BPW ECO Tronic EBS User manual

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

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BPW Operating and Installation Instructions

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Table of Contents
Page
1 Introduction
1.1 ECO Tronic EBS 4
1.2 Abbreviations 7
1.3 Safety information 8
1.4 System layout 9
1.5 General components
1.5.1 Location of components in the trailer 10
1.5.2 Primary features of the Modulator 11
1.5.3 ECU connector identification 13
1.5.4 Overview of electrical connections 14
1.5.5 Wiring diagram - 2M 15
1.5.6 Wiring diagram - 3M 16
1.5.7 Overview of pneumatic connections 17
2 Installation options (Configurations)
2.1 Semi and centre axle drawbar trailers
2.1.1 2S/2M and 4S/2M, side by side 18
2.1.2 4S/3M 19
2.1.3 2S/2M + SL, side by side 20
2.2 Drawbar trailers (full trailers)
4S/3M 21
3 Chassis installation
3.1 Mounting of the Modulator
3.1.1 Position without Trailer Roll Stability (TRS) 22
function
3.1.2 Position with Trailer Roll Stability (TRS) 23
function
3.1.3 Identification of ECO Tronic EBS ports 24
and fixing
- Main Modulator
- Additional Modulator
3.1.4 Painting - protected areas 26
3.1.5 Mounting 27
3.2. Electrical wiring
3.2.1 Wiring schematic 28
3.2.2 Wiring diagram 29
3.2.3 Auxiliary equipment wiring 30
3.2.4 General installation recommendations 31
- cabling
3.2.5 General installation recommendations 32
- ISO 7638
3.2.6 General installation recommendations 33
- junction box
3.2.7 POWER / DIAG /Sensor / AUX cabling 34
3.2.8 POWER (ISO 7638) connections 35
3.2.9 POWER (ISO 1185) / 36
Super AUX connections
3.2.10 DIAG connections 37
3.2.11 DIAG / Side of vehicle connection 38
Page
3.2.12 Connectors / Blanking plugs 39
3.2.13 Sensor / AUX plugs 40
3.2.14 Sensor / AUX connections 41
3.2.15 Sensor connections / cabling 42
3.2.16 COLAS®+/ ILAS®-E connections 43
3.2.17 Auxiliary equipment wiring 44
3.2.18 Multimeter measurements 46
4 Piping
4.1 Pipe recommendations 48
4.2 Brake piping layout
4.2.1 2M, 3-axle semi trailer, side by side 50
4.2.2 3M, 3-axle semi trailer 51
4.2.3 3M, 2-axle drawbar trailer (full trailer) 52
4.3 Air suspension system piping layout
Air suspension levelling valve, COLAS®+ 53
and ILAS®-E
5 Operating and installation instructions
5.1 Brake system 54
5.1.1 Coupling heads 55
5.1.2 Trailer Control Module TrCM 56
5.1.3 Trailer Control Module TrCM+59
5.1.4 Brake lining wear sensoring 63
5.2 Air suspension 64
5.2.1 Standard air suspension valve 65
5.2.2 Level adjustable air suspension valve 68
5.2.3 Air suspension valve with zero point 70
adjustment
5.2.4 COLAS®+ 72
5.2.5 ILAS®-E 75
5.2.6 Shut-off cock 77
5.2.7 3/2-ways magnetic valve 78
5.2.8 Steering axle lock application 79
5.3 Soft Docking 80
6 Hazardous Goods / ADR Installations 87
7 Programming 89
8 System diagnostics
8.1 System diagnostics 91
8.1.1 Warning lamp 92
8.1.2 System check procedure 92
8.1.3 Power up ECO Tronic EBS 93
8.1.4 Other errors shown by the warning lamp 93
8.2 Diagnostic Trouble Codes (DTC) 94
9 Recommended maintenance schedule 97

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Notes on the content
These installation and operating instructions for the ECO Tronic
EBS describe the individual components and functions, as well
as possible configurations. This publication provides assistance
for first installation of an ECO Tronic EBS in a semi trailer,
centre axle drawbar trailer or drawbar trailer (full trailer). It deals
with the configurations 2S/2M, 4S/2M and 4S/3M. As well as
presenting the installation of the ECO Tronic EBS, the document
also discusses possible electrical cablings and provides cable
recommendations. Furthermore, it contains a description of
the extensive options for system diagnosis and fault analysis.
New ECO Tronic product range
ECO Tronic stands for a new product family of intelligent BPW
electronic products in the trailer. The first step is a complete
brake system consisting of, for example, the ECO Tronic EBS,
Trailer Control Module (TrCM), cable sets, Trailer Monitor and
a complete air installation. With the new product range, BPW
has developed its own electronic trailer components so that you
can obtain the entire trailer running gear from a single supplier.
From now on, you will only have one contact for the entire
system. From the axle to the brake, from the air suspension to
the electronic control unit.
The ECO Tronic EBS offers everything that you would expect
from a modern electronic brake system. And much more as
well: this is because in addition to brake control, the ECO
Tronic EBS also offers numerous additional functions. Running
gear data is ready for download at any time, vehicle usage is
recorded and documented, while clever solutions are available
for determining the ideal brake quality – with the new ECO Tronic
EBS from BPW, you can achieve sustainable optimisations in
your fleet management.
Basic functions of an EBS
Companies which want to transport goods from A to B as
safely and efficiently as possible find that an EBS is practically
essential nowadays. This is because EBS offers a whole
range of advantages compared to conventional pneumatic
brake systems: It increases safety due to shorter response
times, thereby reducing braking distances, optimises brake
performance because of improved matching and also simplifies
installation and maintenance processes. These are practical
and commercial advantages with specific benefits, and most
commercial vehicle manufacturers and transport professionals
can no longer do without them nowadays.
In contrast to pneumatically operated brake systems, an EBS
controls the brake cylinder pressure of the disc or drum brakes
individually using electronics. The mechanical pressure applied
to the brake pedal is converted into an electrical signal and
passed on to the control unit. This uses information available
in the data network to calculate the optimum brake pressure,
ensuring that brake forces are optimally distributed throughout
the system. The EBS is connected by a trailer control module
through the CAN interface.
In addition to its straightforward braking function, EBS has driver
assistance functions such as ABS (anti-lock brake system), ALB
(automatic load-dependent braking), as well as a TRS function
(trailer roll stability, not included in the basic kit), thereby offering
additional safety.
What is more, each EBS has a pneumatic fall-back level which
is a statutory requirement for use in emergencies, and permits
conventionally controlled braking in case of an electrical fault.
1.1. ECO Tronic EBS
ECO Tronic is the name of the BPW product range
for electronic trailer components.
The first product is the ECO Tronic EBS with
special trailer-specific features.
ECO Tronic EBS means BPW is the system
supplier with overall responsibility for the intelligent
trailer running gear.
1. Introduction

5
1.1. ECO Tronic EBS
Features of ECO Tronic EBS
The core of the ECO Tronic EBS is the EBS Modulator. Its
compact dimensions mean that it can be installed without
difficulty in all current semi trailers, drawbar trailers (full trailers)
and centre axle drawbar trailers. Its enclosed design ensures
fault-free operation and consists of a corrosion-resistant plastic
module and a weatherproof die-cast aluminium module.
All cable connections of the ECO Tronic EBS are grouped
together on one level for a clear layout, thereby permitting
optimum access. In addition, ease of installation is ensured by
connection designations on the side and the lid of the housing.
The ECO Tronic EBS can be used in a wide range of applications
with its five AUX connections. There is a user-configurable
Super AUX connection available as an option which gives
up to three more functions. Furthermore, the housing has an
integrated quick release valve for the parking brake and two
test connections for pressure gauges.
The numerous basic functions provided as standard mean the
ECO Tronic EBS offers greater safety and convenience. This
includes practical features such as stability control, lifting axle
control or steering axle lock which soon pay their way in day-
to-day operations.
Trailer Roll Stability
In the background, there is an electronic safety system for the
trailer which automatically intervenes in critical driving situations
to provide stability. Sensors integrated in the EBS permanently
measure the lateral acceleration of the trailer for this purpose. If a
critical driving situation is reached then the trailer is immediately
braked. As a result, the risk of skidding and tipping over - e.g.
when cornering or due to a shifting load - is reduced to a
minimum thanks to Trailer Roll Stability.
Lifting axle control
Another practical performance feature of EBS is the automatic
function for lifting and lowering a lifting axle depending on the
load and speed. This allows you to benefit from a significant
convenience feature compared to manual lifting axle operation,
and also reduces your running costs. Using an axle lift reduces
tyre wear when unladen. It goes without saying that the lifting
axle control can be switched over to manual operation on
request at any time, e.g. if the lifting axle is required as a
manoeuvring aid or starting traction control, or when the trailer
needs to be put onto the dynamometer test rig.
Automatic steering axle lock
The basic functions of EBS also include the automatic steering
axle lock. This is activated when reversing and automatically
blocks deflection of the wheels on the trailer’s steering axle.
Automatic service brake activation
In conjunction with an extendable drawbar installation,
automatic actuation of the service brake reduces the gap
between the vehicles, thereby allowing for convenient through-
loading. The ideal solution for greater safety and operating
convenience at the loading ramp.
Safety braking
This EBS function automatically applies the brakes on vehicles
such as tankers when the instrument cabinet is open, therefore
preventing it from moving off. This is a sensible additional feature
because it ensures that lack of attention does not immediately
become a danger.
Paver brake function
This is the perfect EBS function for ensuring the correct distance
between the paver machine and the trailer during road building.
In this case, the paver machine pushes the braked trailer in front
of it, thereby optimising handling and the production process.

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1. Introduction
Intelligent software packages for setting
parameters and operating data analysis
To ensure that the brake system and other running gear
parameters are set perfectly, ECO Tronic EBS has a software
system that is as extensive as it is user-friendly, for setting
parameters and analysing the operating data of the trailer.
Operation and evaluation of the EBS could hardly be easier.
The special feature of ECO Tronic EBS: BPW not only offers
you numerous standard EBS functions but also additional
trailer-specific functions that help you to optimise your fleet
management, reduce service times and therefore save operating
costs.
The Trailer Manager is a software programme for setting
the parameters of ECO Tronic EBS. It is used for the factory
configuration of the available brake and additional functions.
A clear menu system with step-by-step configuration allows
for trouble-free inputs. Missing information is displayed as a
safety feature in order to avoid possible mistakes in the system.
Do you sometimes find it difficult to identify vehicle components?
It is not rare for valuable time to be lost finding out which spare
part can be obtained from where in the shortest possible time.
The additional function of Assembly Data Management (ADM) in
ECO Tronic EBS will be greatly appreciated in this context. This
function gives you a practical tool for reading in and managing
information about the specific running gear and vehicle. Just
one look at the ADM data set allows you to identify spare parts
and maintenance documents unambiguously. At the touch of
a button, you can call them up or request them directly from
the BPW customer network. This saves costs because ADM
can significantly reduce the length of time spent in workshops
and on repair jobs.
The Trailer Analyser allows transport companies to benefit
from a clear evaluation software that offers practical functions
to deliver precise information about journeys and displays
meaningful vehicle bar charts. Whether these functions are
for analysing journeys or for special functions developed by
BPW for the vehicle history, ECO Tronic EBS means that you
are always precisely informed about the status of your trailers,
which gives you the perfect tool for optimum fleet management.
For example, the Trailer Analyser stores up to 1000 journeys
and can output a trip-based evaluation request. Numerous bar
charts on brake pressure, axle load, air suspension pressure and
other key figures of the running gear provide detailed information
about the operating status of trailers.
A practical additional function in the Trailer Analyser has
been specially developed by BPW for ECO Tronic EBS: Road
Condition Monitoring (RCM). This function makes it possible to
record and evaluate precisely what are the profiles of the roads
on which your trailers drive. This means you have a diagnostic
tool at your disposal that gives you a precise insight into vehicle
usage. As a result, Road Condition Monitoring also offers you
the opportunity to increase the resale value of your vehicles.
Priority on safety. This is especially important in the transport
business. ECO Tronic EBS software offers the perfect solution
for this as well. Brake Performance Monitoring (BPM) is an
intelligent additional function developed by BPW for the Trailer
Analyser, and provides you with information about the brake.
Reliable service
With the new ECO Tronic EBS, BPW is for the first time
offering you a complete trailer running gear system including
all electronic components from a single supplier. And this also
means that you benefit from reliable service and fast spare part
delivery, as with all BPW system components.
And what’s more, our range of services also includes training
courses. In these, we can on request provide you with valuable
knowledge about the new ECO Tronic EBS that you can put
to use in your day-to-day business – from professionals for
professionals.
1.1. ECO Tronic EBS
Assembly Data Managment
This is a tool in the Trailer Manager for reading in and
managing information specific to the running gear
and vehicle.
Road Condition Monitoring
This function of the Trailer Analyser can be used for
recording and evaluating road profiles exactly.
Brake Performance Monitoring
An intelligent additional function of the Trailer Analyser
for calculating and evaluating brake quality.

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1.2 Abbreviations
Abbreviations Explanation Description
2S/2M 2 Sensors / 2 Modulators ABS system with 2 rotational speed sensors and 2 modulators
ABS Anti-Lock Braking System Prevents the locking of braked wheels to maintain lateral grip
ADM Assembly Data Management Software function for storing all important vehicle data
ADR Accord européen relatif au transport
international des marchandises
Dangereuses par Route
European agreement on international transport of dangerous goods by
road
ASC Adaptive Surface Control ABS control that dynamically adapts to road conditions
AUX AUXiliary Additional input / output for sensors or actuators / valves
BPM Brake Performance Monitoring Software function for monitoring brake performance
CAN Controller Area Network Data bus system, used for controller communication in vehicles, among
others
COLAS®+ Lift and lower valve Valve for lifting and lowering the vehicle body in the case of air-sprung
vehicles
DCV Double Check Valve Anti-compounding valve to prevent simultaneous application of service
brakes and emergency brakes
DTC Diagnostic Trouble Codes Brake system error / warning codes for diagnosis and repair
EBS Electronic Braking System Electro-pneumatic brake system with CAN communication between the
truck and the trailer
ECE R13 Economic Comission for
Europe Regulation No. 13
European regulation No. 13 - Brake systems
ECU Electronic Control Unit Electronic controller
EEPROM Electrically Erasable Programmable
Read Only Memory
ELS
(LSV)
Electronic Load Sensing
Load Sensing Valve
Function for automatically adapting the braking force to the load of the
vehicle
EOLT End Of Line Test End of line system check to ensure correct system installation
EPRV Electro Pneumatic Relay Valve Electro pneumatically piloted relay valve of the EBS
GGVS Gefahrgut Verordnung Straße Act governing the road haulage of hazardous materials
GPI General Purpose Input AUX option
GPO General Purpose Output AUX option
ILAS®-E Integrated Lift Axle Steering EBS controlled lift axle valve
ISO 1185 Standardised interface between truck and trailer for lighting control
ISO 11992 CAN bus communication standard between truck and trailer for brake
control
ISO 7638 Standardised interface between truck and trailer supplying ABS/EBS
systems with power, transferring a signal for a warning device and, if fitted,
enabling CAN communication as standardised in ISO 11992
LWS Lining Wear System Brake pad wear sensing
LSV Load-Sensing Valve
PPV Pressure Protection Valve Pressure protection valve that separates the brake and air suspension
circuits
PTC Push To Connect Pneumatic connectors to ease installation
QRV Quick Release Valve
RCM Road Condition Monitoring Software function for recording and evaluating road profiles
REV Relay Emergency Valve Relay valve with emergency brake function
RtR Reset to Ride Height Automatic return to ride height
SAUX Super AUX Installation-optimized possibility for three digital inputs
TA Traction Assist Starting traction control
TrCM Trailer Control Module Parking and manoeuvring valve with emergency brake function (and
integrated pressure protection)
TRS Trailer Roll Stability Function that reduces the risk of the trailer rolling over

8
1 Introduction
• All work must be performed by trained specialists in qualified
workshops and authorised companies which have all the
necessary tools and knowledge for performing this work.
• The parameters of the system are only allowed to be set
by specialists who have completed a suitable training course
for this purpose. The parameters for the brake system can
be found in the brake calculation prepared for the vehicle in
question. The brake system calculation must take account of
statutory requirements of the country in question, as well as the
necessary safety provisions. If the set values are changed, the
person who performs this change is responsible for complying
with the statutory requirements of the country in question where
the vehicle is operated, as well as for maintaining safe function
of the system.
• When repairs are carried out on the vehicle, the brake system
must be protected against mechanical, thermal and surge
voltage damage.
• Local safety and accident prevention regulations as well as
regional and national regulations must be complied with.
• The relevant operation and service regulations as well
as safety regulations of the vehicle manufacturer and of the
manufacturers of other vehicle parts shall be adhered to.
• Do not perform repair and installation work unless wearing
protective clothing (gloves, safety boots, safety goggles, etc.)
and using the recommended tools.
• The vehicle must be secured against rolling away during
repair work. Please observe the relevant safety regulations for
repair work on commercial vehicles, in particular the safety
regulations for jacking up and securing the vehicle.
• Following each repair, it is necessary to perform a function
check or a test drive in order to make sure that the brakes are
functioning correctly.
• All exchanged components must be reused or disposed of
in accordance with the applicable environmental regulations,
laws and directives.
• 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.
1.3 Safety information
Various safety information is indicated by different icons in
these installation and operating instructions. Their significance
is described in the overview below.
Icon Significance
This symbol informs you that an
acoustic check is necessary in order
to avoid potential damage to property
or follow-on damage.
This symbol informs you that an
optical check is necessary in order to
avoid potential damage to property or
follow-on damage.
This symbol informs you that the
connection must be clean and dry
before being attached.
Warning note!
Failure to comply with the warning
note can result in a potential
hazardous situation, leading to injury
to personnel.

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1.4 System layout
The system fitted to your trailer may have 2 or 4 sensors and 2 or
3 Modulators, the variants available being 2S/2M, 4S/2M and
4S/3M.
The power supply of the system is via: ISO 7638 - 7 pin
connection - the full EBS function is guaranteed Fig. 1.
The power supply of the ECO Tronic EBS with a 5 pin ISO 7638
connection is also possible. In this case the response time (time
between applying the brake pedal and reaction of the brake
chambers) is increased due to the missing CAN databus while
ABS and ELS functionality is still available (see Fig. 2).
In the optional emergency solution (2M systems only) with stop
light electrical power supply, the ECO Tronic EBS is supplied
with electrical power via the ISO 1185 (24N) plug if the power
supply via the ISO 7638 plug fails. In this case, only the ABS
function and, optionally, the ALB function are in effect. (see
Fig. 3).
ECO Tronic EBS controls a warning device in the dashboard
(pin 5 of ISO 7638 connector).
The warning lamp has two functions:
• As soon as the ECO Tronic EBS is powered via the ISO 7638
plug (Figs. 163 and 164 on page 92), the system performs a
self-test. The result of this test is displayed by means of a
sequence of warning lights.
• The warning lamp indicates by a permanent display, if a fault
has been detected while the vehicle is moving.
Fig. 1
ISO 7638 - 7 Pin
EBS ECO Tronic EBS = full EBS function
Fig. 2
ISO 7638 - 5 Pin
ABS ECO Tronic EBS = EBS function with increased response time
(No CAN data bus)
Fig. 3
ISO 1185 - (24N)
ABS/EBS ECO Tronic EBS = on foot brake application
ABS function only + ELS optional

10
1 Introduction
1.5 General components
Fig. 4 - Overview of the main components and their location in the trailer
1.5.1 Location of components in the trailer
Driver’s information plate
Trailer Monitor
Trailer Control Module (TrCM)
(modified 01.01.2011)
optional
optional
Sensor and Exciter
ISO7638
- 7 pin connector
Modulator

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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 fittings and connections.
In addition the spring brake air, once exhausted, is silenced
using the silencing mechanism.
Service brake test connections
The EBS Modulator provides two additional service brake
connections, which can allow direct connections to the exterior
test points.
Integrated double check valve with distributor
An integrated anti-compounding spring brake distribution
manifold eliminates the need for a secondary manifold and
associated fittings, hence saving installation time and potential
errors.
Bulk head mounting
Three stud mountings, provide interchangeability with com-
petitor systems.
In addition, the mounting method allows much easier installation.
Fig. 5 Integrated quick valve
Fig. 6
Fig. 7
Test connections service brake
Integrated double check valve
Fig. 8

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1.5 General components
Reservoir connections
The EBS Modulator provides two reservoir connections, which
allows complete installation flexibility for vehicle manufacturers.
This flexibility not only provides a rapid installation, but allows
the reduction of pipe lengths.
Alignment of connections
The EBS Modulator has been deliberately designed to ensure
ease of vehicle installation. All the ports and electrical connection
positions have been chosen to provide easy identification and
are aligned to allow brake pipes to be bundled together, thus
providing an efficient cost effective, overall installation package.
Individual electrical connections
The EBS Modulator utilises well-recognised sliding connectors,
and the slide lock mechanism has been improved to allow
each connector to be removed and inserted individually.
This improves installation time and reliability.
Fig. 14
Working pressure: Air 0 - 8.5 bar (max. 9.5 bar)
Operating voltage: 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: Air
Exciter ring: 60 to 120 teeth
BPW EBS Modulator (5 AUX, stability, with integrated
quick release valve and double check valve).
Technical Data
Fig. 12
Fig. 13
ECU
The EBS Modulator provides a sealed for life encapsulated ECU,
thus eliminating interconnections.
1 Introduction

13
1.5 General components
Pin 1 Pin 4
ISO 1185 ISO 7638
Sensor S1A
Sensor S2A
Sensor S1B
Sensor S2B
Fig. 15
AUX 1
COLAS®+
Retarder
Trailer Lamp
ILAS®-E Front
ILAS®-E Rear
AUX Power
Steer Axle Lock
Service Lamp
Overload Lamp
Remote Overload Lamp
Stability Lamp (TRS)
General Purpose Output
TA+
Info Point
Info Point / COLAS®+
AUX 2, AUX 3
COLAS®+
Retarder
Trailer Lamp
ILAS®-E Front
ILAS®-E Rear
AUX Power
Steer Axle Lock
Service Lamp
Overload Lamp
Remote Overload Lamp
Stability Lamp (TRS)
ILAS®-E Front Manual
ILAS®-E Rear Manual
General Purpose Output
TA+
AUX 4
Lining Wear Sensor
General Purpose Input
Control Line Sensor
Soft Docking
Mechanical Height Sensor
AUX 5
Lateral Accelerometer
General Purpose Input
Control Line Sensor
Soft Docking
Mechanical Height Sensor
Trailer Monitor
PC Interface
1.5.3 ECU connector identification - 2S/2M, 4S/2M system
White B-
Red B+
Black 24 V
Yellow Input A
Brown Input B
Green Input C
Blue (not in use)
1
4
ISO 1185-
connection
Junction box
Pin configuration
Super AUX
Input A
Input B
Input C
Version without SAUX Version with SAUX
24 V Switched Output,
Speed indicator
24 V Switched Output,
Input for switching signal
Analogue Input,
5 V Power supply
Analogue Input,
5 V Power supply
ISO 1185 power supply,
three digital inputs,
24 V power supply

14
1 Introduction
1.5 General components
1.5.4 Overview of electrical connections
2A
1A
5
4
3
2
1
1B
2B
6
7
6
7
6
7
6
7
11
10
9
8
4
3
2
1
5
ISO 7638
ISO 1185 (24N)
Fig. 16 - Chassis components with electrical connections
Item Description Notes
1 ECO Tronic EBS label
2 ISO 7638 - 7 pin connector
3Safety back-up cable - ISO 1185 (24N) / or SAUX
optional
4 Trailer Monitor (side of vehicle connection)
5 Modulator
6 ABS sensor
7 Exciter ring
8 COLAS®+ AUX 1, 2 or 3
9 ILAS®-E AUX 1, 2 or 3
10 Lining wear system (LWS) AUX 4 only
11 External roll stability sensor AUX 5 only (as an option for the ECO Tronic EBS of the basic kit)
N.B. AUX to be configured accordingly with Trailer Manager
5

15
Fig. 17
1.5.5 Wiring diagram - 2M
1.5 General components
2
B+IGN
CAN H BIGN
LAMP B
CAN L
B+P
1
2
3
4
5
6
7
BK
RD
BN/W
GN/W
BN
W
YE
CABLE
2 x 1.5mm²
RD
BN
1 x 1.5mm²
CABLE
2 x 4.0mm²
5 x 1.5mm²
W
RD
1
4
N 6
1 x 2.5mm²
BK
YE
N 6
7
12
4
W
PK
RD
GY8
CABLE
7 x 1.5mm²
ISO
12098
(15 PIN)
CABLE
1 x 2.5mm²
3 x 1.5mm²
CABLE
2 x 1.0mm²
PC INTERFACE
CONNECTOR
CABLE
4 x 0.75mm²
W
RD
B
B+
N 4
B
CAN
B+
POWER A
POWER B
SUPER AUX
DIAGN
DIAGN
N 9
CABLE
3 x 0.75mm²
5
AUX
3
DIAG
PWRB
PWRA
2B1B123451A2A
SEN SEN SEN SENAUX AUX AUX AUX AUX
2B1B123451A2A
AUXILIARY
SOLENOID
N 8
CABLE
3 x 0.75mm²
22
AUX
LEFT REAR
SENSOR
CABLE
3 x 0.75mm²
ACCELEROMETER
N 5
AUX AUX
4
5
SEN
A
SEN
1
A
N 1
2A
1A
N 3
N 3
LEFT FRONT
SENSOR
PRESSURE
SENSOR
CABLE
2 x 0.75mm²
N 2
N 2
CABLE
3 x 0.75mm²
2B
1B
N 3
N 3
RIGHT FRONT
SENSOR
RIGHT REAR
SENSOR
SEN
A
SEN
1A
AUX AUX AUX AUX AUX
123
4
5
BK
RD
YE
N 1 N 7
BK YE
RD
CABLE
2 x 0.75mm²
CABLE
3 x 0.75mm²
BK
RD
YE
BK
RD
YE
N 1 N 7
BK
RD
YE
BK RD
YE
CABLE
4 x 0.75mm²
W
RD
BK
Y
BN
G
BU
B
B+
24V
AUX A
AUX B
AUX C
ISO
1185
(24N)
TRAILER LIFT
AXLE LIFT
CLOSE TO LIFT
ISO
7638
(EBS/ABS)
N 1 Auxiliary cabling termination is given in the table below:
Wire colour AUX 1 AUX 2 AUX 3 AUX 4 AUX 5
Red 0 V / 24 V 0 V / 24 V 0 V / 24 V 5 V 5 V
Black B- B- B- B- B-
Yellow Tacho /
Tell-Tale
D
input
D
input
A/D
input
A/D
input
0 V / 24 V : switchable output
B-: earth
D input: digital input (0 V to 24 V)
A/D input: analogue input (0 V to 5 V) or digital input
(0 V to 24 V)
Availability of auxiliaries and pressure sensor function
depend on ECU variant and configuration.
N 2 “Right” is viewed sitting in the driver seat facing forward.
N 3 Sensor connector.
N 4 Side diagnostic connector for use with Trailer Monitor or
PC interface
N 5 Roll stability function accelerometer if fitted, must be plugged
into AUX 5.
Mounting orientation of accelerometer must be as per
instructions supplied by BPW.
N 6 Cable length junction box to ISO 1185 (24N) or ISO 12098
(15 Pin) must not exceed 4 m.
N 7 Maximum load from any auxiliary output not to exceed
1A. All solenoids connected electrically to this unit must
be diode suppressed.
N 8 If the solenoid is not approved by BPW, fit a 1 A, 100 V
minimum, diode as shown.
N 9 Pressure sensor can be fitted to AUX 4 or 5.
Key: W - White BK- Black BN - Brown
BU - Blue RD - Red YE - Yellow
GN - Green PK- Pink GY - Grey

16
1 Introduction
Fig. 18
1.5.6 Wiring diagram - 3M
1.5 General components
N 1 Auxiliary cabling termination is given in the table below:
Wire colour AUX 1 AUX 2 AUX 3 AUX 4 AUX 5
Red 0 V / 24 V 0 V / 24 V 0 V / 24 V 5 V 5 V
Black B- B- B- B- B-
Yellow Tacho /
Tell-Tale
D
input
D
input
A/D
input
A/D
input
0 V / 24 V : switchable output
B-: earth
D input: digital input (0 V to 24 V)
A/D input: analogue input (0 V to 5 V) or digital input
(0 V to 24 V)
Availability of auxiliaries and pressure sensor function
depend on ECU variant and configuration.
N 2 “Right” is viewed sitting in the driver seat facing forward.
N 3 Sensor connector.
N 4 Side diagnostic connector for use with Trailer Monitor or
PC interface.
N 5 Roll stability function accelerometer if fitted, must be
plugged into AUX 5.
Mounting orientation of accelerometer must be as per
instructions supplied by BPW.
N 6 Maximum load for each auxiliary output shall not exceed
1A. All solenoids connected electrically to the Modulator
must be diode suppressed.
N 7 If the solenoid is not approved by BPW, fit a 1 A, 100 V
minimum, diode as shown.
N 8 Pressure sensor can be fitted to AUX 4 or 5.
2
SLAVE ECU
ASSEMBLY
Brake Systems
AUX 1
S1 A
S2 A
AUX 2 AUX 3 AUX 4 AUX 5
S2 B
S1 B
POWER
BA
DIAGN
POWER B
CABLE
2 x 4.0mm²
5 x 1.5mm²
B+IGN
CAN H BIGN
LAMP B
CAN L
B+P
1
2
3
4
5
6
7
BK
RD
BN/W
GN/W
BN
W
YE
RD
BN
CABLE
2 x 4.0mm²
5 x 1.5mm²
PC INTERFACE
CONNECTOR
CABLE
4 x 0.75mm²
N 4
B
CAN
B+
POWER A
POWER B
DIAGN
DIAGN
N 8
CABLE
3 x 0.75mm²
5
AUX
3
DIAG
PWRB
PWRA
2B1B123451A2A
SEN SEN SEN SENAUX AUX AUX AUX AUX
2B1B123451A2A
AUXILIARY
SOLENOID
N 7
CABLE
3 x 0.75mm²
22
AUX
LEFT REAR
SENSOR
CABLE
3 x 0.75mm²
ACCELEROMETER
N 5
AUX AUX
4
5
SEN
A
SEN
1
A
N 1
2A
1A
N 3
N 3
LEFT FRONT
SENSOR
PRESSURE
SENSOR
CABLE
2 x 0.75mm²
N 2
N 2
CABLE
3 x 0.75mm²
2B
1B
N 3
N 3
RIGHT FRONT
SENSOR
RIGHT REAR
SENSOR
SEN
A
SEN
1A
AUX AUX AUX AUX AUX
123
4
5
BK
RD
YE
N 1 N 6
BK YE
RD
CABLE
2 x 0.75mm²
CABLE
3 x 0.75mm²
BK
RD
YE
BK
RD
YE
N 1 N 6
BK
RD
YE
BK RD
YE CABLE
4 x 0.75mm²
ISO
7638
(EBS/ABS)
PSW
Key: W - White BK- Black BN - Brown
BU - Blue RD - Red YE - Yellow
GN - Green PK- Pink GY - Grey

17
1.5 General components
1.5.7 Overview of pneumatic connections
Item Description Notes
1 Emergency coupling with integrated filter
2 Service coupling with integrated filter
3 Trailer Control Module (TrCM)
4 Air reservoir - brake
5 Air reservoir - air suspension
6 Drain valve
7 Modulator
8 Air suspension levelling valve
9 COLAS®+
10 Suspension air bags (bellows)
11 Single diaphragm brake chamber
12 Spring brake chamber
13 Test point
14 Test point (if not integrated in COLAS®+)
1= Item
1= Port
1
12
21
1-2
1
1
1
21
21
11 12 11 12
11 12 11 12
1
22
22
4
11
23
23
23
22
4
23
2
23
7
1
3
11 12
6
1
22
10
8
1
4
6
10 10
10 10 10
1211 12
13
13
13
21
41 14
5
13
24
25
22
1
22
12
21
11
21
AUX1
9
Emergency
Fig. 19 : 3-axle semi trailer - 2S/2M side by side configuration -
2-line air brake system with Trailer Control Module
and spring brake chambers
Service

18
2.1 Semi and centre axle drawbar trailers
2.1.1 2S/2M and 4S/2M, side by side
S1B
S1A
S1B
S1A
S1B
S1A
S1B
S1A
S1B
S1A
S1B
S1A
S1B
S1A
S1B
S1A
S1B
S1A
22
21
S2B
S2A
21
22
22
21 22
21
S1B
S1A
22
21
21
22 21 22 21 22
S1B
S1A
22
21
S1B
S1A
S2B
S2A
21
22 21
22
S2B
S2A
S2B
S2A
22
21
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
- 2S/2M
• Any axle may be a steered axle - 2S/2M and 4S/2M
R.H. Power Cable Connector
L.H. Power Cable Connector
R.H. Power Cable
Connector
L.H. Power Cable
Connector
Modulator
ECU power connectors
Key
22
21
2 Installation options (Configurations)
4S/2M 2S/2M

19
2.1 Semi and centre axle drawbar trailers
2.1.2 4S/3M (recommended for self-steering axle)
S2B
S2A
S1B
S1A
S1B
S1A
21
22
S1B
S1A
2
S1B
S1A
S2B
S2A
21
22
2
S1B
S1A
S2B
S2A
22
21
2
S2B
S2A
S1B
S1A
22
21 2
S2B
S2A
2
S2B
S2A
21
22
S1B
S1A
2
S2B
S2A
21
22
S1B
S1A
2
S2B
S2A
22
21
S1B
S1A
2
S2B
S2A
221
22
S2B
S2A
S1B
S1A
221
22
S1B
S1A
2
S2B
S2A
S1B
S1A
2
S2B
S2A
22
21
22
21
22
21
4S/3M
• Any axle without directly controlled wheels may be lifted.
• Any axle can be a steered axle.
• Master ECU is mounted to EPRV’s. All sensors must be
connected to this Master ECU.
• Directly controlled wheels connected pneumatically to
EPRV’s 21/22 cannot be lifted.
• Slave ECU is mounted to EPRV 2 and is controlled by Master
ECU. Slave ECU/EPRV 2 is shown facing rear but can also
be installed facing forward, left or right, as EPRV 2 is always
select low control.
• Sensed wheel connected pneumatically to EPRV 2 can be
lifted.
Fig. 21
Modulators
Slave ECU
ECU power connectors
Modulator
Key
22
21
2
R.H. Power Cable Connector
L.H. Power Cable Connector

20
2 Installation options (Configurations)
2.1 Semi and centre axle drawbar trailers
2.1.3 2S/2M + SL, side by side (not recommended for self-steered axle)
2S/2M
Modulators
ECU power connectors
Key
22
21
S1B
S1A
S1B
S1A
22
21
21
22
S1B
S1A
21
22 A A A
S1B
S1A
22
21 A
S1B
S1A
22
21 A A
S1B
S1A
21
22
ASelect low valve (SL)
Fig. 22
• Any axle without directly controlled wheels may be a lift axle.
R.H. Power Cable
Connector
L.H. Power Cable
Connector