Zonar V4 Operation manual

V4™Installation/User Guide
REV: 04/06/18

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Contents
Introduction ................................................................................................................................... 5
System Overview .......................................................................................................................... 6
Installation Checklist ..................................................................................................................... 7
V4 Equipment ................................................................................................................................. 8
General Guidelines......................................................................................................................... 9
Layout ......................................................................................................................................... 9
Electrical ..................................................................................................................................... 9
Drill Holes ................................................................................................................................. 10
Cable Management .................................................................................................................. 10
Cable Management Examples ............................................................................................. 10
General Housekeeping............................................................................................................. 11
V4 Mounting Plate and Unit ......................................................................................................... 11
Mounting Areas ........................................................................................................................ 12
Mounting Considerations ........................................................................................................ 12
Orientation and Placement ..................................................................................................... 13
V4 Pin Configuration .................................................................................................................... 14
Power/Data Cables....................................................................................................................... 14
4 Pin, 3 Wire Power Cable ........................................................................................................ 15
Light Duty Power/Data Cable .................................................................................................. 16
To install the light duty cable: ............................................................................................. 16

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9 Pin Diagnostic 500K Cable .................................................................................................... 17
2-Pin Deutsch 500K Cable (Backbone) .................................................................................... 18
4 Pin, 4 Wire Power Cable ........................................................................................................ 18
4 Pin Testing and Cable Management......................................................................................... 19
Power Bundle Wiring – 4 Pin.................................................................................................... 19
Using a Digital Multimeter (DMM) Probe for Testing 4 Pin Cable ........................................... 20
Wiring Guidelines ......................................................................................................................... 21
Fuse Taps Installation.............................................................................................................. 21
Poke and Weave Installation ................................................................................................... 21
External GPS Antenna (Optional) ................................................................................................ 23
Optional GPS Antenna Adhesive Tag (for non-magnetic mounting surfaces)....................... 23
GPS System Check ....................................................................................................................... 24
Check the LEDs......................................................................................................................... 24
Turn Key Off.............................................................................................................................. 25
Turn to Accessory Position ...................................................................................................... 25
System Checklist .......................................................................................................................... 26
System Specifications.................................................................................................................. 27
Electrical ................................................................................................................................... 27
Environmental.......................................................................................................................... 27
GNSS Receiver .......................................................................................................................... 27
Cellular...................................................................................................................................... 27

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External GPS Antenna (optional) ............................................................................................. 27
V4 and Mount Dimensions ........................................................................................................... 28
Typical Installation....................................................................................................................... 29
Installation Example .................................................................................................................... 30
System Installation ...................................................................................................................... 31
Zonar Discrete Input System ....................................................................................................... 32
Warranty ....................................................................................................................................... 33
Notices.......................................................................................................................................... 34
Legal Information......................................................................................................................... 35

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Introduction
Zonar equipment will provide years of reliable service if properly installed and maintained.
Zonar equipment is typically installed in heavy vehicle applications and is often subjected to
extreme temperatures, dust, dirt, vibration, and shock. Proper installation is the critical first
step to equipment longevity and optimal performance.
This guide is meant to be a general guideline for the professional installer and technician.
While we attempt to point out the most common installation questions and issues, common
sense, good housekeeping procedures, attention to detail, safety adherence, and technical
competence of the professional installer are critical for a successful installation.
Please refer to your specific vehicle manufacturer guidelines for the installation of electrical
components and wiring.
Details on operating the V4 and its built-in applications and software are given in this guide.
A professional team of Zonar support technicians and engineers are available to answer your
installation questions. Contact Zonar at 1-877-843-3847 or by email at
[e-mail].

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System Overview

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Installation Checklist
The following is an installation checklist broken down by task.
Task # Task Required? Page # Complete?
1 Inventory all V4 equipment Required 8
2 Layout all cables and accessories according to:Required -
3 -General guidelines Required 9
4 -V4 device and mounting plate instructions Required 11
5 -Power / Data cables instructions Required 14
6 -External GPS Antenna guidelines If used 23
7 -Discrete input system instructions If used 32
8
Disconnect vehicle battery ground cable
Suggested
9Install V4 Power / Data cable. Do not connect 4 Pin
connector to V4 at this time. Do not connect OBDII
connector to vehicle at this time (If used) Required 14
10 Install Discrete Input cable If used 32
11 Install external GPS antenna If used 23
12 Install V4 mount plate & V4 Required 11
13 Interconnectallcables&wirestoV4(except4pinpower) Required 14
14 Reconnect vehicle battery ground cable Suggested -
15 Connect 4 pin power cable to V4 Required 14
16 Start engine Required -
17 Connect OBDII connector to vehicle (if used) Required 14
18 Complete V4 System functional checkout & checklist Required 24
19 Shutdown engine Required -

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V4 Equipment
A. V4 GPS Unit
B. V4 Mounting Plate and Mounting Screws (Provided)
C. GPS Antenna (Optional)
D. GPS Antenna Adhesive Tag (Optional - used for non-magnetic rooftop GPS Antenna
installs)
Note: See External GPS for detailed information on GPS antenna requirements and
recommendations.

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General Guidelines
The following is list of general guidelines for the installation process. It is important to read
these before starting.
Layout
•V4 unit must be located a minimum of 25 cm (10 inches) from any person.
•Do not place Zonar RFID tags, cables, or other equipment in any location or position
which may compromise human or equipment safety.
•Verify placement acceptability with State DOT/Law enforcement prior to installation.
•V4 has a temperature range of -40˚C (-40˚F) to +85˚C (+185˚F). Do not mount V4 in
hot engine compartments or near hot exhaust components.
•Lay all components out prior to installation to check for proper cable length and
interference issues.
•Avoid mounting Zonar equipment, antennas and wiring near other radio equipment
(for example, two-way radios), PA equipment and high energy electrical sources (for
example, cables, relays, amplifiers, etc.).
Electrical
•Consult the vehicle’s manufacturer for specific installation guidelines. (HIGHLY
RECOMMENDED for Multiplex electrical systems)
•All power leads (red and white) must be connected to the vehicle’s protected circuitry
(for example, fuse panel, circuit breaker panel, protected circuits). Never electrically
connect Zonar equipment to unprotected circuits (for example, directly to battery).
•It is also required that all power leads (red and white) be protected with a 3 to 5 amp
fuse and inline fuse holder (included) for optimal system protection.
•Electrical fuses should be installed as close as possible to the source of power.
•Do not connect to the 4 pin power input until all other V4 cables have been connected.

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Drill Holes
•Do not drill into the V4 unit. This will void the warranty.
•Capture all drill chips during drilling operations. Do not allow chips to fall onto
equipment, furnishings, etc.
•Deburr all drill holes on both sides of drilled surface. The following is an example of a
deburr tool:
•All drill holes must have a rubber grommet or similar anti-chaffing system installed to
protect cable assemblies (e.g. plastic conduit).
•Seal all penetration drill holes which may pass rain water.
Cable Management
•Strain relieve and support all cable installations.
•Avoid sharp bends and tight radius installations of cables.
•Avoid moving components (for example, doors, steering shafts, handles, fans, etc.).
•Provide enough cable slack to allow for servicing of equipment (adequate service
loop)
•Avoid routing cables through doors, windows, and other pinch points.
•Avoid routing cables in high personnel traffic areas.
•Avoid routing antenna cables near radio and PA equipment.
Cable Management Examples
CORRECT
INCORRECT
•Bend radius is adequate.
•Hole has grommet.
•Bend radius is too tight.
•Hole has sharp edges.
•Hole has no grommet.