V4R Installation Guide

Introduction

Zonar equipment will provide years of reliable service if properly installed and maintained. Zonar equipment is typically installed in heavy vehicle applications and is often subjected to extreme temperatures, dust, dirt, vibration, and shock. Proper installation is the critical first step to equipment longevity and optimal performance.

This guide is meant to be a general guideline for the professional installer and technician. While we attempt to point out the most common installation questions and issues, common sense, good housekeeping procedures, attention to detail, safety adherence, and technical competence of the professional installer are critical for a successful installation.

Refer to your specific vehicle manufacturer guidelines for the installation of electrical components and wiring.

A professional team of Zonar support technicians and engineers are available to answer your installation questions. Contact Zonar at 1-877-843-3847 or by email at customercare@zonarsystems.com.

 

 

V4R Equipment

COMPONENTS

• V4R™ GPS Unit
• 4 wire power harness
• Magnetic and bolt-thru mounting kits

Optional Accessories:

• External GPS Antenna

 GPS Antenna (Optional)

The V4R utilizes a high performance internal GPS antenna that performs well in most situations. The optional external GPS antenna is only generally used if the V4R is installed in a metallic enclosure.

Power and Data Cables

The 2010 and its dock are NOT waterproof. The equipment must be installed in such a manner as to protect them from moisture. Failure to do so may void warranty.

For 2010 installations with the V4R, for example #3 and #4 listed above, make sure that you order P/N 81496 (vehicle mount for V3R assembly) because it has a waterproof connector that you  may need.

General Guidelines

Layout

1. V4R unit must be located a minimum of 25 cm/10” from any person.
2. Do not place Zonar RFID tags, cables, or other equipment in any location or position which may compromise human or equipment safety.
3. Verify placement acceptability with State DOT/Law enforcement prior to installation.
4. V4R has a temperature range of -40 ̊C (-40 ̊F) to +85 ̊C (+185 ̊F). Do not mount V4R in hot engine compartments or near hot exhaust components.
5. Lay all components out prior to installation to check for proper cable length and interference issues.
6. Avoid mounting Zonar equipment, antennas and wiring near other radio equipment (e.g.,two-way radios), PA equipment and high energy electrical sources (e.g., cables, relays, amplifiers, etc.).

Electrical

1. Consult the vehicle’s manufacturer for specific installation guidelines. (HIGHLY RECOMMENDED for Multiplex electrical systems)
2. All power leads (Red and White Power leads) must be connected to the vehicles protected circuitry (e.g. fuse panel, circuit breaker panel, protected circuits). Never electrically connect Zonar equipment to unprotected circuits (e.g. directly to battery).
3. It is also required that all power leads (Red and White Power leads) be protected with a 3 to 5 amp fuse and inline fuse holder (included) for optimal system protection.
4. Electrical fuses should be installed as close as possible to the source of power.
5. Do not connect to the 4 pin power input until all other V4R cables have been connected.

Do not open V4R housing. Doing so will void the warranty and possibly lead to moisture intrusion.

Drill Holes

1. Do not drill into the V4R unit. This will void the warranty.
2. Capture all drill chips during drilling operations. Do not allow chips to fall onto equipment, furnishings, etc.
3. Deburr all drill holes on both sides of drilled surface. Example deburr tool:

4. All drill holes must have a rubber grommet or similar anti-chafing system installed to protect cable assemblies (e.g. plastic conduit).
5. Seal all penetration drill holes which may pass rain water.

Cable Management

1. Strain relieve and support all cable installations.
2. Avoid sharp bends and tight radius installations of cables.
3. Avoid moving components (e.g. doors, steering shafts, handles, fans, etc.).
4. Provide an adequate “Service Loop” i.e. “cable slack” to allow for servicing of equipment.
5. Avoid routing cables thru doors, windows, and other pinch points.
6. Avoid routing cables in high personnel traffic areas.
7. Avoid routing antenna cables near radio and PA equipment.

CORRECT Bend radius adequate Hole has grommet	INCORRECT Bend radius too tight Hole has sharp edges Hole has no grommet

 

General Housekeeping

1. Capture all drill chips during drilling operations. Do not allow drill chips to fall onto electrical equipment, furnishings, heating ducts, etc. Magnets, sticky tape, vacuums, physical barriers, etc. may all be used to accomplish this task.
2. Remove excess sealant. Sealant should be debris/contaminant free (e.g. drill chips), consistent, and uniform in appearance.
3. Clip excess wire tie protrusions.

V4R Mounting

Suggested Mounting Areas

1. Follow all general guidelines specified above.
2. Antenna configurations:
   1. GPS antenna - V4R utilizes an internal GPS antenna. This antenna works well when the unit has a clear view of the sky (e.g. atop box trailer). If the V4R does not have a clear/unobstructed view of the sky, an optional external GPS antenna must be used.
   2. GSM (cellular antenna) - V4R utilizes an internal cellular antenna. Cellular signals are quite robust and are not easily degraded. As a general rule, if your cellular telephone works in the location you have installed the V4R, this should satisfy the GSM/cellular requirements of the V4R.
3. Mount onto a flat surface large enough to accommodate footprint.
4. Avoid mounting equipment in difficult to access areas.
5. Avoid mounting Zonar equipment, antennas and wiring near other radio equipment (e.g. two-way radios), PA equipment and high energy electrical sources (e.g. cables, relays, amplifiers, etc.).
6. Write down:
   • GPS ID number found on white sticker on GPS unit
   • Vehicle/Asset number (e.g. Bulldozer #56)

Note: Your Zonar Customer Care Representative or Ground Traffic Control™ Administrator will need this information.

Electrical Requirements and Cabling Information

1. Follow all General Guidelines as specified above.
2. It is strongly recommended to connect Zonar devices around the "master kill" circuitry such that they are always powered. Failing to do so may lead to inaccurate data.
3. All power leads must be connected to the vehicle’s protected circuitry (e.g. fuse panel, circuit breaker panel, protected circuits). Never electrically connect Zonar equipment to unprotected circuits (e.g. directly to battery).
4. All power leads (red and white) must be protected with a 3 to 5 amp fuse and inline fuse holder (included) for optimal system protection.
5. Electrical fuses should be installed as close as possible to the source of power.
6. Power Bundle wiring - 4 pin, 4 wires
   1. Red - Constant DC (+8 VDC - +30 VDC), dependent on system type
   2. Black - Battery (-) ground
   3. Green - Chassis ground
   4. White - Ignition - must be connected to a power source that is active only when the engine is running or the system will not track idle time properly.
      1. Engine running (+8 VDC to +32 VDC)
      2. Engine NOT running (0 VDC)
      3. Engine NOT running (key position ACC or Accessory Mode) (0 VDC)

Ground Cable Notes

1. Black - Battery (-) ground
2. Green - Chassis ground

Failure to connect the green ground properly may lead to false engine hours or missing path data.

Power/Data Cable

If power cabling is not connected and powered as described, one or more of the following may occur:

1. Cold Start flags (an indicator that a unit lost and regained constant power)
2. Inaccurate idle and stop times
3. Inaccurate hour meter data
4. Inaccurate mileage data
5. Missing path data
6. Straight line data segments

Contact the vehicle manufacturer for any vehicle specific electrical questions.

 

Wiring Guidelines

The recommended method for power termination on the Zonar V4R system is the use of Add-a-Circuit fuse taps. Whenever possible, use fuse taps for power termination. If fuse taps cannot be used due to the particular make/model/year of the vehicle being installed, then the poke and weave method of termination can be utilized.

Note: All wiring terminations MUST be fused regardless of method of installation used.

Fuse Taps Installation

1. Ensure that the fuse tap seats fully in the correct location.
2. If another fuse, a relay, or any other object in the fuse panel prevents the fuse tap from seating fully, relocate the fuse tap. It is not permissible for the fuse tap to rub or make contact with other items in the fuse panel.
3. In addition, you must be able to re-secure the fuse panel cover or door once the fuse tap is installed.
4. Whenever possible, use an empty location in the fuse panel that does not have an existing fuse. If it is not possible to use an empty location, ensure that the existing fuse is placed in the correct location on the fuse tap. See below for an example.

 CAUTION: Zonar has approved two types of fuse taps. Use of other brands is not authorized. Do not install these fuse kits in fuse panel locations greater than 10 amps.

• LitteFuse brand: Add-a-Circuit
• Bussman brand: Add-a-Fuse

Poke and Weave Installation

Whenever it is not possible to use Add-a-Circuit fuse taps then the poke and weave method must be used.

1. Locate the proper wire where the poke and weave method is to be installed. Strip 3/4” to 1” of insulation from the wire in the vehicle to be installed. Spread the wire strands apart as shown below.

2. Strip 1” to 1 1/2” of insulation from the wire in the fused link to be installed.

3. Insert the wire from the fused link into the spread wire in the vehicle. Wrap around the wire several times.

4. Cover the exposed wires with several wraps of electrical tape or mastic. Place one wire tie over the electric tape over the exact location where the wires are 'wrapped' together. Place another wire tie 1” to 2” from the first wire tie, to secure the two wires together and as stress relief.

External GPS Antenna (Optional)

1. Required when the V4R does not have an upward facing clear view of the open sky.
2. Suggested mounting area: as high on the vehicle as possible, facing upward. Protect from moving machinery and falling debris.
3. Follow all General Guidelines as specified above.
4. May be magnetically mounted or mounted via optional adhesive for non-magnetic surfaces.
5. Ensure a clear antenna view of the open sky.
6. Maintain a minimum of 6 inches from any rooftop edge or ledge.
7. Drill, deburr, grommet, weather seal, cable thru hole as required.
   Drill hole size - 1/2” (.500”); grommet size - 3/8” (.375”).
8. Protect exposed GPS cable with automotive grade impact and cut resistant loom.

Note: For optimal system performance, Zonar recommends rooftop mounting with a clear view of the sky.

System Check

1. Installers are required to perform a full functional check to verify proper installation and operation. A complete functional check requires Ground Traffic Control™ confirmation as status LEDs are not present.
2. Constant power (red wire) check:
   1. Remove inline fuse on red wire and measure voltage at red fuse holder.
3. Ignition (white wire) check:
   1. Power to this lead should only be present when the engine is on and/or GPS tracking is desired. Wiring this to constant power will lead to high and inaccurate idle times.
   2. Remove inline fuse on white wire and measure voltage at fuse holder:
      Engine On = 8 to 30 VDC
      Engine Off = 0 Volts
4. If installed, enable the connected inputs. 
5. Final check:
   1. Turn engine on and allow to run for a minimum of 4 minutes, then turn off engine.
   2. Go to Zonar’s Ground Traffic Control™ and open the GPS Path report. To access the Path report, on the main menu, click Reports, under GPS Track & Trace, select Path.
      Generate the report and export this data to an Excel CSV file. Ensure that the following events are present:
      1. Cold Start
      2. Power-On event
      3. Power-Off event
      4. Discrete Input events (if installed)

Notes:

1. A proper and complete functional check requires the engine to be running.
2. GPS and input data may not be present on new and RMA installs until the vehicle is driven at least 100 feet, at a speed of 5 MPH or greater.

System Checklist

System Specifications

SPECIFICATIONS

• Operating Temp: -40°C (-40°F) to +85°C (+185°F)
• DC Input Range: 8.0Vdc to 30.0Vdc
• IP 67. Protected against the effects of temporary immersion between 15cm and 1m. Duration of test 30 minutes
• IP 69K (high pressure/steam cleaning specification)

GPS Receiver

• Very High Sensitivity Receiver
• Rapid Acquisition of Satellites
• GPS Signal Acquisition, Tracking and Navigation
• Onboard GPS Data Storage

DIMENSIONS

• Length: 9.5 in.
• Width: 8.5 in.
• Height: 2.9 - 3.2 in.

COMMUNICATION
GSM Cellular Transceiver

• GSM (2G) 850/900/1800/1900 MHz
• WCDMA (3G) 850/1900 MHz

 

System Installation

Zonar Discrete Input System

The V4R is capable of recording GPS points when a system on the vehicle is activated or deactivated. See below schematic to tap into an existing switched control circuit.

When installing multiple discrete inputs, ensure that the polarity is consistent on all installed connections. Failure to do so may result in feedback to the wired device, resulting in a failure to operate with the V4 plugged in.

Common V4R Troubleshooting

The majority of all V4R issues fall into six broad categories:

• GPS Signal Strength Issues: The V4R must be given a clear view to the open sky to operate correctly. If this cannot be accomplished an external GPS antenna with a clear view to the sky must be utilized.
• Cellular Signal Strength Issues: The V4R cannot transmit in areas that are not covered by cellular towers (typically remote areas). The V4R will store information until cellular reception is restored and then forward all stored data.
• Cold Starts: These are the most serious issue because they represent a lack of integrity in the constant power supply to the device. Before any other issue can be resolved, it is important to ensure that the V4R has reliable constant power.
• Issues with the Engine Run Signal: These lead to false reporting of engine hours. The problem can be false positive (e.g. V4R records engine hours even if the asset is not running) as well as false negative (e.g. V4R does not record engine hours even though the asset is running).
• V4 Issues: Inside every V4R is a Zonar V4 GPS unit. Therefore, typical V4 issues can arise with any V4R. Since much of the V4R troubleshooting information references LEDs which are hidden inside the waterproof V4R enclosure, in most cases you will need to contact Zonar Customer Care for help.

White Wire (WW) / Switched Power Electrical Test

1. Engage the equipment master switch.
2. Disconnect Zonar harness to V4R case.
3. Connect the negative meter probe to the Zonar Black GND wire.
4. Turn engine off.
5. Refer to the below image and locate the WW pin on the 35-pin connector. Probe this pin with the positive meter probe.
6. To pass the inspection, the meter must show less than 1V.
7. Turn engine on.
8. Probe the WW pin. To pass, the meter should read greater than 5V.

Chassis Ground Electrical Test

1. Connect negative meter probe to Black GND wire.
2. Disengage master switch.
3. Probe Green Chassis GND pin on 35-pin connector with positive meter probe.
4. Meter should show greater than 8V. Note: this test will fail if master switch is on positive side.
5. Probe WW pin on 35-pin connector.
6. Meter should show less than 1V. Note: this test will fail if master switch is on negative side. Only one of these tests is required to pass.

Inspection Results

If both steps 6 and 8 result in PASS, the V4R passes the electrical inspection. However, if the equipment is acting up only under certain conditions (i.e. hot day, rainy weather) the test should be performed again under those conditions.

If either test results in FAIL, perform the WW continuity tests. Once the wiring has been verified, repeat this test. If the result is FAIL again, swap in a new V4R and repeat.

If the inspection does not pass even after swapping in a new V4R, note the failure condition, and contact Zonar Care.

Power and Ground Electrical Tests

Unexplained cold starts are the most serious issues because they represent a lack of integrity in the constant power supply to the device. Before any other issue can be resolved, it is important to ensure that the V4R has reliable constant power. Simply following this procedure may not be enough. However, if the equipment is acting up only under certain conditions (i.e. hot day, rainy weather) the test should be performed again under these conditions.

1. Disengage the equipment master switch.
2. Connect Zonar harness to V4R case.
3. Prepare multi-meter to measure volts.
4. Connect the negative meter probe to Zonar GND wire.
5. Refer to below image and locate the V pin on the 35-pin connector. Probe this pin with the positive meter probe.
6. To pass the inspection, the voltage must be at or near battery voltage. If not, perform the Power and Ground Wiring Inspection. Then repeat this test.
7. If the test passes, power cycle the V4R, and confirm that a Cold Start event occurred on GTC. Otherwise, note the failure condition, and contact Zonar Care.

Test Result

If the Electrical test passes, but the V4R continues to show unexplained cold starts, note the conditions under which the cold starts occur. Repeat the Power and Ground Wiring Inspection procedure and the above procedure under those conditions. If possible, mount the meter in the operator’s cab and run the test continuously for several hours.

Zonar Harness Wiring Schematic

 

Notices

Warning: (Part 15.21)

Changes or modifications not expressly approved by Zonar Systems could void the user's authority to operate the equipment.

Caution: RF Exposure (OET Bulletin 65)

To comply with FCC RF exposure requirements for mobile transmitting devices, the antenna(s) used for this transmitter must be installed to provide a separation distance of at least 25 cm (10 inches) from all persons and must not be co-located or operating in conjunction with any other antenna or transmitter. Users and installers must be provided with antenna installation instructions and transmitter operating conditions for satisfying RF exposure compliance.

Use only supplied and approved antennas. Use of unauthorized antennas or modifications could impair signal quality, void your warranty and/or result in violation of FCC regulations.

FCC Compliance Statement (Part 15.19), IC Compliance Statement (RSS-210)

This device complies with Part 15 of the FCC Rules and with RSS-210 of Industry Canada (IC). Operation is subject to the following two conditions:

1. This device may not cause harmful interference, and
2. This device must accept any interference received, including interference that may cause undesired operation.

Warranty And Legal Notices

For more information regarding Zonar Warranty and Legal Notices, see the Zonar Product Warranty page on our website (https://support.zonarsystems.net).