Handling a complex world.
Fleet Manager 200 Plus
Installation Manual
Version: 4Contents
‘Contents
Introdustion....
System Overview.
Analogue/Digital Inputs
Frequency Inputs.
System Requirements
Safety
Before installation
Installer Requirem
Tools!
Secure the workplace:
During installation.
Positioning af product components:
Installation of Wicing:
After Installation
During Operation
Installation
Installation Requirements
Summary of Installation Steps.
FNIZ00 Plus Harness Installation
Starter Interruation
Code Plug Socket Installation,
Positioning the FM200 Plus Unit nnn oe vn
Signal inputs.....
Analogue/Digital Inputs,
quency Inputs.
Frequency Input Jumper Selection nnn oe vn
Seo eO2DTATMOVTOMAE EERE LOLUDD
Power QUIBUtS nee svvtnentnvienvernn scene secon neree A
"
Speed Sender Power (VEPC)... tt
Positive Drive, so oT
Serial Communization
Loading Device Drivers
€onfiguring Vehicle Properties .
Setting the Real Time Clack.
Speed and RPM Calibration.
gine Speed (RPM) Calibration
Vehicle Speed Calitration...
Testing Installatio
Test Brive
et and Transfer Data...
Troubleshooting...
Maintenance ..
FM200 Plus Specifications...
Declarations ..
‘Type-Approval
Declaration of Conformity.
Restrictions.
‘DO Part Numbers
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vis 208 Page oFIntrodu'
‘System Overview
The DO Fleet Manager 200 Plus (FM200 Pius) is an on-board-samputer for use in vehioles and warking
machines. The system is designed to record a wide range of vehicle and tria related information, including: vehicle
speed, engine speed, engine temperature, fuel consumption, trip start and end times. The F200 Plus interfaces
sdirectly to a large selection of transducers which enable the recording of data, such as: vehicle position. Tuel
‘sonsumption, and vehicle loading.
‘The FII200 Plus is used in conjunction with the DO Fleet Manager application software. This software facilitates
the management ef vehicle, driver and passenger information, definition and management of events to be
monitored by vehicle units, recording of servicing details, analysis of fleet cata and extensive management
reporting,
The primary method af communicating with the FM200 Pius is via the green Vehicle Flug. The plug is used to
extract data from the FN200 Pitys and transfer it to a Personal Camputer, where it can De processed and analysed.
by the WDO Fleet Manager agplication software. Various modems can be connected te the FM200 Pius to
jacilitate wireless communication with the vehicle uni.
‘Vehizle drivers are identified by means of a driver specifie blue plug; identification can be enforced! by interrupting
the vehicle’ starter circuit
AnalogueiDigital Inputs
The FIN1200 Plus is equipped with sight analogue/cigital inputs (11-18), which can be used to monitor either digital
‘or analogue signals. The eighth AnaloguerDigital inout (16) is shared with the fourth frequency input (F4}. Input
signal voltage tange and resolution is selectable from the Fleet Manager sofware. For cigital type inaut signals,
switching thresholds can be defined. in the software, which, when crossed, trigger an event that records the
specified data. Please refer to the “Specifications” section, of this dacument, for mare details
Frequency Inputs
‘The FINIZ00 Pius has four frequeney inputs, which tan be used to retord frequency type signals, The fourth
frequency input (Fé) is shared vith the eighth Analogue’Digital input (I@). Provision is made for = wide range of
signal types. Please refer to the ‘Frequency Input Jumper Selection” section, cf this dacument, for mare details
System Requirements
The FW1200 Plus is designed for use in vehicles, special vehicles and! working machines with a 12 or 24 volte
battery system, The YOO Fleet Manager application software is required to complete the instalaion grocess.
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vis 208 Page etSafety
Before Installation
Installer Requirements:
Installation should only be undertaken by 2 vehicle technician with comprehensive occupation specific
knowledge and wha has complete command of the actions required by the occupation
Installation by an unqualified technician may adversely affect the operating reliability ofthe vehicle and
could endanger other road users
Abasic knawledge of vehicle electrical and mechanical sy
Fleet Manager 200Ftus system.
‘The system should only be installed by a suitably qualified vericle technician with a basic knowledge of
ihe operation of comauters
> Installation technicians should attend a VDO training course ta acquire the skills needed for installation,
configuration and operation of the VOO Fleet Manager system
Installers should consult the vehicle manufacturer's documentation for the specific vehicle make and
model prior to undertaking an installation,
Installers should pay particular attention to the Incatian of fuel systems, hycrsulio systems, compressed air
systems and other electrical and mechanical systems, which may have a bearing on the installation
> Installers should pay attention to any changes to the vehicle systems or seitings, which should be noted
prior to the installation.
Installers should refrain fram smoking and the use of naked flames, which could cause afire in or near the
vehicle
ms is required! to successfully install the VOO
‘Standard technical equioment andl appropriate tools for use with vehicles are required to install the WOO
Fleet Manager 290 Plus system
> Vehisie specific tools may be required far the removal of eonsales and covers,
‘Secure the workplace:
Remove the ignition key from the vehicle ignition lock.
Ensure that the vehicle's engine cannot be unintentionally started during the installation
> Record all data stored in the volatile memery of the vehicle’ systems to ensure that such data can be
restored.
When the negative terminal of the battery is disconnected, all volatile memory will be lost. Please ensure
that such information is recorded priar to disconnection so that systems can be reconfigured correctly.
‘Short-tircuiting the vehicle S electrical system may result in fite, exolosion ef the battery and/or camage ts
other electrical systems
The negative terminal of the vehicle battery should be disconnected before commencing installation. If
ine vehicle has additional batteries, it may be necessary to disconnect the negative terminals of these
batteries toa.
During installation
‘Should it be necessary to remove Seats, covers ar other components. care should be taken ta avai
accidental damage ardior disconnection ef cables.
All components shauld be checked for damage prior to being installed into the vehicle
‘Far small installation openings. a drill should be used
‘ar larger openings, a conical milling cutter, compass saw or file should be used,
> All rough edges sheuld be trimmed.
Careful attention must be paid to the manufscturers "safety regulations for all tools used.
Gils and fuels must be collected in appropriate containers and disposed of in accordance with the law
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vis 208 Paget or 18Positioning of product component:
Installers should ensure that the components of the product de nat influence or hamper the functioning of
ihe vehicle’ systems
5 Gare should be taken to ensure that the produet’ companemts do nat get damaged during installation.
Ensure that sufficient space: is available for all components of the product prior to commencing the
installation.
‘Please pay attention to the rauting of cables and wiring
5 Do not install the product in or near the locatian of mechanical or electrical airsags.
Bo nat drill into supperting or stabilising braces ar besms
Installation of Wiring:
> Note the product’ wire gauge
Ifthe wire gauge is reduced, curent density increases which may cause the wiring to averhea
Cables should be routed in existing channels and should not be routed parallel to ignition cables or ather
cables subject to high current,
Cables should be fixed with cableties ar adhesive tape
Do not route cables over moving parts,
* Do nat fix cables on the steering eolunn
Ensure that the cables are not exposed to pulling, pressure or shearing deformation,
Ifthe cables are routed through drilled holes, rubber grommets or similar protection should be used.
Suitable cable-strigpers shauld be used fo strip insulating material from cables and oable-strippers should
be adjusted ta avoid damaging or separating the wire strand’
Cables should only be connerted using scider or suitable crimping lugs
A proper crimping tool shuld be used on all crimping lugs.
> Careful attention must be paid to the manufacturers”safety regulations for all tools used.
‘Insulate all expasedl wires to prevent short-circults
Connestions to vehicle power supply must be installed with a fuse or current limiting device
2 Be aware that short-aireuiting may be caused by faulty connections and crushed er damaged cables.
' Shortcircuiting the vehicle electrical system may result in fire, explosion of the battery andor damage to
ther elzctrival systems. To prevent this, all connections carrying current must be soldered and insulated
correetly. Other eonnections such as the speed signal, RPM signal, brake light er elutch switch can be
mace with crimping lugs
2 ncarrect connections can lead fo short circuits. Connections should only be made in accordance with the
vehicle § wiring diagram
2 Gurrert and voltage should be measured with a multimeter or diode test Imo,
The use of inadecuate test equipment may resuit in the damage to control devices or cther electric
systems
After Installation
‘Reconnect the vehicle $ ground cable to the negative terminal of the battery
Re-configure the values in the volatile memory cf all systems.
Chest all vehicle functions.
> Explain the functions of the FI200 Pius systern to the customer and give the customer the User Manual
During Operation
° The product must be operated in accordance with operating instructions
Failure to use the product as directed might result in personal injury,
the environment
ial damage and'or damage to
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Pacer 200" Pages ot 15Installation
Installation Requirements.
Please note the requirements specified in the "Safety"ser
Summary of Installation Steps
mid
in of this document
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"0
Page 18FM200 Pius Harness Installation
Please read the ‘Safety”section, of this document, before installing the vehicle hamess,
‘Connect the
M200 Plus hamess wires according to the following table
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Page‘Starter Interruption
The FINZ00 Plus has an internal relay intended exclusively for the interruption of the vehicle § starter circuit
‘Conneat the two starter interruption wires to the corresponding terminals on the back of the vehicle unit. Cut the
‘vie from the ignitian loek to the starter relay and selder the starter interruption wires from the Fh{200 Firs unit
‘onto the-ends of the wires from the starter circuit. These wires can be connected either way
Note: The internal relay is intended only for interrupticn of the lov current stafter circuit This relay should not be
‘used to interrupt the fuel pump or ariy other coriponent of the vehicle electrical system. Fer high current starter
pplication, an adbitional relay will be required
‘Code Plug Socket Installation
Note: Please follow the instructions, regarding the positioning of preduct components, as contained in the “Sat
section, of this document.
The Code Plug Socket must be installed inside the passenger compartment or the driver cabin, to protect
it from possible damage by water or other environmental factors,
The Code Plug Socket should not be installed in or near the vertilstion or heating systems, which may
cause itto overheat,
The Gade Plug Scoket should be installed in a position where it will not be subjested to pressure, impact
or excessive vibration
Select the installation position carefully before proceeding
Mark and drill o cut the required hole
Remave the mounting olip from the socket
Remave the protection film from the adhesive surface of the foam ring and press it fimly against the back
of the interface.
Insert the suoket into the mounting hole and slide
sith the installation,
2 mounting eli inte pasition
Hole size = 13/16"- 20 mm
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vis 208 PagePositioning the FM200 Pius Unit
Note: Please follour the instructions, regarding the positioning of preduct components, as contained in the “Sataty
section, of this document.
> The F200 Plus must be installed insice the passenger compartment or the driver cabin, to protect it from
possible damage by water or other environmental factors.
‘The F200 Plus should nat be installed in or near the v
‘a overheat
‘The FN200 Avs should bé installed! in a position where it will not be subjected to pressure, impact or
excessive vibration
> Select the installation position carefully before proceeding with the installation
5 Mark ane! drill the required holes,
Route cables from the unit to the appropriate senders within the vehicle. Adcitional information can be
found in the ‘Harness Installation"section of this document.
* after connecting the system camponents and pertorming a system test, maunt the vehicle unit securely
making use of the optional metal armoured housing, if required. The armoured housing is available as 3
spare part and is used to protect against tampering
lation or heating systems. which may cause it
Signal Inputs
AnalogueiDigital Inputs
The F200 Plus is equipped with eight analogue/cigital inputs (11-18), which can be used to monitor either digital
‘or analogue signals. The eighth Analogue/igital inout (18) is shared with the fourth frequency input (F4}. Inout
signal voltage range and resolution is selectable from the Fleet Manager software, For cigital type inaut sionals,
sinitohing threshaids can be defined. in the software, whigh, when erossed, trigger an event that records the
specified data. Please refer to the “Specifications” and ‘Harness Installation” sections, of this dacumient, for more
cetails
Frequency Inputs
‘The F120 Plus has four frequeney inputs. which can be used to record frequency type signals. The fourth
frequency input (Fé) is shared with the eighth Analogue’Digital input (IB). Provision is made fore wide range of
signal types. Please refer to the ‘Frequency Input Jumper Selection”, ‘Harness Installation” and “Spec fications”
sections, of this dosument, far more details
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is 20 Page ur 18Frequency Input Jumper Selection
‘The FIIZ00 Fius can accept a large variaty of input signal types. To accommodate the many ocssibilities, 2acn
frequency input (FVSFD, F2/RPM, 3 and Fd) is provided! with = jumper for selecting the appropriate sional
range. These jumpers are located inside the FIM200 Plus as shown
ovacceeo GooGcoOOS
99009000 coD00000
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For most installations, the detault settings will be comect. If the FM200 Piusdloes not correctly detect the input
signal, the following table should be consulted to establish the applicable setting. If the signal type is unknown. try
the options in the arder shown below, starting from the tap. ‘The table shows the jumper position for each signal
pe. Each jumper oositien can be applied to each of the four frequency inputs, The last row in the table she
2 F3 jumper pesition when @ GPS is connected. A summary of this table is provided inside the lid of each
ead nal Range Symbol Inga Details
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Pacer 200"
Faye a8Power Outputs
External Relay Drives
> The FN1200 Aus has two extemal relay drive outputs (Relay Drive 1 & 2), which are suitable for controlling
external relays.
5 These outputs are controlled by the Fh!200 Plus and are configured in Vehicle Properties of the Fleet
anager application software,
‘The Relay Drive Outputs cannect to the qround side of an external relay.
> The maximum cumen, of the extemal relay is limited to 150mA.
Please refer to the “Specifications “and “Hames Installation"sections, of this oocument, for more details,
‘Speed Sender Power (VSPD}
nominal 11 volt de suppiy is provided specifically for powering a speed sensor, requiring extemal power.
SPD outout is internally current limited. Refer to the *FIMZ00 Plus Specifications” Seotion of this
document
This output is centrolies
application software
y the FIM200 Plus ancl is configured in Vehicle Properties of the Flest Manager
Positive Drive
+ The Positive Drive eurput supplies power to FIM200 Plus accessories
This output is controlled oy the FMZ00 Plus and is eonfigured in Vehicle Properties of the Fleet Manager
application software
Aevess to this qutput is via the WOO FNIZ00 Plus Serial Cable.
Refer to the Fh!200 Plus Snecifications” section of this decument.
Serial Communication
The FNI2O0 Plus is equiped with one TTL (S1) andl tua RS232 (32 & 93) serial ports.
+ The F200 Pius Serial Cable is required to connect to these ports.
Please refer io the "Sp ions" section, of this decument, and the FMI200 Plus Serial Cable
coeumentation for more details
Loading Device Drivers.
° The FIN200 Plus is supplied with only the Operating System loaded,
Before the unit can be configured, the Iatest version of FM200 Plus Device Drivers must be loaded.
» The latest Device rivers are contained in the latest version of the Fl Dealer Utility, which can be
downloaded from hia: gidev.com
Load Device Drivers onto effher a 258k Vehicle Plug, or 2584 Device Driver Plug, using the FM Dealer
Utility. Reefer ta the document ‘Haw To Use The Fh Dealer Utility”
Ingert the plug, containing the Device Orivers, into the vehicle ® code plug socket,
The device drivers will be loaded onto the FMZ00 Plus.
+ Refer to the document “FM200 Beep and Flash Codes" for an explanation of the audile and visible
signals, generated by the FI200 us,
Note: Make sure the dats transfer is complete lnefore removing the plug fram the sockat. Successful transfer is
hwo short beeps. If a cifferent keep sequenes is hears, data transfer was unsuccessful and must be
0.00 this, the vehicle plug must Se re-initialsed and the device divers reloaded anto the plug
‘Configuring Vehicle Properties
The configuration of the FikI200 Plus unit is specified in the Fleet Manager application sofware. It
includes the selection of devices connected to each input, and the events assaciated with data measured
on specific inputs.
‘Mare: details can be found in the Fleet Manager application software dacumentation. or online help
the vehicle configuration has been defined, itis loaded onta the Vehicle Plug and transferred to the
vehicle by inserting the plug into the vehicle’ code plug socket
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vis 208Please refer to-the document ‘F200 Beep and Flash Cades”for an explanation of the audible and wisible
signals, generated by the FIM200 Fius:
The latest documentation, finenware and application information can be obtained trem
bttothnew.cidew.com.
Setting the Real Time Clock
The Real Time Clock in the FMZO0 Plus must be set fo the local time. This is done using the blue Driver Plug and
either the FM Dealer Utility of Fleet Manager apolication software, The correct date and time is then leaded into
the FM200 Plus oy inserting the Driver Plug into the vehicle $ code plug socket.
‘Speed and RPM Calibration
‘Vehicle speed and RPM signals are calibrated using the violet calibration plugs labelled “SPD CAL" andl “RPM
‘CAL’, respectively. The calitrations ean be performed using either, the default settings on the ealitration plug, or
bby selecting specific values using the Fl Dealer Litlity. Before calibrating, the blue driver plug should be
initialised.
Engine Speed (RPM) Calibration
Default Settings
The "RPM CALplug is pre-programmed for use at 1000 RPN.
Disarm the system using the blue driver plug
Insert the ‘RPM CAL" violet plug into the code plug sockets
Start the engine
Increase engine speed to 1000 RPM and keop it constant for a few seconds.
Remove the violet plug from the socket.
‘The FN200 Pls will be calibrated to the engine speed of the vehicle
‘Custom Settings
The "RPI CAL"plug can be programmed with custom calisration values
Disarm the system using the blue driver plug
Measure the exact frequency of the RPM signal using the appropriate measurement tools
Set the “RPM CAL"plug to the measured frequency using the ‘FM Dealer Uiility"softare.
Disarm the system using the blue driver plug
Turn the ignition on.
Inger the calipration plug into the cade plug soeket,
The unit will beeo three times indicating that it has been caliorated successfully.
Vehicle Speed Calibration
Default Settings
The "SPD CAL" alug is ore-programmed for use over 10 meters. This value can be changed using
Unilty software. During ealioration, the LED will fash 2s speed pulses are rezeived, and the wait wi
perlels of one second! When the plug is removed, the Unit will Deep three times
Disarm the system using the blue plug
Drive to the beginning of a measured 10 mater distance,
Insert the violet plug labelled "SPD CAL" into the code plug socket
Drive the measured 10 meters.
Remrawve the viol
The FN200 Plus unit is now cai
¢ FM Dealer
beeg in
e vehicle interface,
rated with the correct distance to pulse ratio.
‘Custom Settings
Disarm the system using the blue plug
Drive to the beginning af a demarcated 10 meter distance.
Measure the exact distance ta pulse ratio using the appropriate measurement tools
Set the speed calibration plug “FD CAL"to the correct distance to pulse ratio using the FM Desler Utility
software.
Disarm the system using the blue driver plug and turn the ignition on,
Inger the calipration plug into the code plug soeket,
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vis 208The unit will bea three times indicating that it has been calibrated successfully.
Testing Installation
Test Drive
Disarm the system by inserting the blue plug inte the Code Plug socket
Wait forthe audibia signal.
5 Rettave the plug.
> Start the engine.
Garry out a test drive
Extract and Transfer Data
> Aber the test drive, tum off the ignition.
Wait forthe system to arm, indicated by LED. on the code olug socket, flashing
Insert the green vehicle plug into the code plug socket.
‘ Albeeo indicates the start of data transmission
* The LED on the cade plug socket flickers during data transfer.
A second begp indicates cata transmission is completa.
Remave the green vehicle plug
> Insert the vehicle plug into the dowmload module.
‘Transfer the data ta the PC using the Fleet Manager application software.
Consult the Fleet Manager application software decumentatian for further details.
Troubleshooting
> Alarge assortment of application information, in the form of Knowledge Base Articles (KBA$) can be
accessed from the Support section of: tts
‘Other apolication documents can be found on the Fleet Manager CD, or downloaded from
btto:tivnww.cidov,com.
‘The audible and visual signals generated by the FM200 Plus are described in the dacument:
and Flash Codes"
FMZ00 Beep
ented
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Maintenance
The FI200 Plus unit is maintenance-free,
| rtdty us esaawon tarot
ansesntae 9009 Faye atPlease ensure that the Code Plug sacket is kept clean and free of cust and dirt
FM200 Plus Specifications
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Note: All specifications are typical and are subject ta change without pricr natice.
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"0 Faye 1408Declarations
‘Type-Approval
This product conforms to the requirements of
TH245/EEC, as last amended by Directive 95/54
ype-appraval number: @1°72/245°95/54°255 1°00
022551
Declaration of Conformity
‘We declare on aur avn respansibilty that the product is in compliance with following nermfs) er documents:
DIN EN 55022 (11/2001)
DIN EN 81000.6-2 (08/2000)
Restrictlons.
° The F200 Plus is for use only in earthaound vehicles and vor
The FNI200 Plus must be powered from a battery source
* The FN200
‘30 meters.
signal wires should not exce!
VDO Part Numbers
ee Ceo
10. 723-002015 F200 Plus Kit
X38. 72E-002-080 FN200 Pus Vehicle Unit
x39. 723-002-081 $200 Pius Wiring Hamess
x39, 723-002-082 #200 Plus Senal Cable
98, 723-000-035 Code Plug 256k isame as FM200)
X38. 728-000-087 Cade Plug 98k (same as R200)
X39. 723-002-008 Driver ID Plug tsame 3s FIM200 ano F100)
x39-723-000-054 Passenger Plug
836.723-002-005 Cade Flug Harness
R36. 723-000-031 Tatal housing FMZ00/FN200 Flue
39. 728-000-078 Fleet Manager Application Sofware
239.723.002.008 Download Module
X38-724-002.086 F200 - GPS Interface
x39.723-002-028 Calibration Set (Vielat Code Flug set}
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