WABCO IVTM User guide

IVTM – TIRE PRESSURE MONITORING
FOR COMMERCIAL VEHICLES
SYSTEM DESCRIPTION

IVTM
Tire Pressure Monitoring
for Commercial Vehicles
System Description
Edition 6
This publication is not subject to any update service.
You will find the current version at
http://www.wabco.info/8150100453
© 2013/2015 WABCO Europe BVBA – All rights reserved.
The right of amendment is reserved.
Version 1/02.2013(en)
815 010 045 3

IVTM Table of Contents
4
1Important instructions............................................................................................................5
1.1 Information and Disclaimer...........................................................................................5
1.2 Symbols used...............................................................................................................5
1.3 General information......................................................................................................6
1.4 General safety instructions...........................................................................................6
2Introduction.............................................................................................................................7
2.1 IVTM prevents tire blow-outs........................................................................................7
2.2 IVTM reduces cost........................................................................................................7
3System Description................................................................................................................9
3.1 IVTM Basic Functions ..................................................................................................9
3.2 IVTM at trailer-towing operation .................................................................................10
3.3 Configuration for bus and towing vehicle ...................................................................10
3.4 Configuration for trailers .............................................................................................12
3.5 Certificates..................................................................................................................15
4Components..........................................................................................................................16
4.1 Wheel module.............................................................................................................16
4.2 Electronic Control Unit (ECU).....................................................................................19
4.3 The display .................................................................................................................21
4.4 Connecting cable........................................................................................................21
4.5 Connecting tube .........................................................................................................24
5Operation...............................................................................................................................25
5.1 Warning signals..........................................................................................................25
5.2 Switch on of ignition....................................................................................................25
5.3 Checking pressure values ..........................................................................................26
5.4 Display of faults ..........................................................................................................27
5.5 Adjusting tire pressures..............................................................................................28
5.6 Display of System Errors............................................................................................28
5.7 Operation via SmartBoard..........................................................................................30
6Installation.............................................................................................................................31
6.1 Mounting the wheel modules......................................................................................32
6.2 Mounting the ECU in bus / towing vehicle..................................................................34
6.3 Wiring in towing vehicle/bus .......................................................................................35
6.4 Mounting the ECU in the trailer ..................................................................................36
6.5 Wiring in trailer............................................................................................................36
6.6 Start-up.......................................................................................................................37
7Workshop instructions.........................................................................................................39
7.1 Diagnosis....................................................................................................................40
7.2 Wheel Changes..........................................................................................................41
7.3 Replacing PA tubes....................................................................................................42
7.4 Replacing hose connections ......................................................................................42
7.5 Replacing wheel module I with wheel module II ........................................................43
7.6 Creeping pressure loss ..............................................................................................43
7.7 No reception of the wheel module..............................................................................44
7.8 Disposal......................................................................................................................46

IVTM 1
Important instructions
1 Important instructions
1.1 Information and Disclaimer
We assume no liability for the correctness, completeness or actuality of the infor-
mation in this document. All technical information, descriptions and images are ap-
plicable for the day of printing this document or respective supplements. We retain
the right to any changes as a result of continuous further development.
The content of this document provides no guarantees nor warranted characteristics
nor can it be construed as such. Liability for damages is strictly excluded, as long
as there has been no respective intention or gross negligence on our part or any
forced legal provisions in opposition.
Text and graphics are subjected to our utilisation rights, copying or distribution in
any form require our approval.
Any brand markings, even if not indicated as such, are subject to the rules of the
labelling rights. If legal disputes arise from the utilisation of the information in this
document, these are exclusively to be handled under the regulations of national
law.
In so far as components or individual formulations of this applicable legal status
documentation are no longer or not fully relevant, the remaining parts of the docu-
mentation remain unaffected thereby in their content and validity.
1.2 Symbols used
DANGER
Imminent hazard situation which can cause serious personal injury or death if the
safety instruction is not observed.
WARNING
Potential hazard situation which can cause death or serious personal injury if the
safety instruction is not observed.
CAUTION
Potential hazard situations that can cause minor or moderate to severe injury, or
material loss, if the safety instruction is not observed.
Important instructions, information, or tips that you should always observe.
Reference to information and publications on the Internet
• List
– Step
Consequence of an action
5

1 IVTM
Important instructions
1.3 General information
This publication is directed at trained service technicians employed at workshops
for commercial vehicles.
Proper use
The IVTM system is designed exclusively for monitoring the tire pressure in com-
mercial vehicles.
Carefully read all the safety instructions as well as all the repair and maintenance
instructions in this document before you start maintenance work, repairs or replac-
ing parts.
These instructions must be observed to avoid personal injury or material damage.
WABCO only guarantees the reliability and performance of its products and sys-
tems if all instructions, notes and safety instructions are observed.
1.4 General safety instructions
Before you perform any work on the vehicle (repair, maintenance, replacing parts,
etc.), you must ensure the following:
WARNING
Severe damage to property and injuries to health may result due to improper
assembly or repair work.
– Only trained and qualified personnel may perform repairs on the vehicle.
– Always follow the specifications and instructions of the vehicle manufacturer.
– Always comply with the Company and national accident prevention guidelines
and Health and Safety regulations.
– Wear suitable protective clothing as the situation requires.
– Ensure that the workplace is dry and provided with sufficient lighting.
6

IVTM 2
Introduction
2 Introduction
This chapter gives you an overview of the benefits IVTM provides.
2.1 IVTM prevents tire blow-outs
IVTM stands for Integrated Vehicle Tire Pressure Monitoring. The system is con-
tinuously monitoring tire pressure on all wheels by means of sensors. In the event
of a critical pressure drop, a display in the driver cabin of the towing vehicle warns
the driver in time. Since around 85% of all punctures are caused by driving with
wrong air pressure or creeping pressure loss while in motion, risk of tire burst can
be reduced down to 15% thanks to IVTM.
fig. 2-1: Root causes for roadside emergencies (source: ADAC 2011)
A Tires 31.6%
B Electrics 29.2%
C Engine 20.7%
D Others 18.5%
2.2 IVTM reduces cost
By selecting the correct tires and having them properly maintained, substantial sav-
ings can be achieved per vehicle and year. Maintaining correct inflation pressure
for instance: In practice, about every second tire is run at an air pressure falling be-
low 10 percent of the specified one. Also 20% under nominal pressure is not rarely
observed and this will reduce tire mileage by as much as 20%. This will push up
fuel consumption in each case.
Full tire pressure checks usually take around 30 minutes per vehicle, IVTM can
help reduce or even eliminate this extra work.
So IVTM minimises cost and makes a great contribution to safety on our roads.
IVTM allows employment of Super Singles instead of twin wheels.
IVTM can be easily retrofitted.
7

2 IVTM
Introduction
8
Return of Investment Calculator
Using our Return of Investment Calculator on our website http://www.ivtm.com or
http://www.wabco-auto.com, you are able to calculate use your IVTM offers within a
few stages.
You can either enter your individual application data or use standard profiles for
determining which savings you are able to achieve using the IVTM.
fig. 2-2: Dependence of tire service life from air pressure
A Tire pressure
B Service life reduction
C Tire pressure too low
D Tire pressure too high
fig. 2-3: Consumption vs. air pressure dependency
A Tire pressure
B Fuel consumption
C Tire pressure too low
D Tire pressure too high

IVTM 3
System Description
3 System Description
This chapter describes the mode of operation of the IVTM system. Furthermore,
you will also obtain information concerning technical reports for installing and retro-
fitting.
3.1 IVTM Basic Functions
fig. 3-1: Solo system
A Electronic Control Unit (ECU)
B Wheel module
C Display
Each wheel continuously transmits actual tire pressure to a central electronic con-
trol unit (ECU). The signals of all wheels are evaluated there and the information is
conveyed to a display in the driver's cab.
Measuring
Wheel modules measure the air pressures on the conventional valves every 15
minutes and transmit them to the ECU. If the pressure changes critically then the
wheel module would sent the values in shorter periods.
Evaluating
Evaluation is far more than just comparing a current pressure value with an al-
lowed one and sending a warning message on falling below. The ECU discrimi-
nates a real problem situation from usual pressure fluctuations during vehicle op-
eration also on bad road conditions or uneven load.
In the event that an irregularity occurs then this fact would not only be reported on
the display but the wheel in question would be exactly indicated too.
An IVTM ECU can receive and process data from up to 16 wheel modules each
and further ECUs. Dual tires will each be fitted with individual sensors. Sensor
pressure range is between 2 and 14 bar corresponding to nominal pressure values
from 3 to 10.5 bar.
9

3 IVTM
System Description
10
Displays
WABCO is offers a driver's display for indicating warning messages and tire pres-
sure checking.
For certain vehicles the data can also be transmitted to an integrated display as an
alternative. Detailed description of display functionality is given in chapter "Opera-
tion"(see chapter 5, page 25).
IVTM, and therefore TPI, cannot announce sudden, extreme tire damage caused
by external effects.
3.2 IVTM at trailer-towing operation
Operating mode
Initially, the IVTM system on the trailers will work self-sufficiently if there is a power
supply. In order to display tire pressure and trailer warnings to the driver during
driving, however, it is necessary to install IVTM to both parts of vehicle, which
means one control unit to the trailer and one unit to the towing vehicle.
Any towing vehicle equipped with IVTM could be connected to any trailer equipped
with IVTM.
Variants
The IVTM for trailer vehicles can be operated using the WABCO SmartBoard as
well as for stand-alone versions.
Tire pressure values, in connection with WABCO TCE or EBS, can be transferred
to the towing vehicle's CAN bus via standard CAN data connection according to
ISO 11992 (only in connection with appropriately prepared towing vehicle).
Automatic trailer recognition
Control unit of towing vehicle identifies control unit of trailer automatically: The stop
light is enabled on towing vehicle and trailer when hitting the brake. The trailer
ECU radios a signal with this voltage pulse that is expected by the towing vehicle's
ECU that instant. The towing vehicle thus clearly detects that the trailer belongs to
the tractor/trailer combination and subsequently transmits trailer ECU messages to
the display.
As trailers are usually not permanently powered, it is possible that due to the fre-
quency of wheel modules transmission the tire pressure data for all the wheels of
the trailer is not available in the display for up to 15 minutes after starting the drive.
3.3 Configuration for bus and towing vehicle
In this chapter, you will learn which components you require for your vehicle.
Selection of IVTM components depends on vehicle type, type and number of
wheels and type of systems connected to IVTM but not on the vehicle system volt-
age.
ECU
Trucks, buses or articulated buses are equipped with the ECU 446 220 012 0.
Display
IVTM display 446 221 000 0 is used for the retrofitting of the display and operation
devices. Original equipment, however, will often address a central computer via
CAN with the latter controlling indication of the integrated dashboard-mounted dis-
play.

IVTM 3
System Description
Wheel modules
Select wheel modules and counterweights according to their axle configuration.
The table contains components for three vehicle type examples. Further informa-
tion in chapter "Components", see chapter 4, page 16.
Order
Number Component Comment 4x2 6x2 Articulated bus 6x2
446 220 012 0 ECU Communication with trailer
ECU / warning lamps 111
446 221 000 0 Display 111
894 607 390 0 Wiring harness Cable set, 7-pin
optional 894 607 295 0
(5-pin, no trailer-towing
operation)
111
960 731 051 0 L shape wheel
module for the front axle, rim 22.5", 10 holes 242
960 731 031 0 Wheel module for rear axle, rim 22.5", 10
holes 448
960 730 822 2 Counterweight Balance weight for front
axle wheel module 242
960 731 802 0 PA tube for front axle wheel module,
L-shape 242
960 731 822 2 PA tube for rear axle wheel module,
outside 224
960 731 804 0 PA tube for rear axle wheel module,
inside 224
960 731 801 0 PA tube Super Single 224
Table: 3-1: Components for bus / towing vehicle
Operation via CAN bus
Provided the trailer is equipped appropriately, data exchange can also be made via
CAN bus besides wireless connection between towing vehicle and trailer. Towing
vehicle ECU needs to be connected to vehicular CAN Bus for this purpose too.
Circuit diagrams
Detailed circuit diagrams are – as are the outline drawings of the components –
available on the Online Product Catalogue INFORM at http://www.wabco-auto.com.
Enter wiring diagram product number for opening the file:
• 841 801 970 0: Solobus
• 841 801 971 0: Articulated bus
• 841 801 972 0: Articulated truck / truck
11

3 IVTM
System Description
12
3.4 Configuration for trailers
Transmission types
Trailer and towing vehicle must be equipped with IVTM for displaying trailer IVTM
data in the diver's cab.
Alternatively, trailer data can display in towing vehicle only then when it is equipped
with an integrated display. When the trailer is also equipped with TCE or TEBS
then data transfer can be made to the towing vehicle central computer via CAN.
The following illustration compares both transmission types, wireless connection
and CAN bus, with each other.
fig. 3-2: Data transfer wireless connection (top) and CAN
A IVTM display
B Wheel modules
C IVTM-ECU
D Wireless connection
E IVTM Trailer ECU
F Integrated display
G Central computer
H TEBS/TCE
Stand-alone trailer towing operation
If the trailer should be independently equipped with IVTM, then the pressure re-
lease can be carried out via telemetry or the vehicles own display. When using the
IVTM display, it requires a special box for splash protection or another protected
attachment location. The WABCO SmartBoard can be installed as an alternative.
The driver cannot receive fault messages without IVTM support while the towing
vehicle is in motion.
IVTM with several trailers
Equipment of tractor/trailer combinations with more than one trailer is possible.
Tractor/trailer combinations with two trailers can still be made with wireless con-
nections; roadtrains need CAN bus connection with special ECUs.
Please contact your WABCO partner for more information.

IVTM 3
System Description
IVTM with TEBS D, TEBS E or TCE
Installation in a vehicle with TEBS D, TEBS E or TCE is simple because this
merely has to be plugged into pre-assembled cables. Other systems would require
open wiring that needs to be enclosed by protective housing.
Observe the current installation instructions for the control unit of the ABS / EBS in
the WABCO product database INFORM http://www.wabco-auto.com and / or those
of the vehicle manufacturer.
The circuit diagrams illustrated in the following table in excerpt form can be re-
trieved from INFORM.
Wiring diagrams for trailers
The circuit diagrams shown in excerpt form below can be retrieved from the
WABCO online product database NFORM at http://www.wabco-auto.com. To re-
trieve them, enter the desired circuit diagram number in the "Product number" input
field.
Wiring diagram 841 801 943 0:
Trailer ABS VCS
Cable position 8 (449 314 ... .) is opened and con-
nected to cable position 3 (449 674 273 0) and a
line to the stop light in a wiring box.
Wiring diagram 841 801 946 0:
Trailer ABS VCS II
Cable position 8 (449 336 ... .) is opened and con-
nected to cable position 3 (449 674 273 0), cable
position 11 (449 621 ... .) and a line to the stop light
in a wiring box.
Wiring diagram 841 801 941 0:
Trailer EBS with CAN connection
Cable position 8 (449 614 ... .) is opened and con-
nected to cable position 3 (449 674 273 0) and a
line to the stop light in a wiring box. The ISS output
must not be used and needs to be set to 0 km/h.
13

3 IVTM
System Description
14
Wiring diagram 841 801 945 0:
Trailer EBS D with CAN
Connection is made with cable position 3
(449 377 ... 0 / 449 378 ... 0). The ISS output must
not be used and needs to be set to 0 km/h. IVTM
diagnosis through diagnostic cable 446 300 329 2
via TEBS diagnostic port.
Trailer TCE
Connection like on Trailer EBS D with CAN but with
cable 449 302 ... 0.
Wiring like 841 801 945 0
Wiring diagram 841 801 940 0:
Trailer ECAS
Cable position 3 (449 674 273 0) is introduced into
bottom box of ECAS-ECU and connected there.
One cable to stop light (position 7) is installed addi-
tionally. You need screwed cable glands (PG 11:
894 130 312 2) for two cables.
Wiring diagram 841 801 944 0:
Vario-C
Cable position 3 (449 674 273 0) is introduced into
bottom box of ABS-ECU and connected there. One
cable to stop light (position 7) is installed addition-
ally. You need screwed cable glands (PG 11:
894 130 312 2) for two cables.
Wiring diagram 841 801 942 0:
Trailer EBS and ELM
Cable position 8 (449 344 ... .) is opened and con-
nected to cable position 3 (449 674 273 0) and a
line to the stop light in a wiring box.

IVTM 3
System Description
Wiring diagram 841 801 913 0:
Trailer EBS D and SmartBoard
(from year of manufacture 2004)
The SmartBoard and IVTM are connected to the
Trailer EBS D modulator on port IN/OUT2. CAN 2
must be activated (activation via diagnostic soft-
ware).
1 Trailer EBS D Modulator 480 102 014 0
2 Cable family 449 377 ... 0
3 SmartBoard 446 192 110. 0
4 IVTM
5 Distributor housing
Wiring diagram 841 802 155 0
Trailer EBS-E
IVTM is connected to sub-systems using cable
(449 913... .).
Wiring diagram 841 802 155 0
TEBS E with SmartBoard
IVTM and SmartBoard are connected to sub-
systems using cable (449 916 ... .).
Table: 3-2: Components for trailers
3.5 Certificates
Certificates for mounting and additional mounting of IVTM are available, which sig-
nificantly facilitate approval of vehicle registration papers.
The certificates are not part of this document but can be retrieved from the WABCO
online product database INFORM at http://www.wabco-auto.com. To retrieve them,
enter the search term in the "Index" input field.
Following certificates are stored there:
• Expertise TÜH ATC TB 2002-108.00
• Part certificate of TÜH ATC - TB 2003-023.00
• Type approval 94/9/EG CE 0032, TÜV03 ATEXxxxx
• Operating range: εx II 2G EEx ib IIC T4
15

4 IVTM
Components
16
4 Components
This component description details the properties of basic components.
Other details, such as dimensions, can be accessed via the WABCO online product
database NFORM at http://www.wabco-auto.com. To retrieve them, enter the de-
sired product number in the "Product number" input field.
4.1 Wheel module
CAUTION
Risk due to incorrect handling
– Do not unscrew or remove the module from the bracket.
Any changes of manipulation to the wheel module of any type, especially at-
tempts made to change the battery will destroy the device and may lead to
injuries.
fig. 4-1: Wheel module with connecting hose
The wheel module consists of a compound-filled plastic unit comprising a pressure
sensor, an evaluation circuit, a radio transmitter and a lithium battery.
Battery life under normal operating conditions is minimum 6.5 years. If the battery
is dead the module would not transmit any longer and needs to be replaced with a
new one.
The wheel module is mounted to the rim by the standard lug nuts and is connected
to valve via a PA tube. The result is an easy installation. You will not need to re-
move the tire from the rim when retrofitting.
Data transfer
Wireless transmission is made by 433 MHz signal. If pressure is constant, meas-
ured values are transmitted every 18 minutes (9 minutes with versions that do not
have acceleration sensor), if pressure is changing, frequency of data transfers is
faster.
IVTM can be interrupted in its function if other devices or systems in the vicinity are
also transmitting in the area of 433 MHz. These can be radio sets, radio remote
controls (e.g. for door actuation, cranes, fork lift), insufficiently shielded electrical
drives with high power or other radio transmitters. When IVTM system is removed
from the influencing area, the function is guaranteed again.

IVTM 4
Components
17
Depending on rim crank, use of the normal module according to Figure 4-1 or the
called L-shape or T-shape version is recommended. For details see Table 4-1
d also the chapter on configuration (see chapter 3.3, page 10 and see chap-
so-
an
ter 3.3, page 10).
Application WABCO
number Hole, wheel bolt Bolt circle ØAngle Figure
Trailer: Independent wheel (no Super-Single) 960 731 011 0 26 mm 335 mm 0°
Trailer: Independent wheel (no Super-S
special purposes (e.g. Iveco) ingle), 20° for 960 731 013 0 23 mm 335 mm 0°
Trailer: Independent wheel (no Su
pitch circle diameter 0°per-Single), 23 mm 960 731 017 0 23 mm 335 mm
Trailer: Independent wheel (no Super-Single) 960 731 021 0 32 mm 335 mm 0°
Twin tires, Super-Single 960 731 031 0 26 mm 335 mm 70°
Twin tires, Super-Single 960 731 041 0 32 mm 335 mm 70°
Towing vehicle: Front axle, load axle 960 731 051 0 26 mm 335 mm 60°
Towing vehicle: Front axle, load a 335 mm 0°xle 960 731 053 0 32 mm
Towing vehicle: Front axle, load a 960 731 055 0 26 mm 335 mm 60°xle

4 IVTM
Components
WABCO
number Hole, wheel bolt Bolt circle ØAngle FigureApplication
Towing vehicle: Front axle, load a 960 731 061 0 32 mm 335 mm 33°xle
Twin tires, Super-Single 960 731 073 0 26 mm 285,75 mm 70°
Towing vehicle: Front axle, load axle 960 731 075 0 26 mm 285,75 mm 33°
Twin tires, Super-Single 960 731 081 0 26 mm 225 mm 70°
Counterweight for L-shape wheel module 960 730 822 2
960 730 828 2
26 mm
32 mm
335 mm 0°
Counterweight independent wheels 960 730 820 4 26 mm 335 mm 0°
960 730 825 4 32 mm
Table: 4-1: Wheel modules and counterweights
With twin wheels and Super Single rims, problems may occur with the radio trans-
mission due to the immersion depth. To ensure the quality of the reception, wheel
dules with the T-s 960 7 or 9 731 041 0).mo hape should be used ( 31 031 0 60
18

IVTM 4
Components
19
Counter weight
To prevent the whee causi imbalan on the wheel, a counterweight
ounted on the op 4-2 " ith c terweight",
19.
Axles with twin tires do not need counterweight. In this case, the wheel module of
one wheel serves as counterweight for the wheel module of the other wheel. They
are mounted opposite to one another, see figure 4-3 "Module for twin wheels",
page 19.
l module ng an ce
is m
page
posite side, see figure Module w oun
fig. 4-2: Module with counterweight
Module for tfig. 4-3: w eels
ID code
Special identification code of each wheel module allows unique assignment of
modules to particular wheels. The wheel module will "report" to ECU using this
code. This will exclude pressure signals from other vehicles to be assigned to own
system. Code is dete m s man d and cannot be changed.
This number is imprinted on the wheel module when commissioning.
in wh
rmined when odule i ufacture
Assignment between wheel and wheel module must be absolutely maintained tire-
change procedure. If tires were confused, IVTM could not set off required alarm
when a wheel with low pressure has been wrongly assigned to an axle on which
ssure is still pthis pre ermissible.
Identification code assig determined during initial start-up of the
diagnostic software on commissioning, see chapter 6.6 "Start-up", page 37.
4.2 Electronic Control Unit (ECU)
nment to a wheel is
fig. 4-4: ECU

4 IVTM
Components
20
Mode of function
After system installation, commissioning by PC diagnostic software must be per-
formed.
Any faults occurring during operation are stored in the electronic unit for diagnostic
purposes.
Design
Three standard versions of the electronic control unit (ECU) are employed:
in 220 012
• Trailer: 446 220 013 0
• Trailer Train: 446 220 014 0 (can be cascaded up to 5 times with 16 modules
D)
All ECUs are suitable for 12 or 24 volt operation and can be mounted on the vehi-
Software change
ce pressure has been extended downward to be-
sing
the diagnostic software. The new software allows different reference pressures to
Radio transmission
The ECU is mounted to chassis in central part of vehicle, so that perfect radio con-
tact with all wheel modules and connection between trailer ECU and towing vehicle
ECU is ensured. You should use special brackets for good radio contact.
The ECU immediately recognises all changes from programmed nominal tire pres-
sure values by combined comparison with threshold pressure values and pressure
changes.
Incorrect values of tire pressures are already displayed before departure (if ECU is
permanently powered).
The system may be extended up to 12 wheel modules for towing vehicles and for
trailers up to 16 wheel modules per ECU.
• Tow g vehicle and bus: 446 0
each)
ECUs essentially differ by radio communication signal structure and CAN bus (I
connection. External distinguishing mark by type label only.
Further ECU types are tailored to specific customer requests and have other pin
assignments.
cle frame.
ECUs produced after calendar week 43/07 already have new software installed.
The setting range for the referen
tween 3 and 10.5 bar. The software change allows the reference pressure to be set
within certain tolerances on-board. Furthermore, it is also possible to measure the
signal quality of the radio contact to the wheel modules and to display them u
be set per axle.
fig. 4-5: Bracket 960 901 050 4
ntact is provided by antenna integrated in the control unit housing that
re signal reception from all wheel modules even under most dif-
ficult operating conditions.
Radio co
guarantees pressu