter settings required (EV+AV control)!
3)
Modulator painted black
4)
Can be activated via GenericIO
8
Outline drawings
3.1
VCS II
3
Separate electronic control unit 446 108 085 0
9
3
3.2
10
VCS II
Outline drawings
Vario Compact ABS 400 500 090 0
Outline drawings
VCS II
3
11
3
3.3
12
VCS II
Outline drawings
Cabling diagram
841 801 930 0
Standard version 2S/2M with mixed supply (24N) without CAN
841 801 931 0
Outline drawings
Cabling diagram
VCS II
3
Premium version 4S/2M with mixed supply (24N) and CAN
13
3
VCS II
Outline drawings
Cabling diagram
841 801 932 0
Separate version 2S/2M to 4S/3M optionally with CAN and relay valves
14
841 801 933 0
Outline drawings
Cabling diagram
VCS II
3
Premium version 4S/3M with mixed supply (24N) CAN and GIO
15
4
VCS II
4.1
Power supply cable
Cable overview
5-wire power supply cable
Application for: Standard and Premium ECU
Ø 10,6
For semitrailers (24V)
L
For drawbar trailers (24V)
Order number
L in m
449 125 060 0
6
449 125 100 0
10
449 125 120 0
12
449 125 140 0
14
449 125 180 0
18
Ø 10,6
L
Ø 10,6
For semitrailers with connection
[ combined with 449 375 ... 0 or 449 374 ... 0 (24N) ]
L
For drawbar trailers with connection
[ combined with 449 375 ... 0 or 449 374 ... 0 (24N) ]
449 225 060 0
6
10
449 225 120 0
12
449 225 140 0
14
Ø 10,6
Plug
VCS II electronic
control unit
"POWER"
Cable end type
Plug
ISO 7638
Plug
VCS II electronic
control unit
"POWER"
Application for: Standard and Premium ECU
Order number
L in m
449 132 005 0
0.5
449 132 060 0
6
449 132 080 0
8
449 132 100 0
10
449 132 120 0
12
449 132 150 0
15
Cable end type
Socket
ISO 7638
Coupling
5-wire,
mating component
for
449 375 ... 0
and
449 374 ... 0
Application for: Standard and Premium ECU
449 242 100 0
L in m
10
L
Power supply cable with connection
[ combined with 449 132 ... 0 or 449 242 ... 0 (24V) ]
Ø 10,6
L in m
449 225 100 0
Order number
16
Socket
ISO 7638
Application for: Standard and Premium ECU
Order number
L
Cable end type
Cable end type
Plug
ISO 7638
Coupling 5-wire,
mating component for
449 375 ... 0 and
449 374 ... 0
Application for: Standard and Premium ECU
Order number
L in m
Cable end type
Coupling
5-wire,
mating comPlug
ponent
VCS II electronic
for
control unit
449 132 ... 0
"POWER"
and
449 242 ... 0
449 375 003 0
0.3
449 375 030 0
3
449 375 060 0
6
449 375 100 0
10
449 375 120 0
12
VCS II
Cable overview
Power supply cable for trailer
4
Application for: Standard and Premium ECU
Order number
L in m
449 345 120 0
12
Cable end type
Semi 446 008 380 2 (24V)
446 008 385 2 (12 V)
3 x 1.5 mm²
2 x 4 mm²
449 345 150 0
Drawbar 446 008 390 2 (24V)
Plug
VCS II electronic
control unit
"POWER"
15
446 008 395 2 (12 V)
5-wire Y-power supply cable
For semitrailers (24V) and 24N
Application for: Standard and Premium ECU
Order number
L1
in m
L2
in m
449 124 333 0
6
12
449 124 337 0
12
12
Ø 10,2
1500
Ø 8,4
Ø 10,6
L1
L2
For drawbar trailers (24V) and 24N
Ø 10,2
1500
Ø 8,4
Ø 10,6
L1
449 224 337 0
L1
in m
12
L2
in m
12
L2
Y-power supply cable with connection
[ combined with 449 132 ... 0 or 449 242 ... 0 and 24N ]
Ø 10,2
Ø 8,4
Ø 10,6
Cable end type
Plug
ISO 7638
Plug
and
VCS II electronic
ISO 1185
control unit
(24N)
"POWER"
1 x 1.5 mm²
2 x 2.5 mm²
Application for: Standard and Premium ECU
Order number
L
in m
L2
in m
449 374 281 0
0.25
8
449 374 323 0
1
12
449 374 328 0
3
12
449 374 333 0
6
12
1500
L2
Socket ISO
7638 and
Plug
ISO 1185 VCS II electronic
(24N)
control unit
1 x 1.5 mm²
"POWER"
2 x 2.5 mm²
Application for: Standard and Premium ECU
Order number
L1
Cable end type
Cable end type
Coupling 5wire, and
Plug
ISO 1185 VCS II electronic
(24N)
control unit
1 x 1.5 mm²
"POWER"
2 x 2.5 mm²
17
4
VCS II
Cable overview
7-wire power supply cable
For semitrailers (24V)
Application for: Premium ECU
Ø 13,3
Order number
L
L in m
449 126 060 0
6
449 126 100 0
10
449 126 120 0
12
449 126 140 0
14
Ø 13,3
For drawbar trailers (24V)
Order number
L in m
449 226 060 0
6
449 226 100 0
10
449 226 120 0
12
449 226 140 0
14
Ø 13,3
For semitrailers with connection
[ combined with 449 385 ... 0, 449 384 ... 0 (24N) or 449 386 ... 0 ]
L
Order number
L in m
449 133 003 0
0,3
449 133 030 0
3
449 133 120 0
12
449 133 150 0
15
Ø 13,3
L
Cable end type
Plug
ISO 7638
Plug
VCS II electronic
control unit
"POWER"
Cable end type
Socket
ISO 7638
Coupling 7-wire,
mating component for
449 384 ... 0,
449 385 ... 0
or
Application for: Premium ECU
Order number
L in m
449 233 030 0
3
449 233 100 0
10
449 233 140 0
14
449 233 180 0
18
Power supply cable with connection
[ combined with 449 133 ... 0 or 449 233 ... 0 (24V) ]
Ø 13,3
Plug
VCS II electronic
control unit
"POWER"
Application for: Premium ECU
For drawbar trailers with connection
[ combined with 449 385 ... 0, 449 384 ... 0 (24N) or 449 386 ... 0 ]
18
Socket
ISO 7638
Application for: Premium ECU
L
L
Cable end type
Cable end type
Plug
ISO 7638
Coupling 7-wire,
mating component for
449 384 ... 0,
449 385 ... 0
or
Application for: Premium ECU
Order number
L in m
Cable end type
449 385 003 0
0.3
449 385 030 0
3
449 385 060 0
6
449 385 100 0
10
Coupling 7Plug
wire, mating
component for VCS II electronic
control unit
449 133 ... 0
"POWER"
and
449 233 ... 0
4
VCS II
Cable overview
For semitrailers or drawbar trailers
Application for: Premium ECU
Order number
L
Cable end type
in m
Semi 446 008 404 2 (24V)
Ø 13,3
449 320 120 0
50
12
5 x 1.5 mm²
2 x 4 mm²
L
Drawbar 446 008 414 2 (24V)
ISO 7638 socket is not
included in delivery
449 320 150 0
Plug
VCS II electronic
control unit
"POWER"
15
7-wire Y-power supply cable
For semitrailers (24V) and 24N
Application for: Premium ECU
Order number
Ø 12,6
1500
Ø 8,4
Ø 13,3
L1
449 134 337 0
L1
in m
12
L2
in m
12
L2
For drawbar trailers (24V) and 24N
Ø 12,6
Ø 8,3
Ø 13,3
1500
449 234 337 0
L1
in m
12
L2
in m
12
L2
Y-power supply cable with connection
[ combined with 449 133 ... 0 or 449 233 ... 0 (24V) and 24N ]
Order number
Plug
VCS II
electronic
control unit
"POWER"
Cable end type
Plug
ISO 7638 and
ISO 1185 (24N)
1x 1.5 mm²
2x 2.5 mm²
Plug
VCS II
electronic
control unit
"POWER"
Application for: Premium ECU
L
in m
L2
in m
Cable end type
Ø 12,6
1500
Ø 8,3
Ø 13,3
L1
Socket
ISO 7638 and
ISO 1185 (24N)
1x 1.5 mm²
2x 2.5 mm²
Application for: Premium ECU
Order number
L1
Cable end type
449 384 323 0
1
12
449 384 333 0
6
12
L2
Coupling 7-wire,
mating compoPlug
nent for
VCS II
449 133 ... 0 and
electronic
449 233 ... 0 and
control unit
ISO 1185 (24N)
"POWER"
1x 1.5 mm²
2x 2.5 mm²
19
4
VCS II
Cable overview
7-wire Y-power supply cable + diagnosis
For semitrailers (24V)
Application for: Separate ECU
L1
L1
in m
L2
in m
449 144 057 0
12
1
449 144 157 0
12
3
Ø 12,6
8,4
1500
Ø
Ø
13,3
Order number
L2
For drawbar trailers (24V)
L1
Ø 12,6
,4
Ø8
13,3
Ø
L2
Order number
L1
in m
L2
in m
449 244 048 0
3
1
449 244 155 0
8
3
449 244 157 0
12
3
Y-power supply cable with connection
[ combined with 449 133 ... 0 or 449 233 ... 0 (24V) ]
Ø 12,6
8,4
Ø
13,3
Ø
4.2
Plug
VCS II electronic control
unit
"POWER"
Cable end type
Plug
Plug ISO 7638 VCS II elecand diagnostic- tronic control
socket
unit
"POWER"
Application for: Separate ECU
Order number
L
in m
L2
in m
449 386 143 0
1
3
449 386 148 0
3
3
1500
L2
Socket
ISO 7638 and
Diagnosticsocket
Application for: Separate ECU
1500
L1
Cable end type
Cable end type
Coupling 7-wire,
Plug
mating compoVCS II elecnent for
449 133 ... 0 tronic control
unit
and
"POWER"
449 233 ... 0
Connecting cable
Diagnostic cable
For diagnosis
Application for: Standard and Premium ECU
Ø
5,9
L
For direct diagnostic connection
from ECU to the diagnostic interface
20
Order number
L1 in m
449 615 010 0
1
449 615 030 0
3
449 615 060 0
6
449 615 080 0
8
Cable end type
Diagnostic
socket
Plug
VCS II electronic control
unit
"MOD RD"
Application for: Standard and Premium ECU
Order number
L1 in m
446 300 455 0
6
Cable end type
ECU
Diagnostic
interface
4
VCS II
Cable overview
Y-diagnostic cable
For diagnosis and socket for A-modulator
Application for: Standard and Premium ECU
Order number
7,0
Ø
Ø
5,9
L2
L1
For diagnosis and GIO interface
7,6
Ø
5,9
L2
in m
449 616 148 0
3
3
449 616 153 0
6
3
449 616 156 0
10
3
449 616 157 0
12
3
449 616 158 0
15
3
449 616 235 0
8
5
449 616 248 0
3
6
449 616 253 0
6
6
449 616 293 0
6
8
L1
For diagnosis and RTR function
Diagnostic
Plug
socket and
VCS II elecBayonet socket tronic control
DIN 72585
unit
B1-3.1-Sn/K1
"MOD RD"
Order number
L1
in m
L2
in m
449 617 013 0
6
0.25
449 617 157 0
12
3
449 617 253 0
6
6
449 617 257 0
12
6
Cable end type
Diagnostic
socket and
4 x 1.5 mm²
Plug
VCS II electronic control
unit
"MOD RD"
Application for: Standard and Premium ECU
Order number
L1
in m
L2
in m
449 623 253 0
6
6
449 623 316 0
10
10
Triple cable for diagnosis, GIO interface
and socket for A-modulator
8000
Cable end type
Application for: Premium ECU
Order number
L1
in m
L2
in m
449 618 003 0
1
0.25
449 618 153 0
6
3
449 618 157 0
12
3
449 618 255 0
8
6
Cable end type
Ø
5,9
Ø
8,1
7,6
1500
Ø
7,0
Ø
L2
Cable end type
Application for: Standard and Premium ECU
L2
Ø
L1
in m
L1
4 x 1.5 mm²
and
Plug
Diagnostic
VCS II elecsocket and
tronic control
bayonet socket
unit
DIN 72585
"MOD RD"
B1-3.1-Sn/K1
21
4
VCS II
Cable overview
Diagnosis and GIO interface
For brake pad wear indication
Application for: Standard and Premium ECU
Order number
L2
in m
Ø
Ø
449 619 148 0
3
Cable end type
Diagnostic
socket
and
plug
6 ,0
5,9
L2
L1
in m
3
L1
Plug
VCS II electronic control
unit
"MOD RD"
Triple cable
For diagnosis and GIO interface
and socket for A-modulator
Application for: Premium ECU
Order number
L2
in m
Cable end type
3
Bayonet socket
Plug
DIN 72585 B1VCS II elec3.1-Sn/K1 and
tronic control
plug and
unit
diagnostic"MOD RD"
socket
Ø
7
L1
L1
in m
6
1500
Ø
8,1
10
Ø
5,9
Ø
449 620 156 0
L2
1500
Cable for the ECAS connection
Application for: Standard and Premium ECU
Order number
L
in m
Cable end type
3
PG 11
Plug
4 x 1.5 mm²
VCS II elec2 x 0.5 mm² tronic control
6 push-on conunit
tacts
"MOD RD"
Ø
8,1
For ECAS incl. a diagnostic interface
200
449 336 030 0
L
100
Y-cable for the ECAS connection
For ECAS incl. a diagnostic interface
and socket for A-modulator
L1
L1
in m
L2
in m
Cable end type
12
PG 11
5 x 1.5 mm²
Plug
1 x 0.5 mm²
VCS II elec6 push-on contronic control
tacts and bayounit
net socket
"MOD RD"
DIN 72585
B1-3.1-Sn/K1
Ø
200
Order number
8,1
100
Application for: Premium ECU
Ø
7,0
449 337 328 0
L2
22
3
4
VCS II
Cable overview
Triple cable for the ECAS connection
For ECAS incl. a diagnostic interface
and GIO interface and socket for A-modulator
Application for: Premium ECU
Order number
L1
in m
L2
in m
Cable end type
8
Bayonet socket
DIN 72585
B1-3.1-Sn/K1
Plug
and 3 x 1.5 mm² VCS II elecand PG 11
tronic control
5x 1.5 mm²
unit
1 x 0.5 mm²
"MOD RD"
6 push-on contacts
Ø
7,0
L1
7,0
8000
12
Ø
L2
Ø
8,1
8,1
Ø
449 339 297 0
1500
Y-cable for the ELM connection
For ELM incl. a diagnostic interface
Order number
L1
L1
in m
L2
in m
Cable end type
3
Plug
Diagnostic
VCS II elecsocket and ELM tronic control
socket
unit
"MOD RD"
Ø
Ø
7.0
5.9
Application for: Standard and Premium ECU
449 340 153 0
6
L2
Cable for modulator
For B- and C-modulator
Application for: Separate ECU
L1
Order number
L1
in m
L2
in m
449 534 043 0
1
1
Cable end type
Ø
7,0
Ø
7,0
GELB
449 534 148 0
3
3
449 534 253 0
6
6
BLAU
L2
Order number
L1
in m
L2
in m
449 544 190 0
4
4
1500
Ø
GELB
Plug
VCS II electronic control
unit
"MOD RD"
Application for: Separate ECU
7
For A-, B- and C-modulator
2 x bayonet
socket
DIN 72585
B1-3.1-Sn/K1
Cable end type
BLAU
449 544 248 0
3
6
449 544 333 0
6
12
Ø
7
L1
Ø
7
Ø
8,1
L1
ROT
L2
3 x bayonet
socket
DIN 72585
B1-3.1-Sn/K1
Plug
VCS II electronic control
unit
"MOD RD"
23
4
VCS II
Cable overview
For B-, C-modulator and GIO interface
7
Order number
1500
Ø
GELB
Application for: Separate ECU
L1
in m
L2
in m
Cable end type
8
2 x bayonet
Plug
socket
VCS II elecDIN 72585
tronic control
B1-3.1-Sn/K1
unit
and 2 x 1.5 mm² "MOD RD"
BLAU
449 555 293 0
6
Ø
7
L1
Ø
7
Ø
8,1
L1
50
L2
For A-, B-, C-modulator and GIO interface
Application for: Separate ECU
Order number
L1
in m
L2
in m
Cable end type
12
3 x bayonet
Plug
socket
VCS II elecDIN 72585
tronic control
B1-3.1-Sn/K1
unit
and 2 x 1.5 mm² "MOD RD"
GELB
3000
50
BLAU
449 566 333 0
ROT
24
6
Installation instructions
VCS II
5
Installation of the Vario Compact ABS 2nd generation
5.1
General information
The Vario Compact ABS 2nd generation (VCS II) is simple to install. Only a few hand movements are needed to
activate the system.
The VCS II version 400 500 081 0 (Premium version) can
be configured to up to maximum 4S/3M. The condition
as delivered is 2S/2M, higher configurations (4S/2M or
4S/3M) are recognised automatically.
3a. 2S/2M configuration
• Connect the diagnostic cable 449 615 000 0
(where appropriate, 449 617 000 0 or
449 619 000 0) with the modulator connector
MOD RD (X6)
•
Connect the sensor extension cables
449 712 000 0 with connectors BU1 and YE1.
•
To avoid switching them, it is important that the
respective modulators and wheel sensors are installed on the same side of the vehicle:
The VCS II version 400 500 070 0 (Standard version) is
configured to 2S/2M and cannot be modified.
– Wheel sensor BU1 corresponds to port 2.2
(modulator C)
The VCS II version 446 108 085 0 (separate electronic
control unit) can be configured to up to maximum 4S/3M.
The condition as delivered is 2S/2M, higher configurations (4S/2M or 4S/3M) are recognised automatically.
5.2
1.
2.
Installation of the Premium version
Attach the system to the vehicle
The electronics/valve unit, consisting of the electronic control unit and the Boxer relay valve, should be
installed near the central axle of semitrailers. For
trailers, this unit may be optionally mounted in a position close to the rear or front axle. In any case, the
cable lengths leading to the brake cylinders should
be as short as possible. The device is screwed on
via both flanges, right/left, of the Boxer relay valve.
Use M8 screws with appropriate washers. The device must be installed in such a way that the exhaust
faces downward.
Supply port 1 (M 26x1.5)
•
Control port 4 (M 16x1.5)
•
Up to six discharge ports 2 (three 2.1 and 2.2 for
each side of vehicle, M 16x1.5)
For a 4S/3M configuration, attach the external relay
valve:
3.
– Wheel sensor YE1 corresponds to port 2.1
(modulator B)
•
•
Supply port 1 (M 22x1.5)
•
Control port 4 (M 16x1.5)
•
Two discharge ports 2 (M 22x1.5)
Electrical cabling
For the electrical cabling, please use the circuit diagram 841 801 933 0 (4S/3M)
or 841 801 931 0 (4S/2M).
Attach the power supply cable to the connector
POWER/DIAG (X1) (for part no. see VCS II cabling overview).
3b 4S/2M system
• Connect the diagnostic cable 449 615 000 0
(where appropriate, 449 617 000 0 or
449 619 000 0) with the modulator connector
MOD RD (X6).
•
Connect the sensor extension cables
449 712 000 0 with connectors BU1, YE1, BU2
and YE2.
•
To avoid switching them, it is important that the
respective modulators and wheel sensors are installed on the same side of the vehicle:
– Wheel sensors BU1/BU2 correspond to port
2.2 (modulator C)
Connect the pneumatic line of the ABS relay
valve(s)
Attach the electronics/valve unit:
•
5
– Wheel sensors YE1/YE2 correspond to port
2.1 (modulator B)
•
Attach the power supply cable to the connector
POWER/DIAG (X1) (for part no. see VCS II cabling overview).
3c. 4S/3M system
• Connect the modulator/diagnostic cable
449 616 000 0 (where appropriate,
449 618 000 0 or 449 620 000 0) with the modulator connector MOD RD (X6).
•
Connect the sensor extension cables
449 712 000 0 with connectors BU1, YE1, BU2
and YE2.
•
To avoid switching them, it is important that the
respective modulators and wheel sensors are installed on the same side of the vehicle:
25
5
VCS II
Installation instructions
•
– Wheel sensor BU1 corresponds to port 2.2 of
the Boxer relay valve (modulator C)
– Wheel sensor YE1 corresponds to port 2.1 of
the Boxer relay valve (modulator B)
– Wheel sensors BU2/YE2 correspond to port 2
of the external relay valve (modulator A)
•
4.
5.
6.
7.
After the installation, switch the system on
Supply the system with an operating voltage corresponding to product specification 400 500 081 0.
Power can be supplied via the ISO7638 plug connection or optionally via ISO1185 (24N).
2.
26
Electrical cabling
For the electrical cabling, please use the circuit diagram 841 801 930 0.
3a. 2S/2M configuration (only possible configuration)
• Connect the diagnostic cable 449 615 000 0
(where appropriate, 449 617 000 0 or
449 619 000 0) with the modulator connector
MOD RD (X6).
•
Connect the sensor extension cables
449 712 000 0 with connectors YE1 and YE2.
•
To avoid switching them, it is important that the
respective modulators and wheel sensors are installed on the same side of the vehicle:
Start the PC diagnostic programme
Connect the diagnostic PC using the diagnostic interface and the diagnostic cable 446 300 329 2.
Activate the commissioning sequence
Start the diagnostic software, press the commissioning button and follow the instructions. The commissioning procedure must always be performed to verify the correct allocation of sensors
and modulators! Brakes must be applied to the
wheels at the start of the test!
– Wheel sensor YE1 corresponds to port 2.2
(modulator C)
– Wheel sensor YE2 corresponds to port 2.1
(modulator B)
•
Installation of the Standard version
Attach the system to the vehicle
The electronics/valve unit, consisting of the electronic control unit and the Boxer relay valve, should
be installed near the central axle of semitrailers. For
trailers, this unit may be optionally mounted in a position close to the rear or front axle. In any case, the
cable lengths leading to the brake cylinders should
be as short as possible. The device is screwed on
via both flanges, right/left, of the Boxer relay valve.
Use M8 screws with appropriate washers. The device must be installed in such a way that the exhaust
faces downward.
Connect the pneumatic lines of the electronics/
valve unit
Attach the electronics/valve unit:
•
Supply port 1 (M 26x1.5)
•
Control port 4 (M 16x1.5)
Attach the power supply cable to the connector
POWER/DIAG (X1) (for part no. see VCS II cabling overview, 5-wire only).
4.
After the installation, switch the system on
Supply the system with an operating voltage corresponding to product specification 400 500 070 0.
Power can be supplied via the ISO7638 plug connection or optionally via ISO1185 (24N).
5.
Start the PC diagnostic programme
Connect the diagnostic PC using the diagnostic interface and the diagnostic cable 446 300 329 2.
6.
Activate the commissioning sequence
Start the diagnostic software, press the commissioning button and follow the instructions. The commissioning procedure must always be performed to verify the correct allocation of sensors
and modulators. Brakes must be applied to the
wheels at the start of the test!
7.
End the installation
After successful commissioning, the system is
ready for operation.
End the installation
After successful commissioning, the system is
ready for operation.
5.3
1.
Attach the power supply cable to the connector
POWER/DIAG (X1) (for part no. see VCS II cabling overview).
3.
Up to six discharge ports 2 (three 2.1 and 2.2 for
each side of vehicle, M 16x1.5).
5.4
1.
Installation of the separate electronic control unit
Attach the system to the vehicle
The separate electronic control unit can be installed
anywhere on the vehicle frame. Use the M6 thread
on the back side of the electronic control unit. The
Installation instructions
electronic control unit must be installed so that the
sensor connections YE1, YE2, BU1 and BU2 point
downward.
2.
3.
VCS II
5
3c. 4S/3M system
• Connect the modulator cable 449 544 000 0 (triple cable) with the modulator connector MOD
RD (X6).
Connect the pneumatic line with the ABS valves
Connect the separate ABS valves (ABS relay valve
472 195 031 0, double ABS relay valve
472 195 041 0 or ABS solenoid modulator valves
472 195 018 0 are permitted) as with the VCS 1st
generation.
•
Connect the sensor extension cables
449 712 000 0 with connectors BU1, BU2, YE1
and YE2.
•
To avoid switching them, it is absolutely essential that the respective modulators and wheel
sensors are installed correctly:
Electrical cabling
For the electrical cabling, please use the circuit diagram 841 801 932 0.
– Wheel sensors YE2/BU2 correspond to modulator RD (A)
3a. 2S/2M configuration
• Connect the modulator cable 449 534 000 0
(Y-cable) with the modulator connector MOD RD
(X6).
– Wheel sensor BU1 corresponds to modulator
BU (C)
•
Connect the sensor extension cables
449 712 000 0 with connectors BU1 and YE1.
•
To avoid switching them, it is important that the
respective modulators and wheel sensors are installed correctly:
– Wheel sensor YE1 corresponds to
modulator YE (B)
– Wheel sensor YE1 corresponds to modulator
YE (B)
•
4.
After the installation, switch the system on
Supply the system with an operating voltage corresponding to product specification 446 108 085 0.
Power is supplied via the ISO7638 plug connection.
5.
Start the PC diagnostic programme
Connect the diagnostic PC using the diagnostic interface and the diagnostic cable 446 300 329 2.
6.
Activate the commissioning sequence
Start the diagnostic software, press the commissioning button and follow the instructions. The commissioning procedure must always be performed to verify the correct allocation of sensors
and modulators! Brakes must be applied to the
wheels at the start of the test!
7.
End the installation
After successful commissioning, the system is
ready for operation.
– Wheel sensor BU1 corresponds to
modulator BU (C)
•
Attach the power supply/diagnostic cable to the
connector POWER/DIAG (X1) (for part no. see
VCS II cabling overview).
3b. 4S/2M system
• Connect the modulator cable 449 534 000 0 (Ycable) with the modulator connector MOD RD
(X6).
•
Connect the sensor extension cables
449 712 000 0 with connectors BU1, BU2, YE1
and YE2
•
To avoid switching them, it is absolutely essential that the respective modulators and wheel
sensors are installed correctly:
Attach the power supply/diagnostic cable to the
connector POWER/DIAG (X1) (for part no. see
VCS II cabling overview).
– Wheel sensors YE1/YE2 correspond to modulator YE (B)
– Wheel sensors BU1/BU2 correspond to modulator BU (C)
•
Attach the power supply/diagnostic cable to the
connector POWER/DIAG (X1) (for part no. see
VCS II cabling overview).
27
6
VCS II
VCS II system: 2S/2M, Standard ECU
28
Braking system diagramCentral-axle trailer
841 601 100 0
1-axle
Braking system diagram Central-axle trailer
841 601 101 0
1-axle
VCS II
6
VCS II system: 2S/2M, Separate ECU
29
6
VCS II
VCS II system: 2S/2M, Standard ECU
30
Braking system diagram
841 700 991 0
Semitrailer
1-axle
Braking system diagram
841 700 993 0
Semitrailer
1-axle
VCS II
6
VCS II system: 2S/2M, Separate ECU
31
6
VCS II
VCS II system: 2S/2M, Standard ECU
32
Braking system diagram
841 700 994 0
Semitrailer
1-axle
Braking system diagram Central-axle trailer
841 601 114 0
2-axle
VCS II
6
VCS II system: 2S/2M, Separate ECU
33
6
VCS II
VCS II system: 2S/2M, Separate ECU
34
Braking system diagramCentral-axle trailer
841 601 116 0
2-axle
Braking system diagram Central-axle trailer
841 601 177 0
2-axle
VCS II
6
VCS II system: 2S2M, Premium ECU
35
6
VCS II
VCS II system: 4S2M, Premium ECU
36
Braking system diagramCentral-axle trailer
841 601 110 0
2-axle
Braking system diagram Central-axle trailer
841 601 112 0
2-axle
VCS II
6
VCS II system: 4S3M, Separate ECU
37
6
VCS II
VCS II system: 4S3M, Premium ECU
38
Braking system diagramCentral-axle trailer
841 601 113 0
2-axle
Braking system diagram Central-axle trailer
841 601 118 0
2-axle
VCS II
6
VCS II system: 4S3M, Premium ECU
39
6
VCS II
VCS II system: 4S3M, Premium ECU
40
Braking system diagram
841 601 121 0
Drawbar trailer
2-axle
Braking system diagram
841 601 123 0
Drawbar trailer
2-axle
VCS II
6
VCS II system: 4S3M, Separate ECU
41
6
VCS II
VCS II system: 4S3M, Premium ECU
42
Braking system diagram
841 601 124 0
Drawbar trailer
2-axle
Braking system diagram
841 700 981 0
semitrailer
2-axle
VCS II
6
VCS II system: 4S2M, Premium ECU
43
6
VCS II
VCS II system: 4S2M, Premium ECU
44
Braking system diagram
841 701 120 0
Semitrailer
2-axle
Braking system diagram
841 700 983 0
Semitrailer
2-axle
VCS II
6
VCS II system: 4S3M, Premium ECU
45
6
VCS II
VCS II system: 4S3M, Premium ECU
46
Braking system diagram
841 601 130 0
Drawbar trailer
3-axle
Braking system diagram
841 601 131 0
Drawbar trailer
3-axle
VCS II
6
VCS II system: 4S3M, Premium ECU
47
6
VCS II
VCS II system: 2S2M, Premium ECU
48
Braking system diagram
841 701 060 0
Semitrailer
3-axle
Braking system diagram
841 701 062 0
Semitrailer
3-axle
VCS II
6
VCS II system: 2S2M, Premium ECU
49
6
VCS II
Braking system diagram
841 701 151 0
VCS II system: 2S2M, 12 V, Premium ECU
50
Semitrailer
3-axle
Braking system diagram
841 700 971 0
Semitrailer
3-axle
VCS II
6
VCS II system: 4S3M, Premium ECU
51
6
VCS II
VCS II system: 4S2M, Premium ECU
52
Braking system diagram
841 700 973 0
Semitrailer
3-axle
Braking system diagram
841 601 140 0
Drawbar trailer
4-axle
VCS II
6
VCS II system: 4S3M, Premium ECU
53
6
VCS II
VCS II system: 4S3M, Premium ECU
54
Braking system diagram
841 601 141 0
Drawbar trailer
4-axle
Braking system diagram
841 601 143 0
Drawbar trailer
4-axle
VCS II
6
VCS II system: 4S3M, 12 V, Premium ECU
55
6
VCS II
VCS II system: 4S3M, Premium ECU
56
Braking system diagram
841 701 002 0
Semitrailer
4-axle
Braking system diagram
841 701 080 0
Semitrailer
5-axle
VCS II
6
VCS II system: 4S3M, Premium ECU
57
6
VCS II
VCS II system: 4S3M, Premium ECU
58
Braking system diagram
841 701 081 0
Semitrailer
5-axle
59
60
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