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Stoneridge Electronics Ltd

Electronic Road Speed LimiterTraining Course

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Stoneridge Electronics LtdCOPYRIGHT

This training course and all material used and issued throughout this course is the sole Copyright of Stoneridge Electronics Ltd.

The information contained in this document is the Property of Stoneridge Electronics Ltd. and should not be disclosed, reproduced in whole or in part, or used under any condition by anyone without the written authority of Stoneridge Electronics Ltd.

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Course Plan

Health & Safety Brief

Introduction to Stoneridge Electronics

Road Speed Limiter Legislation & Vehicle Requirements

The Stoneridge Electronics 9700 Electronic Road Speed Limiter

Lunch

Fitting the 9700 Electronic Road Speed Limiter

Calibrating and Programming the 9700 Electronic Road Speed Limiter

Using a MKII Tachograph Programmer as a Speed Simulator

Testing a Programmed 9700 Electronic Road Speed Limiter

Practical Exercise Using a 9700 Electronic Road Speed Limiter

Exam

Issue of Certificates and Calibration Packs

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Statement

This course has been written in conjunction with VOSA published Road Speed Limiter documents

This is a VOSA approved training course

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Section 1

Health & Safety

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Health & Safety

In the event of the fire alarm sounding, personnel should leave the building by the nearest practical exit, keeping traffic routes clear for emergency services, and gather at assembly point 6 at the front of the building

DO NOT STOP TO TAKE POSSESSIONS WITH YOU OR GO BACK FOR THEM

DO NOT RE-ENTER THE BUILDING UNTIL INSTRUCTED BY THE EVACUATION COORDINATOR OR HIS DEPUTY

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Health & Safety

CAR PARKING

CAR PARKING

CAR PARKING

FIRE ROAD

1 2 3 4 5 6

ASSEMBLY AREAS

Assemble Here

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Health & Safety

This is a no smoking facility

Smoking is only permitted in the designated area at the side of the facility

Lunch, Coffee & Tea are provided free of charge in the Canteen

Toilet Facilities are at the front end of the building

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Section 2

Stoneridge Company Profile

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(1) – 50% Ownership

(2) – 20% Ownership

AlphabetStoneridge

Electronics Group Actuator/Sensor Products

Finance

StoneridgeWarren, OH, USA

Chihuahua,Mexico

Warren, OH Stoneridge Electronics- Stockholm, Sweden- Örebro, Sweden- Tallinn, Estonia- Dundee, Scotland, UK

Pollak Electronics- El Paso, TX- Juarez, Mexico

PST Electrônica JV(1)- Campinas, Brazil- Manaus, Brazil

Minda/Stoneridge JV(2)-Pune

Canton, MA

Juarez, Mexico

Cheltenham, England, UK

Pollak Actuators - Boston, MA

Hi-Stat - Lexington, OH

Hi-Stat Sensors- Sarasota, FL- Lexington, OH

Pollak Switch Products

Stoneridge Sales

China Representative Office

Monclova,Mexico

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Stoneridge Electronics Locations

Sales & Support:

Stuttgart, Germany Frankfurt, GermanyNuremberg, Germany Madrid, SpainParis, FranceBayonne, France

Dundee, Scotland Örebro, Sweden Bromma, Sweden Tallinn, Estonia

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UK – Design, Manufacture & Sales

• Dundee• 100+ employees• 7400 m²

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Overview Stoneridge Electronics Products

Instrument Clusters

Tachographs

Multiplex Systems

Power Distribution Centre

ECU’s

Telematics Systems

Road Speed Limiters

Rolling Roads

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Stoneridge Electronics Customers

Off RoadVCESame Deutz-FahrCase New Holland

BusScaniaVolvoEvoBusJonckheere PlaxtonIRISBus

TrucksScaniaVolvo Daimler ChryslerMANRenault DAF

AutomotiveRenaultFordEberspächer

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Section 3

Road Speed Limiter Legislation and Requirements

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RSL Fitting Centre Requirements

It is a European legislative requirement that that only EU Member State approved RSL fitting centres carry out the installation of vehicle RSL systems

In the UK VOSA is the body responsible, on behalf of the Secretary of State for Transport, for examining the arrangements made for thecalibration and sealing of road speed limiters by both Sponsored and independent firms or businesses

In order to be an Authorised RSL fitting centre the centre must meet requirements as set by VOSA in their documents ‘Arrangements for Authorisation’ and ‘Conditions of Authorisation for RSL Sealers’

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RSL Fitting Centre Requirements

For sponsored Authorised Sealers, the sponsor is responsible for the provision of suitable equipment and the training of the Authorised Sealer and for monitoring the quality of the calibration and sealing work undertaken by their agents

The sponsor also has a responsibility to the sponsored Authorised Sealer with regard to the following:

• To issue a unique seal number or code

• To ensure the agent has the appropriate calibration and sealing equipment for the speed limiter make concerned

• To be responsible for arranging quality assurance checks

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RSL Fitting Centre Requirements – Staff Training & Equipment

Only Authorised Sealer staff who have received training considered appropriate by the VOSA are to be permitted to seal RSL systems

Sufficient equipment must be available to Authorised Sealer staff, to allow them to calibrate and seal, in a static condition, each make of speed limiter which they are authorised to seal. Test equipment will be calibrated in accordance with the equipment manufacturer’s instructions and records of such calibration checks will be retained for inspection as necessary

Arrangements must be made to ensure the safe custody of speed limiter sealing equipment, i.e. sealing pliers, seals and plaques and “plates”, when not in use

The sealing pliers will have a unique seal code that shall be applied to all RSL seals or other sealing devices to identify the Authorised Sealer

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RSL Fitting Centre Requirements – Records

A register of road speed limiters sealed will be kept. This could be a file of speed limiter installation/calibration records. The register will show the following details:

– Date of sealing (and location if approved as mobile Authorised Sealer)– Vehicle VIN/Chassis Number, Make and Model– Brief description of work carried out e.g. installation, calibration or repair– Set speed (mph or kph)– Tyre sizes (and ‘W’ factor of Tachograph if it is supplying the speed limiter

signal)– Make of speed limiter– Serial number of the ECU or the calibrated speed controlling device– Name and signature of sealing fitter– Unique Authorised Sealer code, trading name and address

Note: Authorised Sealer documentation will be retained and available for at least 5 years from the date when the speed limiter work was undertaken

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RSL Fitting Centre Requirements –Access to Premises & Quality Assurance

VOSA Examiners will be permitted, on production of their authority if so required, during normal business hours, to examine the register, to inspect the equipment and to satisfy themselves that the Conditions of Authorisation are being complied with

If the Authority of a Fitting Centre to Seal RSL systems in withdrawn by VOSA or if the Centre ceases to operate, then the Centre MUST surrender all RSL sealing equipment and “plates” to the Sponsor

VOSA Authorised Sealers must have their operation to be independently monitored for quality assurance. A Sponsored Authorised Sealer’s quality assurance monitoring may be performed by the Sponsoring speed limiter manufacturer or an agent nominated by him. In the case of independent Authorised Sealer, quality assurance monitoring will be performed by an independent agent nominated by him

The quality assurance inspection must check that all the Conditions of Authorisation are being complied with

The maximum period between quality checks will be 18 months. As a minimum the check will ascertain whether all the Conditions of Authorisation are being complied with

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RSL Vehicle Legislation - Initial PCV Legislation

The first speed limiter law in the UK applied only to Coaches, defined as vehicles with more than 16 passenger seats, as follows:

• Coaches registered on or after 01/04/1974, but before 01/01/1988must be fitted with an RSL set at 112.65 km/h (70mph)

Buses, defined as vehicles with more than 8 passenger seats, that have a gross vehicle weight of 7501 Kg or greater have speed limiter restrictions as follows:

• Provided the buses were registered between the inclusive dates of 01/01/1988 and 30/09/2001 they must be fitted with an RSL set at100 km/h

All Buses and Coaches that were registered before 01/04/1974 DO NOT require a RSL system to be fitted

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RSL Vehicle Legislation – Initial HGV Requirements

Goods vehicles that have a gross vehicle weight of 12001 Kg or greater and that are capable of exceeding a speed of 90 km/h, have speedlimiter restrictions as follows:

• Provided the vehicles were registered between the inclusive dates of 01/01/1988 and 30/09/2001 they must be fitted with an RSL set such that the vehicles stabilised speed does not exceed 90 km/h

All Goods vehicles of any gross weight, that were registered before 01/01/1988 DO NOT require a Road Speed Limiter system to be fitted

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RSL Vehicle Legislation – 92/6/EEC Changes

EU Council Directive 92/6/EEC, which was adopted on 10/02/1992, requires that Goods Vehicles that have a gross vehicle weight of 7501 Kg to less than 12001 Kg and that are capable of exceeding a speed of 96 km/h have speed limiter restrictions as follows:

• Provided the vehicles were registered between the inclusive dates of on or after 01/08/1992 to 30/09/2001 they must be fitted with an RSL set such that the vehicles stabilised speed does not exceed 96 km/h

All Goods vehicles with a gross weight of 7501 Kg to less than 12001 Kg that were registered before 01/08/1992 AND All goods vehicles with a gross weight of 3501 Kg to less than 7501 Kg that were registered before 01/10/2001 DO NOT require a Road Speed Limiter system to be fitted

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RSL Vehicle Legislation – 2002/85/EC Changes

EU Council Directive 2002/85/EC, which amends Council Directive 92/6/EEC and which was adopted on 05/11/2002 had a great impact on speed limiter requirements with regard to Passenger Carrying Vehicles and Goods Vehicles

In terms of buses, the changes are as follows:

• All PCV’s with a Gross weight of 7501 Kg to less than 10001 Kg and that were registered on or after 01/10/2001 AND all PCV’s with a gross weight of 10001 Kg or greater and that were registered on or after 01/01/2005 must be fitted with an RSL set such that the vehicles stabilised speed does not exceed 100 km/h

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• PCV’s with a Gross weight of less than 7501 Kg and a Euro III or later engine and that were registered on or after 01/10/2001 but before 01/01/2005 must be fitted with an RSL set such that the vehiclesstabilised speed does not exceed 100 km/h. The RSL must be fitted by 01/01/2006 for international journeys and by 01/01/2007 for UK national journeys. Note: Vehicles registered before 01/01/2005 with a Euro II or earlier diesel and petrol engines are exempt from this requirement

• All PCV’s, except note below, regardless of Gross weight and engine type, that were registered on or after 01/01/2005 must be fitted for all journeys with an RSL set such that the vehicles stabilised speed does not exceed 100 km/hNote: For PCV’s with a gross weight that does not exceed 5000 Kg, that are used for UK national journeys only, the RSL requirement is active only from 01/01/2008

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In terms of Goods Vehicles the RSL laws and changes are as follows:

• All HGV’s with a Gross weight of 12001 Kg or more and that were registered on or after 01/01/1988 must be fitted with an RSL set such that the vehicles stabilised speed does not exceed 90 km/h

• All HGV’s with a Gross weight of 7501 Kg to less than 12001 Kg and that were registered between 01/08/1992 and 31/12/2004 must be fitted with an RSL set such that the vehicles stabilised speed does not exceed 96 km/h. For vehicles of this type registered on or after 01/01/2005 they must be fitted with an RSL set such that the vehicles stabilised speed does not exceed 90 km/h

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• Goods Vehicles with a Gross weight of 3501 Kg to less than 7501 Kg and a Euro III or later engine and that were registered on or after 01/10/2001 but before 01/01/2005 must be fitted with an RSL set such that the vehicles stabilised speed does not exceed the value 90 km/h

• The RSL must be fitted by 01/01/2006 for international journeys and by 01/01/2007 for UK national journeys

• Note: Vehicles as above with a Euro II or earlier diesel or petrol engine are exempt from this requirement and DO NOT require RSL fitment

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• All Goods Vehicles, except note below, with a Gross weight of 3501 Kg or more, regardless of engine type, that were registered on or after 01/01/2005 must be fitted for all journeys with an RSL set such that the vehicles stabilised speed does not exceed 90 km/h

• Note: For Goods Vehicles with a gross weight of 3501 to less than 7501 Kg, that are used for UK national journeys only, the RSL requirement is only active from 01/01/2008

Please Note that a summary table of the Road Speed Limiter Requirements for all types and ages of Goods Vehicle and Passenger Carrying Vehicles is included as an Appendix

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Section 4

The Stoneridge Electronics 9700 Electronic Road Speed Limiter

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9700 ERSL System Description & Operation – General Theory

The Stoneridge 9700 Electronic Road Speed Limiter (ERSL) must only be used on vehicles that have an electronic accelerator throttle control that is connected to a vehicle ECU

It must be noted that the Stoneridge 9700 ERSL is not suitable for use on vehicles that use a CANbus based Cruise Control System

If a vehicle allows a Cruise Control switch to set the vehicle Cruise Control speed without reference to the accelerator throttle position then the 9700 ERSL must not be used as a speed limiting device

IN ALL CASES, ONCE A 9700 ERSL IS FITTED INTO A VEHICLE THE VEHICLE MUST BE ROAD TESTED TO ENSURE ROAD SPEED LIMITING FUNCTION IS SUCCESSFUL AT ALL TIMES WHETHER OR NOT AN INDEPENDENT CRUISE CONTROL SYSTEM IS OPERATIONAL

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An electronic accelerator pedal has no mechanical connection to the vehicle fuel system but has a potentiometer output signal that is proportional to the pedal position. When the pedal is not depressed, the potentiometer output is at the ‘Idle’ voltage level

As the pedal is pressed the potentiometer output increases proportionally to the pedal position until the stage when the pedal is fully depressed and the potentiometer output is at the ‘Wide-open-throttle’ (WOT) voltage level

The Stoneridge 9700 ERSL controller is an electronic ECU that is used to intercept the potentiometer output signals from the accelerator as shown in the diagram later in this section

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The ERSL controller must receive a known accurate ‘speed’ signal from the vehicle which is used to give an accurate indication of vehicle speed. This is usually from the vehicle Tachograph, which is a legally calibrated instrument, but may be from another vehicle source such as the ABS ECUNote: A Tachograph V-pulse signal can only be used as an ERSL input for Tachograph K-factors in the range 2300 to 59800

The ERSL controller is programmed with a user specified ‘Speed Limit’value, e.g. 90km/h

When the speed of the vehicle, as determined from the legally calibrated Tachograph output signal or equivalent, reaches the set speed limit the ERSL controller adapts the intercepted accelerator output signals and prevents vehicle acceleration

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The ERSL controller modifies the received accelerator signal in such a way that the modified signal sent to the vehicle ECU replicates an accelerator pedal that is in the correct position for the ERSL set speed

Any further increase in accelerator pedal depression and hence output voltage will be suppressed by the ERSL controller such that a modified potentiometer output signal will be sent to the vehicle ECU and hence the stabilised vehicle speed will remain just below the set ERSL speed limit value

If the vehicle slows down the ERSL controller will slightly increase the modified potentiometer output signal sent to the vehicle ECU and hence keep the vehicle speed at the required ERSL speed limit value

If vehicle pedal is raised such that the position is at a level below the ERSL set limit then the ERSL will pass the accelerator output signal to the vehicle ECU unmodified

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It should be noted that for training purposes we use a Tachograph B7 V-pulse output signal for the Vehicle Speed Signal Source as shown in the ERSL system block diagram below:

Vehicle ECUStoneridge ERSLAccelerator

Unmodified Potentiometer Output

ERSL Modified Potentiometer Output

Vehicle Speed Signal

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9700 ERSL System Description & Operation – Connections

The Stoneridge 9700 ERSL system connections are shown below. The vehicle ECU connectors used will depend on the vehicle type

Accelerator Pedal

Stoneridge 9700 ERSL Controller

Vehicle ECU Connections

Tachograph Connections:Yellow - SpeedWhite - Power

RS232 Programming Connections

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Section 5

Fitting The 9700 Electronic Road Speed Limiter

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Fitting the 9700 ERSL System – 9700 Controller Inspection

Before fitting a 9700 ERSL ECU the following must be checked before continuing with the installation:

• the 9700 label MUST show the correct type approval number, i.e. E4 92/24 2004/11 0094 00

• The 9700 ECU must show no physical signs of damage or tampering to the external casing or screws

If either of the above conditions are not met for a particular 9700 ERSL ECU, the unit MUST NEVER be fitted to a vehicle

Check Type Approval Number on Label

Check casing for signs of damage

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Fitting the 9700 ERSL System – 9700 Controller

The Stoneridge 9700 ERSL control ECU is shown below. The external connections from the 9700 ECU are made via a 36 Way connector asshown, the pin out connections are listed as follows:

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Fitting the 9700 ERSL System – 9700 Controller Pin Connections

RS232 Receive (Rx)Purple30

Tachograph +12/24V (A1)Pink18

RS232 GndBlack27

RS232 Transmit (Tx)Blue31

Tachograph V-pulse Signal (B7)Orange33

Tachograph Gnd (A5)Black17

Pedal Signal 1 +5VRed16

Pedal Signal 1Green15

Pedal Signal 1 GndBlack14


Pedal Signal 2White12



Pedal Signal 3Pale Green / Black Stripe9


Vehicle ECU +5VRed7

Vehicle ECU Pedal Signal 2White6

Vehicle ECU Pedal Signal 1Green5

Vehicle ECU Pedal Signal 3Pale Green / Black Stripe4

Vehicle ECU GndBlack3

DescriptionWire ColourD-type Pin Number

The Pin-out connections for the 9700 Controller are as shown below Pin numbers not listed have no connection requirements

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Fitting the 9700 ERSL System – Accelerator Pedal Types

Three main Electronic pedal types are currently available; 5, 6 and 9-wire –see individual Vehicle Application sheets for full details

6-wire is the most common type and is typically used in the following vehicles: Iveco Daily, All LDV vehicles, Renault, Vauxhall, Land Rover, Mitsubishi, Ford etc. The 6 connections are as follows:

• Vref1, Signal1, Gnd1, Vref2, Signal2 and Gnd2

9-Wire types are less common but are used on some versions of the Ford Transit. The 9 connections are as follows:

• Vref1, Signal1, Gnd1, Vref2, Signal2, Gnd2, Vref3, Signal3 and Gnd3

5-Wire types are also less common but are used on the IVECO Eurocargo. The 5 connections are as follows, Note: IVS is idle validation switch:

• Vref1, Signal1, Gnd1, IVS1 and IVScom

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Fitting the 9700 ERSL System – Wiring the Accelerator Pedal

Once the type of accelerator pedal fitted into the vehicle has been identified the connections to the pedal must be identified in order to determine which of the 9700 controller connections should be made

If a Stoneridge ERSL Application Sheet is available for the Vehicle type being fitted with the 9700 ERSL ECU then the Application sheet should be used for a description of wiring instructions and fitting instructions etc

If no application sheet is available for the vehicle type into which the 9700 ERSL is to be fitted, then a multi-meter capable of measuring DC voltage and carrying out resistance and continuity measurements should be used to determine the pedal connections using the method as described below:

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To identify ‘Vref’ signal, set vehicle ignition to ON and multi-meter to the DC voltage setting, 0-20V range

• Connect multi-meter negative terminal to vehicle battery negative and probe accelerator pedal wires with the multi-meter positive terminal

• All the pedal ‘Vref’ signals, 3 maximum, will be fixed at +5V

To identify the ‘Gnd’ signal wire, switch vehicle ignition OFF and disconnect the vehicle battery positive terminal. Set the multi-meter to the resistance setting, 0-200R

• The ‘Gnd’ signal wires will have a very low resistance to the battery negative terminal

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To identify ‘Vref’ and ‘Gnd’ signal pairs, switch vehicle ignition OFF. Disconnect the vehicle battery positive terminal and the pedal connections to the vehicle ECU. Set the multi-meter to a resistance setting, 20K range

• Connect multi-meter negative to a known pedal signal ‘Gnd’ wire

• The known ‘Vref’ signal wires should be probed until a resistance reading of typically a few Kilo-ohms is shown on the multi-meter to match up with the known signal ‘Gnd’ connection under test

• Repeat process until all the ‘Vref’ and ‘Gnd’ connections have been matched up

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To identify pedal signal wires, switch vehicle ignition OFF. Disconnect the vehicle battery positive terminal and the pedal connections to the vehicle ECU. Set the multi-meter to a resistance setting, 20K range

• Connect multi-meter negative to a known pedal signal ‘Gnd’ wire

• The known Pedal signal wires should be probed until a resistancereading of typically 2K to 5K is shown on the multi-meter to match up with the known signal ‘Gnd’ connection under test

• Repeat process until all the ‘Pedal Signal’ and ‘Gnd’ connections have been matched up

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Once all the accelerator pedal wire functions have been identified, next the existing pedal-vehicle ECU wires must be cut so that the 9700 ERSL ECU can be wired using the 9700 pin-out connections listed above

All of the in-line connections made to the pedal, vehicle ECU and the 9700 (including unused wires) must be placed in black sealing boxes, 6955-596, in a similar manner to that shown below. The sealing boxes should be secured using Tachograph sealing wire and a suitably marked VOSA approved seal again similarly to as shown below

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Fitting the 9700 ERSL System – Mounting the 9700 Controller

The Stoneridge 9700 ERSL control ECU is shown below. It must be fitted using the four M4 clearance holes in the corners of the ECU. The 9700 ECU must be positioned in a suitable location in the vehicle cab that is dry and away from extreme heat

The 9700 is supplied secured with a red security seal label as shown to prevent tampering attempts. If the security seal is not present do not usethe 9700 ECU

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Fitting the 9700 ERSL System – Securing the 9700 ECU Connections

The Stoneridge 9700 ERSL control ECU connections should be secured using a sealing shroud as shown below. The shroud itself should be secured using Tachograph sealing wire and a suitably marked VOSA approved seal. Note: it MUST be ensured that the connector cannot be removed without first breaking the seal

Connector Before Sealing Connector Fitted

and Sealed

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Fitting the 9700 ERSL System – RSL Plaques

Once the Stoneridge 9700 ERSL ECU has been fully fitted into the vehicle and calibrated and programmed as per the next section, a RSL plaque must be fitted inside the vehicle. The plaque, examples shown below, must be clearly visible and easily accessible, and must contain the following details:

• Date of RSL calibration

• RSL Fitting Station Address

• Name of the Technician Who Fitted the RSL

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Section 6

Calibrating and Programming The 9700 Electronic Road Speed Limiter

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Calibrating the 9700 ERSL System – Executing the PC Software

The Stoneridge 9700 ERSL control ECU software is ‘run’ on the PC by clicking on the ‘ERSL’ Icon on the PC desktop

The first time the software is ‘run’ after installation, there will be no default language set. Select the required flag as shown below for English, Swedish, German, Spanish, Italian or French as the default language

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Calibrating the 9700 ERSL System – Security Dongle

The Stoneridge ERSL Software MUST be executed in conjunction with a software key (dongle) for security purposes

If the software is run without the security dongle fitted then the following screen will be shown

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When the Dongle is inserted for the first time it will require an activation code for security purposes

The code can be obtained from the Stoneridge Electronics Workshop Technical Helpline

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The security Dongle must be re-activated after a period of one year – the new code can again be obtained from the Stoneridge Electronics Workshop Technical Helpline

If it is 30 days or less until the dongle expiry date, a warning will be displayed each time the software is executed as shown

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If the security Dongle is not re-activated before the one year expiry period, when the ERSL software is executed the following screen will be displayed and the software will not execute until the dongle is re-activated as described above

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Calibrating the 9700 ERSL System – Main Menu – Configuration

With a valid, activated dongle inserted the Main ERSL screen will be displayed as shown

Initially the Configuration options must be selected by clicking the button circled yellow opposite

Configuration options allow new users to be created, the 9700 ECU port settings to be updated, and the default language selection to be changed

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Calibrating the 9700 ERSL System – User Settings

Assuming the Configuration button was selected as described previously, the following screen will be displayed for the ‘User Settings’ option as circled yellow

When the software is first installed there will be no ‘Users’ available and hence no ERSL programming/calibration will be possible

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Calibrating the 9700 ERSL System – Adding Users

A ‘User’ is created by inputting a User ID and password, which must be confirmed. The ID MUST BE the Technicians ERSL certificate identifier code and the password MUST be at least 4 characters long

Clicking the ‘Add’ button’, as circled yellow, will create the User and a ‘User Added’ pop-up will be displayed to confirm the User is created – click OK to acknowledge

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If a User ID or the password are not at least 4 characters long, as shown below, then when ‘add’ is clicked a warning pop-up will be displayed and the ID or password will have to be updated before it will be accepted

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The User Setting screen will then be as shown

After clicking the ‘Close’ button, as circled yellow, the screen will return to the ERSL main menu screen

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Calibrating the 9700 ERSL System – System Settings

The ‘System Settings’ Option, as circled yellow, is used firstly to define which PC communications port is required for the ERSL connection. Secondly, the ‘System Settings’ option, is used for language selection

Click the ‘drop-down’ buttons, as circled green, to select a new port or language setting. If changes are made, click ‘Save’, as circled red, to update, a pop-up will be displayed to confirm the settings changes

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Calibrating the 9700 ERSL System – Connecting the 9700 ECU

From the Main ‘ERSL’ screen the 9700 ECU to be programmed must be ‘Connected’

The 9700 RS232, or USB if using a RS232 to USB converter, connector must be connected to the required PC port, as selected in the ‘configuration’ section previously

The ‘Connect’ button, as circled yellow, must be clicked to begin communications between the PC and the 9700 ECU

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If the PC is successfully ‘Connected’ to the 9700 ERSL ECU, next the details of the vehicle in which the 9700 ECU is to be fitted and the ERSL installer details, including a security password, should be added

The Vehicle Identification Number (VIN) or chassis number, which can be up to 17 characters long, and the Vehicle Registration Number (VRN) must be entered. The Installer ID code must be selected from the drop down list of Users, as circled yellow

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If the password input for the selected user is not correct, then a warning pop-up will be displayed as shown

The correct password should be input to continue

Once the Vehicle details have been entered, Click ‘OK’, circled green, to return to the Main ERSL Screen

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Calibrating the 9700 ERSL System – 9700 ECU Pre Check

Once in the ‘Connected’mode, the 9700 ECU to be programmed must be checked for previous programming

The monitoring function will automatically become active to pre-check the 9700 ECU for programming

If the ‘Go’ button, as circled yellow, is green this must be clicked to initiate monitoring

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Calibrating the 9700 ERSL System – 9700 ECU Pre Check

The pre-check will begin as indicated by the ‘Monitoring’green light being active, as circled red

The ‘Speed Limit’ programmed (if any), the ‘Set Pulse’ level and the pedal signal levels, as circled yellow, can then be checked

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Calibrating the 9700 ERSL System – Pedal Calibration

Once vehicle and installer details have been input and the pre-check has been completed, the ‘Pedal Calibration’ operations must then be carried out

Pedal Calibration will initially begin automatically. The ‘GO’button, as circled yellow, is not active until the Pedal calibration sequence has been completed. This then allows the Pedal calibration to be updated

The Pedal Calibration active indicator, as circled red, will flash green

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Calibrating the 9700 ERSL System – Set Idle Levels

Initially the required number of pedal signals (maximum 3 depending pedal type) should be selected, as circled yellow

Once the number of pedal signals required has been selected, next the ‘Idle’ signal levels should be identified

With the accelerator pedal not pressed, the ‘Set IDLE’ button as circled green, must be clicked to set the Pedal ‘Idle’signal levels

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Calibrating the 9700 ERSL System – Set Idle Levels

It should be noted that once the pedal calibration is initiated and until a new speed limit value is programmed, then the current ERSL programmed values are reset

If an attempt is made to ‘disconnect’ the ERSL ECU from the PC then a Warning Message will be displayed as shown.

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Calibrating the 9700 ERSL System – Set WOT levels

Next the ‘Wide open Throttle’(WOT) signal levels have to be identified. Fully depress the accelerator pedal and the displayed WOT levels will increase on the screen

Once the ‘WOT’ signal levels have stabilised, click the ‘Set WOT’ button, as circled yellow, to set the fully depressed pedal ‘WOT’ signal levels

After the ‘Set WOT’ Pedal Calibration operation is complete, fully release the accelerator pedal

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Calibrating the 9700 ERSL System – Speed Calibration Initiating

After Pedal Calibration, next the ‘Speed Calibration’ operations are required

Speed Calibration will automatically be initiated. The ‘GO’ button, as circled yellow, is not active until the Speed calibration sequence has been completed. This allows the Speed calibration to be updated in future

The ‘Speed Calibration’ active indicator, as circled red, will flash green to indicate the speed calibration mode is active

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Calibrating the 9700 ERSL System – Setting Speed

With the ‘Speed Calibration’active indicator flashing green, the next stage is to program the 9700 Control parameter ‘Setting Speed’

The setting speed value should first be input in the box circled yellow

This value is typically 60km/h and allows the ERSL software to determine the rate of speed pulses from the Tachograph, for the required control speed

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With the ‘Set Speed’ value at 60 km/h, a MKII Tachograph Programmer or equivalent, should be connected to the Tachograph in order to ‘Speed Simulate’ the ERSL system at the required Setting Speed value of 60km/h

When executing the MKII Speed Simulation function –see description in next section – the MKII Speed Simulator speed, the Tachograph speed and the ‘setting speed’ value must all be the same, 60 km/h in this case

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To ensure the Tachograph and MKII displayed speeds are the same, the MKII must have the actual Tachograph ‘K-factor’parameter set before starting the speed simulation

With the MKII and ERSL system Tachograph displayed speeds both stable and at the programmed ‘Setting Speed’ value, the ‘Set Speed/Pulse’ button, as circled yellow, must be clicked

The ERSL system control ‘setting speed’ Tacho Pulse rate has now been programmed

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After the ‘Set Speed/Pulse’button has been clicked, the ‘Tacho Pulse at Setting Speed’ value will be stored as circled yellow

The ‘Speed Limit Value’ field will then automatically be opened, as circled green opposite

The MKII can then be disconnected from the ERSL Tachograph as the ‘Setting Speed’ operations are completed

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Calibrating the 9700 ERSL System – Setting ERSL Speed Limit

The next stage is to set the Speed Limit value for the ERSL system

This is done by typing the required value into the ‘Speed Limit Value’ box as shown circled yellow

Clicking the ‘Set Speed Limit’button, as circled green opposite, will result in the required Speed Limiter speed being programmed into the 9700 ERSL ECU

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Calibrating the 9700 ERSL System – Speed Monitoring

Next the ‘Monitoring’ section of the ERSL system software will be automatically executed

The ‘Monitoring’ active indicator, as circled red, will flash green to indicate the speed Monitoring mode is active

The Pedal signal levels, as circled yellow, will be updated as the accelerator pedal is operated

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When ‘Monitoring’ is active, the programmed Speed limit value and the equivalent Tachograph Speed pulse rate at that speed will then be displayed in the Monitoring area of the screen, as circled yellow and Green respectively

As the accelerator pedal is operated the displayed pedal signals will alter accordingly as circled red

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Once Monitoring is finished, the disconnect button, as circled yellow, MUST then be clicked

This will cause the VOSA required PC ERSL database to be updated with a record of the ERSL calibration and programming data

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Calibrating the 9700 ERSL System – Exiting

Once the ERSL has been disconnected, i.e. the ‘Connect’button, as circled yellow, is again displayed then it is safe to shut down the ERSL software

This is done by clicking the ‘Exit’ button circled green

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Section 7

Using the Stoneridge MKII Tachograph Programmer as a Speed

Simulator

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Stoneridge MKII Programmer – Introduction

Menu options are navigated using the ‘left/right’arrow keys

‘Enter’ key is used to select options or to terminate a parameter entry

‘Menu’ key is used to return to the main menu and abort the current menu item

‘Send’ key is used to transmit parameters to any connected Tachograph

‘Delete’ key allows the deletion of an entered value

‘0..9’ keys are alpha-numeric for the entry of data strings

‘ON/OFF’ key is used for turning unit on and off

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Stoneridge MKII Programmer – Speed Simulator Function

The speed simulator function is used to inject speed pulses into a Tachograph. This can be used to check the accuracy of the Tachograph speed pointer or speed stylus position. When the Tachograph is still fitted in the vehicle, the speed simulator function is also useful for verifying the operation of speed or distance related ancillaries such as a Road Speed Limiter

The MKII programmer is connected to a round speedometer type Tachograph i.e. 8300/8400/1318 using a Jack-socket cable and a crocodile clip to the vehicle earth connection. A flexible jack extension cable is also required to enable the Tachograph to be closed during the test

For a radio-sized Tachograph i.e. 2400/1324, the MKII is connected to the Tachograph using a D-shaped programming lead (6-way 2400, 4-Way 1324)

The method of the test is as described below,

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K=8000 Pul/kmSpeed=50 km/h

The Programmer will now inject speed pulses into the Tachograph.

Enter speed: km/h

Key in the speed required and press ENTER. Note that there is a minimum detectable speed for each Tachograph type, which depends on the K-factor but may be up to 20km/h. Below this, the speed will reset to 0km/h.

Select K-factor:8000 Pul/km?

Press the DELETE key, and enter the value of K-factor that the Tachograph is currently set to into the Programmer. Then press ENTER.

VR8400 MAIN MENU:SPEED SIMULATOR

Select SPEED SIMULATOR from the MAIN MENU and press ENTER

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VR8400 MAIN MENU:SPEED SIMULATOR

Press ENTER to key in a new speed or MENU to return to the MAIN MENU.

Distance=1090 mPress <ENTER>

When the test is completed press ENTER. The unit will now display the total distance covered (in metres).

K = 8000 Pul/kmSpeed=51 km/h

Use the ↑ and ↓ (1 and 4) keys to increase or decrease speed.

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Section 8

Testing a Programmed 9700 Electronic Road Speed Limiter

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Testing the 9700 ERSL System

Once the 9700 ERSL ECU has been fully calibrated and programmed as described previously, the 9700 can then be fitted to the vehicle and tested either on the road, with a rolling road or by using the MKII Programmer speed simulator function described above

Alternatively the programmed values can be checked with the ERSLsoftware running and the vehicle fitted with the ERSL running on a rolling road

As shown below (circled yellow and green), the ‘Vh speed’ and ‘Input Pulse’ rates along with the Pedal Signals can be seen to change when driving on the rolling road. The Vh Speed and Input Pulse rates are similar to that of the set speed and set pulses at wide open throttle, which shows that the limiter is responding

Also the Pedal Signals should be in the same ratio from the original IDLE and WOT results seen in the pedal calibration field

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Testing the 9700 ERSL System – PC Software – Monitoring

Clicking the ‘Full screen’ button, circled red opposite, will result in the full screen window being displayed, similar to that below

The pedal signal and speed levels will rise as the speed throttle and hence speed increases. When the speed reaches the set Speed Limit value the graph will show pedal and speed values stable at the required levels

‘Full screen’ mode can be stopped by clicking the red ‘x’button on the window

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Testing the 9700 ERSL System – PC Software – Monitoring

Pedal Voltage / speed levels increasing

Click to End Full Screen Mode

Pedal Voltage / speed levels stabilised at set speed limit levels

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Testing the 9700 ERSL System – Ending Monitoring

Stopping the PC ERSL monitoring function is achieved by Clicking the ‘Disconnect’button in the monitoring section as circled yellow

Clicking the ‘Disconnect’ button will also disconnect the Communications link between the PC and the 9700

The ERSL Software can then be shut down by clicking the ‘Exit’button as shown below circled green

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Testing the 9700 ERSL System – Shutting Down

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Section 9

Practical Exercise Using a 9700 Electronic Road Speed Limiter

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Practical Exercise Using the 9700 ERSL System

Objective• The objective is to calibrate, program and test a Stoneridge 9700

ERSL system

Equipment Required• Stoneridge 9700 ERSL ECU, Stoneridge ERSL Training Case, PC

running the Stoneridge 9700 ERSL Software, ERSL Software Key

Exercise• Calibrate, Program and test with a MKII programmer the supplied

Stoneridge 9700 ERSL ECU so that it can be fitted into a bus weighing 6500 kg that was first registered on 01/06/2005. The Vehicle VIN is ‘RSL9700STONERIDGE’ and the Vehicle VRN is ‘ST05ABC’

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