Zonar V4 User manual
4/10/2019 V4 User Manual and Installation Guide – Zonar Systems Support
https://support.zonarsystems.net/hc/en-us/articles/360017847851-V4-User-Manual-and-Installation-Guide 1/27
V4 User Manual and Installation
Guide
Updated · January 23, 2019
Introduction
System Overview
Installation Checklist
V4 Equipment
General Guidelines
V4 Mounting
V4 Pin Configuration
Power And Data Connections
4 Pin Testing and Cable Management
Wiring Guidelines
External GPS Antenna (Optional)
GPS System Check
System Checklist
System Specifications
V4 and Mount Dimensions
Typical Installation
System Installation
Zonar Discrete Input System
Notices
Warranty And Legal Notices
4/10/2019 V4 User Manual and Installation Guide – Zonar Systems Support
https://support.zonarsystems.net/hc/en-us/articles/360017847851-V4-User-Manual-and-Installation-Guide 2/27
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 oen 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.
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 soware 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 customercare@zonarsystems.com.
System Overview
4/10/2019 V4 User Manual and Installation Guide – Zonar Systems Support
https://support.zonarsystems.net/hc/en-us/articles/360017847851-V4-User-Manual-and-Installation-Guide 3/27
Installation Checklist
Task
#Task Required? Complete?
1 Inventory all V4 components and accessories Required
2 Lay out all cables and accessories in accordance with: Required
3 - General guidelines Required
4 - V4 device and mounting plate instructions Required
5 - Power / Data cable instructions Required
4/10/2019 V4 User Manual and Installation Guide – Zonar Systems Support
https://support.zonarsystems.net/hc/en-us/articles/360017847851-V4-User-Manual-and-Installation-Guide 4/27
6 - External GPS antenna guidelines If used
7 - Discrete input system instructions If used
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
10 Install Discrete IO cable If used
11 Install external GPS antenna If used
12 Install V4 mount plate and V4 Required
13 Interconnect all cables & wires to V4 (except 4-pin power) Required
14 Reconnect vehicle battery ground cable Suggested
15 Connect 4-pin power cable to V4 Required
16 Start engine Required
17 Connect OBDII connector to vehicle (if used) Required
18 Complete V4 System function checkout checklist Required
19 Shut down engine Required
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 rooop GPS Antenna installs)
Note: See External GPS for detailed information on GPS antenna requirements and recommendations.
4/10/2019 V4 User Manual and Installation Guide – Zonar Systems Support
https://support.zonarsystems.net/hc/en-us/articles/360017847851-V4-User-Manual-and-Installation-Guide 5/27
General Guidelines
Layout
1. V4 unit must be located a minimum of 25cm (10 in) from any person.
2. Do not place Zonar RFID tags, cables, or other equipment in any location or position which may compromise
human or equipment safety.
3. Verify placement acceptability with State DOT/Law enforcement prior to installation.
4. 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.
5. Lay all components out prior to installation to check for proper cable length and interference issues.
6. Avoid mounting Zonar equipment, antennas and wiring nearother radio equipment (e.g. two-way radios), PA
equipment and high energy electrical sources (e.g. cables, relays, amplifiers, etc.).
Electrical
4/10/2019 V4 User Manual and Installation Guide – Zonar Systems Support
https://support.zonarsystems.net/hc/en-us/articles/360017847851-V4-User-Manual-and-Installation-Guide 6/27
1. Consult the vehicle’s manufacturer for specificinstallation guidelines. (HIGHLY RECOMMENDED forMultiplex
electrical systems)
2. All power leads (red and white) must beconnected to the vehicle's protected circuitry (e.g. fuse panel, circuit
breaker panel, protected circuits). Never electrically connect Zonar equipment to unprotected circuits (e.g. directly
to battery).
3. It is also required that all power leads (red and white) be protected with a 3 to 5 amp fuse and inline fuseholder
(included) for optimal system protection.
4. Electrical fuses should be installed as close as possible to thesource of power.
5. Do not connect to the 4 pin power input untilall other V4 cables have been connected.
Drill Holes
1. Do not drill into the V4 unit. This will void the warranty.
2. Capture all drill chips during drilling operations. Do not allow chips to fall onto equipment, furnishings, etc.
3. Deburr all drill holes on both sides of drilled surface. Example deburr tool:
4. All drill holes must have a rubber grommet or similar anti-chafing system installed to protect cable assemblies (e.g.
plastic conduit).
5. Seal all penetration drill holes which may pass rain water.
Cable Management
1. Strain relieve and support all cable installations.
2. Avoid sharp bends and tight radius installations of cables.
3. Avoid moving components (e.g. doors, steering shas, handles, fans, etc.).
4. Provide an adequate “Service Loop” i.e. “cable slack” to allowfor servicing of equipment.
5. Avoid routing cables thru doors, windows, and other pinchpoints.
6. Avoid routing cables in high personnel traic areas.
7. Avoid routing antenna cables near radio and PA equipment.
CORRECT
Bend radius adequate
Hole has grommet
INCORRECT
Bend radius too tight
Hole has sharp edges
Hole has no grommet
4/10/2019 V4 User Manual and Installation Guide – Zonar Systems Support
https://support.zonarsystems.net/hc/en-us/articles/360017847851-V4-User-Manual-and-Installation-Guide 7/27
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/contaminant free (e.g. no drill chips), consistent, and uniform in
appearance.
3. Clip excess wire tie protrusions.
V4 Mounting
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.
4/10/2019 V4 User Manual and Installation Guide – Zonar Systems Support
https://support.zonarsystems.net/hc/en-us/articles/360017847851-V4-User-Manual-and-Installation-Guide 8/27
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 Traic Control Administrator.
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 diicult 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.
Orientation and Placement
1. Horizontal with clear (non-metallic) view of sky
4/10/2019 V4 User Manual and Installation Guide – Zonar Systems Support
https://support.zonarsystems.net/hc/en-us/articles/360017847851-V4-User-Manual-and-Installation-Guide 9/27
2. Zonar logo towards sky
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)
4/10/2019 V4 User Manual and Installation Guide – Zonar Systems Support
https://support.zonarsystems.net/hc/en-us/articles/360017847851-V4-User-Manual-and-Installation-Guide 10/27
6. 10 Pin ECM input (SAE J1708/J1939 & OBDII equipped vehicles)
Power And Data Connections
Connecting to Vehicle Electrical and Data System
Do not connect to the 4 pin power input until all other V4 cables have been connected.
There are four primary methods to connect the V4 to your vehicle’s electrical and data system:
1. 4 Pin, 3 Wire Power Cable (part# 10007)
2. Light Duty Power Cable (part# 81153)
3. 9 Pin Diagnostic Cable (part# 81523) with optional 6 Pin adapter (part# 81632)
4. 2 Pin Deutsch Backbone Cable (part# 81517)
Additionally there is a fih uncommon cable specifically used to wire around battery disconnect systems:
5. 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.
4 Pin, 3 Wire, Power Cable (Part# 10007)
Use this cable for equipment NOT equipped with any of the following databuses:
OBDII (light duty/commuter vehicles)
JBus 1708/1587 (heavy duty vehicles 2010 and earlier)
JBus 1939 (heavy duty vehicles 2006 and later)
See wiring procedures below.
NOTE: Requires vehicle to physically move at least 5 MPH for at least 100 feet to properly complete new install
checkout. If this is not performed GPS and discrete IO data will not be present in GTC until those thresholds are met.
Light Duty Cable Kit (part# 81153)
This kit consists of two parts:
Light Duty, Power/Data Cable (part# 81008)
Light Duty Breakout (part# 80999)
4/10/2019 V4 User Manual and Installation Guide – Zonar Systems Support
https://support.zonarsystems.net/hc/en-us/articles/360017847851-V4-User-Manual-and-Installation-Guide 11/27
Use on light duty vehicles equipped with OBDII Diagnostic Port™.
Requirements:
1. OBDII Diagnostic Port
2. Sticker or plate under the hood explicitly stating "OBDII
Compliant" or "OBDII Certified". See example to right.
3. Do not use on hybrid vehicles.
4. The Light Duty cable cannot be installed on vehicles that
already have third party aermarket equipment installed on the
OBDII network (e.g. wheelchair li transmission lockout, boom
truck transmission lockout, fuel monitoring devices, etc.)
OBDII_sticker.png
Failure to comply with these requirements may cause interference with the safe and normal
operation of the vehicle.
Installation:
1. Connect to OBDII diagnostic port with engine running.Failure to perform this step may trigger a false Check Engine
light on the dash on first engine start aerinstallation. This will require the fault to be manually cleared.
2. Required.Drive vehicle for a minimum of 100 feet at 5 MPH or more to properly complete new install checkout. If
this is not performed GPS and discrete IO data will not be present in Ground Traic Control™ until those thresholds
are met.
9 Pin Diagnostic Cable (part# 81523)
Use this cable on heavy duty vehicles with SAE J1939 databuses. The cable connects to the 9 Pin Deutsch diagnostic
port, typically found beneath the driver-side dashboard.
4/10/2019 V4 User Manual and Installation Guide – Zonar Systems Support
https://support.zonarsystems.net/hc/en-us/articles/360017847851-V4-User-Manual-and-Installation-Guide 12/27
6 Pin Adapter (part# 81632)
Use with 9 Pin diagnostic cable to connect to J1708/1584 databuses using a 6 pin Deutsch diagnostic port.
2 Pin Deutsch Backbone Cable (part# 81517)
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. The
necessary adapters should be provided with the initial installation kit, but if assistance is needed, contact Zonar
Customer Support for additional information.
See 4 Pin Testing and Cable Management and Wiring Guidelines for procedures.
4/10/2019 V4 User Manual and Installation Guide – Zonar Systems Support
https://support.zonarsystems.net/hc/en-us/articles/360017847851-V4-User-Manual-and-Installation-Guide 13/27
4 Pin, 4 Wire Power Cable (part# 10030)
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 Traic Control
until those thresholds are met.
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)
4/10/2019 V4 User Manual and Installation Guide – Zonar Systems Support
https://support.zonarsystems.net/hc/en-us/articles/360017847851-V4-User-Manual-and-Installation-Guide 14/27
Green - Chassis ground (Cable P/N 10030 only).
White - Switched Power
Engine running (+8 VDC to +32 VDC)
Engine not running (0 VDC)
Engine 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: Contact the vehicle manufacturer for any specific electrical questions.
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 Support 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.
4/10/2019 V4 User Manual and Installation Guide – Zonar Systems Support
https://support.zonarsystems.net/hc/en-us/articles/360017847851-V4-User-Manual-and-Installation-Guide 15/27
Wiring Guidelines
The wiring guidelines in this section are for unterminated power and ground leads—4 Pin and Backbone. The
authorized method for power termination on the Zonar V4 system is the use of Add-a-Circuit fuse taps. Whenever
possible, use fuse taps for power termination. If fuse taps cannot be useddue to the particular make/model/year of the
vehicle being installed, then the poke and weave method of termination can be utilized.
Note: All wiring terminations MUST be fused regardless of method of installation used.
Fuse Taps Installation
1. Ensure that the fuse tap seats fully in the correct location.
2. If another fuse, a relay, or any other object in the fuse panel prevents the fuse tap from seating fully, relocate the
fuse tap.
It is not permissible for the fuse tap to rub or make contact with other items in the fuse panel
.
3. In addition, you must be able to re-secure the fuse panel cover or door once the fuse tap is installed.
4. Whenever possible, use an empty location in the fuse panel that does not have an existing fuse. If it is not possible
to use an empty location, ensure that the existing fuse is placed in the correct location on the fuse tap. See below
for an example.
4/10/2019 V4 User Manual and Installation Guide – Zonar Systems Support
https://support.zonarsystems.net/hc/en-us/articles/360017847851-V4-User-Manual-and-Installation-Guide 16/27
CAUTION: Zonar has approved two types of fuse taps. Use of other brands is not authorized. Do not install these
fuse kits in fuse panel locations greater than 10 amps.
LitteFuse brand: Add-a-Circuit
Bussman brand: Add-a-Fuse
Poke and Weave Installation
Whenever it is not possible to use Add-a-Circuit fuse taps then the poke and weave method must be used.
1. Locate the proper wire where the poke and weave method is to be installed. Strip 3/4” to 1” of insulation from the
wire in the vehicle to be installed. Spread the wire strands apart as shown below.
2. Strip 1” to 1 1/2” of insulation from the wire in the fused link to be installed.
3. Insert the wire from the fused link into the spread wire in the vehicle. Wrap around the wire several times.
4/10/2019 V4 User Manual and Installation Guide – Zonar Systems Support
https://support.zonarsystems.net/hc/en-us/articles/360017847851-V4-User-Manual-and-Installation-Guide 17/27
4. Cover the exposed wires with several wraps of electrical tape or mastic. Place one wire tie over the electric tape
over the exact location where the wires are 'wrapped' together. Place another wire tie 1” to 2” from the first wire tie,
to secure the two wires together and as stress relief.
External GPS Antenna (Optional)
External antennas are generally only necessary if the V4 GPS unit is enclosed in a radio signal interfering area (e.g.
metallic box, under seats, on dashboards with flat windshields, and in cabs or cockpits constructed primarily from
metallic material).
The suggested installation point is the centerline of the vehicle roof, with minimal cable run to prevent wind and car
wash damage. Ensure that there is a clear antenna view of the open sky, and maintain a minimum of 6 inches from any
rooop edge or ledge. See below.
4/10/2019 V4 User Manual and Installation Guide – Zonar Systems Support
https://support.zonarsystems.net/hc/en-us/articles/360017847851-V4-User-Manual-and-Installation-Guide 18/27
Drill, deburr, grommet, weather seal, and cable thru hole as required. Drill hole size - 1/2” (.500”); grommet size - 3/8”
(.375”).
Optional
GPS Antenna Adhesive Tag (for non-magnetic mounting surfaces)
Whenever possible, avoid installing adhesive in cold, wet, or damp conditions. Ideal application range is: 70˚F to 100˚F
(21˚C to 38˚C).
1. Clean and dry the surface prior to placement to obtain optimum adhesion. The best surface cleaning solvent is an
isopropyl alcohol/water mixture (rubbing alcohol).
2. Remove the backing from the peel and stick to the surface.
3. Press and hold mounting position for 10 seconds to assure good adhesion.
GPS System Check
At a minimum, the installer must perform a system check to verify proper installation. If at all possible a full and
complete checkout using Zonar’s Ground Traic Control® website should be performed. Not all installers will have
access to this area; check with a Zonar Customer Service representative if in doubt. This procedure covers the
minimum requirements for a system installer.
Check the LEDs
Turn the key on, and with the engine running check the LEDs on the GPS unit within 2 minutes. They should display the
following sequence aer everything is connected.
LED Condition
CELLULARSolid green. If blinking, ensure unit is an area with cellular coverage.
GPS Solid green or orange. If blinking, the GPS is acquiring satellite positioning (antenna must have a clear view
to sky). Do not proceed further until GPS LED is solid.
STATUS
Solid green. If blinking, check the cables at the GPS unit and the vehicle connector. Also check the integrated
4 Pin power pigtail at the GPS unit. If the cables and the 4 Pin power pigtail are good, use a standalone 4 Pin
power cable.
Note: STATUS will blink fast red when power is removed and the device is operating on internal backup
power.
Note: STATUS will blink blue upon startup If Bluetooth is enabled while the device is in pairing mode.
DATALINK
1
Single green blink per second if J1708/J1587 data is present.
Single green blink per second if good communication between the Light Duty cable and the GPS device.
4/10/2019 V4 User Manual and Installation Guide – Zonar Systems Support
https://support.zonarsystems.net/hc/en-us/articles/360017847851-V4-User-Manual-and-Installation-Guide 19/27
Single red blink per second if no ECM connection or if ECM connection not working properly.
DATALINK
2
Single green blink per second if J1939 data is present.
Single green blink per second if good communication between the Light Duty cable and the GPS device.
Single red blink per second if no ECM connection or if ECM connection not working properly.
Turn Key O
Turn the key o, and check the STATUS LED on the GPS unit. It should be blinking green—solid may indicate an issue
properly seeing the engine. Contact Zonar Customer Support if in doubt.
Note: Disregard the other LEDs for this check.
Turn to Accessory Position
Turn the key to the accessory position with the engine o. STATUS LED must be blinking.
Note: A proper and complete system/LED functional check requires the engine to be running.
System Checklist
4/10/2019 V4 User Manual and Installation Guide – Zonar Systems Support
https://support.zonarsystems.net/hc/en-us/articles/360017847851-V4-User-Manual-and-Installation-Guide 20/27
System Specifications
Electrical
DC Input Range: 8 VDC to 32 VDC
Operating Current: 100 mA @12V (typical without peripherals)
500 mA @12V (maximum without peripherals)
Other manuals for V4
1
Table of contents
