VDO Compact Test Computer II User Manual Download

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www.dtco.vdo.com

Intended only for the servicing and installation of the CTC II and
the Roller Interface Module

This documentation may not be transferred to third parties
without the written permission of the Continental Trading GmbH.

Summary of Contents for Compact Test Computer II

Page 1: ...nterface Module Installation Instructions Intended only for the servicing and installation of the CTC II and the Roller Interface Module This documentation may not be transferred to third parties without the written permission of the Continental Trading GmbH ...

Page 2: ...hall accept no liability for program errors and for incorrect information in the documentation or for any consequential damages arising from this CTC II Roller Interface Module and DTCO 1381 are registered trademarks of the Continental Corporation SmarTach is a registered trademark of ACTIA SE5000 and SE2400 are registered trademarks of Stoneridge Electronics The above mentioned trademarks are use...

Page 3: ... Installation Manual Document History A2C59512810 Continental Trading GmbH III Roller Interface Module Edition 01 2009 Document History As at 21 January 2009 Date Chapter page Topic revision action taken 01 2009 First edition ...

Page 4: ... 11 Installing connections 11 Connection J1 Power supply 12 Connection J2 Magnetic valve for lifting bar 13 Connection J3 Roller sensor 14 Connection J4 Light barrier 15 Connection J13 Trailing cable interface optional 16 Hardware prescaler SW1 19 Sealing the Roller Interface Module 20 Switching on the Roller Interface Module 21 Switching off the Roller Interface Module 21 Configuring the CTC II 2...

Page 5: ...Condition This denotes practical tips for installation or for checking system components Tip This denotes legal regulations or contains explanations about device associations and background knowledge Important This denotes dangers which may cause material damage or injury to persons To avoid possible injury to persons always pay special attention to the note s pertaining to this pictogram Caution ...

Page 6: ...components In the following description the service technician is expected to have comprehensive occupation specific knowledge and to be in complete control of the necessary and relevant tasks Technical requirements To enable the technician to carry out tasks reliably the premises and equipment must comply with the pertinent legal regulations of the country in which they are used Before installing...

Page 7: ...nt in the Roller Interface Module operates by means of dangerous electric voltage When the Roller Interface Module is open it must be switched off only then may authorised persons carry out work on the module Remove the key to prevent anyone switching on the module accidentally Caution Danger of explosion The Roller Interface Module may not be operated in areas which may be endangered by explosion...

Page 8: ...for any damage caused by improper use Moisture and dampness Prevent moisture or dampness from seeping into the module The Roller Interface Module may not be operated in the proximity of water Do not place any liquid container like a tumbler etc on or beside the module this will avoid any spillage getting into the device Environmental requirements Protect the Roller Interface Module from heat and c...

Page 9: ...modifications to accessories may be made EMC regulations Never use accessories which have not been recommended by the manufacturer they can cause accidents and operational disruptions Notes on the sealing of the Roller Interface Module If sealing is required the following sealing may be carried out for the Roller Interface Module Sealing of the housing cover The power supply installation must be c...

Page 10: ...place rolling road test stand 1 The following warning notice must be put up in a highly visible location Noise Zone Wear Hearing Protection 2 The following sign measuring 200 x 300 or 350 must be put up in a highly visible location During measuring entry to the pit is forbidden Supplier Fa Klar Neuer Weg 12 16 D 42111 Wuppertal 3 The cover plate of the rollers and projecting parts like light barri...

Page 11: ...face Module 2 Bluetooth module 3 Key switch 4 Fuse 5 Power connection see the Chapter entitled Connection J1 Power supply on Page 12 6 Power connection screw connection 7 Lifting bar connection see the Chapter entitled Connection J2 Magnetic valve for lifting bar on Page 13 8 Lifting bar screw connection 9 Roller sensor connection see the Chapter entitled Connection J3 Roller sensor on Page 14 10 ...

Page 12: ...connection 12 Hardware prescaler see the Chapter entitled Hardware prescaler SW1 on Page 19 13 Light barrier connection see the Chapter entitled Connection J4 Light barrier on Page 15 14 Optional trailing cable interface see the Chapter entitled Connection J13 Trailing cable interface optional on Page 16 The power supply installation must be carried out by an electrician Important Danger of short ...

Page 13: ...30 V AC 2 N N 230 V AC 3 PE Protective earth conductor PE J2 Lifting bar 1 L 230 V AC normal open contact NOC 2 L 230 V AC normal closed contact NCC 3 N N 230 V AC 4 PE Protective earth conductor PE J3 Roller sensor 1 Roller sensor signal white 2 12V DC green 3 Earth brown 4 Earth colourless J4 Light barrier 1 Light barrier signal white 2 12V DC brown 3 Earth blue Colour relates to the original se...

Page 14: ...green The CTC II and the Roller Interface Module are connected via Bluetooth green flashing The Roller Interface Module is waiting to connect with the CTC II red Communication error with the Bluetooth module e g Bluetooth module is not responding To rectify the error switch the Roller Interface Module off then on again red flashing Protocol error between CTC II and the Roller Interface Module The ...

Page 15: ...ideal environmental temperature is between 0 C and 40 C The power supply installation must be carried out by an electrician Condition Check the supply voltage before connecting and commissioning the Roller Interface Module The system is factory set at an input voltage of 100 to 240 V Caution 1 1 Loosen screw connection 1 2 Push the end of the cable through the union nut the washer and the cable as...

Page 16: ...Power supply A2C59512810 Continental Trading GmbH 12 Roller Interface Module Edition 01 2009 Connection J1 Power supply Connection diagram Captions PE 230 J1 3 2 1 Fig 3 Connection diagram plug J1 power supply Roller Interface Module J1 terminal Function Crosssection 1 L 1 mm2 2 N 1 mm2 3 PE 1 mm2 ...

Page 17: ...le Edition 01 2009 Connection J2 Magnetic valve for lifting bar Connection diagram Captions 3 2 2 1 4 J2 Fig 4 Connection diagram plug J2 lifting bar Roller Interface Module J2 terminal Function Crosssection 1 Control voltage L for pneumatic valve 230V AC normal open contact NOC 1 mm2 2 Control voltage L for pneumatic valve 230V AC normal closed contact NCC 1 mm2 3 Control voltage N 1 mm2 ...

Page 18: ... case of double roller sets the roller sensor and the light barrier can be connected with one 7 pole connecting cable In the case of brake test stands the roller sensor may have its own cable Important 2 3 4 1 J3 gn br ws Fig 5 Connection diagram plug J3 roller sensor Colour relates to the original sensor cable Roller Interface Module J3 terminal Function Crosssection 1 Roller sensor signal 0 15 m...

Page 19: ...s In the case of double roll sets the roller sensor and the light barrier can be connected with one 7 pin connecting cable In the case of test benches for brakes the light barrier may have its own cable Important 2 3 1 J4 br bl ws Fig 6 Connection diagram plug J4 light barrier Colour relates to the original sensor cable Roller Interface Module J4 terminal Function Crosssection 1 Light barrier sign...

Page 20: ...ortant To install the trailing cable connection serial connection cable a press cut must be broken out of the Roller Interface Module s housing If the press cut is broken out unnecessarily the protection class of the Roller Interface Module will be affected Check whether or not the Bluetooth module has to be replaced basing the check on the operating status of the Roller Interface Module as well a...

Page 21: ... 17 Roller Interface Module Edition 01 2009 To install the connection for the trailing cable A B 1 1 1 1 Remove the Bluetooth module from the spacer bolts Press the three spacer bolts 1 on the Bluetooth module together one after the other using pliers A and remove the Bluetooth module from the spacer bolts B 2 2 3 3 J15 J15 2 Close the J15 contact 3 with the jumper 2 ...

Page 22: ...driver 4 Push the trailing cable interface through the opening from the inside 5 Secure the trailing cable interface using the union nut 6 Plug the connection cable plug into the J13 8 pin plug connector see Pos 14 Fig 1 on Page 7 The trailing cable connection has now been installed in the Roller Interface Module The trailing cable to the CTC II can now be connected When laying the cables make sur...

Page 23: ...1 OFF ON Fig 7 Hardware prescaler SW1 Switch Prescaler setting 1 Position ON 1 x sensor signal frequency Position OFF no sensor pulses 2 Position ON 1 2 x sensor signal frequency Position OFF no sensor pulses 3 Position ON 1 4 x sensor signal frequency Position OFF no sensor pulses 4 Position ON The split sensor signal will be forwarded to the CPU normal operation Position OFF Firmware Update Mode...

Page 24: ...sure that the sealing pliers are adjusted correctly and that the assigned seal number is used the sealing wire is short making it impossible to open the cover the sealing wire does not cause any short circuits Not every country s legal regulations stipulate that sealing must take place Always adhere to your country s valid legal regulations Important You have connected all the Roller Interface Mod...

Page 25: ...safety instructions on Page 3 Condition Turn the key of the Roller Interface Module clockwise upwards to Position I The LED on the Roller Interface flashes green The Roller Interface Module now attempts to establish a Bluetooth connection with the CTC II If the LED turns green the Roller Interface Module is connected to the CTC II via Bluetooth Important Turn the key of the Roller Interface Module...

Page 26: ...ce Module CTC II configuration is carried out in the Service menu The Service menu is password protected You receive the password directly from the Continental Trading GmbH by e mail Please remember to handle your Roller Interface Module password as carefully as you would handle a cover seal Make sure that only authorised persons know the password Giving the password to unauthorised third parties ...

Page 27: ...rvice Version Distance roller Distance Settings road Length measuring track Setting roller Test stand type Roller adjustment Auto roller adjustment Roller direct Length measuring track Number wheel turns Min test speed Max test speed Communication Bluetooth address Connection Field strength PIN mode System Download Language Clock calibration Load change over times Calibration mode Automatic measur...

Page 28: ...gth of the measured track Default value 20 m Setting roller Test stand type Double roller Brake tester Brake double Setting the test stand type Double roller rolling road test stand Both wheels of a drive axle are powered The characteristic coefficient imp km is determined from one drive axle The number of drive axles is not requested Brake tester Brake test stand Only one wheel of the drive axle ...

Page 29: ...rcumference 100 5000 mm Measuring roller circumference input in mm Pulses 10 999 Input of the imp rev of the measuring roller number of teeth Length measuring track 20 10000 m Entering the length of the measured track to determine the W value and the vehicle constants The default value is predefined by the setting of the test stand type 20 m for the brake test stand 200 m for the rolling road test...

Page 30: ...tion Setting the PIN mode off Function for entering the PIN of the workshop card via the CTC II is switched off PIN direct The workshop card PIN can be entered using directly via the CTC II The PIN is not saved in the CTC II User selection The workshop card PIN can be entered using and user selection via the CTC II The workshop card PIN is saved in the CTC II and protected by a 4 digit password Up...

Page 31: ...on the CTC II starts automatically and the initial menu is displayed 1 Open the Adjustments menu 2 Open the Service menu The Service menu is password protected You receive the password directly from the Continental Trading GmbH by e mail Important The Password Entry screen is displayed 3 Enter the password and confirm PASSWORD PUT PASSWORD IN CONTINUE WITH KEY Use the button to change from numeric...

Page 32: ...apter entitled Connection overview on Page 7 Important 1 Open the Communication menu 2 Open the Bluetooth address menu The saved value is shown in the Actual display 3 Enter the Bluetooth address Use the button to change from numerical to alphabetical entry Press the button to correct wrong entries Important When programming has been completed the newly entered value will be shown in the Actual di...

Page 33: ...stablished between the CTC II and the Roller Interface Module see the Chapter entitled Operating status of the Roller Interface Module on Page 10 Tip The bar in the first display line indicates the quality of the Bluetooth connection Up to 5 bars are displayed The more bars displayed the better the quality of the Bluetooth connection If too many errors occur the connection is terminated CF 0 0 BR ...

Page 34: ...play will be shown 3 Return to the Communication menu RSSI BER C 0 0 I 0 500 CANCEL WITH KEY C 1 2 3 4 RSSI BER C NO CONNECTION I NO CONNECTION CANCEL WITH KEY C Field Range of values Meaning RSSI 32786 0 The value indicates the received signal strength indication RSSI 0 Signal is being received in very good quality 32786 no connection BER 0 3000 This value indicates the bit error rate In the init...

Page 35: ...e Bluetooth module with the trailing cable interface connection see the Chapter entitled Connection J13 Trailing cable interface optional on Page 16 The CTC II and the Roller Interface Module are connected via Bluetooth Condition 1 Open the Communication menu 2 Open the Connection menu The saved value is shown in the Actual display 3 Change the connection to serial When programming has been comple...

Page 36: ...on the test stand Calculation with display and saving of the roller adjustment value distance of the measuring roller per electric pulse in cm imp Measurement of wheel circumference on the road Carry out the automatic roller adjustments with a typical test vehicle with the largest possible wheels Important The following test sequences are written in a easily comprehensible style Important Fig 8 Me...

Page 37: ... the Chapter entitled Starting configuration on Page 27 2 Open the Setting roller menu 3 Open the Roller adjustment menu 4 Open the Auto roller adjustment menu 5 Enter the wheel circumference determined on the road and confirm 6 Bring the vehicle up to test speed or drive the measuring roller 7 Start wheel circumference measurement on the roller The CTC II ends the measurement independently The CT...

Page 38: ...rotection IP 54 Contamination level II Dimensions 200 x 180 x 95 mm Weight 1 5 kg Switching output for lifting bar brakes Alternating contact supply voltage contact load 0 6 A fused via device fuse Connections Voltage output for sensor supply 12V DC 15 1 A short circuit proof Roller pulse 0 2 5 cm imp NPN input Light barrier for wheel circumference measurement NPN input Correction value setting 9 ...

Page 39: ...01 22 000 01 Pulse adapter for brake test stand 1601 30 015 00 Light barrier X12 140 072 001 Universal pulse generator X12 140 066 001 Bluetooth Replacement Set Connection cable with an 8 pin plug connection and an interface for the trailing cable plus a union nut 20 m of trailing cable A2C59512915 Serial connection cable A2C59512181 CTC II set sender unit test Test cable sender unit test Operatin...

Page 40: ...___________ ______________________________________________________________________________________________________ ______________________________________________________________________________________________________ ______________________________________________________________________________________________________ _______________________________________________________________________________...

Page 41: ... The following warning notice must be put up in a highly visible location Noise Zone Wear Hearing Protection The sign measuring 200 x 300 or 350 must be put up in a highly visible location During measuring entry to the pit is forbidden Supplier Neuer Weg 12 16 Fa Klar Fa Klar D 42111 Wuppertal The cover plate of the rollers and projecting parts like light barriers etc must be visibly flagged with ...

Page 42: ...Roller Interface Module Appendix Drilling jig for wall mounting Installation Manual Appendix Drilling jig for wall mounting ...

Page 43: ...A2C59512810 Edition 01 2009 VDO A trademark of the Continental Corporation ...

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