ABS SENSOR TEST UNIT 884 019 288 0 -...

USER MANUAL

ABS SENSOR TEST UNIT 884 019 288 0

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Table of contents1 General information ......................................................................................................................................... 4

2 Safety information ............................................................................................................................................ 52.1 General safety instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

3 General sensor information ............................................................................................................................ 6

4 Components ..................................................................................................................................................... 74.1 Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5 Installation ...................................................................................................................................................... 12

6 Mounting requirements ................................................................................................................................. 13

7 Sources of faults to be tested ....................................................................................................................... 147.1 ABS sensor air gap . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147.2 Sensor voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147.3 Pole wheel eccentricity / run-out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147.4 Tooth shape fault . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147.5 Total tooth pitch error (total pitch error) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

8 Limit values .................................................................................................................................................... 158.1 Framework parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

9 Establishing communication ........................................................................................................................ 169.1 LAN communication (TCP/IP) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169.2 Serial communication (RS232) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179.3 Bus systems (PROFIBUS, PROFINET) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189.4 Start telegram (master) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189.5 Result telegram (slave) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

10 Result report ................................................................................................................................................... 20

11 Software usage and options ......................................................................................................................... 2111.1 Start menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2111.2 Standard mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2211.3 Expert mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2311.4 Analysis of the last measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2411.5 Analysis of previous measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2611.6 Analysis details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2711.7 System details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2811.8 Details on the settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

12 Common error codes ..................................................................................................................................... 31

13 Maintenance and calibration ......................................................................................................................... 3313.1 Disposal / recycling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Edition 1 Version 1 (11.2017) 815 010 225 3 (en)

This publication is not subject to any update service. You will find the current version at http://www.wabco.info/i/696

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General information Safety information

1 General informationPurpose of this document

This document is directed toward vehicle and axle manufacturers. It explains the testing of the correct functioning of mounted standard and mini sensors in conjunction with the pole wheel by means of the ABS sensor / pole wheel test unit (ASTU).

Disclaimer

We assume no liability for the correctness, completeness or up-to-dateness of the information in this document. All technical information, descriptions and images are applicable for the date on which this document or respective supplements were printed. We reserve the right to make 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 damage is strictly excluded unless it is based upon intent or gross negligence on our part or unless this contradicts other mandatory or statutory regulations.

Text and graphics are subject to our right of use, copying or distribution in any form requires 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 documentation remain unaffected thereby in their content and validity.

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Safety information

2 Safety information

2.1 General safety instructions

Observe all necessary regulations and instructions: � Read this publication carefully.

� Adhere to all instructions, information and safety information to prevent injury to persons and damage to property.

� WABCO will only guarantee the safety, reliability and performance of their products and systems if all the information in this publication is adhered to.

� Always adhere to the specifications and instructions.

� Observe all accident regulations of the respective company as well as regional and national regulations.

Make provisions for a safe work environment: � Only trained and qualified technicians may carry out work on the vehicle

and vehicle parts.

� Use personal protective equipment if required (protective goggles, respiratory protection, ear protectors, safety shoes).

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General sensor information Components

3 General sensor informationThe test device consists of the WABCO ABS sensor / pole wheel test unit (ASTU) 884 019 288 0 incl. the corresponding, pre-installed software. With this software, the sensor signal of a complete wheel rotation can be evaluated.

The test can be performed at a sensor signal frequency within the mandatory range between 30 and 200 Hz (ideal sector 50 - 100 Hz) at any speed. The speed should not vary more than on normal roller test stands. The number of teeth on the pole wheel can be determined indirectly via the identified frequency if you use a known speed.

WABCO sensors and pole wheels can be checked for faultless functioning so that faults (pole wheel damage, sensor damage, assembly faults etc.) can be ruled out. When using non-WABCO sensors and/or pole wheels, please consult your WABCO contact person.

Your direct contact to WABCO

In addition to our online services, trained members of staff are there to help you at our WABCO Service Partners to directly answer any technical or business-related questions you may have.

Contact us if you need assistance:

� Find the right product

� Diagnosis support

� Training

� System support

� Order management

You can find your WABCO partner here: http://www.wabco-auto.com/en/how-to-find-us/contact/

http://www.wabco-auto.com/en/how-to-find-us/contact/

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Components

4 Components – Check the components for visible transport damage.

– After receipt, check that the delivery is complete

The delivery consists of:

� the ASTU

� a power supply unit with mains connection cable

� an accessory package

This package contains:

� one housing 10-pin industrial connector HAN with metal cable gland

� one industrial connector HAN insert 10-pin

� one cover for industrial connector HAN 10-pin

� if applicable. dummy plugs for unused sensor inputs

Furthermore, all necessary accessories for connecting a cable to the ASTU sensor input are included.

Depending on the number of channels:

� industrial connector HAN grommet 8-pole

� industrial connector HAN insert 8-pole

� crimp plug HAN DD

� metal union M20

With this accessory, the 10-pin control socket can either be covered or the connection used.

! The dummy plugs must be plugged into all unused sensor inputs of the ASTU to avoid interference.

Furthermore, all necessary accessories for connecting a cable to the ASTU sensor input are included.

! Please note that the connection of the sensors to be tested must be made by you.

You need standard tools for cable connections and a crimping tool that can crimp HAN DD contacts.

The connectors used are industrial connectors of the HAN (R) series from Harting.

As sensor cable we recommend the data cable UNITRONIC® FD CP (TP) PLUS 1 x 2 x 0.5 mm² grey from LappKabel 0030964.

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Components Components

4.1 Connections

4.1.1 Connections on the front of the WABCO ABS sensor / pole wheel test unit (ASTU)

1 2

NUMBER FUNCTION1 Main switch Switch for switching On/Off2 USB input Input for mouse or keyboard

ASTU is built into a RatiopacPRO housing from Schroff (order number 24571-838). This occupies 6 U (266 mm) and is 19" (84 HP / 449 mm) wide. Due to the connectors on the rear panel, approx. 500 mm must be provided as installation depth.

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Components

4.1.2 Connections on the rear of the WABCO ABS sensor / pole wheel test unit (ASTU)

PORT DESCRIPTIONA Sensor socket (9-pin Harting) for sensor 1 (sensor 2 is optional)

Sensor connection via PIN 1 + 2PIN 3 shielding

B USB sockets2 sockets for the connection of mouse, keyboard, storage media etc.

C Serial port RS232 25-pin Sub-DD LAN

To register the device in a network or to operate it via PC (TCP/IP)E GND (ground)

Grounding is absolutely necessary to avoid measuring errors due to electrical interference

F Power supplyThe test device requires a voltage of 24 V. An external power supply unit is included in the delivery.PIN 1 = +24VPIN 2 = Ground

G Control (relay outputs)There are 4 potential-free relay outputs available on the 10-pin Harting socket field for connection of external lamps or for evaluation. The output loads may not exceed 24V/1A. PIN 1 + 2 relay 1PIN 3 + 4 relay 2PIN 5 + 6 relay 3PIN 7 + 8 relay 4

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Components Installation

PORT DESCRIPTIONH

OptionalDigital input/output (IO / optional)For some start modes, a 24V digital input module is used to start or reset the ASTU software. By default, the input levels are 24V for the logical value TRUE and 0V for the logical value FALSE. In the standard configuration, a change from FALSE to TRUE triggers a start or a reset.A1 - DI0 / Digital Input 1 from NI9421A2 - DI1 / Digital Input 2 from NI9421A3 - DI2 / Digital Input 3 from NI9421A4 - DI3 / Digital Input 4 from NI9421A5 - DI4 / Digital Input 5 from NI9421A6 - DI5 / Digital Input 6 from NI9421A7 - DI6 / Digital Input 7 from NI9421A8 - DI7 / Digital Input 8 from NI9421B1 - PIN not available on-siteB2 - Supply voltage of the ASTU +24VB3 - Supply voltage of the ASTU +24VB5 - GroundingB7 - Ground of the ASTU 0VB8 - Ground of the ASTU 0VB9 - PIN not available on-site

IOptional

Connector for sensor 3 & 4 (optional)Sensor connection via PIN 1 + 2PIN 3 shielding

JOptional

RJ45 - Connector for PROFINET (optional)For registering the device in a PROFINET network

The PIN assignment of the serial port is listed below.

PIN ASSIGNMENT25-pin on the ASTU 9-pin

2 23 37 5

25-pin on the ASTU 25-pin2 33 27 7

SCOPEBaud rate 1200 / 4800 / 9600Parity noneData bits 8Stop bit 1

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Installation

5 Installation

Observe all necessary regulations and instructions: � Only use an undamaged power supply

� Do not intervene manually in a running measurement

� Avoid contact with rotating components

Check the basic functionality of the device after delivery:

– Use either the enclosed power supply unit or any 24V supply which can supply a current of at least 4A to PIN 1 and 2 of the voltage input socket, depending on how the ASTU is equipped.

– Connect the power supply unit to the corresponding input socket of the ASTU and switch on the device.

Ö The monitor shows the boot process of the integrated PC. The WABCO ASTU software then starts.

– Establish a sufficiently large connection for equipotential bonding.

– Connect at least one sensor input to the sensor to be tested.

Ö The device is now ready for operation.

Depending on your evaluation or control requirements, the serial port, a LAN port, digital inputs and outputs as well as the PROFIBUS or -NET interface can also be connected, depending on the available equipment. The settings must be made in the'' System'’, "Configuration'' menu, see chapter "11.8 Details on the settings" on page 28.

If you want to make your own entries on the ASTU, there are USB ports (one on the front and two on the back) available in addition to the touch screen. Devices not included in the scope of delivery, such as keyboard and mouse as well as external USB storage devices can be connected here.

! A data backup must be made before each change to the system.

! The customer is responsible for virus protection and firewall protection.

! In principle, all ABS sensors can be tested, please contact your responsible WABCO contact person.

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Mounting requirements Sources of faults to be tested

6 Mounting requirementsAdequate shielding of the sensor cable is important to increase the measurement accuracy.

! The sensor cable should always be kept as short as possible.

– Make sure that the cable shielding is also connected to the sensor input of the ASTU (PIN3).

! As sensor cable we recommend the data cable UNITRONIC® FD CP (TP) PLUS 1 x 2 x 0.5 mm² grey from LappKabel 0030964.

If you have any problems obtaining a suitable cable in this form, please contact your WABCO representative.

– Do not make any changes to the pin assignments of the ASTU connector plugs; use an adapter instead if necessary.

This ensures the long-term availability of replacement devices by WABCO, because in the event of a fault, standard WABCO devices can continue to be used as replacements in the future.

You can find your WABCO partner here: http://www.wabco-auto.com/en/how-to-find-us/contact/

! The cable must not be laid together with high-current lines or in a wiring harness with lines for inductance control.

! The supply voltage may only have a superimposed alternating voltage of 60 mV and must be free from voltage peaks due to interference.

– Make sure that the unit is properly grounded using a special connector on the back of the unit (E).

http://www.wabco-auto.com/en/how-to-find-us/contact/

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Sources of faults to be tested

7 Sources of faults to be tested

7.1 ABS sensor air gapThe ABS sensor air gap is the gap between the pole wheel and sensor. The bigger the air gap the smaller the sensor signal.

7.2 Sensor voltageThe minimum and maximum voltage is determined on the basis of the measured data. Here, the minimum voltage must be greater than the minimum value calculated on the basis of the entered pole wheel data (number of teeth and pole wheel diameter). The voltage information is displayed as an RMS value and normalised to 100 Hz.

7.3 Pole wheel eccentricity / run-outIdeally, the distance between sensor and pole wheel remains constant on a rotating wheel. Bearing clearance, assembly and production tolerances produce a wobbling movement in the pole wheel, which causes a fluctuating signal strength. A change in the air gap between sensor and pole wheel is checked via the ratio Umax/Umin.

7.4 Tooth shape faultThe error detection is made via amplitude level evaluation and the half-cycle period of the sinusoidal sensor signal. If one or more faults occur, either the manufacturer's tolerance does not correspond to the pole wheel specifications of WABCO or the tooth geometry is damaged.

7.5 Total tooth pitch error (total pitch error)The total tooth pitch error of a pole wheel results from the deviation of the individual separations (tooth or gap). If these deviations are outside the specifications of WABCO, this results in signal frequency fluctuations and faulty ECU speed processing. Therefore, a relatively constant speed, such as on a roller test stand, is required for testing the overall tooth pitch errors.

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Limit values Establishing communication

8 Limit values

8.1 Framework parameters

DESCRIPTION LIMIT VALUEPermissible frequency range = 30 - 200 HzPermissible number of teeth = 60 - 120Permissible pole wheel diameter = 50 - 280 mmMax. permitted run-out = 2.0 - 2.2 Umax/Umin

(depending on the sensor voltage)Minimum response voltage = 50 mVeff

Minimum required sensor Voltage at 100 Hz

= 0.33 Veff (depending on pole wheel diameter, number of teeth)

Maximum amplitude error ≤ 15 %Maximum half-cycle error ≤ 10 %Maximum total tooth pitch error (total pitch error)

≤ 1.5 degrees

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Establishing communication

9 Establishing communicationThe test unit can be started remotely from an external PC or manually. The following connection types are available:

� LAN (TCP/IP)

� Serial (RS232)

� PROFIBUS (optional)

� PROFINET (optional)

� Digital input (optional) / output

The interface for the remote control unit can be set up via the configuration menu of the device.

9.1 LAN communication (TCP/IP)The LAN connection can also be used to start a measurement. During start-up, a connection to the TCP server is initiated. After each measurement, the ABS sensor test unit will respond with a result telegram within 60 seconds (internal timeout).

Both the start and result telegrams are formatted in plain text, using a semicolon as separator and an end character:

START;<Job ID>;<Operating mode>;<Number of teeth>;<Pole wheel diameter>;<Sensor type>;<Unique axle serial number>;<Nominal speed value>;<Final character>;<End sign>

Example: START;54;12;100;230;1;1234567;200;CR/LF is interpreted as:

SELECTION EDITION DESCRIPTIONCommand START Start of the measurementJob ID 54 Sequential numberOperating mode 12 Channel 1 and 2 combined

Number of teeth 100 Number of teethPole wheel diameter 230 mm Pole wheel diameterSensor type 1 (normally 1) 1 for standard sensor

2 for mini sensorUnique serial number of the axle

1234567 Is used a file name for the measurement

Nominal value speed 200 in rpm Default value start telegram

End character CR/LF Measurement is finished

Normal TCP result telegram:

After the measurement, the result is sent back to the TCP server in the following form:

RESULT;<Job ID>;<Error code channel A>;<Error code channel B>;<reserved>;<reserved>;CR/LF

Some examples of a result:

RESULT;54;0;0;;;CR/LF (part A and B OK)

RESULT;54;1;0;;;CR/LF (part A NOK, part B OK)

RESULT;54;255;255;;;CR/LF (Internal error)

For a statistical analysis, extended information can optionally be activated in the configuration menu:

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Establishing communication Establishing communication

Extended TCP result telegram (multi-channel; must be switched on separately in the options):

Extended TCP result telegram (one channel):

After the measurement, the result is returned to the TCP server with some details for channel A:

RESULT; <Job ID>; <Error code channel A>; <reserved>; <Umax>; <Umin>; <Umax/Umin>; <Amplitude deviation>;

<Half period deviation>; <Total pitch error>; CR/LF; CR/LF; CR/LF

After the measurement, the result is returned to the TCP server with some details for channels A and B:

RESULT; <Job ID>; <Fault code channel A>; <Fault code channel B>;

<Umax A>;<Umin A>;<Umax/Umin A>;<Amplitude deviation A>;<Half period deviation A>;<Total pitch error A>;< reserved>;

<Umax B>;<Umin B>;<Umax/Umin B>;<Amplitude deviation B>; <Half period deviation B>; <Total pitch error B>; CR/LF

Example:

RESULT;54;1;1;6.878;3.433;2.004;18.775;99.935;351.855; ;6.873;3.381;2.033;14.503;98.995;42.682;\r\n

9.2 Serial communication (RS232)The RS232 is compatible with the predecessor device.

The measurements are carried out according to the following logic: In the serial start mode, a measurement is carried out after transmission of the start parameters (A, B, C, D). The result is returned by the ASTU (E, F,... T).

! The PC or the test device must acknowledge each data block sent within one second.

The test device returns to the initial state and waits for the next data block if the data is incorrect or not acknowledged within one second. The data is always sent in a block of 5 ASCII characters.

CUSTOMER DEVICE (e.g. PC)

DATA EXAMPLE

WABCO TEST DEVICE COMMENT

Test device waiting for dataSensor type A0001Number of teeth on pole wheel

B0100

Diameter C0150Detection ratio (mini sensor only)

D0.55 N/A with standard sensor

Test is startedMeasuring time: 1-2 sec.Evaluation: approx. 0.1 sec.Transmitting measured values

E0000 Test statusF0060 Rotational speed (min-1)G0100 Frequency (Hz)H0.70 U/max (Veff) (normalised to 100Hz)I0.69 U/min (normalised to 100Hz)J1.02 Umax/Umin (pole wheel eccentric)

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Establishing communication

CUSTOMER DEVICE (e.g. PC)

DATA EXAMPLE

WABCO TEST DEVICE COMMENT

K0000 Number of tooth shape errorsL00.9 max. amplitude error (%) DeselectableM00.5 max. half-cycle error (%) DeselectableN00.1 max. total tooth pitch error (%) Deselectable

Transmitting limiting valuesO0.73 U/max (Veff) (normalised to 100Hz) Deselectable

(n/a standard sensor)P0.19 U/max (Veff) (normalised to 100Hz) DeselectableQ2.06 Umax / Umin

(Pole wheel eccentricity)Deselectable

R15.0 max. amplitude error (%) DeselectableS10.0 max. half-cycle error (%) DeselectableT01.5 max. total tooth pitch error (%) Deselectable

Test device waiting for data

9.3 Bus systems (PROFIBUS, PROFINET)Currently there is only one start telegram (from the master) and one result telegram (from the slave) and therefore only one command per subscriber. The first byte after the telegram header is a telegram ID or a command byte. This is intended for future extensions of the interface.

Communication is generally based on PROFIBUS. A PROFINET or PROFIBUS translator is used for PROFINET communication. The PLC is always the master and contains the PROFINET or PROFIBUS device configuration. The required GSD (PROFIBUS) and GSDML (PROFINET) configuration files are supplied with the device and are required by your PLC programmer.

9.4 Start telegram (master)The start command for the measurement must transmit the following parameters in the specified order:

NUMBER PARAMETERS SIZE DATA TYPE VALUE RANGE1 Command 1 byte UINT START = 0x012 Operating mode 2 byte UINT 0 ... 343 Number of teeth on pole

wheel1 byte UINT 20 ... 120

4 Pole wheel diameter 2 byte UINT 50 ... 280 mm5 Sensor type 1 byte UINT 1 or 26 Axle serial number 10 byte ASCII7 Nominal value speed 2 byte UINT 200 …2000 RPM8 Job ID 2 byte UINT 0 … 65535

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Establishing communication Result report

Number 2: Operating mode

OPERATING MODE

MEASUREMENT

1, 2, 3, 4 Input separate12 Input 1+2 simultaneously13 Input 1+3 simultaneously14 Input 1+4 simultaneously23 Input 2+3 simultaneously24 Input 2+4 simultaneously34 Input 3+4 simultaneously

Number 5: Sensor type

NUMBER SENSOR1 Standard Sensor2 Mini Sensor

Number 6: Axle serial number

In case the serial number contains letters, 10 ASCII characters are reserved. The serial number is used for the measurement file name in reports. Please use unique serial numbers.

Number 8: Job ID

Use a unique job ID to confirm that a specific start belongs to a particular result. The specified job ID is returned with the result telegram.

The start command for the measurement must transmit the following parameters in the specified order:

9.5 Result telegram (slave)NUMBER PARAMETERS SIZE DATA TYPE VALUE RANGE

1 Command 1 byte UINT RESULT = 0x102 Error no. Channel A 1 byte UINT 0 ... 2553 Error no. Channel B 1 byte UINT 0 … 2554 reserved 1 byte5 reserved 1 byte6 Job ID 2 byte UINT 0 … 655357 Status UINT 0 … 38 Watchdog UINT 0 … 1

Error no. = 0 signals "OK"

Error no. = 1 signals "Pole wheel not OK"

Error no. = 255 signals "Measurement not OK"

Status = 0 signals "Device not ready"

Status = 1 signals "Device waiting for start"

Status = 2 signals "Measurement running" (currently not used)

Status = 3 signals "Analysis running" (currently not used)

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Result report

10 Result reportThe ABS sensor / pole wheel test unit creates and prints reports for each measurement on demand. The standard Windows printer is always used to print one A4 report per axle side and it is possible to activate the automatic printout of each or every xth report in the configuration dialogue (see below).

For 2-channel measurements, one sheet is printed for each channel (see upper right corner of the report):

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Software usage and options Software usage and options

11 Software usage and optionsThe following chapters describe the individual functions and options of the test device in more detail.

11.1 Start menuThe individual functions of the start menu are explained below. Depending on the access rights, there is the function of the:

� Standard (user) mode

� Expert mode

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Software usage and options

11.2 Standard mode

1: This area shows the menu structure of the software. In standard mode, only the "Start", "Current measurement" and "System" tabs are displayed (recommended for normal operation). If the user requires more detailed information, the "Expert Mode" can be selected in the settings so that the tabs "Load measurement" and "Loaded Analysis" become visible.

2: This area shows the status of the measurement. The left window shows the status of the measurement and the current operating mode of the device (e. g. manual operation, operation via LAN). The right window displays the result of the measurement. If you have purchased a device with one-channel operation, only one window for channel A is displayed. If you use the option with two simultaneous measurement channels, 2 result windows are displayed.

3: Area in which the error details are displayed if the measurement was not successful.

SOURCE DESCRIPTIONSensor or wiring Testing error! Sensor voltage too low. The air gap between the sensor and

the pole wheel is too large!

Pole wheel Installation error! Air gap between sensor and pole wheel changes too much! Run-out!

Pole wheel or rotational speed Half-period error too big!

Pole wheel Pole wheel fault! Check tooth shape!

Pole wheel or rotational speed Total tooth pitch error too big!

Start telegram Input error! Please verify entered pole wheel tooth count and wheel speed!

4: Start button (only for manual operation)

5: Button to cancel a running measurement (only for manual operation)

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11.3 Expert modeThe expert mode can be switched on separately under System/Configuration.

1: This area shows the menu structure of the software. In standard mode, only the "Start", "Measurement" and "System" tabs are displayed (recommended for normal operation). If the user requires more detailed information, the "Expert Mode" can be selected in the settings so that the tabs "Load measurement" and "Loaded Analysis" become visible.

2: This area shows the status of the measurement. The left window shows the status of the measurement and the current operating mode of the device (e. g. manual operation, operation via LAN). The right window displays the result of the measurement. If you have purchased a device with one-channel operation, only one window for channel A is displayed. If you use the option with two simultaneous measurement channels, 2 result windows are displayed.

3: Area in which the error details are displayed if the measurement was not successful.

SOURCE DESCRIPTIONSensor or wiring Testing error! Sensor voltage too low. The air gap between the sensor and

the pole wheel is too large!Pole wheel Installation error! Air gap between sensor and pole wheel changes too much!

Run-out!Pole wheel or rotational speed Half-period error too big!Pole wheel Pole wheel fault! Check tooth shape!Pole wheel or rotational speed Total tooth pitch error too big!Start telegram Input error! Please verify entered pole wheel tooth count and wheel speed!

4: Start button (only for manual operation)

5: Button to cancel a running measurement (only for manual operation)

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11.4 Analysis of the last measurementThe areas of the view for the analysis of the last measurement are explained below:

1: In this area, the measurement curve of the last measurement is displayed.

2: Here you can select which measurement channels should be displayed (only for multi-channel devices).

3: The results of the evaluation are displayed in this area.

4: In this area, the view can be enlarged in order to be able to recognise details more easily in the event of anomalies.

NUMBER PARAMETERSUeff max (V) Maximum voltage amplitudeUeff min (V) Minimum voltage amplitudeUmax/Umin (V/V) Voltage ratio gives indication of run-outMeasuring range The measuring range used (10V, 5V, 0.2V) is determined automaticallyAmplitude error (%) see above in manualHalf-period error (%) see above in manualTotal tooth pitch error (%) see above in manualFrequency (Hz) Tooth frequency of the measurementVoltage (V) Average voltage of the measurement to control the measurement

hardware after calibration

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NUMBER PARAMETERSRotational speed (rpm) Is calculated from the tooth frequency and the number of teeth and

serves as a plausibility check.

The nominal speed can be entered in the manual mode of the start telegram.

In automatic mode it comes together with the start telegram.

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11.5 Analysis of previous measurementsBelow the areas for the analysis of previous measurements are explained (only visible in expert mode):

1: Click on the yellow folder to determine the path to be used for loading the measurement file (TDMS file).

2: Here you can select which measurement channels are to be displayed.

3: In this area, the measurement curve of the loaded measurement is displayed.

4: Result of the loaded measurement.

5: Display of the parameters set at the time of measurement. These parameters were transferred with

the start command.

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11.6 Analysis detailsThe areas of the view for the analysis of previous measurements are explained below (only visible in expert mode):

1: In this area of the program, the results of the loaded analysis are graphically visualised in detail.

2: In this area, the corresponding results are displayed as values.

NUMBER PARAMETERSUeff max (V) Maximum voltage amplitudeUeff min (V) Minimum voltage amplitudeUmax/Umin (V/V) Ratio gives indication of the pole wheel run-outMeasuring range The measuring range used (10V, 5V, 0.2V) is determined automaticallyAmplitude error (%) see above in manualHalf-period error (%) see above in manualTotal tooth pitch error (%) see above in manualFrequency (Hz) Tooth frequency of the measurementVoltage (V) Average voltage of the measurement to control the measurement

hardware after calibrationRotational speed (rpm) Is calculated from the tooth frequency and the number of teeth and

serves as a plausibility check

3: Result display of the previous measurement.

! If there is a fault, the type of fault is displayed here.

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11.7 System detailsIn the following, the software areas relating to system details and entries in the configuration menu are explained.

1: If a system error occurs, the corresponding information is displayed in this area. In the case of an inactive error, the system can be reset to its normal state by pressing the' Delete error report' button. In the case of an active fault, the description can be used to immediately correct the fault or to request assistance from your contact person at WABCO.

2: Displays the currently used software version.

3: The "Close program" button is used to exit the program. By clicking on "Configuration" you can access the system settings. Before that, the system asks you for a password. The password preset by WABCO is "0000". It is recommended that you change the password in the system settings.

4: In case of automatic operation via an external computer (TCP/IP, PROFINET), this area displays the received start telegram. In manual operation, the set parameters are displayed here.

5: In manual operation, the set parameters are displayed here.

! Note: It is not possible to change the values in this screen. To prevent misuse, this is only possible in the password-protected area under Configuration.

6: Displays the currently set limit values.

! Note: It is not possible to change the values in this screen. To prevent misuse, this is only possible in the password-protected area under Configuration.

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11.8 Details on the settingsThis chapter explains the various functions and setting options of the device in more detail.

1: By default, each measurement file is stored on an internal hard disk of the device. If you want to save the files on a connected external hard disk, you can select a new path here.

2: This area displays the threshold values recommended by WABCO for the measurements. Any error can be reduced for a more stringent measurement. Increasing the values is not permitted.

3: This menu can be used to set up a printer. By activating the checkbox "Enable printing" a printout via the Windows standard printer is executed. The print frequency can be used to set whether each measurement should be printed or only a selection.

4: In this area the language settings can be made. The sampling rate of the measurement can also be set. A sampling rate between 2.5KHz and 10KHz is recommended. This area also allows you to select the start mode of the device. Depending on your requirements, you can choose between serial operation and operation via LAN (further options available).

(ii) Speed test: If this option is activated, the unit checks whether the speed of the rotating wheel matches the preset wheel speed in the device.

(iii) Expert mode: If this option is selected, the "Load measurement" and "Loaded Analysis" tabs in the menu can be opened.

(iv) Delete old data: If this field is selected, the software automatically deletes the oldest stored measurements as soon as the preset memory is occupied.

5.1: Activate "Wait for constant speed": The ASTU is designed in such a way that a measurement is not started until the axle rotates at a constant speed. If the field "Wait for constant speed" is activated, the instrument waits until the wheel rotates at a constant speed until the measurement starts. This function is intended for manual operation in order to delay the manual start of the measurement and thus facilitate operability. The system waits until the "Cancel" button is pressed.

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5.2: Maximum period deviation: This setting defines which speed deviation is tolerated by the device. The higher the value, the more tolerant the device is to speed deviations within one wheel revolution. If the value is set too high, the "Wait for constant speed" function starts the measurement too early.

5.3: Timeout for automatic start: The "Wait for constant speed" function may also be useful for automatic starting if the production sequences can no longer be changed. However, to prevent the assembly line from being blocked indefinitely, e. g. if the maximum period deviation (see above) is set too low, the system will wait no longer than this timeout period.

6: The following parameters must be defined in the start telegram before starting the measurement:

Sensor type:The ASTU supports two sensor types, the WABCO standard sensor and WABCO mini sensor. The design of the sensor's axial cable outlet or radial cable outlet is irrelevant.

Serial no. axle:Specification is part of the file name used to store the measurement results.

Channel A / Channel B: Assignment of the sensors / axle sides to the measurement channels.

Number of teeth:Number of teeth on the pole wheel. Parameter must be entered and is used together with the sampling diameter and the wheel speed to determine the sensor voltage.

Sampling diameter:The diameter with which the sensor samples the pole wheel. This measurement can be taken from the drawing and is used together with the number of teeth and the wheel speed to determine the sensor voltage.

Wheel speed: Drive speed of the wheel or wheel hub in revolutions per minute.Job ID:

Sequential number is part of the file name.

7: Manual pole wheel parameters: If the pole wheel has an unsupported number of teeth (see chapter "8.1 Framework parameters" on page 14), the voltage values can be set here. The sensor voltage values to be set must be requested from WABCO.

8: Setting up the TCP server (not yet supported).

9: In case of interference, a filter can be set here. The number of averages can be set between 1 and 10. If a 1 is entered, the signal remains unfiltered. At 10 the maximum filtering is reached. The filter value 4 has proved effective in practice.

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Common error codes Common error codes

12 Common error codesThe following table shows the common error codes see chapter "11.7 System details" on page 27:

ERROR ID ERROR CODE DESCRIPTION

Error on init - Initialisation failed

Print report - Printing out the report has failed

Configuration error 5079 The configuration contains unexpected settings

Manage configuration 5018 The rotation speed in the start telegram is invalid

Manage preselected start with DI 5060 Please release start condition to reset

PROFIBUS read write error - PROFIBUS input/output error

Error receiving short serial telegram

- Error when receiving the abbreviated start telegram

Cancel TCP IP telegram 6002 Measurement cancelled

TCP IP manage telegrams - TCP IP error when processing the telegrams

Automatic start telegram 5009 ID of the resource not specified

Close (DAQ) - Close (DAQ)

Read measurement data - Read measurement data

Set measurement range (DAQ) - Set measurement rage (DAQ)

Start sampling (DAQ) - Start sampling (DAQ)

Stop sampling (DAQ) - Stop sampling (DAQ)

Process measurement data

6060 Interpolation failed

5019 Number of teeth is not supported (check configuration)

5012 Invalid channel in start telegram

5017 Invalid speed in start telegram

6001 Measurement cancelled

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Common error codes

EEC declaration of conformityWe

WABCO Standard GmbH Vehicle Brakes Division

declare that the

ABS sensor / pole wheel test unit 884 019 288 0

complies with the requirements of

EN 60204-1 EN 61439-1

according to Low Voltage Directive 2014/35/EU and Electromagnetic Compatibility Directive 2014/30/EU.

The test results can be found in Test Report No. 1C212A3, Elektrotechnik Ladwig GmbH.

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Maintenance and calibration

13 Maintenance and calibrationThe ABS sensor / pole wheel test unit is maintenance-free.Depending on the application, the sensor cable may be subject to a certain amount of wear and tear (wear of connector, damage to the cable, etc.) and should be checked regularly and replaced if necessary.The test unit itself must be calibrated every two years. WABCO offers various service plans for this purpose. Please contact your WABCO contact person.

13.1 Disposal / recycling � The system components are electronic scrap and must not be disposed of together with domestic waste. When disposing components, observe all the laws and regulations applicable in your country.

� This applies in particular to sensors that contain lithium batteries. These are solidly potted inside the housing and can not be replaced. Once they have reached the end of their life, dispose of the sensors while observing all the laws and regulations that apply in your country.

� WABCO strives to protect the environment. As with other old devices, all components can be returned to WABCO. Speak to your WABCO sales partner about this.

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017industry as it maps a route toward

autonomous driving, WABCO also uniquely connects trucks, trailers, cargo, drivers, business partners and fleet operators through advanced fleet management systems and mobile solutions. WABCO reported sales of $2.8 billion in 2016. Headquartered in Brussels, Belgium, WABCO has 13,000 employees in 40 countries. For more information, visit

www.wabco-auto.com

WABCO (NYSE: WBC) is a leading global supplier of technologies and services that improve the safety, efficiency and connectivity of commercial vehicles. Founded nearly 150 years ago, WABCO continues to pioneer breakthrough innovations for advanced driver assistance, braking, stability control, suspension, transmission automation and aerodynamics. Partnering with the transportation

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