INSTALLATION GUIDE For PreSet Plus® SmartHub™, SmartTrack™ Asset Management, SmartAir™ TPMS, SmartAir™ Line Pressure, and SmartAir™ Axle Load Revision-A ConMet Digital Products
TABLE OF CONTENTS 1. Best Practices ..................................................................................................... 2 2. SmartAir™ Tire Pressure Monitoring System (TPMS) Overview .................. 3 2.1. 2.2. 2.3. 2.4. 2.5. TPMS Upfit Kit ............................................................................................................................................. 3 SmartAir TPMS Installation .............................................................................
5.5. 5.6. 5.7. 5.8. 5.9. Sensor Node Installation ........................................................................................................................... 32 Steer Hubs ................................................................................................................................................ 33 Drive Hubs ................................................................................................................................................ 34 Trailer Hubs ...
Keep in mind that this installation guide applies to ConMet Digital products only and should not be used in installing or servicing any other equipment. The information supplied here is for instructional purposes. It is not intended as a replacement for hub service manuals and hub installation instructions, which must be reviewed before use and service.
If installing the SmartAir TPMS as an upfit to an existing gateway, there are no additional steps beyond what is mentioned in this section. If you are installing the system in addition to a new gateway installation, please refer to Section 6.
Figure 2: Tire Positions 2.3. TPMS with Automatic Tire Inflation System (ATIS) integration If the trailer is equipped with an Automatic Tire Inflation System (ATIS), and the air hoses are not equipped with check ports, the hoses will need to be upfitted with integral check ports to accommodate the TPMS sensors. Depending on the system design, the hoses may be secured to a fitting at the center of the hub cap or there is a rotary union integrated into the sides of the hub cap.
Figure 2: ATIS/TPMS Hose Integration 2.4. Alternate TPMS Sensor Installation Method Depending on the ATIS configuration, it may be more suitable to install the TPMS sensors with interconnected Tee fittings at the valve stem. These should also be hand tightened only. Tools should never be used as overtightening can potentially damage hose or valve stem threads, (figure 3). Figure 3: ATIS/TPMS T-Fitting Integration 2.5. SmartAir™ TPMS Checklist Item Description 1.
3. SmartTrack™ Asset Management 3.1. Gateway Overview SmartTrack Asset Management is a service provided from data collected by the ConMet gateway, which can be upfit to a tractor or trailer and can pair with other ConMet Digital sensors. The gateway sends the captured data to the ConMet cloud database, where it can be viewed using the ConMet digital portal or accessed via the ConMet application program interface (API) suite to a customer’s data portal or a preferred telematics provider. 3.2.
Zip ties Cable management 3/4” Self-tapping screws Gateway mounting hardware Circuit expander (fuse tap) Tractor power connection method 3.3. Additional Tools and supplies not included It is expected that the installer will have all the following common additional installation supplies and tools onhand; they are not provided with the upfit kit but may be necessary to successfully install the gateway device. There may be scenarios that require specialized tools that are not listed here.
The tandem slide assembly, or bogie, can be moved by the driver to accommodate load distribution and is typically where the ABS/AUX power source is located. Therefore, when mounting to an area that is stationary such as the floor or support beams, the power harness should follow the expansion harness to accommodate the movement in the slide assembly. A suitable location would be beyond the last position of the tandems.
Figure 6: Beyond last position of bogie 3.4.2. Trailer - Gateway Sub Trailer Wiring The wiring diagram below is applicable to trailer gateway installations. All the gateway harnesses have been connectorized for a seamless installation on a trailer. This configuration can be used for SmartAir TPMS as well as SmartHub integrations. Once the Gateway has been securely mounted, make the following connections referenced in figure 7. 1. Secure the 6-PIN connector (1) from the Gateway to the 6-PIN Splitter (2).
1. Gateway power harness 2. 2-way splitter to marker light and ABS pass-through cables 3. Trailer maker light pass-through cable 4. Jumper cable to 5-PIN ABS pass-through cable 5.
3.4.3. Gateway Status Lights After the wiring connections have been completed you should then confirm that the gateway is online. To do this, observe the status lights that are located at the top left corner (figure 8). Please refer to the status light conditions in figure 9.
3.4.4. Tractor - Gateway Mounting Using the proper plastic panel pry tools, identify a mounting location for the gateway under the front dash area that provides enough space to fully reassemble the dash back to its OEM condition. The preferred mounting location is typically near power and ignition circuits and away from any moving parts. It should never be secured to serviceable panels or in an area that is surrounded by metal as the gateway needs a clear path to the sky for optimal performance (figure 10).
Figure 12: Recommended Mounting Locations Location Potential Power Sources 1. Driver front top dash Behind instrument cluster 2. Driver front under dash Ignition switch, brake switch 3. Center front console Constant ACC plug, brake switch 4. Center front radio Radio or navigation 5. Center front top dash Fuse panel 6. Passenger under dash Passenger fuse panel 3.4.5.
Figure 13: 12V Circuit Expander If the power or the switched circuit needs to be extended, the wire should be of adequate gauge for the current requirements. Additionally, all wire connections, and/or removed wire insulation during circuit validation, should always be sealed prior to reassembling your access area. The preferred ground connection method is one self-tapping screw through a ring terminal crimped onto the black ground wire from the gateway and screwed into chassis ground (figure 14).
Figure 15: Wiring Harness 3.5. Gateway Installation Checklist Item Description Check 1. Adequate gateway cable lengths have been considered to allow movement of tandem axles on trailers 2. The gateway has been secured with a mechanical method to prevent movement and away from moving parts 3. All power and ground connection sources have been validated with a digital multimeter prior to connection 4. All wire to wire connections have been made with the provided connectorized solution 5.
3/8"-16 x 1/4" Hex cap bolt Bracket mounting option 5/16"-18 x 3/4" Self-tapping hex screw Bracket mounting option 3/8-16 Nylon locking nut Bracket mounting option (2) ¼” PTC tee fitting Air line connection method 4.3.
Figure 16: Proper PSM Orientation Figure 17: PSM Mounting Bracket 10089005 A 05-2021 Installation Guide for ConMet Digital Products Page 18 of 37
4.4.2. Trailer - Pneumatic Sensor Module Wiring Method The wiring diagram below (figure 18), is applicable to Pneumatic Sensor Module trailer installations. All the harnesses have been connectorized for a seamless installation on a trailer. If this is not an upfit to a preinstalled gateway and a new gateway is being installed, please refer to Section 3. Once the Gateway has been securely mounted, make the following connections listed below: 1.
Figure 18: Pneumatic Sensor Module Wiring 10089005 A 05-2021 Installation Guide for ConMet Digital Products Page 20 of 37
4.4.3. Trailer - Pneumatic Sensor Module Plumbing Once the air has been purged from the system, locate your air line connection points both for an air spring as well as the supply air line. Next, cut your supplied air lines to the proper length that will reach the air supply input labeled “galley” which is on the same side as the connector and the primary suspension input port labeled “port 3” on the mounted PSM (figure 19).
Figure 20: Recommended Trailer PSM Plumbing Finally, check for leaks at all your connection points with soapy water. If bubbles are present at any of the connection points, the air line as well as fitting should be inspected and re-installed per guidelines. 4.4.4. Tractor - Pneumatic Sensor Module Mounting Identify a mounting location for the Pneumatic Sensor Module (PSM) inside the cab of the tractor.
There are several locations that can be used in the cab area of a truck (figure 21) where you will typically have access to a constant power source. Figure 21: Potential PSM Mounting Locations Location Potential Connection Points 1. Driver front top dash Behind instrument cluster 2. Driver front under dash Ignition switch, brake switch 3. Center front console Constant ACC plug, brake switch, media 4. Center front radio Radio or navigation 5. Center front top dash Fuse panel 6.
Figure 22: Proper External PSM Mounting Orientation If mounting externally, the PSM should be secured to the provided bracket assembly using three zinc plated 3/8” x 1” bolts and nylock nuts. The bracket can then be secured to the trailer framing with two 5/16”-18 x 3/4” Self-tapping hex screws (figure 23). The PSM can also be mounted without the bracket directly to a surface that has adequate space behind it and will not impede any moving parts using the self-tapping screws.
1. It’s preferable to use an open fuse socket but not all will be configured to supply power. If using an open fuse socket in the tractor, DO NOT install a fuse in the lower part of the circuit expander. 2. If using an open socket in the fuse panel, it’s important to identify which side of the socket is providing power so that you can orient the circuit expander correctly. 3.
Figure 25: Exterior Tractor Wiring If the 12V power circuit needs to be extended, the wire should be of adequate gauge for the current requirements. The extension should be made using the proper weatherproof adhesive lined butt connector. An alternate ground connection method is one self-tapping screw through a ring terminal crimped onto the white ground wire from the (PSM) and screwed into chassis ground (figure 26).
Figure 27: PSM Wire Harness 4.4.7. Tractor - Pneumatic Sensor Module Plumbing Once the air has been purged from the system, locate your air line connection point for the air springs. Next, cut your supplied air line to the proper length that will reach the primary suspension input port on the mounted PSM labeled port 3. The supplied air lines should be cut with a proper pneumatic air line cutting tool at a 90° and should be free of debris and scarring on the outside of the line.
Figure 28: Trailer PSM Plumbing You should be mindful of sharp edges as well as moving parts when routing and securing air lines. It’s a best practice to route the lines along existing harnesses and secure them with zip ties. If the PSM is mounted inside the cab of the tractor, it will be necessary to exit the tractor to gain access to your air line connection point. It is preferable to use an existing grommet or boot in the firewall providing there is enough space to accommodate the air line.
1. 4.5. SmartAir™ Line Pressure / Axle Load Checklist Item Description Check 1. Adequate PSM cable lengths have been considered to allow movement of tandem axles 2. The PSM has been secured in the correct orientation with a mechanical method to prevent movement and away from moving parts 3. All power and ground connection sources have been validated with a digital multimeter prior to connection 4. All wire to wire connections have been made with the provided connectorized solution 5.
Figure 30: PreSet Plus® SmartHub technology depiction 5.2. Installation Supplies Here you will find a list of tools and supplies that are needed to perform a complete SmartHub installation, including sensors and gateways. As the installer, you should confirm that you have the necessary tools and supplies prior to scheduling an installation. 5.3.
Figure 32: SmartHub Upfit Kit Item Purpose Gateway Reports TPMS, SmartHub or Axle Load / Air Line Data Power cable Connectorized inputs for power and ground (2) 10’ extension harnesses For trailer marker light input ABS pass-through cable Gateway power and ground connection method for trailer Zip ties Cable management 1” Self–tapping screws Gateway mounting hardware Circuit expander (fuse tap) Tractor power connection method Note: The sensor nodes are specific to each hub type - steer, drive
Digital multimeter Verifying circuits Wire brush or wire brush attachment for rotary tool Preparing hub surfaces for application Cordless drill For use with self-tapping screws T10 Torx bit with ¼” drill drive For use with self-tapping screws T25 Torx bit Interior dash disassembly / reassembly Socket set Asset disassembly / reassembly Wire strippers / cutters Gateway wiring connections Utility knife Customizing harness Plastic panel pry tools Removing interior trim panels Supplies Purpose
Figure 33: SmartHub Sensor Activation 5.6. Steer Hubs For installation of a SmartHub sensor on a steer hub, first locate the wheel pilot closest to the ground. Sensor nodes should only be adhered directly to a metal surface. So, if this is a painted iron hub, prepare the sensor mounting surface by using a wire brush or wire brush attachment for a drill to remove paint from the surface of the wheel pilot. Use a clean cloth to remove all residue (oil, road grime, rust, etc.
Apply the adhesive to the bottom of the shim and position the sensor node on the wheel pilot closest to the ground with the narrower side pointing left when facing the hub. Secure the sensor to the hub by firmly holding it in place for no less than 40 seconds on the wheel pilot against the flange. The sensor node should nest into the corner between the wheel pilot and flange (figure 35). The vehicle should remain stationary for at least 1 hour. Figure 35: Steer Hub Sensor 5.7.
Figure 36: Drive Hub Sensor 5.8. Trailer Hubs For trailer hub installations, first locate the sensor mounting position. It can be positioned anywhere on the hub barrel that is not in line with the fill port. It should also be centered and not in line with a wheel stud as this could impede wheel removal or tool access to the lugs. Sensor nodes should only be adhered directly to a metal surface.
Figure 37: Trailer Hub Sensor 5.9. SmartHub Installation Checklist Item Description 1. The hub sensor mounting area has been adequately cleaned prior to adhering the sensor to the hub 2. The two-part burst pack has been adequately mixed together 3. All applicable smart hub sensors have been oriented correctly, not in line with a fill port and/or centered between wheel studs 4.
6. FCC Changes or modifications not expressly approved by the party responsible for compliance could void the user’s authority to operate the equipment. This device complies with part 15 of the FCC Rules. 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.
