Voith-Spec VR123

Specification Retarder
Retarder ECU VERA™ for MAN-Force
Revision status:
Index Date Revisions
00 2010-01-12 First edition
01 2010-01-13 Chapter 4: separate diagrams for application without and with ABS
chapter 1.1.1: 1 engine brake step plus 2 Retarder brake steps;

chapter 1.5 : speed signal “B7 / C3”;
02 2010-07-22
chapter 5: ECU part number: 153.00491511 for VR123 / 1500
Nm / 2.85 bar
Sources
[1] Technical Description for the Customer, Retarder DIGIPROP Control Units,
VOITH Work Sheet cbt-0015 / Index 08 / 00-03-01
[2] Hardware-Specification "VERA™_2007-Standard" 3623-020958
[3] Instruction Manual for Voith diagnosis software “WinDia®”
Revision Index: 02 Date: 2010-07-22

Date: 2010-01-12 Voith Turbo Produktgruppe Drive Line 3623- 021056
Issued by: ardtm-Scher Postfach 1555 74555 Crailsheim Germany
Tel. +49 79 51 32 15 55 Fax +49 79 51 32 15 06
File: Spec_021056 support-retarder@voith.com www.voith.com Page 2 of 16
Table of Contents:
1 Basic Functions 4
1.1 Operating concept 4
1.1.1 Manual operation (retarder stage switch): “1 plus 2 brake steps” 4
1.1.2 Foot pedal operation 5
1.2 Accelerator pedal (option) 6
1.3 ABS (option) 6
1.4 Engine brake relay (Option) 7
1.5 Vehicle speed 7
1.5.1 General 7
1.5.2 “B7 / C3 signal” 7
1.6 Stop light relay (option) 8
1.7 Lubrication Pulse 8
1.8 Down regulations 8
1.9 Retarder pilot light 9
1.9.1 General 9
1.9.2 Standard functions of pilot light 9
2 Diagnosis Functions 10
2.1 General information 10
2.2 Flash Code Diagnosis 10
2.2.1 General 10
4.2.2 Triggering conditions 10
4.2.3 Triggering steps 10
2.2.4 Indication example 11
2.2.5 Special trigger pin 11
2.2.6 Erasing the error memory 11
2.3 Voith Diagnosis Software “WinDia®” 11
3 Error codes 12
4 Wiring Diagram 14
4.1 Application without ABS 14
4.2 Application with ABS 15
5 Part Numbers ECU and harness 16

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1 Basic Functions
1.1 Operating concept
1.1.1 Manual operation (retarder stage switch): “1 plus 2 brake steps”
1 engine brake step plus 2 Retarder brake steps (no v-constant function)
Hand lever Ret. Torque Current Control pressure

Function
position [%] [mA] [bar]
0 all systems OFF 0 0 0
1 engine brake ON 0 0 0
engine brake ON
2 plus 50 441 ± 100 1,41 ± 0,15
Retarder brake step 1
engine brake ON
3 plus 100 540 ± 100 2,85 ± 0,15
Retarder brake step 2
If the retarder stage switch is not in position 0 after ignition-ON / RESET, there will be no
function of prop valve current (no control pressure). In this case, the retarder stage switch
has to be put in position 0.
Automatic switch-off (prop valve current = 0) with “vehicle speed < ca. 10 km/h”.
“Voith service-function”:
Only in manual operation.
Purpose: Check of ECU, prop valve and retarder for correct function, leakages etc. . .
Conditions: Vehicle in standstill (v = 0 km/h), RESET. Retarder stage switch has to be

moved from position 0 to 2 and back to 0.
From now on it is possible to get the prop valve in operation according to the pressure
steps.
Pilot light: ON (in hand position 1 … 3).

Engine brake relay and stop light relay: ON (in hand position 2 and 3),

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1.1.2 Foot pedal operation
Realized by 2 switches (micro switch, pressure swith …), connected to stand-alone ECU
pins (not connected to the hand lever pins). Later-on tests will be started to operate the
engine brake also by foot.
Foot Torque Current Control pressure

Function
steps [%] [mA] [bar]
0 Retarder OFF 0 0 0
1 brake step 1 50 441 ± 100 1,41 ± 0,15
2 brake step 2 100 540 ± 100 2,85 ± 0,15
FOOT BRAKE PEDAL

(EXAMPLE)
Retarder foot operation steps

1 2
10
α
Service break pressure p in bar

360
F
8
Pedal force F in N
P
280
6
200
4
120
2
40
0
0 2 6 10 14 18 22 26 30 34
Pedal angle in degree α
Vehicles with ABS:
A “foot-off-switch” has to be installed in the dashboard (see wiring in chapter 4).

In the driver’s manual the function of this switch has to be explained:
- switch-off the Retarder foot operation during slippery road !!!
- switch-off the Retarder foot operation during check of the foundation bake system
Vehicles without ABS: additional “Retarder-OFF-switch”, see chapter 1.3 and 4.1.

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1.2 Accelerator pedal (option)

An accelerator pedal switch (accel. > 0 / = 0) can be wired to pin X1/17.
Accel. > 0 (X1/17 open) ⇒ braking torque goes to 0

Accel. > 0 → idle (X1/17 connected to PLUS) ⇒ braking torque increases via ramp
to step value
(with 0,5s delay and 3s ramp time)
During acceleration > 0 (-> retarder torque = 0) the VERA™ output pin X2/1 (engine brake
relay) switches off.
Note: If the accelerator pedal function is not used, so the pin X1/17 has to be connected
permanently to PLUS (= U_Batt / terminal 15; see wiring diagram, chapter 4).
Voith recommends to install an accelerator pedal switch in order to avoid engine operation
against retarder.
1.3 ABS (option)

The (optional) ABS signal (ABS active / passive) is wired to the ABS-pin (X1/13).
ABS active (ground signal to X1/13) ⇒ braking torque goes to 0
ABS active → passive (X1/13 open or “High”) ⇒ br. torque with time delay (1 sec)
plus ramp (4 sec) back to step value
During ‘ABS active’ (-> retarder torque = 0) the VERA™ output pin X2/1 (engine brake
relay) switches off.
Safety: Vehicles without ABS

Due to safety aspects, there has to be installed an additional “Retarder-OFF-switch” in the
dashboard (see wiring in chapter 4.1, pin X1/17).
In the driver’s manual the function of this switch has to be explained:
“Switch-off the Retarder during slippery road, especially in vehicles without ABS” !!!
Note: Same VERA™ ECU for vehicles with or without ABS.

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1.4 Engine brake relay (Option)
Pin X2/1 (OUT1) is used for the control of the Engine brake relay.
Condition for Engine Brake ON:

- hand lever in position 1 .. 3 (AND ABS not active, accelerator pedal released)
Later-on tests will be started to operate the engine brake also by foot.
1.5 Vehicle speed
1.5.1 General
The vehicle speed signal is wired to pin X1/11.
Should no signal be available, then this means a severe error for the retarder system, i.e.
the retarder cannot be activated any more (VOITH safety concept).
For specification of high and low voltage level please refer to

- Hardware-Specification "VERA™_2007-Standard" 3623-020958.
Voith recommends to install an exclusive signal for retarder ECU purposes (in case that
further ECUs are connected to 1 speed signal, these ECUs could get mutual influence and
functional problems; best way is to use a speed signal amplifier / splitter).
1.5.2 “B7 / C3 signal”

The “B7 / C3 signal” is a standardized vehicle speed signal, and with use of this signal
type, there is no need for any adaptation of the Retarder ECU.
The B7 / C3 signal is spezified in the INTERNATIONAL STANDARD ISO 16844-2; in this

standard the signal is designated as “B7 speed output signal”.
Specification of the “standard B7 / C3 speed signal”: v [km/h] = 225 ▪ T_i / T_p
The Retarder ECU has to measure the pulse time T_i and the periodic cycle time T_p of
the B7 / C3 signal to calculate the vehicle speed v.
Remark: ECU internally the retarder rotor speed is calculated with using the parameters
rear axle ratio = 4.0
tire diameter = 1 m.
This “standard” calculation is not relevant for the retarder operation.

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1.6 Stop light relay (option)
Pin X1/16 (BLR) is used for the control of the brake light relay.
In case that pin X1/16 is not used (left open): no error.
Condition for stop light ON:

- hand lever in position 2 or 3 (AND ABS not active, accelerator pedal released)
- foot step 1 or 2 (AND ABS not active, accelerator pedal released)
1.7 Lubrication Pulse

Lubrication pulses are necessary for the retarder during speed > 0 with torque = 0
(“retarder off”).
The interval period time depends on the oil temperature:

T_Oil < 120 °C period 180 sec
T_Oil 120 °C to 180 °C period linear decreasing from 180 sec to 10 sec
T_Oil > 180 °C period 10 sec
Propvalve pulse current: 493 mA / 200 msec
The operation of the lubrication pulse is independent of the vehicle speed (0 or > 0) and
independent of any speed signal fault !!!
1.8 Down regulations

Water temperature parameters are: start 95 °C
end 105 °C
constant 100 °C
Oil temperature parameters are: start 180 °C

end 210 °C

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1.9 Retarder pilot light
1.9.1 General
The retarder pilot light is controlled by ground connection (pin X1/15 “active low”).
It is activated prior in case of control unit failure (highest priority: error indicator light).
Optional it is possibly to connect a LED instead a lamp. In this case it is necessary to join
in parallel a resistor 2200Ω / 0.5W.
1.9.2 Standard functions of pilot light
OFF ¾ Brake step = 0

¾ Brake step > 0 AND Retarder braking torque = 0
(due to hand position 1, ABS active, accelerator pedal pressed or high
temperature water / oil)
ON / ¾ Error signal steady light in case of severe and minor errors
FLASHING
¾ Status signal steady light when Retarder brake steps are
active (hand, foot)
¾ Torque adaptation flashing at braking torque adaptation cooling
(0…99%) water or retarder oil (hand, foot > 0)
(torque reduction > 75 % after 1 sec.)
¾ Flash code output flash code of actual errors
¾ Lamp test 5 seconds ON after ignition ON

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2 Diagnosis Functions
2.1 General information
2 possibilities for diagnosis and service purposes are realized:

a) without PC / laptop: error flash code via pilot light (pinX1/15)
b) with PC / laptop: diagnosis via serial data flow (ISO-K) and Voith PC-tool “WinDia®”
2.2 Flash Code Diagnosis
2.2.1 General
To read-out actual errors from the ECU (one or more faults are actual) without PC-based
service tool "WinDia®", the indication of an error code is possible by means of the pilot
light (= RKL) flashing function. If several faults are active, these are indicated one by one.
After indication of all errors, at a further triggering, the flash code begins with the "first
error" again.
Ex.: Malfunction code 32 occurs

Malfunction code 17 occurs
Malfunction code 28 occurs
) 1st triggering of flash code ⇒ 17 is indicated

) 2nd triggering of flash code ⇒ 28 is indicated
) 3rd triggering of flash code ⇒ 32 is indicated
) 4th triggering of flash code ⇒ 17 is indicated
4.2.2 Triggering conditions

The flash code can be triggered only if
♦ the retarder stage switch (= hand lever / foot) is in position 0 AND
♦ the vehicle is standing (speed = 0 km/h).
4.2.3 Triggering steps

1. Stage switch position 0
Flash code of the "first error" is indicated
Repetition of steps 1 ... 3 to trigger the next flash code

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2.2.4 Indication example
For error 32:
The number of tens places is first indicated as long ON times: 2 seconds each
The numbers of units are then indicated as short ON times: 0.5 seconds each
Intervals between each ON time: 1 second each
RKL ON
RKL OFF
Pause ahead and after one flash code indication: 3 sec each
2.2.5 Special trigger pin
Usually the error flash code is triggered by moving the hand / foot lever.
If a hand / foot signal error is active, this triggering is no more possible.

In this situation (and for all other errors) a U_Batt signal to X2/9 can be used for triggering.
The OEM is responsible for a good accessibility of this pin X2/9 or the related wire for
service purposes (if necessary).
2.2.6 Erasing the error memory

Erasing the error memory is only possible with the Voith Diagnosis Software “WinDia®” or
with an OEM tool, which operates togehther with the Voith KWP 2000 communication (see
chapter 2.3).
2.3 Voith Diagnosis Software “WinDia®”
Diagnosis via serial data flow (VERA™ pin X1/12; ISO-K, alike international standard
protocol “KWP 2000” / ISO14230) using the Voith PC-tool “WinDia®” and an appropriate
interface.
For more details please refer to

Instruction Manual for Voith diagnosis software “WinDia®” (available via Internet).

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3 Error codes
Remarks: s = Valence (V) severe fault, no retarder braking torque
m = Valence (V) minor fault, retarder braking torque possible
Flash KWP
Errors description V Conditions SPN
FMI
Code
1 ECU-internal fault conc. parameters s directly after ignition-ON 3004 9
2 ECU-internal fault conc. EEPROM s directly after ignition-ON 3005 9
3 ECU-internal fault conc. ROM s ca. 10 s 3005 9
ECU-internal fault conc. safety

4 s 60 ms 3003 9
component
1 s; ECU-internal PWM signal / status signals / AD
5 Prop valve fault No. 1 s signal not plausible
744 5

744 6

744 9
9 Terminal 15 undervoltage s 60 s; limit 17.5 V, hysteresis 0.5 V 158 2
10 Terminal 15 overvoltage s 10 s; limit 33 V, hysteresis 0.5 V 158 1
Hand lever / foot undefined switch

11 s 2 s; signal pattern / closing sequence not plausible 3013 3
condition
12 Hand lever / foot short to ground s 1 s; U ≤ 0.3 x UB_ECU-internal 3013 5
13 Hand lever / foot short to battery s 10 s; U ≥ 0.7 x UB_ECU-internal 3013 6
16 TW – fault AND TO - fault s both temperature sensors are faulty flash code
TW - sensor interruption or short to

17 m1 1 s; RSensor > 1540 Ω 3001 10
battery
18 TW - sensor short to ground m1 1 s; RSensor < 760 Ω 3001 5
TO - sensor interruption or short to

19 m2 1 s; RSensor > 2000 Ω 3002 10
battery
20 TO - Sensor short to ground m2 1 s; RSensor < 760 Ω 3002 5
21 Speed signal interruption s 2 s; no pulses and 2,5 V < U ≤ 4.8 V 3030 10
22 Speed signal short to battery s 2 s; no pulses and U > 4.8 V 3030 6
Pilot light interruption or short to

23 s 1 s; output OFF and U ≤ 0.3 x UB_ECU-internal 3031 10
ground
1
TW – Sensor error: max. 50% braking torque possible
2
TO – Sensor error: full braking torque possible; no reduction
Both Sensors error: no braking torque possible

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24 Pilot light short to battery s 3 s; output ON and U ≥ 0.7 x UB_ECU-internal 3031 6
25 Pressure sensor supply fault m 500 ms; U < 4.5 V or U > 5.5 V (pin X3/9) 764 9
Press. sensor interruption or short to

26 m 1 s; U ≤ 0.3 V 764 5
ground
27 Pressure sensor short to battery m 1 s; U ≥ 4.7 V 764 6
28 Pressure sensor “not plausible” m “prop valve current ↔ sensor signal” not plausible 764 3
29 ABS signal short to ground s 60 s; U < 0.3 x UTerminal 15 3032 5
30 ABS signal “level undefined” s 5 s; 0.3 x UTerminal 15 < U < 0.7 x UTerminal 15 3032 8
31 ABS input path defectiv (ECU-internal) s signals of both internal ABS paths not plausible 3032 9
33 Brake light (BLR) short to ground m 1 s; output ON and U ≤ 0.3 x UB_ECU-internal 3033 5
Engine brake (OUT1; X2/1) short to

35 m 1 s; output ON and U ≤ 0.3 x UB_ECU-internal 3034 5
ground
Engine brake (OUT1; X2/1) interruption
36 m 1 s; output OFF and U > 0.7 x UB_ECU-internal 3034 10
or short to battery

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4 Wiring Diagram
4.1 Application without ABS

CABLE HARNESS DASHBOARD Kabel E-Fach CUSTOMER INSTALLATION Kundeninstallation
153.00505310
BROWN braun TERMINAL 31 (GROUND)

CONTROL UNIT VERA™
X1/14 GND
Klemme 31 (Masse)
Steuergerät VERA™
PILOT LIGHT Kontrollleuchte

8A
YELLOW / GREEN gelb / grün TERMINAL 15 (IGNITION LOCK)
X1/15 RKL
Klemme 15 (Zündschloss)
8A
RED rot
X1/07 U-BATT
GAS > 0 : OPEN (RETARDER OFF)
TOGGLE SWITCH WITH X1/17

GREY / BLACK grau / schwarz
X1/17 n-MOT INTEGRATED WARNING LAMP
ACCELERATOR PEDAL SWITCH Umschalter mit integrierter
Warnleuchte WITHOUT
Leergasschalter
A.P. SWITCH
ohne
Gaspedalschalter
BLUE / WHITE blau / weiß DIAGNOSTIC K-LINE

X1/12 ISO-K
Diagnose K-Leitung
BLUE blau TACHOGRAPH SIGNAL

X1/11 C3
Tachosignal
ORANGE orange STOP LIGHT RELAY

X1/16 BLR
Bremslichtrelais
BLACK schwarz ABS ECU (OPTION)

X1/13 ABS
GND = RETARDER OFF Masse = Retarder AUS ABS Signal (Option)
8
VIOLET violett
X1/10 RSS +
PINK rosa 7
X1/05 RSS 1 1
HAND LEVER
BLUE blau 6 Retarderstufenschalter
X1/06 RSS 2 2
ORANGE orange 5
X1/08 RSS 3 3
VIOLET violett
ON FOOT ON / OFF
Fuss Ein / Aus
2 x GREY / BLACK
2 x grau / schwarz
FOOT CONTROL SWITCH

2 Fussbremsschalter
GREY grau
X1/18 RSS 5
BEIGE beige
X1/04 RSS 0
153.00212120 ENGINE BRAKE RELAY

X2/01 OUT 1
Motorbremsrelais
CABLE HARNESS RETARDER Kabel Retarder

153.00042220 / 153.00503110
YELLOW / GREEN gelb / grün 1
X3/02 TW
TEMPERATURE SENSOR WATER
2 Temperatursensor Wasser
BLUE blau
X3/01 TW GND
VIOLET violett 1
X3/05 TO
TEMPERATURE SENSOR OIL
2 Temperatursensor Öl
WHITE weiß
X3/06 TO GND
PINK rosa 1
X3/03 PROP-H
PROPORTIONAL VALVE
GREY grau 2 Proportionalventil
X3/04 PROP-L
GREY / BLACK grau / schwarz 2

X3/07 DS SIGNAL
U
BROWN / WHITE braun / weiß 4
X3/08 DS GND
PRESSURE SENSOR
RED / WHITE rot / weiß 1 Drucksensor
X3/09 DS +5V
3
P
VENTILATION WIRE
0,3 ... 2m

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4.2 Application with ABS

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5 Part Numbers ECU and harness
ECU with 1 + 2 hand steps, 2 foot steps:
Voith part no. 153.00491511
VR123, 1500 Nm / 2,85 bar
Cable harness:
Voith offers wiring harnesses:
- X1-harness = “dashboard-harness” (U_Batt, gnd, ABS, speed, hand, foot …)
part no. 153.00505310 length 5m
- X2-harness = “additional functions” (engine brake relay: X2/1)
part no. 153.00212120 length 0.25 m
- X3-harness = “Retarder VR123 harness” (protected with corrugated pipe)
( part no. 153.00042220 length 13 m “standard harness” )
part no. 153.00503110 length 13 m adapted for VR123TL

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Specification Retarder

Retarder ECU VERA™ for MAN-Force

Index Date Revisions

00 2010-01-12 First edition

chapter 1.1.1: 1 engine brake step plus 2 Retarder brake steps;

[2] Hardware-Specification "VERA™_2007-Standard" 3623-020958

[3] Instruction Manual for Voith diagnosis software “WinDia®”

Revision Index: 02 Date: 2010-07-22

5 Part Numbers ECU and harness 16

Revision Index: 02 Date: 2010-07-22

1.1 Operating concept

1.1.1 Manual operation (retarder stage switch): “1 plus 2 brake steps”

Hand lever Ret. Torque Current Control pressure

Only in manual operation.

Conditions: Vehicle in standstill (v = 0 km/h), RESET. Retarder stage switch has to be

Pilot light: ON (in hand position 1 … 3).

Revision Index: 02 Date: 2010-07-22

Foot Torque Current Control pressure

FOOT BRAKE PEDAL

Retarder foot operation steps

Service break pressure p in bar

Vehicles with ABS:

A “foot-off-switch” has to be installed in the dashboard (see wiring in chapter 4).

Revision Index: 02 Date: 2010-07-22

1.2 Accelerator pedal (option)

Accel. > 0 (X1/17 open) ⇒ braking torque goes to 0

1.3 ABS (option)

Safety: Vehicles without ABS

Note: Same VERA™ ECU for vehicles with or without ABS.

Revision Index: 02 Date: 2010-07-22

Condition for Engine Brake ON:

1.5 Vehicle speed

For specification of high and low voltage level please refer to

1.5.2 “B7 / C3 signal”

The B7 / C3 signal is spezified in the INTERNATIONAL STANDARD ISO 16844-2; in this

Specification of the “standard B7 / C3 speed signal”: v [km/h] = 225 ▪ T_i / T_p

Revision Index: 02 Date: 2010-07-22

Condition for stop light ON:

1.7 Lubrication Pulse

The interval period time depends on the oil temperature:

Propvalve pulse current: 493 mA / 200 msec

1.8 Down regulations

Oil temperature parameters are: start 180 °C

Revision Index: 02 Date: 2010-07-22

1.9.2 Standard functions of pilot light

OFF ¾ Brake step = 0

Revision Index: 02 Date: 2010-07-22

2.1 General information

2 possibilities for diagnosis and service purposes are realized:

2.2 Flash Code Diagnosis

Ex.:  Malfunction code 32 occurs

) 1st triggering of flash code ⇒ 17 is indicated

4.2.2 Triggering conditions

4.2.3 Triggering steps

Revision Index: 02 Date: 2010-07-22

2.2.5 Special trigger pin

If a hand / foot signal error is active, this triggering is no more possible.

2.2.6 Erasing the error memory

2.3 Voith Diagnosis Software “WinDia®”

Ex.: Malfunction code 32 occurs