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.

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General Housekeeping
1. Capture all drill chips during drilling operations. Do not allow drill chips to fall onto
electrical equipment, furnishings, heating ducts, etc. Magnets, sticky tape, vacuums,
physical barriers, etc. may all be used to accomplish this task.
2. Remove excess sealant. Sealant should be debris and contaminant free (for example,
no drill chips), consistent, and uniform in appearance.
3. Clip excess wire tie protrusions.
V4 Mounting Plate and Unit
To comply with FCC RF exposure requirements for mobile transmitting devices, this device
must be installed to provide a separation distance of at least 25 cm (10 inches) from all
persons. See General Guidelines.
The installation technician must record which V4 unit is being installed in each vehicle.
1. Find the GPS ID # on the back of the unit labeled “GPSID (S/N) 18xxxxxx.”
2. Record the asset (vehicle name) and the GPS being installed—this is important
information for Zonar Customer Care or the Ground Traffic Control Administrator.

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Mounting Areas
Mount onto an interior flat surface that is large enough to accommodate the footprint.
Suggested mounting areas include the following:
•Horizontal mount on dashboard under an angled windshield free of metallic
obstructions
•Overhead compartment mount with a clear non-metallic view of the sky (for example,
under a fiberglass roof or fairing).
Note: Verify placement acceptability with state DOT/law enforcement prior to installation.
Enclosed areas require an external GPS.
Mounting Considerations
•Avoid mount areas with difficult access or areas that do not allow for direct diagnostic
LED viewing.
•Do not mount near other radio equipment such as two-way radios, PA equipment and
high energy electrical sources (e.g., cables, relays, amplifiers, etc.).
•Avoid dirty, dusty, or damp mount areas (for example, near floors and entry ways).
•To prevent water damage, do not install below windows or doors that open to the
vehicle’s exterior.
Note: If enclosing in a radio-shielded area (for example, metallic enclosure) an external GPS
antenna may be necessary for proper operation and performance.

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Orientation and Placement

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V4 Pin Configuration
1. External GPS antenna (Optional)
2. 4 Pin Power Input (Disconnect first, Reconnect last)
3. 6 Pin Accessory Port: Z Pass™/Operator ID
4. 8 Pin for 2010/2020/Connect Dock
5. 12 Pin Discrete Input (Optional)
6. 10 Pin ECM input (SAE J1708/J1939 & OBDII equipped vehicles)
Power/Data Cables
The V4 has the following primary cables for connecting to the vehicle electrical and data
system:
•4 Pin, 3 Wire Power Cable (Part# 10007)
•Light Duty (LD) Power Cable (Part# 81008 with LD Breakout Part# 80999)
•9 Pin Diagnostic 500K Cable (Part# 81523) with optional 6-9 pin adapter (Part# 81632)
•2 Pin Deutsch 500K Cable (Part# 81517)
Additionally, there is a fifth uncommon cable specifically used to wire around battery
disconnect systems: 4 Pin, 4 Wire power cable (Part# 10030).
See General Guidelines before you begin. Do not connect to the 4 pin power input until all
other V4 cables have been connected.

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4 Pin, 3 Wire Power Cable
Use this cable for equipment that does not have OBDII, SAE J1708/J1587 or SAE J1939 data
buses. For wiring procedures see 4 Pin Testing and Cable Management.
This cable requires the vehicle to physically move at least 5 MPH for at least 100 feet to
properly complete new installation checkout. If this is not performed, GPS and discrete input
data will not be present in Ground Traffic Control until those thresholds are met.

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Light Duty Power/Data Cable
Use this cable for light duty vehicles that are equipped with the OBDII Diagnostic Port.
This cable has the following requirements:
•The vehicle should have a sticker or plate under the hood explicitly stating “OBDII
compliant” or “OBDII Certified,” for example:
•Do not use on hybrid vehicles.
•Do not install on vehicles that already have third-party aftermarket equipment
installed on the OBDII network (for example, wheel chair lift transmission lockout,
boom truck transmission lockout, fuel monitoring devices, etc.)
Failure to comply with these requirements may cause interference with the safe and
normal operation of the vehicle.
To install the light duty cable:
1. Connect to the OBDII diagnostic port with the engine running. Failure to perform this
step may trigger a false check engine light on the dash on first engine start after
installation. This will require the fault to be manually cleared.
2. Required. Move the vehicle at least 5 MPH for at least 100 feet to properly complete
new installation checkout. If this step is not performed the GPS and discrete IO data
will not be present in Ground Traffic Control™ until those thresholds are met.

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9 Pin Diagnostic 500K Cable
Use this cable on heavy duty vehicles with SAE J1939 data buses. The cable connects to the 9
Pin Deutsch diagnostic port. The optional 6 - 9 pin adapter (Part# 81632) is available for J1708
connections.

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2-Pin Deutsch 500K Cable (Backbone)
Use this cable on heavy duty vehicles with SAE J1708/J1587 (older) or SAE J1939 (newer) data
buses. The cable connects to the data network backbone.
Note: This cable requires specific adapters dependent on vehicle make/model/year and
engine manufacturer. Contact Zonar Customer Care for additional information.
See 4 Pin Testing and Cable Management and Wiring Guidelines for procedures.
4 Pin, 4 Wire Power Cable
This cable is similar to the Pin, 3 Wire Cable but it adds a green chassis ground wire. This
power cable is only needed for vehicles equipped with negative side battery disconnect
switches (typically construction equipment).
This cable requires the vehicle to physically move at least 5 MPH for at least 100 feet to
properly complete new installation checkout. If this is not performed, GPS and discrete input
data will not be present in Ground Traffic Control until those thresholds are met.

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4 Pin Testing and Cable Management
The 4 pin power cable is used on Non-J1708/J1939 and non-OBDII installs. It is also used on
J1708/J1939 installs with switched power issues (as indicated by flashing “Status” LED with
engine running). See General Guidelines and the following requirements.
1. All power leads must be connected to the vehicles protected circuitry (for example, the
fuse panel and circuit breaker panel protected circuits). Never electrically connect Zonar
equipment to unprotected circuits (for example, directly to the battery).
2. All power leads (red and white) must be protected with a 3 to 5 amp fuse and inline fuse
holder (included) for optimal system protection.
3. Electrical fuses should be installed as close as possible to the source of power.
4. For vehicles equipped with “noise kill” switches (late model school buses) – Do not wire
any Zonar equipment to the “noise kill” circuitry.
Power Bundle Wiring – 4 Pin
•Red – Constant DC (+8 VDC to +32 VDC), dependent on system type
•Black – Battery Ground must be less than 1 ohm (measure from 4 Pin connector to
chassis attachment point)
•Green - Chassis ground (Cable P/N 10030 only).
•White - Switched Power
oEngine running (+8 VDC to +32 VDC)
oEngine not running (0 VDC)
oEngine not running (key position ACC or Accessory Mode) (0 VDC)
The white wire must be connected to a power source that is active only when the
engine is running or the system will not track idle time properly.
Note: Please contact the vehicle manufacturer for any specific electrical questions.

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If power cabling is not connected and powered as described in the Power Bundle Wiring
section, one or more of the following conditions may occur. Contact Zonar Customer Care for
additional information.
•Cold Start flags (an indicator that a unit lost and regained constant power)
•Inaccurate idle and stop times
•Inaccurate hour meter data
•Inaccurate mileage data
•Missing path data
•Straight line data segments
Using a Digital Multimeter (DMM) Probe for Testing 4 Pin Cable
A digital multimeter (DMM) is a test tool that is used to measure two or more electrical values
such as voltage (volts), current (amps), and resistance (ohms). It is a standard diagnostic tool
for technicians in the electrical industry.
Improper use of the DMM probe may damage the pins causing an intermittent connection. Be
sure the probe only makes contact with the outside edge of the female connector. If the
probe is inserted into the connector it may distort the pin and ruin the connection.