Table of Contents

Table of Contents........................................ ................................................................ 1

Calibration Unit ........................................... ................................................................ 1

Control Unit ................................................BTC ......................................................... 2

Mobile Test Computer ................................MTC ........................................................ 3

Test Computer 1319 ..................................TC ........................................................... 4

Hand Test Computer ..................................HTC ......................................................... 5

Rolling Road Test Computer ......................ATC ......................................................... 6

Stationary Test Computer ..........................STC ......................................................... 7

Calibration Test Stand ...............................(Nixie Display) ......................................... 8

Calibration Test Stand ...............................(LED) ....................................................... 9

Diagnoser with Additional I/O Module......... .............................................................. 10

Distance RPM Constant Testing Device..... .............................................................. 11

Rotary Frequency Constant Testing Device .............................................................. 12

Power Supply Unit (9 voltages)................... .............................................................. 13

Power Supply Unit (3 voltages)................... .............................................................. 14

Rolling Road Test System .........................APS ....................................................... 15

Rolling Road Test System .........................APS ....................................................... 16

Clock-Tester................................................ .............................................................. 17

PA 2000 ...................................................... .............................................................. 18

Tachograph Repair System TRS ................ .............................................................. 20

Calibration Test Stand ...............................FTP 88 .................................................. 21

Pulse Counter ............................................ZG 20/84 ............................................... 22

Frequency Generator .................................FG 94 .................................................... 23

Calibrated Digital Test Stand .....................DFG 1.................................................... 24

Motometer HBG 10 ..................................... .............................................................. 25

BA00-1602-322002 © Continental Automtive GmbH Page 1

BA00-1602-322002 © Continental Automtive GmbH Page 2
Calibration Unit
KBE 1602-32
Operating Instructions
Imprint

© 03/2011 Continental Automotive GmbH

Responsible for the contents:

Continental Automotive GmbH

Heinrich Hertz Str. 45
D-78052 Villingen-Schwenningen

We reserve the right to make modifications in the technical details of the description, data
and illustrations in these operating instructions.

Page 2 © Continental Automotive GmbH BA00-1602-322002

Table of Contents
1 Important Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2 General Product Description General . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
2.1 Calibration Unit Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 List of the Calibrateable Testing Devices . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.3 Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
2.4 Display. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
2.5 Inputs / Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
2.6 Representation of a Calibration Sequence . . . . . . . . . . . . . . . . . . . . . . . 12
3 Delivery Content . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
3.1 Calibrating Cable 1602-78-120 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
3.2 Calibrating Cable 1602-78-121 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
3.3 Calibrating Cable 1602-78-122 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3.4 Calibrating Cable 1602-78-123 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3.5 Calibrating Cable 1602-78-124 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.6 Retrofit Set Clock Test 1601-89-005-00 . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.7 Retrofit Set CTC X12-160-278-003 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.8 Retrofit Set Calibration ATC-PC NG X12-160-278-005. . . . . . . . . . . . . . 19
3.9 CTCII Calibration Set A2C59512982 . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
3.10 Measuring Accessory Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.11 Test Encoder A2C53320966 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
3.12 Disk with Certificates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
4 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
4.1 Calibration Data KBE 1602 #... . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
4.2 Calibration Label for Calibration Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

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Page 5 © Continental Automotive GmbH BA00-1602-322002
 Important Safety Instructions

1 Important Safety Instructions

Before performing initial operation on the advice, please read the safety and operating in-
structions carefully. In this way, personnel are protected and damage to the device is avo-
ided. Deliver these operating instructions to all other users of the device so that they are
also informed of all functions and information concerning the device.

• Scope
The device may only be used for the purpose for which it was manufactured. The
manufacturer may not be held responsible for damages occurring in the course of in
proper operation.

• Danger of Explosion
Electrical devices may not be used in potentially explosive areas. Do not use the de-
vice in the vicinity of inflammable liquids or gases.

• Voltage Supply
The device may only be connected to the mains voltages listed on the device or in
the operating instructions.

• Mains Cable
When laying the cable make sure that it does not pose a risk of tripping and that it
cannot be damaged by other objects. Special care should be take at the point of
emergence from the device, plugs, and sockets. If the machine is not to be used for
an extendet period of time, remove the mains plug from the socket.

• Ventilation
In order to guarantee a malfunction-free operation of the device and to protect it from
overheating, the device has ventilation apertures. These apetures must never be
blocked or covered.

• Moisture and Dampness

Prevent the penetration of moisture and dampness. The device may not be operated
in the vicinity of water. Do not place any filled vessels (drinking cups, etc.) on the
device so that no lipuid penetrates into the device.

• Soiling
Protect the device from the penetration of dust and dirt.

• Operating Note
Avoid excessive shocks and vibrations. Do not operate the keys with sharp object.

• Heat
The ideal ambient temperatur is + 25°C. The device must be protected from direct
sunlight and may not be installed in the vicinity of heat sources, such as heater fans,
heaters, furnaces, or other devices which creat heat.

• Electricial Shocks
Dangerous electrical short circuits can be caused by metal objects, such as screws
or wires, getting into the device.

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Important Safety Instructions

• Opening of Device
The device corresponds to the required safety regulations. Only authorised person-
nel may open the device. There is danger of electrical shock when parts on the in-
side of the device are touched.

• Cleaning
Pull the mains plug before cleaning the device. Use no volatile solvents, such as al-
cohol, paint thinner, or naphtha, and no abrasive cleaning agents when cleaning the
device.

• Maintenance and Repairs

The device may be repaired or maintained only by qualified service personnel. The
user may perform no maintenance on the device other than the tasks described in
the operating instructions.

• Accessories
The accessories may not be modified. Never use accessories which were not re-
commended by the manufacturer, as accidents and breakdowns could result.

Page 7 © Continental Automotive GmbH BA00-1602-322002

 General Product Description General

2 General Product Description General

2.1 Calibration Unit Features

The introduction of a quality assurance system is becoming more and more important.
This is determined by numerous internal and external influences and stipulations. The ve-
hicle manufacturers and their affiliated workshops are increasingly implementing quality
assurance systems with official, verifiable quality standards.
The testing devices used in workshops have a high quality rating. The testing devices
must be monitored, calibrated, and serviced in order for the product or system, this means
that the measuring results of a series compaison measurements must be referred to a sui-
table measuring standard.
Portable testing devices should preferably be checked in a calibration laboratory. If the
necessary testing devices must be permanently present and available in the workshops,
they should be calibrated there. In addition, stationary test stands cannot be brought into
a laboratory for calibration and should also be locally calibrated
For these reasons, a portable calibration unit has been developed for the calibration of the
Siemens VDO Automotive AG testing devices. By means of this calibration unit, it is pos-
sible to calibrate all Siemens VDO Automotive AG devices listed under Section 2.2.
A great advantage of the calibration unit is that no additional testing devices or auxiliary
units, such as power supply units, voltmeters, or frequency counters, are required for local
calibration. All calibrating signals, including the voltage supply of the portable testing de-
vices, are provided by the calibration unit.

2.2 List of the Calibrateable Testing Devices

The following testing devices can be calibrated by means of the calibration unit.

1602-04-000 Mobile test computer, MTC

1602-31-000 Test computer 1319, TC
1602-19-000 Hand test computer, HTC
1601-26-000 Rolling road test computer, ATC
1601-25-000 Stationary test computer, STC
1601-17/0 Calibration test stand (design with Nixie dispaly)
1601-17/5 Calibration test stand (design with LED)
1602-02-000 Diagnoser with additional I/O module
1602-10-000 Distance RPM constant testing device (WK tester)
1602-12-000 Rotary frequency constant testing device (DFK tester)
1601-18-000 Power supply unit
1601-14-000 Power supply unit
1601-21-000 Rolling road test system (double roller, Kienzle roller, performance test
1601-21-000 Rolling road test system (adaption to brake test stand)
1602-13-000 Clock tester
X12-052-000-005 Calibration test stand, FTP 88
X12-340-016-001 Puls counter ZG 20/84
X12-397-049-001 Frequency generator ZG 94
X12-052-000-004 Calibrated Digital Test Stand DFG 1
1601-06 Tachographen Reparatur System, TRS

X12-140-062-001 HBG 10 Motometer

1601-26-050 Rolling road testcomputer, PC-version
PA 2000

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Controls

2.3 Controls

Back side

1 Shift key for speed (3.2 km/h or 50 km/h)

2 Shift key for automatic or manual mode
3 Start key for 100 pulses
4 Shift key for LS1 or LS2 light barrier
5 Shift key for ATC or MTC mode
6 Clear button
7 230 V mains switch
8 230 V mounting jack

Page 9 © Continental Automotive GmbH BA00-1602-322002

 Display

2.4 Display

11 Display for voltage

12 LED for level height
13 Display for frequency and counter
14 Grey button for switching over „COUNT“ to „FREQ“
15 Red button = reset counter
By pressing the grey button the display will be switched over from counter-mode to fre-
quency mode. The mode is indicated for 3 sec. by the text „COUNT“. By pressing the grey
button again within these 3 sec. the display will be switched over to the frequency-mode.
This will be indicated by the text „FREQ“. Switching over from frequency to counter follows
accordingly.

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Inputs / Outputs

2.5 Inputs / Outputs

20 - Ground
21 + 24 V output voltage
22 + 24 V onboard power supply plug, output voltage
23 Test jack, input / output
24 E2 banana socket, test jack input
25 E1 3.5-mm jack bush, test jack input
26 A2 3.5-mm jack bush, test jack output
27 A1 2-mm jack bush, test jack output
28 V voltage test jack
29 - Ground, voltage test jack

Page 11 © Continental Automotive GmbH BA00-1602-322002

 Representation of a Calibration Sequence

2.6 Representation of a Calibration Sequence

4. Test Set-Up: Calibration of Manual Distance Pulse Recording Brief Description

4. Test Set-Up: Calibration of Manual
Distance Pulse Measurement Technical Data
Before setting up the test, make sure that the mains switch is at the „0“
(=mainsof symbol.
Back side Function Test

Calibration Sequence
Mains switch
Certificate
Connection

A Calibration unit 1 Shift key for speed=3.2 kph or 50 h

B Calibration Cable 1602.78.120 2 Shift key for autom or manual mode
C MTC cradle 4.Shift key for ATC or MTC mode
D BTC I 5 Shift key for LS1 or LS2 light barrier
E I/O testing cable (MTC component) 14 Shift key for switch frequency dis-
play / counter display

Calibration Sequence - Overview (Sample Representation of the MTC Testing

Device)
Calibration instructions are available for each testing device to be calibrated. The calibra-
tion sequence remains the same for all testing devices and consists of the following steps.

1. Short Description
All controls and display elements of the testing device are explained in the short descrip-
tion. The detailed operating instructions for the testing device can be found in the respec-
tive manual

2. Technical Data
Tabular listing of the technical data, such as voltage, current, display, interfaces, measu-
ring rages, etc.

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Representation of a Calibration Sequence

3. Function Test
If a function is required before the actual calibration procedure, this test will be explained
in detail in the „Function Test“ chapter.

4. Calibration Sequence
According to the tested device, the calibration sequence can consist of serveral steps.
Each calibration step consists of:

a.) Test set-up for the corresponding calibration procedure.

Diagram of the calibration unit with the tested device and any necessary aids, such
as calibrating lines, the test lines of the tested device used, the test encoder, etc.

b.) Measuring preparation for calibration unit

The required setting of the calibration unit for the correct calibration of the respective
tested device is described here.

c.) Measuring preparation for the tested device

Here, the required setting of the corresponding tested device for the respective ca-
libration procedure is described.

d.) Calibration sequence

In this chapter, the calibration sequence procedure is described. In addition, the
measuring values which must be entered into the cerificate provided for the tested
device will be listed.

e.) Concluding tasks

In the „Concluding Tasks“ chapter, a description is provided how the calibrating label
must be made and onto which part of the tested device it is to be attached.

5. Certificate
A sample cerificate is located in Appendix for each set of calibration instructions. Empty
cerificates for all testing devices can be found in the last thumb-index of the notebook.
These certificates can be copied and filled out at the calibration site.

Page 13 © Continental Automotive GmbH BA00-1602-322002

 Delivery Content

3 Delivery Content
The SDS calibration unit is stored in a stable aluminium case, which contains a set of ope-
rating instructions for the calibration unit and a set of calibration instructions for the testing
devices, in addition to all necessary test lines and the test encoder. All calibration certi-
ficates are also located on a 3.5“ disk. 50 calibration labels which can be reordered as
required are also included in delivery.

1 piece Notebook with 31 thumb-indexes containing:

Calibration unit operating instructions
Tested device calibration instructions
Tested device certificate
1 piece Calibrating cable 1601-78-120-00
1 piece Calibrating cable 1601-78-121-00
1 piece Calibrating cable 1601-78-122-00
1 piece Calibrating cable 1601-78-123-00
1 piece Calibrating cable 1601-78-124-00
1 piece Measuring accessory set
1 piece Test encoder 1602-0118-000-000
1 piece 3,5" disk with tested device certificates
50 pieces Calibration labels 1602-51-124-00

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Calibrating Cable 1602-78-120

3.1 Calibrating Cable 1602-78-120

The following tested devices can be calibrated in connection with the calibration unit and
the calibrating cable:

1602-04-000 Mobile test computer, MTC

1602-19-000 Hand test computer, HTC
1601-26-000 Rolling road test computer, ATC
1601-21-000 Rolling road test system (APS) (double roller, Kienzle roller, per-
fomance test stand)
1601-21-000 Rolling road test system (APS) (adaptation to brake test stands)

brown
yellow
green

black
white
red

yellow
brown

green
white

grey

1 Sub D plug to calibration unit

2 Plug with bayonet nut for ATC, MTC, TC
3 Terminal (rd), brown cable (+ 24 V)
4 Terminal (bk), white cable (R - pulses)
5 Terminal (bk), green cable (L - pulses)
6 Terminal (bk), yellow cable (R - pulses 0 V)
7 Terminal (bk), grey cable (0 V)

Page 15 © Continental Automotive GmbH BA00-1602-322002

 Calibrating Cable 1602-78-121

3.2 Calibrating Cable 1602-78-121

The following testing devices can be calibrated in connection with the calibration unit and
the calibrating cable:

1602-02-000 Diagnoser with additional I/O module

1602-12-000 Rotary frequency constant testing device (DFK)

brown

green

1 Sub D-plug to the calibration unit

2 Amp bush for diagnoser
3 DIN plug for rotary frequency constand testing device (DFK)

BA00-1602-322002 © Continental Automotive GmbH Page 16

Calibrating Cable 1602-78-122

3.3 Calibrating Cable 1602-78-122

The following testing devices can be calibrated in connection with the calibration unit and
the calibrating cable.
1601-25-000 Stationary test computer STC
1602-13-000 Clock tester
X12-052-000-005 Calibration test stand
brown
FTP 88
green
white

1 Sub D plug to calibration unit

2 AMP bush for 8-pulse/4-pulse test cable of the STC / FTP88
3 DIN plug to clock tester

Page 17 © Continental Automotive GmbH BA00-1602-322002

 Calibrating Cable 1602-78-123

3.4 Calibrating Cable 1602-78-123

The following testing devices can be calibrated in conjunction with the calibration unit and
the calibrating cable. The calibrating cable connected to test encoder for calibration of me-
chanical drive.
1601-25-000 Stationary test computer STC
1601-17/0 Calibration test stand
1601-17/5 Calibration test stand
brown
black

blue

1 Sub D plug to calibration unit

2 Adaptation to test sensor
3 Internal wiring

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Calibrating Cable 1602-78-124

3.5 Calibrating Cable 1602-78-124

The following testing devices can be calibrated in conjunction with the calibration unit and
the calibrating cable (calibrating cables 1602-78-120 and 124 are required for calibration):
1602-31-000 Test computer 1319, TC

1 2-pole mode plug

2 Banana plug

3.6 Retrofit Set Clock Test 1601-89-005-00

3.7 Retrofit Set CTC X12-160-278-003

• Calibration cable Impulse

• Calibration cable light barrier

3.8 Retrofit Set Calibration ATC-PC NG X12-160-278-005

3.9 CTCII Calibration Set A2C59512982

• Calibration cable impulsr

• Calibration cable light barrier
• Calibration cable Roller Interface Module

Page 19 © Continental Automotive GmbH BA00-1602-322002

 Measuring Accessory Set

3.10Measuring Accessory Set

Consisting of:
2 terminal test probes with gripping pliers
2 test probes with elastic insulating sleeves
2 highly flexible measuring lines, cross section of 1 mm2 and 1 m length
Each set of tools is in red and black.

3.11Test Encoder A2C53320966

The test encoder is required for the calibration of the mechanical drive of the STC,
Calibration Test Stand 1601-17/0, 1601-17/5 and FTP 88

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Disk with Certificates

3.12Disk with Certificates

A disk onto which all of the tested device certificates are stored in Winword 6.0 format is
included in the supply schedule.
Tree Structure on disk:

Page 21 © Continental Automotive GmbH BA00-1602-322002

 Technical Data

4 Technical Data
Voltmeter Display 5-digit LED
Charakter height: 14,2 mm
Measuring range +/-200mV - +/-200V
Temperature range -10 °C bis 50 °C
Temperature coefficient < 100 ppm
Display accuracy: 0,1% und
+ / - 1 digit across entire measuring
range at 25 °C

Frequency / Impulse Counter Display 6-digit LED

Character height 14,2 mm
Frequency measuring range
1 Hz to 20 kHz
Counter 1 -999999 pulses
Temperature range -10 °C to 50 °C
Temperature coefficient < 100 ppm
Display accuracy 0,1% and
+ / - 1 digit across entire measuring
range at 25 °C

A1 frequency output 250 Hz

Pulse width 2000 µs
5 V max. 1 mA
Temperature coefficient< 8 ppm

A2 frequency output Frequency output f max = 1,2 kHz

5 V max. 1 mA
Temperature coefficient < 8 ppm

E1, E2 frequency inputs Frequency input f max = 20 kHz

5 V max. 1 mA
U - Low = 0 - 2 Volt,
U - High = 2,5 - 20 Volt

Interfaces 8 V sensor supply

max. 25 mA

Voltage output 24 V DC
max. 1A

Mains voltage 230 V AC

Power consumption approx. 250 mA

Operating temperature + 0 °C to + 50 °C

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Calibration Data KBE 1602 #...

4.1 Calibration Data KBE 1602 #...

In order to guarantee the functional safety and accuracy of the calibration unit, it must be
calibrated by the manufacturer yearly.
Before calibration unit can be calibrated, it must be warmed up for at least 30 minutes.

In order to calibrate the voltage metering function and frequency outputs and inputs, the
following basic setings must be set on the calibration unit.

• After the voltage has been switched on, the value 0.00 must be shown in the fre-
quency display. If not, switch to the frequency mode by means of the grey „C“ key
(by pressing two times).
• The „D“ switch must be set to 50 km/h or 3.2 km/h, according to measurement
• The „E“ switch must be set to „Automatic“.
In order to calibrate the calibration unit´s counter input, the following basic settings must
be changed on the calibration unit.

• Switch witch the grey „C“ key into the counter mode. (by pressing two times)
• The counter can be reset by pressing the red „B“ key.

DES ACT Tolerance

Item 1 Inputs for voltmeters 5V ± 0,05 V

12 V ± 0,05 V

24 V ± 0,05 V

Item 2 Frequency input E2 10 Hz ± 0,1 Hz

100 Hz ± 0,1 Hz

1000 Hz ± 0,5 Hz

Item 2 Counter input E2, 1000 p, scaler 8 = 125 Imp. ± 1 Impuls

Output voltage (at UMAINS= 220 V/AC, idling) 24 V ± 2,5 V

Crystal adjustment (Stability ± 5 ppm) TP 1 MHz ± 0,2 Hz

Page 23 © Continental Automotive GmbH BA00-1602-322002

 Calibration Data KBE 1602 #...

Sub D jack PIN 5, 15, 16 50 km/h 3,2 km/h

Complementary - Puls

DES ACT DES ACT

f = 1388,888 Hz f = 86,805 Hz

t t = 720,000 µs t = 11520,000 µs

Diagr. 1 allowed difference +/-0,001Hz +/-0,001Hz

Sub D jack PIN 7, output A2

Diagnostic pulse

DES ACT DES ACT

f = 69,444 Hz f = 4,34027 Hz

t t = 14,40000 ms t = 230,4000 ms

Diagr. 2 allowed difference +/-0,001Hz +/-0,00001Hz

Sub D jack PIN 20, 10

Light barrier

DES ACT DES ACT

f = 3,47222 Hz f = 0,217013 Hz

t t = 288,000 ms t = 4,6080 ms

Diagr. 3 allowed difference +/-0,00001Hz +/-0,00001Hz

Output A1

Pulse 2000 µs

DES ACT

t = 2000 µs

allowed difference +/-1µs

t

Diagr.4

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Calibration Data KBE 1602 #...

Sub D jack PIN 9

Clock test

DES ACT

t = 1,000 sec

Diagr. 5 allowed difference +/-0,000001sec

Sub D jack PIN 13

Level display: green LED in front panel
Voltage at VG jack > 5,5 Volt, LED has to light up
Voltage at VG jack < 4,8 Volt, LED must not light up. Switching threshold: Volt

Sub D25 jack

Pin 1, 2, 3 and Banana plug black > + 24V
Pin 23, 24, 25 and Banana plug red >GND Voltage ACT: Volt

Page 25 © Continental Automotive GmbH BA00-1602-322002

 Calibration Label for Calibration Unit

4.2 Calibration Label for Calibration Unit

When the calibration procedure has been completed, the calibration unit receives a cali-
bration label on which the valid duraton of the calibration is marked

Year Month
The date of validity is marked by cutting out or (marking) the corresponding month an
year fields on the calibration label.

The calibration label must be attached to the back side of the calibration unit. The surface
onto which the calibration label is to be attached must first be cleaned.
Back side of the Calibration Unit

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Control Unit BTC

BTC I / BTC II / BTC III / TKG

Testing Instructions
Table of Contents
1 BTC I, BTC II, BTC III, TKG Device Description . . . . . . . . . . . . . . . . . . . . . . . . .4

2 BTC I, BTC II, BTC III, TKG Testing Instructions. . . . . . . . . . . . . . . . . . . . . . . . .5

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 BTC I, BTC II, BTC III, TKG Device Description

1 BTC I, BTC II, BTC III, TKG Device Description

Key Assignment for BTC I, ( MTC, STC, TC ) BTC III, TKG.

= Cursor control

= Cursor control

= Enter key

= Shift key:
Letters/numbers

=Function keys

= Special keys

= Special key ( Clear )

Key Assignment for BTC II ( ATC ).

The keyboard of the BTC II corresponds to that of the hand terminal shown above.
The F5 through F12 function keys are assigned in accordance with the ATC program.

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BTC I, BTC II, BTC III, TKG Testing Instructions

2 BTC I, BTC II, BTC III, TKG Testing Instructions

The following tests are to be performed by means of the service program:
1. Check state of storage battery charge.

2. Carry out display test.

Procedure:
- Call service program by means of F12 key.
- Proceed with key.

- Selected BTC self-test by means of cursor key.

- Proceed with key.

- Cursor is blinking at system memory battery.

- Proceed with key.

- Display of memory battery status appears.

- Proceed with key.

- Continue to LCD menu by means of cursor key.

- Proceed with key.

- Continue to LCD charakter menu by means of cursor key.

- Proceed 2x by means of key.

- The display test can be cancelled at any time by means of the key.
- Return to the test menu by pressing the key repeatedly.

Page 5 © Continental Automotive GmbH BA00-1602-322002

Mobile Test Computer MTC

MTC 1602-04
Calibration Instructions
Seite 2 © Continental Automotive GmbH BA00-1602-322002
Table of Contents
1 Brief Description (BTC I) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.1 Brief Description (Cradle 1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3 MTC Function Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
4 Test Set-Up: Calibration of Manual Distance Pulse Measurement . . . . . . .8
4.1 Measuring Preparations of the Calibration Unit. . . . . . . . . . . . . . . . . . . . . 9
4.2 Measuring Preparations of the MTC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.3 Calibration Sequence for Manual Distance Pulse Measurement . . . . . . . 9
5 Test Set-Up: Calibration of Automatic Distance Pulse Measurement . . . .10
5.1 Calibration Sequence for Automatic Distance Pulse Measurement . . . . 11
6 Test Set-Up: Calibration of the k Pulse . . . . . . . . . . . . . . . . . . . . . . . . . . .12
6.1 k Measurement/Setting Program. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7 Test Set-Up: Calibration of km/h Control. . . . . . . . . . . . . . . . . . . . . . . . . .14
7.1 Calibration Sequence for km/h Control (k = 2500 pulses/km) . . . . . . . . . 15
7.2 Calibration Sequence for km/h Control (8000 pulses/km). . . . . . . . . . . . 15
7.3 Calibration Sepeunce for km/h Control (24000 pulses/km). . . . . . . . . . . 15
8 Test Set-Up: Calibration of Odometer . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
8.1 Calibration Set-Up for Odometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
9 Test Set-up: Calibration of Engine Speed Test . . . . . . . . . . . . . . . . . . . . .18
9.1 Measuring Preparations of the Calibration Unit. . . . . . . . . . . . . . . . . . . . 19
9.2 Measuring Preparations of the MTC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
9.3 Calibration Sequence for Engine Speed Pulse (DI) Measurement . . . . . 19
9.4 Calibration Sequence for Pulse Width. . . . . . . . . . . . . . . . . . . . . . . . . . . 20
9.5 Calibration Sequence for Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . 20
10 Test Set-Up: Calibration of Clock - Tester. . . . . . . . . . . . . . . . . . . . . . . . .21
10.1 Measuring Preparations of the Calibration Unit. . . . . . . . . . . . . . . . . . . . 22
10.2 Measuring Preparations of the ATC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
10.3 Calibration Sequence for Clock - Tester . . . . . . . . . . . . . . . . . . . . . . . . . 22
11 Concluding Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23
12 Sample Certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

BA00-1602-322002 © Continental Automotive GmbH Page 3

Page 4 © Continental Automotive GmbH BA00-1602-322002
 Brief Description (BTC I)

1 Brief Description (BTC I)

1 BTC I control unit

2 Alphanumerical LCD, 4 lines with 20 characters each
3 Alphanumerical keypad with special characters

The BTC I has two serial interfaces:

• On back side, COM 1, infrared data transfer to cradle (RS 232 data format)
• On front side, COM 2, RS 232

BA00-1602-322002 © Continental Automotive GmbH Page 5

Brief Description (Cradle 1)

1.1 Brief Description (Cradle 1)

5 Cradle 1 with measuring electronics

6 Connecting jack for test plug
7 Connecting jack for light barrier
8 Connecting jack for voltage supply

Additional, i.e., detailed, descriptions can be found in the respective operating instruc-
tions.

Page 6 © Continental Automotive GmbH BA00-1602-322002

 Technical Data

2 Technical Data
Display : alphanumerical
4 lines with characters each
5-mm character height
Keyboard : 32 keys, doubly assigned with spe-
cial characters
Interfaces, BTC I : COM 1, infrared, RS 232 data format
COM 2, RS 232
Interfaces,cradle 1 : Frequency input 1 (k, w pulse)
f max = 6 kHz
U - Low = 0 - 2 Volt,
U - High = 2.5 - 20 Volt
Frequency input 2 (sensor pulses)
f max = 6 kHz
U - Low = 0 - 2 Volt,
U - High = 2.5 - 20 Volt
Frequency input 3 (light barrier)
f max = 6 kHz
U - Low = 0 - 2 Volt,
U - High = 2.5 - 20 Volt
Frequency output (k pulse)
f max = 6 kHz, max. 12 V, max. 30 mA
Voltage supply : 10,8 V - 30 V direct voltage with re-
serve voltage protection
Power supply unit : BTC I, voltage supply 8 V + 10%
electronics supply + 5 V +/- 5 %
Power consumption : approx. 500 mA
Operating temperature : + 5 °C to + 40 °C

Measuring ranges : w = 500 - 99999 pulses/km

k = 2400 - 99999 pulses/km
v = 10 - 200 kph
n = 50 - 5000 rpm
I = 300 - 3000 µs
DI = 200 - 3000 pulses/100 rev.

Odometer : 0 - 9999 pulses

3 MTC Function Test

The following items must be carried out to perform a function test.
For the display and keypad testing procedures, see the control unit testing instructions.

BA00-1602-322002 © Continental Automotive GmbH Page 7

Test Set-Up: Calibration of Manual Distance Pulse Measurement

4 Test Set-Up: Calibration of Manual Distance Pulse Measu-

rement
Before setting up the test, make sure that the mains switch is at the „0“ (=mains off)
position.

A Calibration unit 1 Shift key for speed = 3,2 km/h or 50

B Calibrating cable 1602.78.120 km/h
C MTC cradle 2 Shift key for autom. or manual mode
D BTC I 4 Shift key for ATC or MTC mode
E I/O testing cable (MTC component) 5 Shift key for LS1 or LS2 light barrier
14 Shift key (grey) for switching over
from counter-mode to frequency-
mode

Page 8 © Continental Automotive GmbH BA00-1602-322002

 Measuring Preparations of the Calibration Unit

4.1 Measuring Preparations of the Calibration Unit

• Switch 1, 3, 2 km/h position

• Switch 2, manual position
• Switch 4, MTC position
• Switch 5, LS2 position

4.2 Measuring Preparations of the MTC

• Connect the MTC to the calibration unit by means of the 1602-78-120 „B“ calibrating
line
• The „E“ I/O line, which is an MTC component, is connected to the MTC cradle and
the A2 measuring jack of the calibration unit.
• Connect the calibration unit to 230 V by means of a voltage cable and activate the
voltage by means of the mains switch.
• The value 0.00 must be shown in the frequency display of the calibration unit. If this
is not the case, the grey key (14) must be pressed two times in order to activate the
frequency display.

4.3 Calibration Sequence for Manual Distance Pulse Measure-

ment

• The selection menu appears when the calibrator is switched on.

• Select the „Manual measuring track“ program by means of the arrow key of the
BTC I
• Press the key twice.
• The „W value XXXX p/m“ mask appears.
• Press the „Start 100 pulses“ key on the calibration unit.
• 100 pulses to the MTC are counted. In the display mask, the pulse is shown in
approx. 1 sec. time „pulse _______/pulse
• Observe the pulse frequency, and when the display no longer changes, press the
key.
• Then enter the length of the measuring track: 20.00.
Acknowledge by means of key.
• The measured value is shown in the BTC I display. W value = 5000 p/km.
• Enter the measured value into the certificate.
• The selection menu reappears after the measurement has been completed.
• The measurement is to be carried out 3 times.

BA00-1602-322002 © Continental Automotive GmbH Page 9

Test Set-Up: Calibration of Automatic Distance Pulse Measurement

5 Test Set-Up: Calibration of Automatic Distance Pulse

Measurement
The test can be set up as described under Chapter 4. Key 2 calibration unit must be swit-
ched from manual to automatic.

Page 10 © Continental Automotive GmbH BA00-1602-322002

 Calibration Sequence for Automatic Distance Pulse

5.1 Calibration Sequence for Automatic Distance Pulse

Measurement
• Select „Automatic measuring track“ in selection menu by means of the key.
• After „Automatic measuring track“ has been selected, „W value XXXXX“ appears on
the display of the BTC I.
• After approx. 1-2 sec., the calibration unit starts the measurement.
• A starting bar is shown in the display of the BTC I as start indicator.
• After approx. 5 sec., the measurement is ended and the measured value „W value
1000 p/km“ is shown on the display of the BTC I.
• Enter measured value into the certificate.
• The measurement is to be carried out 3 times.

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Test Set-Up: Calibration of the k Pulse

6 Test Set-Up: Calibration of the k Pulse

The test can be set up as described under Section 5. The MTC test line (E) must be re-
moved from the „A2“ jack bush and inserted into the „E1“ jack bush.

Page 12 © Continental Automotive GmbH BA00-1602-322002

 k Measurement/Setting Program

6.1 k Measurement/Setting Program

• Select the „k measurement/setting“ program in the selection menu by means of the
arrow key.
• The measured frequency appears in the frequency display calibration unit.
• The measured k value appears in the display of the BTC I
• The LED of the calibration unit must light during the k measurement.
• Enter measured values into the certificate:
1. Measured value of frequency display
2. Level size: yes/no (level size = yes when the LED is lit)
3. k value display of BTC I
• Cancel the k measurement by means of the key of the BTC I.

BA00-1602-322002 © Continental Automotive GmbH Page 13

Test Set-Up: Calibration of km/h Control

7 Test Set-Up: Calibration of km/h Control

The test can be set up as described under Section 6.

Page 14 © Continental Automotive GmbH BA00-1602-322002

 Calibration Sequence for km/h Control (k = 2500 pul-

7.1 Calibration Sequence for km/h Control (k = 2500 pulses/

km)

• Select the „Device test“ program in the selection manu by means of the arrow key
of the BTC I.
• After that, an additional menu mask appears and the „Variable speed“ program is
started by means of the arrow key.
• Enter a speed of 020 km/h and a k value of 02500 pulses/km.
(for a description of the input procedure, see the operating instructions of the MTC
1602-04)
• The following speeds are to be selected and the corresponding frequency is to be
checked: 020, 050, 080, 100, 125, 150, and 180 km/h. The corresponding frequency
is shown on the frequency display of the calibration unit and must be entered into
the certificate (see calibration certificate)
• Finally, if the „km/h control“ test ends at a k value of 2500 pulses/km and a speed of
180 km/h, a km/h value of 000 must be entered.
• After that, the program returns to the selection menu.

7.2 Calibration Sequence for km/h Control (8000 pulses/km)

• Select the „Variable speed“ program by means of the arrow key of the BTC I.
• Test the speed between 020 and 180 km/h and a k value of 08000 pulses/km, as
described under Section 7.1.
• Finally, if the „km/h control“ test at a k value of 8000 pulses/km and a speed of
180 km/h has been completed, a km value of 000 must be entered.
• After that, the program returns to the selection menu.

7.3 Calibration Sepeunce for km/h Control (24000 pulses/km)

• Proceed as described under Section 7.2. The k value of 8000 pulses/km must be
changed to 24000 pulses/km.

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Test Set-Up: Calibration of Odometer

8 Test Set-Up: Calibration of Odometer

The test can be set up as described under Section 7.

Before calibrating the odometer, request the version numbers of the BTC I and the cradle.
• Press the key of the BTC I. After that, the version numbers of the BTC I and the
cradle will appear in the display of the BTC I.

Page 16 © Continental Automotive GmbH BA00-1602-322002

 Calibration Set-Up for Odometer

Example:

A calibration of the odometer is only possible as of Version 05 (BTC I and cradle).

If the version numbers are less than 05, the odometer cannot be calibrated. The following
must be entered under „Comments“:
Certificate issued. Calibration of odometer not possible.
The version numbers of the cradle and the BTC I must also be entered, e.g., Cradle = 05,
BTC I = 05.

An update to the newest version is recommended.

8.1 Calibration Set-Up for Odometer

• The frequency display of the calibration unit must be switched into the counter mode
by means of the grey key (14) by pressing two times. 0 must light up in the display.
• If 0 is not in the display, set the counter to 0 by means of the red key.
• Select the „Odometer test“ program by means of the arrow key of the BTC I.
• Enter a k value of 08000 pulses/km (for the operation of the odometer, see the MTC
1602.04 operating instructions).
• After the k value has been entered and acknowledged by means of the key, the
MTC outputs a frequency and the calibration unit counts the output pulses. This
counting procedure is not important for the measuring result, however, only the fi-
gure change of the TCO is activated.
• Start the odometer measurement by means of the key. At the same time, the
red key of the counter display must be pressed. In this way, the counter of the cali-
bration unit is set to 0 and the measurement is started.
• Observe the counter display of the calibration unit and stop the „Odometer“ program
by means of the key of the BTC I when 1000 is shown on the display.
• The driven measuring track is shown on the display of the BTC I in meters.
• Enter the measured value into the certificate.
1. Measured BTC I value as desired value
2. Measured value of calibration unit as actual value
• Switch off the voltage of the calibration unit.

BA00-1602-322002 © Continental Automotive GmbH Page 17

Test Set-up: Calibration of Engine Speed Test

9 Test Set-up: Calibration of Engine Speed Test

Before setting up the test, make sure that the mains switch is at the „0“ (=mains off)
position.

A Calibration unit 1 Shift key for speed = 3.2 km/h or 50

B Calibration cable 1602-78-120 km/h
C MTC cradle 2 Shift key for autom. or manual mode
D BTC I 4 Shift key for ATC or MTC mode
E I/O testing cable (MTC component) 5 Shift key for LS1 or LS2 light barrier
14 Shift key (grey) for switching over
from counter-mode to frequency -
mode

Page 18 © Continental Automotive GmbH BA00-1602-322002

 Measuring Preparations of the Calibration Unit

9.1 Measuring Preparations of the Calibration Unit

• Switch 1, 50 km/h position

• Switch 2, autom. position
• Switch 4, MTC position
• Switch 5, LS2 position

9.2 Measuring Preparations of the MTC

• Connect the MTC to the calibration unit by means of the 1602-78-120 calibrating
line.
The rotary frequency constant (DFK) line, which is an MTC component, is connected
to the MTC cradle and the A1 measuring jack of the calibration unit.
• Switch on the voltage of calibration unit.

9.3 Calibration Sequence for Engine Speed Pulse (DI) Measu-

rement

• Select „Engine speed pulse measurement“ by means of the key.

• After the program is started, the following appears in the display of the BTC I: DI
value=
• An engine speed pulse measurement requires approx. 25 sec.
• Wait until at least three measurements have been completed.
• After the third measurement, the following appears in the display of the BTC I: DI
value = 5760 p/rev.
• Enter the measured value into the cerificate.
• Cancel program by means of the key.
• After that, the program switches back to the selection mask.

BA00-1602-322002 © Continental Automotive GmbH Page 19

Calibration Sequence for Pulse Width

9.4 Calibration Sequence for Pulse Width

• Select „Pulse width“ measurement by means of the arrow key.

• After the program is staarted, the following appears in the display of the BTC I-pulse
value =
• Wait until at least three measurements have been completed.
• After the third measurement, the following appears in the display of the BTC I-pulse
value = 2000 µs
• Enter the measured value into the certificate.
• Cancel program by means of the key.

9.5 Calibration Sequence for Engine Speed

• Select „N engine speed“ measurement by means of the arrow key.

• After the program is started, the following appears in the display: Engine speed =
• Wait until at least three measurements have been completed.
• After the third measurement, the following appears in the display in the display of the
BTC I: Engine speed = 220 1/min.
• Enter the measured value into the certificate.
• Cancel program by means of the key.

Page 20 © Continental Automotive GmbH BA00-1602-322002

 Test Set-Up: Calibration of Clock - Tester

10 Test Set-Up: Calibration of Clock - Tester

Before setting up the test, make sure that the mains switch is at the „0“ (= mains off)
position.

A Calibration unit 1 Shift key for speed 3.2 km/h or 50 km/h

B Calbr. cabel 1602-78-136 2 Shift key for autom. or manual mode
C ATC - cradle 4 Shift key for ATC or MTC
D BTC I 5 Shift key for LS1 or LS2
E Plug cabinet 14 Shift key (grey) for switching over from
counter-mode to frequency mode

Before calibrating the odometer, check the version numbers of the BTC I and the cradle.
• Press the key of the BTC I. After that, the version numbers of the BTC I and the
cradle will appear in the display of the BTC I.

BA00-1602-322002 © Continental Automotive GmbH Page 21

Measuring Preparations of the Calibration Unit

Example:

A calibration of the clock - tester is only possible as of Version 06 (BTC I and cradle). If
the verison numbers are less than 06, the odometer cannot be calibrated. The following
must be entered under „Comments“:

Certificate issued. Calibration of clock - tester not possible.

The version numbers of the cradle and the BTC I must also be entered, e.g. Cradle = 04,
BTC I = 05.

An update to the newest version is recommended.

10.1Measuring Preparations of the Calibration Unit

• Switch 1, 50 km/h position

• Switch 2, autom. position
• Switch 4, ATC position
• Switch 5, LS2 position

10.2Measuring Preparations of the ATC

• Connect the ATC to the calibration unit by means of the 1602-78-136 calibrating line.
• Switch on the voltage of the calibration unit. The red LED in the calibrating line
1602-78-136 has to light up in a 1 second-cycle.

10.3Calibration Sequence for Clock - Tester

• Select the program „test device“ by means of the arrow key of the BTC I in the
selection-menu.
• After that a further menu-mask appears on the display. Select the prgram „clock
test“ by menas of the arrow key.
• Start the clock - test by means of the key.
• A clock - tester measurement requires about 15 sec. At the end appears the diver-
gence of the range of tolerance in sec./24h.
• By means of the key, the measurement can be reapeted.
• Returning to the selection-menu by means of the „C“ key.

Page 22 © Continental Automotive GmbH BA00-1602-322002

 Concluding Tasks

11 Concluding Tasks
After the calibration procedure has been completed, the voltage of the calibration unit
must be switched off and the calibrating cable must be removed. The certificate must be
filled out completely with the signature of the inspector and his/her company stamp.
Any recognised defects, such as damage, missing parts, etc. must be entered into the cer-
tificate under „Comments“.
After calibration, the respective measuring device receives a calibration label, on which
the duration of calibration validity is marked.

Year Month
The date of validity is marked by cutting out (marking) the corresponding month and year
fields on the calibration label.

The calibration label must be attached to the back side of the cradle. The surface onto
which the calibration label is to be attached must first be cleaned.

BA00-1602-322002 © Continental Automotive GmbH Page 23

Sample Certificate

12 Sample Certificate

A sample certificate for the MTC is located in the Appendix. All measured values are in
italics and bold print (4000). The certificate must be filled out completely, including the si-
gnature of the inspector and his/her company stamp. If a measured value is not within the
acceptable tolerance, no certificate may be issued. The date of validity entered into the
certificate must correspond to the date of validity on the calibration label attached to the
testing device.

Page 24 © Continental Automotive GmbH BA00-1602-322002

 Sample Certificate

CALIBRATION CERTIFICATE
Mobile Test Computer MTC

Device type : MTC 1602.04 Cradle no. : 123456

BTC no. : 123456 Certificate no. : M/2008/06/001

Date : 04.06.2008 valid until : 04.06.2009

The proper function of the above-mentioned testing device has been tested and
calibrated. The measuring devices used for calibration meet national standards.

Calibration Unit Device no.:

1602.32 0066

1.) Test of manual distance pulse measurement

The distance pulse measurement test was carried out 3 times.

Desired value Tolerance Actual value

1. 5000 pulses/km r 2 pulses/km 5000

2. 5000 pulses/km r 2 pulses/km 5000
3. 5000 pulses/km r 2 pulses/km 5000

2. ) Test of automatic distance pulse measurement

The distance pulse measurement test was carried out 3 times.

Desired value Tolerance Actual value

1. 1000 pulses/km r 1 pulses/km 1000

2. 1000 pulses/km r 1 pulses/km 1000
3. 1000 pulses/km r 1 pulses/km 1000

3.) k pulse test

Desired value Tolerance Actual value

135 Hz r 15 Hz 128,45
Level display correct yes/no yes
1000 pulses/km r 1 pulses/km 1000

Page 1 of 3

BA00-1602-322002 © Continental Automotive GmbH Page 25

Sample Certificate

CALIBRATION CERTIFICATE
Mobile Test Computer MTC

4.) km/h control test (k value = 2500 pulses/km)

Desired value Tolerance Actual value

20 km/h 13,89 Hz r 1 Hz 0013,88

50 km/h 34,71 Hz r 1 Hz 0034,72
80 km/h 55,55 Hz r 1 Hz 0055,57
100 km/h 69,44 Hz r 1 Hz 0069,44
125 km/h 86,71 Hz r 1 Hz 0086,77
150 km/h 104,15 Hz r 1 Hz 0104,15
180 km/h 125,00 Hz r 1 Hz 0124,95

5.) km/h control test (k value 8000 pulses/km)

Desired value Tolerance Actual value

20 km/h 44,44 Hz r 1 Hz 0044,43

50 km/h 111,11 Hz r 1 Hz 0111,12
80 km/h 177,76 Hz r 1 Hz 0177,75
100 km/h 222,22 Hz r 1 Hz 0222,23
125 km/h 277,75 Hz r 1 Hz 0277,76
150 km/h 333,33 Hz r 1 Hz 0333,33
180 km/h 400,00 Hz r 1 Hz 0399,96

6.) km/h control test (k value 24000 pulses/km)

Desired value Tolerance Actual value

20 km/h 133,33 Hz r 2 Hz 0133,32

50 km/h 333,33 Hz r 2 Hz 0333,34
80 km/h 533,28 Hz r 2 Hz 0533,28
100 km/h 666,67 Hz r 2 Hz 0666,68
125 km/h 833,25 Hz r 2 Hz 0833,23
150 km/h 1000,00 Hz r 2 Hz 0999,95
180 km/h 1200,00 Hz r 2 Hz 1199,85

Page 2 of 3

Page 26 © Continental Automotive GmbH BA00-1602-322002

 Sample Certificate

CALIBRATION CERTIFICATE
Mobile Test Computer MTC
7.) Odometer test (k = 8000 pulses/km)

Desired value Tolerance Actual value

(BTC display) (frequency display of calibration unit)

at least 1000 rev.

1000 r 2 rev. 1000

8.) Engine speed pulse (DI) ratio test

Desired value Tolerance Actual value

5760 pulses/100 rev.. r 2 pulses/100 rev. 5760

9.) Impulse width test

Desired value Tolerance Actual value

2000 µs r 5 µs 2000

10.) Revolution speed measurement

Desired value Tolerance Actual value

220 min-1 r10 min-1 220

11.) Clock tester

Desired value Tolerance Actual value

0,0 sec/24h r 1 sec/24h 0,00

Comments:

Continental Automotive GmbH is a

company certified according to
DIN EN ISO 9001: 2000 Company stamp/Signature of inspector

Page 3 of 3

BA00-1602-322002 © Continental Automotive GmbH Page 27

Test Computer 1319 TC

TC 1602-31
Calibration Instructions
Seite 2 © Continental Automotive GmbH BA00-1602-322002
Table of Contents
1 Brief Description (BTC I) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.1 Brief Description (Cradle 2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3 Functional Test TC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
4 Test Set-Up: Calibration of k Pulse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
4.1 Measuring Preparations of the Calibration Unit. . . . . . . . . . . . . . . . . . . . . 9
4.2 Measuring Preparations of the TC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.3 Calibration Sequence for k Pulse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5 Test Set-Up: Calibration of km/h Control. . . . . . . . . . . . . . . . . . . . . . . . . .10
5.1 Calibration Sequence for km/h Control (k = 2500 pulses/km) . . . . . . . . . 11
5.2 Calibration Sequence for km/h Control (8000 pulses/km). . . . . . . . . . . . 11
5.3 Calibration Sequence for km/h Control (24000 pulses/km). . . . . . . . . . . 11
6 Test Set-Up: Calibration of Odometer . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
6.1 Calibration Sequence for Odometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
7 Concluding Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
8 Sample Certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

BA00-1602-322002 © Continental Automotive GmbH Page 3

Page 4 © Continental Automotive GmbH BA00-1602-322002
 Brief Description (BTC I)

1 Brief Description (BTC I)

1 BTC I control unit

2 Alphanumerical LCD, 4 lines with 20 characters each
3 Alphanumerical keypad with special characters

The BTC I has two serial interfaces.

• On back side, COM 1, infrared data transfer to cradle (RS 232 data format)
• On front side, COM 2, RS 232

BA00-1602-322002 © Continental Automotive GmbH Page 5

Brief Description (Cradle 2)

1.1 Brief Description (Cradle 2)

5 Cradle 1 with measuring electronics

6 Connecting jack for test plug
7 Connecting jack for voltage supply

Additional, i.e., detailed descriptions can be found in the respective operating instructions.

Page 6 © Continental Automotive GmbH BA00-1602-322002

 Technical Data

2 Technical Data
Display : alphanumerical
4 lines with 20 characters each
5 mm character height
Keyboard : 32 keys, doubly assigned with spec-
ial characters
Interfaces, BTC I : COM 1, infared RS 232 data format
COM 2, RS 232
Interfaces, cradle 2: Frequency input (k, w pulse)
f max = 6 kHz
U - Low = 0 - 2 Volt,
U - High = 2.5 - 20 Volt
Frequency output (k pulse)
f max = 6 kHz, max. 12 V,
max. 30 mA
Power supply unit : BTC I, voltage supply
8 V + 10 %
electronic supply + 5 V +/- 5 %
Voltage supply : 10,8 V - 30 V direct voltage with re-
verse voltage protection
Power consumption : approx. 500 mA
Operating temperature : + 5 °C to + 40 °C

3 Functional Test TC
The following itmes must be carried out to perform a function test.
For the display and keypad testing procedures, see the control unit testing instructions.

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Test Set-Up: Calibration of k Pulse

4 Test Set-Up: Calibration of k Pulse

Before setting up the test, make sure that the mains switch is at „0“ (= mains off) position.

A calibration unit 1 Shift key for speed

B Calbr. cable 1602-78-120 = 3.2 km/h or 50 km/h
C TC cradle 2 Shift key for autom. or manual
D BTC I mode
E Programming line 4 Shift key for ATC oder MTC
FTCO 1319 (TC component) mode
F Calbr. cable 1602-78-1245 Shift key for LS1 oder LS2 light
barrier
14 Shift key (grey) for switching
over from counter-mode to
frequency-mode

Page 8 © Continental Automotive GmbH BA00-1602-322002

 Measuring Preparations of the Calibration Unit

4.1 Measuring Preparations of the Calibration Unit

• Switch 1, 3.2 km/h position

• Switch 2, manual position
• Switch 4, MTC position
• Switch 5, LS2 position

4.2 Measuring Preparations of the TC

• Connect the TC to the calibration unit by means of the 1602-78-120 „B“ calibrating
line. The „E“ FTCO programming line, which is a TC component, is connected to the
TC cradle and the BTC I.
The 1602-78-124 „F“ calibrating cable is inserted into the FTCO 1319 programming
line and connected to the „E2“ jack of the calibrator.

• Connect the calibration unit to 230 V by means of a voltage cable and activate the
voltage by means of the mains switch.
• The value 0.00 must be in the frequency display of the calibration unit. If this is not
the case, the grey key (14) must be pressed two times to activate the frequency dis-
play.

4.3 Calibration Sequence for k Pulse

• Select the „k measurement/setting“ program in the selection menu by means of the

key.
• Assume k value by means of the key.
• The measured frequency appears in the frequency display of the calibration unit.
• The LED of the calibration unit must light during the k measurement.
• Enter the measured values in the certificate:
1. Measured value of frequency display
2. Level size: yes/no (level size = yes when the LED is lit)
• Cancel the k measurement by menas of the key of the BTC I.

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Test Set-Up: Calibration of km/h Control

5 Test Set-Up: Calibration of km/h Control

The test can be set up as described under Section 4.

Page 10 © Continental Automotive GmbH BA00-1602-322002

 Calibration Sequence for km/h Control (k = 2500 pul-

5.1 Calibration Sequence for km/h Control (k = 2500 pulses/km)

• Select the „Device test“ program in the selection menu by means of the arrow
key of the BTC I.
• After that, an additional menu appears and the „Variable speed“ program is started
by means of the arrow key.
• Enter a speed of 020 km/h and a k vlaue of 02500 pulses/km.
(for a description of the input procedure, see the operating instructions of the MTC
1602-04)
• The following speeds are to be selected and the corresponding frequency is to be
checked: 020, 050, 080, 100, 125, 150 and 180 km/h. The corresponding frequency
is shown on the frequency display of the calibration unit and must be entered into
the certificate (see calibration certificate).
• Finally, if the „km/h control“ test ends at a k value of 2500 pulses/km and a speed of
180 km/h, a km/h value of 000 must be entered.
• After that, the program returns to the selection menu.

5.2 Calibration Sequence for km/h Control (8000 pulses/km)

• Select the „Variable speed“ program by means of the arrow key of the BTC I.
• Test the speed between 020 and 180 km/h and a k value of 08000 pulses/km, as de-
scribed under section 5.1.
• Finally, if the „km/h control“ test at a k value of 8000 pulses/km and a speed of
180km/h, has been completed, a km value of 000 must be entered.
• After that, the program returns to the selecetion menu.

5.3 Calibration Sequence for km/h Control (24000 pulses/km)

• Proceed as described under Section 5.2. The k value of 8000 pulses/km must be
changed to 24000 pulses/km.

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Test Set-Up: Calibration of Odometer

6 Test Set-Up: Calibration of Odometer

The test can be set up as described under Section 5.

Before calibrating the odometer, request the version number of the BTC I and the cradle.
• Press the key of the BTC I. After that, the version numbers of the BTC I and the
cradle will appear in the display of the BTC I.

Page 12 © Continental Automotive GmbH BA00-1602-322002

 Calibration Sequence for Odometer

Example:

A calibration of the odometer is only possible as of Version 05 (BTC I and cradle).

If the version numbers are less than 05, the odometer cannot be calibrated. The following
must be entered under „Comments“:

Certificate issued. Calibration of odometer not possible.

The version numbers of the cradle and the BTC I must also be entered, e.g., cradle = 04,
BTC I = 05.
An update to the newest verison is recommended.

6.1 Calibration Sequence for Odometer

• The frequency display of the calibration unit must be switched into the counter mode
by pressing the grey key (14) two times. On mode display 0 must light up.
• If 0 is not in the display, set the counter to 0 by means of the red key.
• Select the „Odometer test“ program by means of the arrow key of the BTC I.
• Enter a k value of 08000 pulses/km.
(for the operation of the odometer, see TC 1602.31 operating instructions).)
• After the k value has been entered and acknowledged by menas of the key, the
TC output pulses and the calibration unit counts the output pulses. This counting
procedure is not important for measuring result, however, only the figure change of
the TCO is activated.
• Start the odometer measurement by means of the key. At the same time,the
red key of the counter must be pressed. In this way, the counter of the calibration
unit is set to 0 and the measurement is started.
• Observe the counter display of the calibration unit and stop the „Odometer“ program
when 1000 is shown on the display by means of the key of the BTC I.
• The driven measuring track is shown on the display of the BTC I in meters (desired
value)
• The measured distance is shown in the frequency display of the calibration unit (ac-
tual value).
• Enter both measured values into the certificate.

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Concluding Tasks

7 Concluding Tasks
After the calibration procedure has been completed, the voltage of the calibration unit
must be switched off and the calibrated cable must be removed. The certificate must be
filled out completely with the signature of the inspector and his/her company stamp.
Any recognized defects, such as damage, missing parts, etc. must be entered into the cer-
tificate under „Comments“.
After calibration, the respective measuring device receives a calibration label, on which
the duration of calibration validity is marked.

Year Month
The date of validity is marked by cutting out (marking) the corresponding month and year
fields on the calibration label.

The calibration label must be attached to the back side of the cradle. The surface onto the
calibration label is to be attached first be cleaned.

Page 14 © Continental Automotive GmbH BA00-1602-322002

 Sample Certificate

8 Sample Certificate

A sample certificate for the TC is located in the Appendix. All measured values are in ita-
lics and bold print (4000). The certificate must be filled out completely, including the si-
gnature of the inspector and his/her company stamp. If a measured value is not within the
acceptable tolerance, no certificate may be issued. The date of validity entered into the
certificate must correspond to the date of validity on the calibration label attached to the
testing device.

BA00-1602-322002 © Continental Automotive GmbH Page 15

Sample Certificate

Page 16 © Continental Automotive GmbH BA00-1602-322002

 Sample Certificate

BA00-1602-322002 © Continental Automotive GmbH Page 17

Hand Test Computer HTC

HTC 1602-19
Calibration Instructions
Table of Contents
1 Brief Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3 HTC Functional Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
4 Test Set-Up: Calibration of Manual Distance Pulse Measurement . . . . . . .7
4.1 Measuring Preparations of Calibration Unit. . . . . . . . . . . . . . . . . . . . . . . . 8
4.2 Measuring Preparations of the HTC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3 Calibration Sequence for Manual Distance Pulse Measurement . . . . . . . 8
5 Test Set-Up: Calibration of k Pulse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
5.1 Calibration Sequence for k Pulse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Test Set-Up: Calibration of km/h Control . . . . . . . . . . . . . . . . . . . . . . . . .11
6.1 Calibration Sequence for km/h Control (k = 2500 pulses/km) . . . . . . . . . 12
6.2 Calibration Sequence for km/h Control (8000 pulses/km). . . . . . . . . . . . 12
6.3 Calibration Sequence for km/h Control (24000 pulses/km). . . . . . . . . . . 12
Test Set-Up: Calibration of Odometer 13
7.1 Calibration Sequence for Odometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Concluding Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
9 Sample Certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

BA00-1602-322002 © Continental Automotive GmbH Page 2

 Brief Description

1 Brief Description

1 LCD, 2 lines with 16 characters each

2 Function keys
3 Multicolour keypad with special keys
4 Cable connection (Voltage supply, jack plug for electronic tachographs)
5 Test line for sensor
6 Test line for I/O jack plug
7 Voltage supply

Additional, i.e., detailed descriptions can be found in the respective operating instructions.

BA00-1602-322002 © Continental Automotive GmbH Page 4

Technical Data

2 Technical Data
Display: LCD with backlight
2 lines with 16 characters each
5 mm characters height
Keyboard : Numerical keypad with special
characters
Interfaces : 8-V sensor supply, max. 25 mA
Frequency input f max = 6 kHz
U - Low = 0 - 2 Volt,
U - High = 2.5 - 20 Volt
Frequency output f max = 6 kHz
8 V max. 39 mA
Voltage supply : 10.8 V - 30 V DC with reverse
voltage protection
Power consumption : ca. 125 mA
Operating temperature : + 5 °C - + 40 °C

Page 5 © Continental Automotive GmbH BA00-1602-322002

 HTC Functional Test

3 HTC Functional Test

During a function test, the following items must be carried out..
Display test :
• Press keys „C“ (bottom left) and (top right) simultaneously.
• Connect voltage supply to HTC.
• A test mask appears in the display.
Test - 1602.19.000
Devel. test program
• Release keys „C“ and .
• When the is pressed, all controllable LED segments appear in the display.
• When keys „0“ through „9“, „Period“, „C“, and are pressed, the respective
symbol appears in all character positions on the display.

Keys F1 through F4 can be tested as follows:

• Press F1: cursor blinks at top left of display
• Press F2: cursor blinks at top right of display
• Press F3: cursor blinks at bottom left of display
• Press F4: cursor blinks at bottom right of display

It is possible to return to the test mask by pressing the key.

In order to cancel the test program, the voltage supply must be interuppted.

BA00-1602-322002 © Continental Automotive GmbH Page 6

Test Set-Up: Calibration of Manual Distance Pulse Measurement

4 Test Set-Up: Calibration of Manual Distance Pulse Measu-

rement
Before setting up the test, make sure that the mains switch is at the „0“ (= mains off)
position.

Back side

Mains switch

Connection

A Calibration unit 1 Shift key for speed = 3.2 km/h or 50 km/h

B HTC 2 Shift key for autom. or manual model
C I/O test cable 4 Shift key for ATC or MTC mode
( HTC component )
D Voltage supply 5 Shift key for LS1 or LS2 light barrier
( HTC component )
14 Shift key (grey) for switching over from
counter-mode to frequency-mode
22 Onboard power supply jack

Page 7 © Continental Automotive GmbH BA00-1602-322002

 Measuring Preparations of Calibration Unit

4.1 Measuring Preparations of Calibration Unit

• Switch 1, 3.2 km/h position

• Switch 2, manual position
• Switch 4, MTC position
• Switch 5, LS2 position

4.2 Measuring Preparations of the HTC

• Connect the HTC to the A2 measuring jack of the calibration unit by means of the
I/O line.
• Insert the plug of the HTC’s onboard power supply to the onboard power supply jack
of the calibration unit.
• Connect the calibration unit to 230V by means of a voltage cable and turn on the vol-
tage by means of the mains switch of the calibration unit.
• The value 0.00 must be shown in the frequency display of the calibration unit. If this
is not the case, grey key (14) must be pressed two times to activate the frequency
display.

4.3 Calibration Sequence for Manual Distance Pulse Measure-

ment

• The selcetion menu appears when the calibrator is switched on.

• When the F1 key is pressed, „Manual measurement“ appears on the display of the
HTC.
• Press key. The „Manual distance pulse measurement“ program is thus start-
ed. The message „Start measurement“ appears in the display of the HTC.
• Press the „Start 100 pulses“ key on the calibration unit.
• 100 pulses to the MTC are counted. In the display mask, the pulse is shown in
approx. 1sec. time „pulse ________/ „.
• Observe the pulse frequency, and when the display no longer changes, press the
key.
• Then enter the lenght of the measuring track in meters: > 20.00 <
• The measured value is shown in the HTC display: W = 500 pulses/km
• Enter measured value into certificate. The selection menu reappears after the
key is pressed again.
• The measurement is to be carried out 3 times.

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Test Set-Up: Calibration of k Pulse

5 Test Set-Up: Calibration of k Pulse

The test can be set up as described under Section 4. The HTC test line (C) must be re-
moved from the „A2“ jack bush and inserte into the „E1“ jack.

Back side

Mains switch

Connection

Page 9 © Continental Automotive GmbH BA00-1602-322002

 Calibration Sequence for k Pulse

5.1 Calibration Sequence for k Pulse

• The k measurement is started by pressing the F2 key of the HTC.

• The measured frequency appears in the frequency display of the calibration unit.
• The measured k value appears in the display of the HTC.
• The LED of the calibration unit must light during the k measurement.
• Enter measured values in certificate:
1. Measured value of frequency display.
2. Level size: yes/no (level size = yes when the LED is lit)
3. k value display of the remote control.
• Cancel the k measurement by means of the „C“ key of the HTC.

BA00-1602-322002 © Continental Automotive GmbH Page 10

Calibration Sequence for k Pulse

6 Test Set-Up: Calibration of km/h Control

The test can be set up as described under Section 5.

Back side

Mains switch

Connection

Page 11 © Continental Automotive GmbH BA00-1602-322002

 Calibration Sequence for km/h Control (k = 2500 pul-

6.1 Calibration Sequence for km/h Control (k = 2500 pulses/km)

• The „Speed test“ program is started by pressing the F3 of the HTC.

• Enter a speed of 20 km/h an a k value of 2500 pulses/km.
(for a description of the input procedure, see the operating instructions of the HTC
1602-19)
• The following speeds are to be selected and the corresponding frequency is to be
checked: 20, 50, 80, 100, 125, 150 and 180 km/h. The corresponding frequency is
shown on the frequency display of the calibration unit and must be entered into the
certificate (see calibration certificate).
• If the „km/h control“ test ends at a k value of 2500 pulses/km and a speed of
180 km/h, the „C“ key of the HTC must be pressed.
• After that, the program retuns to the selection menu.

6.2 Calibration Sequence for km/h Control (8000 pulses/km)

• The „Speed test“ program is started by pressing the F3 of the HTC.

• Test the speed between 20 and 180 km/h and a k value of 8000 pulses/km, as des-
cribed under Section 6.1.
• If the „km/h control“ test at a k value of 8000 pulses/km and a speed of 180 km/h
has been completed, the „C“ key of the HTC must be pressed.
• After that, the program returns to the selection menu.

6.3 Calibration Sequence for km/h Control (24000 pulses/km)

• Proceed as described under Section 6.2. The k value of 8000 pulses/km must be
changed to 24000 pulses/km.

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Calibration Sequence for km/h Control (24000 pulses/km)

7 Test Set-Up: Calibration of Odometer

Note: Distance test only possible in case of Version 1601-19-001 !

The test can be set up as described under Section 6.

Back side

Mains switch

Connection

Page 13 © Continental Automotive GmbH BA00-1602-322002

 Calibration Sequence for Odometer

7.1 Calibration Sequence for Odometer

• The frequency display of the calibration unit must be switched into the counter mode
by means of the grey key (14) by pressing it two times. 0 must be in the display.
• If 0 is not in the display, set the counter to 0 by means of the red key.
• The „Speed test“ program is started by pressing the F3 of the HTC.
(for operating of the odometer, see the HTC 1602-19 operating instructions )
• Enter a k value of 8000 pulses/km and a speed of 20 km/h.
• After the speed has been entered and acknowleged by means of the key, the
HTC outputs a frequency and the calibration unit counts the output pulses. This
counting procedure is not important for the measuring result, however, only the fi-
gure change of the TCO is activated.
• Start the odometer measurement by means of the key. At the same time, the
red key of the counter display must be pressed. In this way, the counter of the cali-
bration unit is set to 0 and the measurement is started.
• Observe the counter display of the calibration unit and stop the „Odometer“ program
by means of the key of the HTC when 1000 is shown on the display.
• The driven distance in meters (desired value) is shown in the display of the HTC.
• The measured distance (actual value) is shown in the frequency display of the cali-
bration unit.
• Enter both measured values into the certificate.

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Calibration Sequence for Odometer

8 Concluding Tasks
After the calibration procedure has been completed, the voltage of the calibration unit
must be switched off and the calibrating cable must be removed. The certificate must be
filled out completely with the signature of the inspector and his/her company stamp.
Any recognised defects, such as damage, missing parts, etc. must be entered into the cer-
tificate under „Comments“.
After calibration, the respective measuring device receives a calibration label, on which
the duration of calibration validity is marked.

Year Month
The date of validity is marked by cutting out (marking) the corresponding month and year
field on the calibration label.

The calibration label must be attached to the front side of the HTC. The surface onto
which the calibration label is to be attached first be cleaned.

attach the
calibration
label on the
front side

Page 15 © Continental Automotive GmbH BA00-1602-322002

 Sample Certificate

9 Sample Certificate

A sample certificate for the HTC is located in the Appendix. All measured values are in
italics and bold print (4000). The certificate must be filled out completely, including the si-
gnature of the inspector and her/his company stamp. If a measured value is not within the
acceptable tolerance, no certificate may be issued. The date of validity entered into the
certificate must correspond to the date of validity on the calibration label attached to the
testing device.

BA00-1602-322002 © Continental Automotive GmbH Page 16

Sample Certificate

CALIBRATION CERTIFICATE
Hand Terminal HBG 10

Device type : HBG 10 Certificate no. : M/2008/06/001

Serial no. : 123456 Valid until : 04.06.2009

Date : 04.06.2008

The proper function of the above-mentioned testing device has been tested and
calibrated. The measuring devices used for calibration meet national standards.

Calibration Unit Device no.:

1602.32 0066

1. ) Test of automatic distance pulse measurement

Desired value Tolerance Actual value

1. 5000 Imp/km r 2 Imp/km 5000

2. 5000 Imp/km r 2 Imp/km 5000
3. 5000 Imp/km r 2 Imp/km 5000

2.) km/h control test (k value = 2500 pulses/km)

Desired value Tolerance Actual value

20 km/h 13,89 Hz r 1 Hz 0013,88

50 km/h 34,71 Hz r 1 Hz 0034,72
80 km/h 55,55 Hz r 1 Hz 0055,57
100 km/h 69,44 Hz r 1 Hz 0069,44
125 km/h 86,71 Hz r 1 Hz 0086,77
150 km/h 104,15 Hz r 1 Hz 0104,15
180 km/h 125,00 Hz r 1 Hz 0124,95

Page 1 of 2

Page 17 © Continental Automotive GmbH BA00-1602-322002

 Sample Certificate

KALIBRIERZERTIFIKAT
Handbediengerät HGB 10

3.) km/h control test (k value = 8000 pulses/km)

Desired value Tolerance Actual value

20 km/h 44,44 Hz r 1 Hz 0044,43

50 km/h 111,11 Hz r 1 Hz 0111,12
80 km/h 177,76 Hz r 1 Hz 0177,75
100 km/h 222,22 Hz r 1 Hz 0222,23
125 km/h 277,75 Hz r 1 Hz 0277,76
150 km/h 333,33 Hz r 1 Hz 0333,33
180 km/h 400,00 Hz r 1 Hz 0399,96

4.) km/h control test (k value = 24000 pulses/km)

Desired value Tolerance Actual value

20 km/h 133,33 Hz r 2 Hz 0133,32

50 km/h 333,33 Hz r 2 Hz 0333,34
80 km/h 533,28 Hz r 2 Hz 0533,28
100 km/h 666,67 Hz r 2 Hz 0666,68
125 km/h 833,25 Hz r 2 Hz 0833,23
150 km/h 1000,00 Hz r 2 Hz 0999,95
180 km/h 1200,00 Hz r 2 Hz 1199,85

Bemerkungen :

Continental Automotive GmbH is a

company certified according to
DIN EN ISO 9001: 2000 Company stamp/Signature of inspector

Page 2 of 2

BA00-1602-322002 © Continental Automotive GmbH Page 18

Sample Certificate

Page 19 © Continental Automotive GmbH BA00-1602-322002

Rolling Road Test Computer ATC

ATC 1601-26
Calibration Instructions
 Sample Certificate

BA00-1602-322002 © Continental Automotive GmbH Page 20

Table of Contents
1 Brief Description ( BTC I ) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.1 Brief Description (Cradle 0) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3 ATC Functional Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
4 Test Set-Up: Calibration of k pulses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
4.1 Measuring Preparation of the Calibration Unit . . . . . . . . . . . . . . . . . . . . . 8
4.2 Measuring Preparations of the ATC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3 Setting of Correction Values and Test Stand Type . . . . . . . . . . . . . . . . . . 8
4.4 Calibration Sequence for k Pulse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5 Test Set-Up: Calibration of Automatic Test . . . . . . . . . . . . . . . . . . . . . . . .11
5.1 Roller Correction/ Speed Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.2 Calibration Sequence for Automatic Test . . . . . . . . . . . . . . . . . . . . . . . . 12
6 Test Set-Up: Calibration of km/h Control. . . . . . . . . . . . . . . . . . . . . . . . . .13
6.1 Calibration Sequence for km/h Control (k = 2500 pulses/km) . . . . . . . . . 14
6.2 Calibration Sequence for km/h Control (8000 pulses/km). . . . . . . . . . . . 14
6.3 Calibration Sequence for km/h Control (24000 pulses/km). . . . . . . . . . . 14
7 Test Set-Up: Calibration of Odometer . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
7.1 Calibration Sequence for Odometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
8 Test Set-Up: Calibration of Clock - Tester. . . . . . . . . . . . . . . . . . . . . . . . .17
8.1 Measuring Preparations of the Calibration Unit. . . . . . . . . . . . . . . . . . . . 18
8.2 Measuring Preparations of the ATC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
8.3 Calibration Sequence for Clock - Tester . . . . . . . . . . . . . . . . . . . . . . . . . 18
9 Inspection of Entire Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
9.1 ATC Setting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
9.2 Vehicle Function Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
10 Concluding Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
11 Sample Certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

BA00-1602-322002 © Continental Automotive GmbH Page 2

Page 3 © Continental Automotive GmbH BA00-1602-322002
 Brief Description ( BTC I )

1 Brief Description ( BTC I )

1 BTC I control unit

2 Alphanumerical LCD, 4 lines with 20 characters each
3 Alphanumerical keypad with special characters

The BTC I hast two serial interfaces:

• On the back side, COM1, infrared data transfer to cradle (RS 232 data format)
• On front side, COM2, RS 232

BA00-1602-322002 © Continental Automotive GmbH Page 4

Brief Description (Cradle 0)

1.1 Brief Description (Cradle 0)

5 Cradle 0 with measuring electronics

1 Connecting jack for test plug
2 Connecting jack for light barrier
3 Connecting jack for voltage supply

Additional, i.e., detailed descriptions can be found in the respective operating instructions.

Page 5 © Continental Automotive GmbH BA00-1602-322002

 Technical Data

2 Technical Data
Display : alphanumerical LCD
4 lines with 20 each
5 mm character height
Keyboard : 32 keys, doubly assigned with spe-
cial characters
Interfaces, BTC I : COM1, infrared, RS 232 data format
COM2, RS 232
Interfaces, cradle 1 : Frequency input 1 (k, w pulses)
f max = 6 kHz
U - Low = 0 - 2 Volt,
U - High = 2.5 - 20 Volt
Frequency input 2 (roller pulses)
f max = 6 kHz
U - Low = 0 - 2 Volt,
U - High = 2.5 - 20 Volt
Frequency input 3 (light barrier)
f max = 6 kHz
U - Low = 0 - 2 Volt,
U - High = 2.5 - 20 Volt
Frequency output (k pulses)
f max = 6 kHz, max. 12 V,
max. 30 mA
Voltage supply : 10.8 V - 30 V DC with re-
verse voltage protection
Power supply unit : BTC I, voltage supply
8 V + 10 %
electronics supply + 5 V +/- 5 %
Power consumption : approx. 500 mA
Operating temperature : + 5 °C - + 40 °C
Measuring ranges w = 500 - 99999 pulses / km
k = 2400 - 99999 pulses/ km
v = 10 - 200 km/h
n = 50 - 5000 min -1
I = 300 - 4000 µs
DI = 200 - 3000 pulses / 100 Umdr.
Odometer 0 - 9999 pulses
design for taximeter Distance = 0.0 - 6000.0 m
Time = 0.0 - 99.9 s

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ATC Functional Test

3 ATC Functional Test

The following items must be carried out to perform a function test.
For the display and keypad testing procedures, see the control unit testing instructions.

4 Test Set-Up: Calibration of k pulses

Before setting up the test, make sure that the mains switch is at the „0“ (= mains off)
position.

Back side

Mains Switch

Connection

A Calibration unit 1Shift key for speed

B Calibr. cable 1602-78-120 = 3.2 km/h o 50 km/h
C ATC cradle 2 Shift key for autom. or manual
D BTC I model
E I/O testing cable 4Shift key for ATC or MTC mode
(ATC component) 5 Shift key for LS1 or LS2 light
barrier
14 Shift key (grey) for switching over
from counter-mode to frequency-
mode
Page 7 © Continental Automotive GmbH BA00-1602-322002
 Measuring Preparation of the Calibration Unit

4.1 Measuring Preparation of the Calibration Unit

• Switch 1, 50 km/h position

• Switch 2, autom. position
• Switch 4, ACT position
• Switch 5, LS2 position

4.2 Measuring Preparations of the ATC

• The ATC is removed from the connecting line of the roller dynamometer and con-
nected to the calibration unit by means of the 1602-78-120 calibrating line. The I/O
line, which is an ATC component, is connected to the ATC cradle and the „E1“
measuring jack.
• Connect the calibration unit to 230 V by means of voltage cable and activate the volt-
age by means of the mains switch.
• The value 0.00 must be shown in the frequency display of the calibration unit. If this
is not the case,the grey key (14) must be pressed two times to activate the frequency
display.

4.3 Setting of Correction Values and Test Stand Type

• Press the „CLEAR“ key of the calibration unit and keep it pressed. The display of the
BTC I switches to the selection menu.
• The „Correction value entry“ program is started by means of the „F1“ of the BTC II.
• Set the correction value to + 0.0%
(for description, see ATC 1601-26 operating instructions)
• After correction value has been entered, the selection menu reappears.
• The next two steps for setting the test stand type must be taken only when the ATC
has been connected to a brake test stand and break test stand is set as test stand
type.
• Select the „Test stand type“ program by means of the arrow key of the BTC I.
• Set the test stand type to „Double roller“
(for desciption, see the ATC 1601-26 operating instructions)
• Release the „CLEAR“ key of the calibration unit.

BA00-1602-322002 © Continental Automotive GmbH Page 8

Calibration Sequence for k Pulse

4.4 Calibration Sequence for k Pulse

Back side

Mains switch

Connection

• Press the „CLEAR“ key of the calibration unit and keep it pressed.
• Wait until the ATC switches from the speed display to the selection menu.
• The k measurement is started by means of the special „K“ key of the BTC I. Release
the „CLEAR“ key of the calibration unit.

Page 9 © Continental Automotive GmbH BA00-1602-322002

 Calibration Sequence for k Pulse

• The measured frequency appears in the display of the calibration unit.

• The measured k value appears in the display of the BTC I.
• The LED of the calibration unit must light during the k measurement.
• Enter the measured values of frequency into the certificate:
1. Measured value of frequency display
2. Level size: yes/no (level size = yes when the LED is lit)
3. k value display of remote control

• Cancel the k measurement by means of the „C“ key of the BTC I.

BA00-1602-322002 © Continental Automotive GmbH Page 10

Test Set-Up: Calibration of Automatic Test

5 Test Set-Up: Calibration of Automatic Test

The test can be set up as described under Section 4. The ATC test line (E) must be re-
moved from „E1“ jack bush and inserted into „A2“ jack bush.

Back side

Mains switch

Connection

Page 11 © Continental Automotive GmbH BA00-1602-322002

 Roller Correction/ Speed Display

5.1 Roller Correction/ Speed Display

• Check the speed display.

• If the 50 km/h speed display deviates by ± 0.2 km/h, a roller correction calculation is
necessary.
Calculation of roller correction (test stan roller adaption)

Desired value Tolerance Actual value

50.0 km/h ± 0,2 km/h

If the deisred value and the actual value are both equal to 50 km/h ± 0.2 km/h, the
test stand has no roller correction value. The constant is RC = 1.00 (calculation with
2 decimal places). If the actual value is greater or lesser than 50 km/h, the roller set
of the test stand has a roller correction value. This value is calculated by means of
the following formula:

Desired value
RC = = RC =
Actual valuet

The actual values of the distance pulse and the tyre circumference must be correc-
ted by means of this RC constant.

• Enter the roller correction value into the certificate.

5.2 Calibration Sequence for Automatic Test

Distance Pulse and Tire Circumference Measurement

• Press the special „A“ key of the BTC I.
• At the end of the measurement, the measured values of the tyre circumference will
be shown in mm and those of the distance pulse in pulses/km.
• Enter both measured values into the certificate.
• Cancel the automatic test by means of the „C“ key of the BTC I.
• The automatic test must be carried out twice.

BA00-1602-322002 © Continental Automotive GmbH Page 12

Test Set-Up: Calibration of km/h Control

6 Test Set-Up: Calibration of km/h Control

The test can be set up as described under Section 5. The ATC test line (E) must be re-
moved from „A2“ jack bush and inserted into the „E1“ jack bush.

Back side

Mains switch

Connection

Page 13 © Continental Automotive GmbH BA00-1602-322002

 Calibration Sequence for km/h Control (k = 2500 pul-

6.1 Calibration Sequence for km/h Control (k = 2500 pulses/km)

• Press the „CLEAR“ key of the calibration unit and keep it pressed.
• Wait until the ATC switches from the speed display to the selection menu.
• The menu window for the selection of the speed test is opend by means of the spe-
cial „F3“ key of the BTC I.
• Release the „CLEAR“ key of the calibration unit.
• Select the „Variable speed“ program by means of the key of the BTC I.
• Enter a speed of 020 km/h and a k value of 02500 pulses/km.
(for a description of the input procedure, see the operating instructions of the
ATC 1601-26).
• The following speed are to be selected and the corresponding frequency is to be
checked: 020, 050, 080, 100, 125, 10 and 180 km/h.
• The corresponding frequency is shown on the frequency display of the calibration
unit and must be entered into the certificate (see calibration certificate).
• Finally, if the „km/h control“ test ends at a k value of 2500 pulses/km and a speed of
180 km/h, a km/h value of 000 must be entered.
• After that, the program returns to the selection menu.

6.2 Calibration Sequence for km/h Control (8000 pulses/km)

• Select the „Variable speed“ program by means of the key of the BTC II.
• Test the speed betweeen 020 and 180 km/h and a k value of 08000 pulses/km, as
described under Section 6.1.
• Finally, if the „kph control“ test at k value of 8000 pulses/km and a speed of 180 km/h
has been completed, a km/h value of 000 must be entered.
• After that, the program returns to the selection menu.

6.3 Calibration Sequence for km/h Control (24000 pulses/km)

• Proceed as described under Section 6.2. The k value of 8000 pulses/km must be
changed to 24000 pulses/km.

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Test Set-Up: Calibration of Odometer

7 Test Set-Up: Calibration of Odometer

The test can be set up as described under Section 6.

Back side

Mains switch

Connection

Before calibrating the odometer, check the version numbers of the BTC I and the cradle.
• Press the key of the BTC I. After that, the version numbers of the BTC I and the
cradle will appear in the display of the BTC I.

Page 15 © Continental Automotive GmbH BA00-1602-322002

 Calibration Sequence for Odometer

Example:

A calibration of the odometer is only possible as of Version 05 (BTC I and cradle).

If the version numbers are less than 05, the odometer cannot be calibrated. The following
must be entered under „Comments“:

Certificate issued. Calibration of odometer not possible.

The version numbers of the cradle and the BTC I must also be entered, e.g., cradle = 04.
BTC I = 05.
An update to the newest version is recommended.

7.1 Calibration Sequence for Odometer

• The frequency display of the calibration unit must be switched into the counter mode
by means of the grey key (14) by pressing it two times. 0 must be in the display.
• If 0 is not in the display, set the counter to 0 by means of the red key.
• Select the „Odometer test“ program by means of the arrow key of the BTC I.
• Enter a k value of 08000 pulses/km.
(for the operation of the odometer, see the ATC 1601-26 operating instructions).
• After the k value has been entered and acknowleged by means of the key, the
MTC outputs a frequency and the calibration unit counts the output pulses. This
counting procedure is not important for the measuring result, however, only the fi-
gure change to the TCO is activated.
• Start the odometer measurement by means of the key. At the same time, the
red key of the counter must be pressed. In this way, the counter of the calibration
unit is set to 0 and the measurement is started.
• Observe the counter display of the calibration unit and stop the „Odometer“ program
by means of the key of the BTC I when 1000 is shown on the display.
• The driven measuring track is shown on the display of the BTC I.
• Enter the measured value into the certificate.
1. Measured BTC I value as desired value.
2. Measured value of calibration unit as actual value.

BA00-1602-322002 © Continental Automotive GmbH Page 16

Test Set-Up: Calibration of Clock - Tester

8 Test Set-Up: Calibration of Clock - Tester

Before setting up the test, make sure that the mains switch is at the „0“ (= mains off)
position.

A Calibration unit 1 Shift key for speed 3.2 km/h or 50 km/h

B Calbr. cabel 1602-78-136 2 Shift key for autom. or manual mode
C ATC - cradle 4 Shift key for ATC or MTC
D BTC I 5 Shift key for LS1 or LS2
E Plug cabinet 14 Shift key (grey) for switching over from
counter-mode to frequency mode

Before calibrating the odometer, check the version numbers of the BTC I and the cradle.
• Press the key of the BTC I. After that, the version numbers of the BTC I and the
cradle will appear in the display of the BTC I.

Page 17 © Continental Automotive GmbH BA00-1602-322002

 Measuring Preparations of the Calibration Unit

Example:

A calibration of the clock - tester is only possible as of Version 06 (BTC I and cradle). If
the verison numbers are less than 06, the odometer cannot be calibrated. The following
must be entered under „Comments“:

Certificate issued. Calibration of clock - tester not possible.

The version numbers of the cradle and the BTC I must also be entered, e.g. Cradle = 04,
BTC I = 05.

An update to the newest version is recommended.

8.1 Measuring Preparations of the Calibration Unit

• Switch 1, 50 km/h position

• Switch 2, autom. position
• Switch 4, ATC position
• Switch 5, LS2 position

8.2 Measuring Preparations of the ATC

• Connect the ATC to the calibration unit by means of the 1602-78-136 calibrating line.
• Switch on the voltage of the calibration unit. The red LED in the calibrating line
1602-78-136 has to light up in a 1 second-cycle.

8.3 Calibration Sequence for Clock - Tester

• Select the program „test device“ by means of the arrow key of the BTC I in the
selection-menu.
• After that a further menu-mask appears on the display. Select the prgram „clock
test“ by menas of the arrow key.
• Start the clock - test by means of the key.
• A clock - tester measurement requires about 15 sec. At the end appears the diver-
gence of the range of tolerance in sec./24h.
• By means of the key, the measurement can be reapeted.
• Returning to the selection-menu by means of the „C“ key.

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Inspection of Entire Installation

9 Inspection of Entire Installation

At the end of the calibration procedure, the voltage of the calibration unit must be switched
off and the calibrating cable must be removed. A function test must then be performed.

9.1 ATC Setting

• Set tire correction value.

• Set test stand type.

9.2 Vehicle Function Test

• Automatic test.
• Enter vehicle identification number.
• Print out installation plate and make sure that the printout is error-free.
• Compare the measured valued in the installatiion plate with those in the display of
the BTC I.

Page 19 © Continental Automotive GmbH BA00-1602-322002

 Concluding Tasks

10 Concluding Tasks
After the calibration procedure has been completed, the voltage of the calibration unit
must be switched off and the calibrating cable must be removed. The certificate must be
filled out completely with the signature of the inspector and his/her company stamp.
Any recognised defects, such as damage, missing parts, etc. must be entered into the cer-
tificate under „Comments“.
After calibration, the respective measuring device receives a calibration label, on which
the duration of calibration validity is marked.

Year Month
The date of validity is marked by cutting out (marking) the corresponding month and year
fields on the calibration label.

The calibration label must be attached to the back side of the cradle. The surface onto
which the calibration label is to be attached must first be cleaned.

Cradle

Calibration label

Rating plate

BA00-1602-322002 © Continental Automotive GmbH Page 20

Sample Certificate

11 Sample Certificate

A sample certificate for the ATC is located in the Appendix. All measured values are in
italics and bold print (4000). The certificate must be filled out completely, including the si-
gnature of the inspector and her/his company stamp. If a measured value is not within the
acceptable tolerance, no certificate may be issued. The date of validity entered into the
certificate must correspond to the date of validity on the calibration label attached to the
testing device.

Page 21 © Continental Automotive GmbH BA00-1602-322002

 Sample Certificate

CALIBRATION CERTIFICATE
Rolling Road Test Computer (ATC)

Device type : ATC 1601.26 Cradle no. : 12345

BTC no. : 10101 Certificate no. : M/2008/06/001

Date : 04.06.2008 Valid until : 04.06.2009

The proper function of the above-mentioned testing device has been tested and
calibrated. The measuring devices used for calibration meet national standards.

Calibration Unit Device no.:

1602.32 0066

1.) k pulse test

Desired value Tolerance Actual value

135 Hz r 15 Hz 136,57

Level display correct yes/no yes

1000 pulses/km r 1 pulses/km 1000

Page 1 of 4

BA00-1602-322002 © Continental Automotive GmbH Page 22

Sample Certificate

CALIBRATION CERTIFICATE
Rolling Road Test Computer (ATC)

2.) Calculation of roller correction (RC) and check of

speed display
Calculation of roller correction (test stand roller adaptation)

Desired value Tolerance Actual value

50 km/h r 0.2 km/h 50,1

If the desired value and the actual value are both equal to 50 km/h ± 0,2 km/h, the test stand
has no roller correction value. The constant is RC = 1.000 (calculation to 3 decimal places).
If the actual value is greater than or lesser than 50 km/h, the roller set of the test stand has a
roller correction value. This value is calculated by means of the following formula:

Desired value
RC= RC = 1,000
Actual value

The actual values of the distance pulse and the tyre circumference must be corrected
by means of this RC constant.
Example: Measured distance pulse = 7500 pulses/km. Tyre circum. = 2666 mm. RC = 1.5
Measured distance pulse = 7500 pulses/km 1.5 = 5000 pulses/km (actual value)
Measured tyre circumference = 2666mm * 1,5 = 4000 mm (actual value).

3.) Automatic test of distance pulse and tyre circumference measurement

The test of the distance pulse and tyre circumference measurement was carried out twice.

Desired value Tolerance Actual value

1. w 5000 pulses/km r 5 pulses/km Measured value RC = 5000

l 4000 mm r 4 mm Measured value * RC = 4000

2. w 5000 pulses/km r 5 pulses/km Measured value RC = 5001

l 4000 mm r 4 mm Measured value* RC = 4001

If the test stand has a roller correction function, the tolerance increases by ± 2 pulses/km for
the distance pulse measurement and by ± 2 mm for the tyre circumference measurement.

Page 2 of 4

Page 23 © Continental Automotive GmbH BA00-1602-322002

 Sample Certificate

CALIBRATION CERTIFICATE
Rolling Road Test Computer (ATC)

4.) km/h control test (k value = 2500 pulses/km)

Desired value Tolerance Actual value

20 km/h 13,89 Hz r 1 Hz 0013,88

50 km/h 34,71 Hz r 1 Hz 0034,72
80 km/h 55,55 Hz r 1 Hz 0055,57
100 km/h 69,44 Hz r 1 Hz 0069,44
125 km/h 86,79 Hz r 1 Hz 0086,77
150 km/h 104,15 Hz r 1 Hz 0104,15
180 km/h 125,00 Hz r 1 Hz 0124,95

5.) km/h control test (k value = 8000 pulses/km)

Desired value Tolerance Actual value

20 km/h 44,44 Hz r 1 Hz 0044,43

50 km/h 111,11 Hz r 1 Hz 0111,12
80 km/h 177,76 Hz r 1 Hz 0177,75
100 km/h 222,22 Hz r 1 Hz 0222,23
125 km/h 277,75 Hz r 1 Hz 0277,76
150 km/h 333,33 Hz r 1 Hz 0333,33
180 km/h 400,00 Hz r 1 Hz 0399,96

6.) km/h control test (k value = 8000 pulses/km)

Desired value Tolerance Actual value

20 km/h 133,33 Hz r 2 Hz 0133,32

50 km/h 333,33 Hz r 2 Hz 0333,34
80 km/h 533,28 Hz r 2 Hz 0533,28
100 km/h 666,67 Hz r 2 Hz 0666,68
125 km/h 833,25 Hz r 2 Hz 0833,23
150 km/h 1000,00 Hz r 2 Hz 0999,95
180 km/h 1200,00 Hz r 2 Hz 1199,85

Page 3 of 4

BA00-1602-322002 © Continental Automotive GmbH Page 24

Sample Certificate

CALIBRATION CERTIFICATE
Rolling Road Test Computer (ATC)

7.) Odometer test (k = 8000 pulses/km)

Desired value Tolerance Actual value

(BTC display) (frequency display of calibration unit)

at least 1000 rev.

1000 r 2 rev. 1001

8.) Clock test

Desired value Tolerance Actual value

0,0 sec/24h r 1 sec/24h 0,0

Comments:

Continental Automotive GmbH is a

company certified according to
DIN EN ISO 9001: 2000 Company stamp/Signature of inspector

Page 4 of 4

Page 25 © Continental Automotive GmbH BA00-1602-322002

Stationary Test Computer STC

STC 1601-25
Calibration Instructions
Table of Contents
1 Brief Description (Front side). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.1 Brief Description (Back side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
3 STC Functional Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
4 Test Set-Up: Calibration of k Pulse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
4.1 Measuing Preparations for Calibration Unit. . . . . . . . . . . . . . . . . . . . . . . 11
4.2 Measuring Preparations of the STC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
4.3 Calibration Sequence for k Pulse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5 Test Set-Up: Calibration of the Mechanical Drive for km/h . . . . . . . . . . . .12
5.1 Measuring Preparations of Calibration Unit. . . . . . . . . . . . . . . . . . . . . . . 13
5.2 Measuring Preparations of the STC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
5.3 Calibration Sequence of Mechanical Drive for km/h . . . . . . . . . . . . . . . . 13
6 Test Set-Up: Calibration of Mechanical Drive for 1/min . . . . . . . . . . . . . .14
6.1 Calibration Sequence of Mechanical Drive for 1/min . . . . . . . . . . . . . . . 14
7 Test Set-Up: Calibration of Mechanical Drive for rev. . . . . . . . . . . . . . . . .15
7.1 Calibration Sequence of Mechanical Drive for rev. . . . . . . . . . . . . . . . . . 15
8 Test Set-Up: Calibration of Output Voltage . . . . . . . . . . . . . . . . . . . . . . . .16
8.1 Measuring Preparations of the Calibration Unit. . . . . . . . . . . . . . . . . . . . 17
8.2 Measuring Preparations of the STC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8.3 Calibration Sequence for Output Voltage . . . . . . . . . . . . . . . . . . . . . . . . 17
9 Test Set-Up: Calibration of km/h Control (v = 8 pulses/rev.) . . . . . . . . . . .18
9.1 Measuring Preparations of the Calibration Unit. . . . . . . . . . . . . . . . . . . . 19
9.2 Measuring Preparations of the STC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
9.3 Calibration Sequence for km/h Control (v = 8 pulses/rev.) . . . . . . . . . . . 19
10 Test Set-Up: Calibration of 1/min Control (n = 4 pulses/rev.) . . . . . . . . . .20
10.1 Calibration Sequence for 1/min Control (n = 4 pulses/rev.) . . . . . . . . . . 21
11 Test Set-Up: Calibration of kph Control. . . . . . . . . . . . . . . . . . . . . . . . . . .22
11.1 Calibration Sequence for km/h Control
(k =2500 pulses/km) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
11.2 Calibration Sequence for km/h Control (8000 pulses/km). . . . . . . . . . . . 23
11.3 Calibration Sequence for km/h Control (24000 pulses/km). . . . . . . . . . . 23
12 Test Set-Up: Calibration of Odometer . . . . . . . . . . . . . . . . . . . . . . . . . . . .24

BA00-1602-322002 © Continental Automotive GmbH Page 2

12.1 Calibration Sequence for Odometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
13 Test Set-Up: Calibration Clock - Tester . . . . . . . . . . . . . . . . . . . . . . . . . . 26
13.1 Measuring Preparations for the STC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
13.2 Calibration Sequence for Clock - Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
14 Concluding Tasks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
14.1 Sample Certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Page 3 © Continental Automotive GmbH BA00-1602-322002

 Brief Description (Front side)

1 Brief Description (Front side)

1 Plug-in for operating test coputer (BTC)

2 Display (measured value display)
3 Display (current/ voltage display)
4-11 Function keys
12 Switch for function keys
13 Set-point knob
14 Current regulator
15 Voltage regulator
16 v/n connecting jack
17 K connecting jack
18 Output voltage jack
19 Shift key for current/ voltage display
20 Mains switch

BA00-1602-3220002 © Continental Automotive GmbH Page 4

Brief Description (Back side)

1.1 Brief Description (Back side)

21 Fuse T 1.6
22 Fuse T 4
23 Fuse FF 10
24 Mains jack
25 Drive output for mechanical shaft connection

Additional, i.e., detailed, descriptions can be found in the respective operating instruc-
tions.

Page 5 © Continental Automotive GmbH BA00-1602-3220002

 Technical Data

2 Technical Data
Standard Version:
Display: 4-digit numerical LCD
( v/n/rev.)
Digit height = 13 mm
4-digit numerical LCD (V/A)
digit height = 13mm
Interfaces: Frequency output (k pulse)
f max. 150 Hz, max 10V, max 30 mA
Frequency output (8 pulses)
f max. 6 kHz 150 Hz, max 10V,
max 30 mA
Frequency output (4 pulses)
f max. 3 kHz, max 10V, max 30 mA
Mains connection : 187 - 242 V, 50 Hz
Operating temperature : + 5 °C to + 40 °C
Device constant : fixed k = 1000 rev./km
Power supply unit: 5 - 30 V max. 3A variable
6 V, 12 V, 24 V 3A fixed
Measuring ranges ( machanical drive): 10 - 200 km/h
160 - 3333 rpm
0 - 9999 revolutions

Automatic Version (Additional Functions) :

Measuring ranges (electronic): 10 - 200 km/h
0 - 9999 revolutions
Device constant: 2400 to 99999 pulses/km
Counter (distance) 0 - 9999 pulses

BA00-1602-3220002 © Continental Automotive GmbH Page 6

STC Functional Test

3 STC Functional Test

1 Plug-in for operating test coputer (BTC)

2 Display (measured value display)
3 Display (current/ voltage display)
4-11 Function keys
12 Switch for function keys
13 Set-point knob
14 Current regulator
15 Voltage regulator
16 v/n connecting jack
17 K connecting jack
18 Output voltage jack
19 Shift key for current/ voltage display
20 Mains switch

Page 7 © Continental Automotive GmbH BA00-1602-3220002

 STC Functional Test

The following itmes must be carried out to perform a function test:

Display Test:
• Turn set-point knob (13) to left until the limit stop.
• Set the display selection switch (12) to switch position STC.
• For the 4 - 11 function keys, only the 6 V function key (8) may be pressed
(locked into place).
• Switch on the STC by means of the mains switch (20). After that, 000.0 must be
shown in the display (2).
• Press function key (5) until it locks into place.
• Press test key (4).
• After that, 8888 must be shown in the display (2).

Internal Crystal Control:

• For the 4 - 11 function keys, only 6 V function key (8) may be pressed.
• Press test key (4).
• The value 4915 ± 2 must be shown in the display (2).

Function Test for Speed (km/h) Measuring Range:

• Turn the set-point knob (13) to right until approx. 100 km/h is shown in the
display (2).
• Before calibrating the device, let it warm up for 10 minutes.
• Turn the set-point knob to the rigth until the limit stop. A value of at least 190.0 must
be shown in the display (2).
• Turn the set-point knob back to the left limit stop. 000.0 must be shown in the display
(2). A decimal point must light up between the 3rd and 4th digit of the display.

Function Test for Engine Speed (1/min) Measuring Range:

• Press function key (5) until it locks into place (position n).
• 0000 must be shown in the display (2)
• Turn set point knob (13) slowly to the right and ceck whether the three right-
hand digit displays show the values 0 to 9 or whether the left-hand digit displays
shows the value 0 to 3.
• After the right limit stop has been reached, a value of at least 3000 must be shown in
the display.
• Turn the set-point knob back to the left limit stop.

In case of an automatic STC, the BTC I should be tested as well.

See testing regulations for BTC I, BTC II, BTC III and TKG.

BA00-1602-3220002 © Continental Automotive GmbH Page 8

Test Set-Up: Calibration of k Pulse

4 Test Set-Up: Calibration of k Pulse

Before setting up the test, make sure that the mains switch is at the „0“ (= mains off)
position

Back side

Mains Switch
Ground line

Connection

A Calibration unit 1 Shift key for speed

B Testing cable (jack plug) = 3.2 km/h or 50 km/h
(STC component) 2 Shift key for autom. or manual
mode
D STC
E Measured value display4 Shift key for ATC oder MTC mode
F Voltage display 5 Shift key for LS1 oder LS2 light
O Switch for function selection barrier
P Set-point knob 14 Shift key (grey) for switching over
from counter-mode to frequency-
mode

Page 9 © Continental Automotive GmbH BA00-1602-3220002

 Measuing Preparations for Calibration Unit

4.1 Measuing Preparations for Calibration Unit

• Switch 1, 50 km/h position

• Switch 2, autom. position
• Switch 4, ATC position
• Switch 5, LS2 position

4.2 Measuring Preparations of the STC

• Turn set-point knob „P“ to the left until the limit stop.
• Set function selection switch „O“ to KX10
• Insert the testing cable (jack plug line), which is an STC component, into the
pulses/km jack bush of the STC an into the „E1“ jack bush of the calibration unit
(measuring line part of delivery content).
• Insert the ground wire into the „-“banana socket (black) of the STC and the „-“banana
socket (black) of the calibration unit labelled „output“.
• Connect the calibration unit to 230 V by means of a voltage cable, then switch on the
voltage.
• The value 0.00 must be shown in the frequency display of the calibration unit. If this
is not the case, grey key (14) must be pressed two times to activate the frequency
display.
• Connect the STC to 230 V by means of a voltage cable, then switch on the voltage.

4.3 Calibration Sequence for k Pulse

• After the STC is switched on, the measuring frequency for the k measurement is out-
putted.
• The measured frequency appears in the frequency display of the calibration unit.
• The measured k value appears in the measured value diplay of the STC.
• The LED of the calibraion unit must light during the k measurement.
• Enter measured values in the certificat
1. Measured value of frequency display
2. Level size: yes/no (level size = yes when the LED is lit)
3. k vlaue display of STC
• At the end of the calibration sequence, the testing cable (jack plug line) must be re-
moved. The ground may not be removed.

BA00-1602-3220002 © Continental Automotive GmbH Page 10

Test Set-Up: Calibration of the Mechanical Drive for km/h

5 Test Set-Up: Calibration of the Mechanical Drive for km/h

Back side

Mains switch

Main voltage

Ground line

A Calibration unit 1 Shift key for speed

B Calibrating cable 1602-78-123 = 3.2 km/h or 50 km/h
D STC 2 Shift key for autom. or manual
E Measured value display mode
F Voltage display 4 Shift key for ATC oder MTC
mode
G Functiong key for test 5 Shift key for LS1oder LS2
H Function key for v/n light barrier
I Function key for Start/Stop 14 Shift key (grey) for switching
from counter-mode to fre-
J Function key for v/n/rev. quency-mode
O Switch for function selection
P Set-point knob
X Test sensor 1602-0118-000-000 (10 pulses)

Page 11 © Continental Automotive GmbH BA00-1602-3220002

 Measuring Preparations of Calibration Unit

5.1 Measuring Preparations of Calibration Unit

• Switch 1, 50 km/h position

• Switch 2, autom. position
• Switch 4, ATC position
• Switch 5, LS2 position

5.2 Measuring Preparations of the STC

• Set display selection switch „O“ to STC.

• None of the „G-J“ function keys of the STC may be pressed (locked into place).
• Screw the 1602-0118-000-000 (10 pulses) test sensor on the back side of the STC
to the mechanical drive.
• Connect the 1602-78-123 calibrating cable to the test sensor and to the calibration
unit.
• The value 0.00 must be shown in the frequency display of the calibration unit. If this
is not the case, grey key (14) must be pressed two times to activate the frequency
display.

5.3 Calibration Sequence of Mechanical Drive for km/h

• Turn set-point knob „P“ of the STC to the right until 20.0 km/h is shown in the mea-
sured value display of the STC.
• The following speeds are to be selected and the corresponding frequency is to be
checked: 20, 50, 80, 100, 125, 150 and 180 km/h. The corresponding frequency is
shown on the frequency display of the calibration unit and must be entered into the
certificate (see calibration certificate).
• If the test of mechanical drive for km/h has been completed, turn the set-point knob
of the STC to the left until the limit stop.

BA00-1602-3220002 © Continental Automotive GmbH Page 12

Test Set-Up: Calibration of Mechanical Drive for 1/min

6 Test Set-Up: Calibration of Mechanical Drive for 1/min

The test can be set up as described under Section 5. In addition, the „H“ ( v ) key of the
n
STC must be pressed (locked inot place).

Back side

Mains switch

Connection

Ground line

6.1 Calibration Sequence of Mechanical Drive for 1/min

• Turn the set-point to the right until 1000 1/min is shown in the measured value
display of the STC.
• Select the following engine speeds one after the other and check the corresponding
frequency: 1000, 2000, 3000 1/min.
• The frequency is shown in the frequency display of the calibration unit and must be
entered into the certificate.
• If the test of the mechanical drive for 1/min has been completed, turn the set-point
knob to the left until the limit stop.

Page 13 © Continental Automotive GmbH BA00-1602-3220002

 Test Set-Up: Calibration of Mechanical Drive for rev.

7 Test Set-Up: Calibration of Mechanical Drive for rev.

The test can be set up as described under Section 6. In addition, the „I“ and „J“ keys of
the STC must be pressed (locked into place).

Back side

Mains switch

Connection

Ground line

7.1 Calibration Sequence of Mechanical Drive for rev.

• The frequency display of the calibration unit must be switched into the counter mode
by pressing the grey key (14) two times. 0 must be in the display.
• If 0 is not in the display, set the counter to 0 by means of the red key.
• Turn set-point knob „P“ slowly to the right until the counting procedure in the measu-
red value display begins.
• Observe the measured value display of the STC and when a measured value of
1000 has been reached, turn the set-point knob to the left until limit stop.
• Enter the measured value into the certificate:
1. Measured STC value as desired value
2. Measured value of calibration unit as actual value.
The actual value is greater by a factor of 1.25, as a test sensor with 10 pulses/rev.
is used (standard = 8 pulses/rev.)
• When the calibration sequence has come to an end, remove the calibrating cable
and the test sensor. The ground wire may not be removed.

BA00-1602-3220002 © Continental Automotive GmbH Page 14

Test Set-Up: Calibration of Output Voltage

8 Test Set-Up: Calibration of Output Voltage

Back side

Mains switch
Ground line

Connection

ACalibration unit 1 Shift key for speed

B Measuring line, red = 3.2 km/h or 50 km/h
C Ground wire, black 2 Shift key for autom. or manual
D STC mode
E Measured value display 4 Shift key for ATC oder MTC
mode
FVoltage display 5 Shift key for LS1 or LS2 light
KFunction key for 6 V barrier.
LFunction key for 12 V14 Shift key (grey) for switching
over from counter-mode to
MFunction key for 24 V frequency-mode
NFunction key for variable voltage
QCurrent regulator
RVoltage regulator
TMains switch

Page 15 © Continental Automotive GmbH BA00-1602-3220002

 Measuring Preparations of the Calibration Unit

8.1 Measuring Preparations of the Calibration Unit

• Switch 1, 50 km/h position

• Switch 2, autom. position
• Switch 4, ATC position
• Switch 5, LS2 position

8.2 Measuring Preparations of the STC

• Press „K“ (6 V) function key until it locks into place.

• Set the „Q“ current controller to 2 ampere.
• Turn the „R“ voltage regulator to the left until the limit stop.
• Set the display shift key „S“ to position „U“.
• Insert the measuring line (red) into the „+“ banana socket of the STC and the „V“ ba-
nana socket (red) of the calibration unit labelled „output“ (measuring line in delivery
content).

8.3 Calibration Sequence for Output Voltage

• After the test has been set up, the measured value appears in the voltage display of
the calibration unit.
• Enter the measured value into the certificate.
• Press the „L“ (12 V) key of the STC until it locks into place.
• The measured value appears in the voltage display of the calibration unit.
• Enter the measured value into the certificate.
• Press the „M“ (24 V) key of the STC until it locks into place.
• The measured value appears in the voltage display of the calibration unit.
• Press the „N“ key of the STC until it locks into place.
• Turn the „R“ voltage regulator of the STC to the right until a voltage value of 5 V
appears in the „F“ voltage display of the STC.
• The measured value appears in the voltage display of the calibration unit.
• Enter the measured value into the certificate.
• Turn the „R“ voltage regulator of the STC to the right until a voltage value of 12 V
appears in the „F“ voltage display of the STC.
• The measured value appears in the voltage display of the calibration unit.
• Enter the measured value into the certificate.
• Turn the „R“ voltage regulator of the STC to the right until a voltage value of 24 V
appears in the „F“ voltage display of the STC.
• The measured value appears in the voltage display of the calibration unit.
• Enter the measured value into the certificate.
• At the end of the test, remove the measuring line (red) from the STC an the cali-

BA00-1602-3220002 © Continental Automotive GmbH Page 16

Test Set-Up: Calibration of km/h Control (v = 8 pulses/rev.)

brator. The ground wire may not bei removed.

9 Test Set-Up: Calibration of km/h Control (v = 8 pulses/rev.)

Back side

Mains switch

AMP - plug Connection

Ground line

AMP - jacks

A Calibration unit 1 Shift key for speed

B Calibr. cable 1602-78-122 = 3.2 km/h or 50 km/h
C Testing cable, 4/8 pulses 2 Shift key for autom. or manual
(STC component) mode
D STC 4 Shift key for ATC or MTC
mode
E Measured value display 5 Shift key for LS1 or LS2 light
F Voltage display barrier
14 Shift key (grey) for switching
over from counter-mode to
frequency-mode.

Page 17 © Continental Automotive GmbH BA00-1602-3220002

 Measuring Preparations of the Calibration Unit

9.1 Measuring Preparations of the Calibration Unit

• Switch 1, km/h position

• Switch 2, autom. position
• Switch 4, ATC position
• Switch 5, LS2 position

9.2 Measuring Preparations of the STC

• Set „O“ display selection to STC.

• None of the „G-J“ function keys may be locked into place.
• Connect the „B“ 1602-78-122 calibrating cable to the calibration unit.
• Connect the testing cable 4/8 pulses (STC component) to the STC.
• Attach the calibration cable (AMP plug) and the testing cable (AMP bush:
v = 8 pulses) to each other.
• The value 0.00 must be shown in the frequency display of the calibartion unit. If this
is not the case, grey key (14) must be pressed two times to activate the frequency
display.

9.3 Calibration Sequence for km/h Control (v = 8 pulses/rev.)

• Turn set-point knob „P“ of the STC to the right until 20.0 km/h is shown in the mea-
sured value display of the STC.
• The following speeds are to be selected and the corresponding frequency is to be
checked: 20, 50, 80,100, 125, 150 and 180 km/h. The corresponding frequency is
shown on the frequency display of the calibration unit and must be entered into the
certificate (see calibration certificate).
• If the test has been completed, turn the set-point knob of the STC to the left until
limit stop.

BA00-1602-3220002 © Continental Automotive GmbH Page 18

Test Set-Up: Calibration of 1/min Control (n = 4 pulses/rev.)

10 Test Set-Up: Calibration of 1/min Control (n = 4 pulses/rev.)

The test can be set up as described under Section 9. The „H“ ( vn ) function key of the
STC must be pressed until it locks into place. The calibrating cable must be removed from
the „v = 8pulses“ AMP bush inserted into the „n = 4 pulses“ AMP bush.

Back side

Mains switch

AMP - plug
Connection
Ground line

AMP - jacks

Page 19 © Continental Automotive GmbH BA00-1602-3220002

 Calibration Sequence for 1/min Control (n = 4 pulses/

10.1Calibration Sequence for 1/min Control (n = 4 pulses/rev.)

• Turn the set-point knob „P“ of the STC to the right until 1000 1/min is shown in the
mesuring value display of the STC.
• Select the following engine speeds one after the other: 1000, 2000, 3000 1/min. The
frequency is shown in the frequency display of the calibration unit and must be en-
tered into the certificate (see calibration certificate).
• If the test has been completed, turn the set-point knob to the left until limit stop.

Note:
If a standard-design STC is being calibrated, skip the following chapters to Chapter 13
„Concluding Tasks“ to complete the calibrations procedure. If an automatic STC is
being calibrated, an extended calibration must be performed.

BA00-1602-3220002 © Continental Automotive GmbH Page 20

Test Set-Up: Calibration of kph Control

11 Test Set-Up: Calibration of kph Control

In the case of an automatic STC (Test Set-Up: 11), the test can be set up as described
under Section 9. In addition, the BTC I must be inserted into the corresponding STC
mount. Set the „O“ function switch of the STC to the „BTC“ position.
Attach the calibrating cable (AMP plug) and the testing cable (AMP bush: v = 8 pulses) to
each other.

Back side

Mains switch

Ground line
AMP - plug
Connection

AMP - jacks

A Calibration unit 1 Shift key for speed

B Calibrating cable = 3.2 km/h or 50 km/h
1602-78-122 2 Shift key for autom. or manual
C Testing cable, 4/8 pulses mode
(STC component)) 4 Shift key for ATC or MTC mode
D STC 5 Shift key for LS1 or LS2 light
E Measured value display barrier
FVoltage display 14 Shift key (grey) for switching
O Function selection switchover from counter-mode to
U BTC I frequency-mode

Page 21 © Continental Automotive GmbH BA00-1602-3220002

 Calibration Sequence for km/h Control (k =2500 pul-

11.1Calibration Sequence for km/h Control

(k =2500 pulses/km)

• Select the „Variable speed“ program by means of the arrow key of the BTC I.
• Enter a speed of 020 km/h and a k value of 02500 pulses/km.
(for a description of the input procedure, see the operating instructions of the
STC 1601-25)
• The following speeds are to be selected and the corresponding frequency is to be
checked: 020, 050, 080, 100, 125, 150 and 180 km/h. The corresponding frequency
is shown on the frequency display of the calibration unit and must be entered into
the certificate (see calibration certificate).
• Finally, if the „km/h control“ test ends at a k value of 2500 pulses/km and a speed of
180 km/h, a km/h value of 000 must be entered.
• After that, the program returns to the selection menu.

11.2Calibration Sequence for km/h Control (8000 pulses/km)

• Select the „Variable speed“ program by means of the arrow key of the BTC I.
• Test the speed betweeen 020 and 180 km/h and a k value of 08000 pulses/km, as
described under Section 11.1.
• Finally, if the „km/h control“ test at a k value of 8000 pulses/km and a speed of
180 km/h has been completed, a km value of 000 must be entered.
• After that, the program returns to the selection menu.

11.3Calibration Sequence for km/h Control (24000 pulses/km)

• Proceed as described under Section 11.2. The k value of 8000 pulses/km must be
changed to 24000 pulses/km.

BA00-1602-3220002 © Continental Automotive GmbH Page 22

Test Set-Up: Calibration of Odometer

12 Test Set-Up: Calibration of Odometer

The test can be set up as described under Section 11.

Back side

Mains switch

Ground line
AMP - plug
Connection

AMP - jacks

Before calibration of the odometer, request the version numbers of the BTC I and the
cradle.

Press the key of the BTC I. After that, the version numbers of the BTC I and the cradle
will appear in the display of the BTC I.

Page 23 © Continental Automotive GmbH BA00-1602-3220002

 Calibration Sequence for Odometer

Example:

A calibration of the odometer is only possible as of version 05 (BTC I and cradle).

If the version numbers are less than 05, the odometer cannot be calibrated. The following
must be enterd under „Comments“:

Certificate issued. Calibration of ofometer not possible.

The version numbers of the cradle and the BTC I must also be entered, e.g., cradle = 04,
BTC I = 05.
An update to the newest version is recommended.

12.1Calibration Sequence for Odometer

• The frequency display of the calibration unit must be switched into the counter mode
by pressing the grey key (14) two times. 0 must be in the display
• If 0 is not in the display, set the counter to 0 by means of the red key.
• Select the „Odometer test“ program by means of the arrow key of the BTC I.
• Enter a k value of 08000 pulses/km.
(for the operation of the odometer, see the STC 1601-25 operating instructions.)
• After the k value has been entered and acknowleged by means of the key, the
STC outputs a frequency and the calibration unit counts the output pulses. This
counting procedure is not important for the measuring result, however, only the fi-
gure change of the TCO is activated.
• Sart the odometer measurement by means of the key. At the same time, the
red key of the counter must be pressed. In this way, the counter of the calibration
unit is set to 0 and the measurement is started.
• Observe the counter display of the calibration unit and stop the „Odometer“ program
by means of the key of the BTC I when 1000 is shown on the display.
• The driven measuring track is shown on the display of the BTC I in meters.
• Enter the measured value into the certificate.
1. Measured BTC I value as desired value
2. Measured value of calibration unit as actual value.

BA00-1602-3220002 © Continental Automotive GmbH Page 24

Test Set-Up: Calibration Clock - Tester

13 Test Set-Up: Calibration Clock - Tester

The test can be set up as described under Section 11.
Back side

Mains switch

Connection

A Calibration unit 1 Shift key for speed = 3.2 km/h or 50 km/h

B Calbr. cable 1602-78-136 2 Shift key for autom. or manual mode
C STC 4 Shift key for ATC or MTC
D BTC I 5 Shift key for LS1 or LS2
E LED clock stroke 14 Shift key for switching over from counter-
mode to frequency-mode

Before calibration of the odometer, request the version numbers of the BTC I and the
cradle.
Press the key of the BTC I. After that, the version numbers of the BTC I and the cradle
will appear in the display of the BTC I.

Page 25 © Continental Automotive GmbH BA00-1602-3220002

 Measuring Preparations for the STC

Example:

A calibration of the clock - tester is only possible as of Version 06 (BTC I and cradle). If
the version numbers are less than 06, the clock tester connot be calibrated. The following
must be entered under „Comments“:

Certificate issued. Calibration of clock - tester not possible.

The version nmbers of the cradle and the BTC I must also be entered, e.g. Cradle = 04,
BTC I = 05.

An update to the newest version is recommended.

13.1Measuring Preparations for the STC

• Connect the STC to the calibration unit by means of the 1602-78-136 calibrating line.
• Switch on the voltage of the calibration unit. The red LED „E“ on the calibrating line
1602-78-136 have to ligth up in a 1 second-cycle.

13.2Calibration Sequence for Clock - Test

• Select the program „Clock-Test“ by means of the arrow key in the selection menu.
• After that a further menu-mask appears on the display. Select the program „clock -
tester“ by means of the arrow key.
• Start the clock - test by means of the key.
• A clock - tester measurement requires about 15 sec. At the end appears the div-
ergence of the range of tolerance in sec./24h.
• By means of the key, the measurement can be repeated.
• Returning to the selction-menu by means of the „C“ key.

BA00-1602-3220002 © Continental Automotive GmbH Page 26

Concluding Tasks

14 Concluding Tasks
After the calibration procedure has been completed, the voltage of the calibration unit
must be switched off and the calibrating cable must be removed. The certificate must be
filled out completly with the signature of the inspector and his/her company stamp.
Any recognised defects, such as damage, missing parts, etc. must be entred into the cer-
tificate under „Comments“.
After calibration, the respective measuring device receives a calibration label, on which
the duration of calibration validity is marked.

Year Month
The date of validity is marked by cutting out (marking) the corresponding month and year
fields on the calibration label.

The calibration label must be attached to the frontside of the STC. The surface onto which
the calibration label is to be attached must first be cleaned.

Calibration label

Page 27 © Continental Automotive GmbH BA00-1602-3220002

 Sample Certificate

14.1Sample Certificate

A sample certificate for the STC is located in the Appendix. All measured values are in
italics and bold print (4000). The certificate must be filled out completely, including the si-
gnature of the inspector and his/her company stamp. If a measured value is not within the
acceptable tolerance, no certificate may be issued. The date of validity entered inot the
certificate must correspond to the date of validity on the calibration label attached to the
testing device.

BA00-1602-3220002 © Continental Automotive GmbH Page 28

Sample Certificate

CALIBRATION CERTIFICATE
Stationary Test Computer

Device type : STC 1601.25 BTC no. : 123456

Serial no. : 123456 Certificate no. : M/2008/06/001

Date : 04.06.2008 Valid until : 04.06.2009

The proper function of the above-mentioned testing device has been tested and
calibrated. The measuring devices used for calibration meet national standards.

Calibration Unit Device no.:

1602.32 0066

Standard Version Test (Mechanical Drive)

1.) k pulse test

Desired value Tolerance Actual value

135 Hz r 15 Hz 128,45
Level display correct yes/no yes
100 pulses/km r 1 pulses/km 100

2.) Test of mechanical drive with digital km/h display

Desired value Tolerance Actual value

20 km/h 55,55 Hz r 1 Hz 055,48

50 km/h 138,88 Hz r 1 Hz 138,76
80 km/h 222,22 Hz r 1 Hz 222,25
100 km/h 277,77 Hz r 1 Hz 277,95
125 km/h 347,22 Hz r 1 Hz 347,34
150 km/h 416,66 Hz r 1 Hz 416,57
180 km/h 500,00 Hz r 1 Hz 499,86

Page 1 of 5

Page 29 © Continental Automotive GmbH BA00-1602-3220002

 Sample Certificate

CALIBRATION CERTIFICATE
Stationary Test Computer

3. ) Test of mechanical drive with digital rpm display

Desired value Tolerance Actual value

1000 rpm 166,66 Hz r 1 Hz 166,69

2000 rpm 333,33 Hz r 1 Hz 333,39
3000 rpm 500,00 Hz r 1 Hz 499,86

4.) Test of mechanical drive with digital rev. display

Desired value Tolerance Actual value

at least 1000 rev.

(test stand display) (calibration unit display x 1.25)

1000 r 2 rev. 1250

5.) Voltage test (fixed voltage 6V, 12V, 24V)

Soll - Wert Toleranz Ist - Wert

6 Volt r 0,3 Volt 05,96

12 Volt r 0,6 Volt 11,95
24 Volt r 1,2 Volt 23,94

6.) Voltage test (variable voltage 5V - 24V)

Soll - Wert Toleranz Ist - Wert

5 Volt r 0,25 Volt 05,97

12 Volt r 0,6 Volt 11,96
24 Volt r 1,2 Volt 23,98

Page 2 of 5

BA00-1602-3220002 © Continental Automotive GmbH Page 30

Sample Certificate

CALIBRATION CERTIFICATE
Stationary Test Computer

Standard Version Tests (Electronic Control System)

7.) km/h control test (v = 8 pulses/rev.)

Desired value Tolerance Actual value

20 km/h 44,44 Hz r 1 Hz 044,42

50 km/h 111,11 Hz r 1 Hz 111,15
80 km/h 177,76 Hz r 1 Hz 177,76
100 km/h 222,22 Hz r 1 Hz 222,24
125 km/h 277,75 Hz r 1 Hz 277,78
150 km/h 333,33 Hz r 1 Hz 333,31
180 km/h 400,00 Hz r 1 Hz 399,94

7.1) rpm control test (n = 4 pulses/rev.)

Desired value Tolerance Actual value

1000 rpm 66,67 Hz r 1 Hz 066,69

2000 rpm 133,33 Hz r 1 Hz 133,35
3000 rpm 200,00 Hz r 1 Hz 199,98

Page 3 of 5

Page 31 © Continental Automotive GmbH BA00-1602-3220002

 Sample Certificate

CALIBRATION CERTIFICATE
Stationary Test Computer
Automatic Version Tests (Speed v)
8.)km/h control test (k vlaue = 2500 pulses/km, v = 8 pulses.)

Desired value Tolerance Actual value

20 km/h 13,89 Hz r 1 Hz 0013,88

50 km/h 34,71 Hz r 1 Hz 0034,72
80 km/h 55,55 Hz r 1 Hz 0055,57
100 km/h 69,44 Hz r 1 Hz 0069,44
125 km/h 86,71 Hz r 1 Hz 0086,77
150 km/h 104,15 Hz r 1 Hz 0104,15
180 km/h 125,00 Hz r 1 Hz 0124,95

8.1) km/h control test (k value = 8000 pulses/km, v = 8 pulses.)

Desired value Tolerance Actual value

20 km/h 44,44 Hz r 1 Hz 0044,43

50 km/h 111,11 Hz r 1 Hz 0111,12
80 km/h 177,76 Hz r 1 Hz 0177,75
100 km/h 222,22 Hz r 1 Hz 0222,23
125 km/h 277,75 Hz r 1 Hz 0277,76
150 km/h 333,33 Hz r 1 Hz 0333,33
180 km/h 400,00 Hz r 1 Hz 0399,96

8.2) km/h control test (k value = 24000 pulses/km, v = 8 pulses.)

Desired value Tolerance Actual value

20 km/h 133,33 Hz r 2 Hz 0133,32

50 km/h 333,33 Hz r 2 Hz 0333,34
80 km/h 533,28 Hz r 2 Hz 0533,28
100 km/h 666,67 Hz r 2 Hz 0666,68
125 km/h 833,25 Hz r 2 Hz 0833,23
150 km/h 1000,00 Hz r 2 Hz 0999,95
180 km/h 1200,00 Hz r 2 Hz 1199,85

Page 4 of 5

BA00-1602-3220002 © Continental Automotive GmbH Page 32

Sample Certificate

CALIBRATION CERTIFICATE
Stationary Test Computer

Automatic Version Tests (Electronic Control System)

9.) Odometer test (k value = 8000 pulses/km)

Desired value Tolerance Actual value

at least 1000 rev.

(BTC display) (calibration unit display)

1000 r 2 rev. 1000

10.) Clock test

Desired value Tolerance Actual value

0,0 sec/24h r 1 sec/24h 0,00

Comments :

Continental Automotive GmbH is a

company certified according to
DIN EN ISO 9001: 2000 Company stamp/Signature of inspector

Page 5 of 5

Page 33 © Continental Automotive GmbH BA00-1602-3220002

Calibration Test Stand (Nixie Display)

EAP/0 1601-17/0
Calibration Instruction (Design with Nixie Display)
Seite 2 © Continental Automotive GmbH BA00-1602-322002
Table of Contents
1 Brief Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3 Calibration Test Stand Function Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
4 Test Set-Up: Calibration of k Pulse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
4.1 Measurement Preparations of the Calibration Unit . . . . . . . . . . . . . . . . . . 9
4.2 Measurement Preparations of the Calibration Test Stand . . . . . . . . . . . . 9
4.3 Calibration Sequence for k Pulse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5 Test Set-Up: Calibration of the Mechanical Drive for km/h . . . . . . . . . . . .10
5.1 Measurement Preparations of the Calibration Unit . . . . . . . . . . . . . . . . . 11
5.2 Measurements Preparations of the Calibration Test Stand. . . . . . . . . . . 11
5.3 Calibration Sequence of mechanical drive for km/h . . . . . . . . . . . . . . . . 11
6 Test Set-Up: Calibration of Mechanical Drive for 1/min . . . . . . . . . . . . . .12
6.1 Calibration sequence of the Mechanical Drive for 1/min . . . . . . . . . . . . . 12
7 Test Set-Up: Calibration of the Mechanical Drive for rev. . . . . . . . . . . . . .13
7.1 Calibration Sequence for Mechanical Drive for rev. . . . . . . . . . . . . . . . . 13
8 Concluding Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
9 Sample Certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

BA00-1602-322002 © Continental Automotive GmbH Page 3

Page 4 © Continental Automotive GmbH BA00-1602-322002
 Brief Description

1 Brief Description

1 Main Switch, 230V

2 Fuse T 800
3 Display test key
4 Function selection switch
5 4-digit Nixie tube display
6 Set-point knob
7 k setting switch
8 k measurement jack bush (optional)
9 Connecting jack for remote control
10 Automatic cut-out 230V/ 1A

Additional, i.e., detailed, descriptions can be found in the respective operating instruc-
tions.

BA00-1602-322002 © Continental Automotive GmbH Page 5

Technical Data

2 Technical Data
Display: Nixie tube display
Digit height 16mm
Interfaces: Frequency output (k pulse)
f max. 150 Hz, max. 15 V, max 30 mA
Mains connection: 230 V, 50 - 60 Hz
Operating temperature : + 5 °C to + 40 °C
Measuring ranges : 0 - 9999 revolutions
v = 10 - 180 km/h
k = 160 - 3000 min-1
Device constant : fixed k = 1000 rev/km
Mechanical drive :
One revolution of the shaft corresponds to one meter pulse at k = 1000.
1 km/h = 2.777 m/s = 2.777 shaft revolutions.
Test of drive by means of 1602-0118-000 test sensor shows 10 pulses per revolution.
min. 10 kph 27,77 Hz +/- 1 Hz
max. 180 kph 500,00 Hz +/- 1 Hz

3 Calibration Test Stand Function Test

The following items must be carried out to perform a function test.

Page 6 © Continental Automotive GmbH BA00-1602-322002

 Calibration Test Stand Function Test

Displaytest:
• Turn set-point knob (6) to the left until the limit stop.
• Set the function selection switch (4) to km/h.
• Turn „k setting“ switch (7) to „Off“ (downwards).
• Switch on calibration test stand by means of mains switch (1) and check whether the
corresponding lamp lights up.
• 000.0 must be shwon in the display (5). A decimal point must light up between the
3rd and the 4th digit of the display.

Internal Crystal Control:

• Press „Control“ key (3).
• The value 300.0 ± 0.2 must be shown on the display (5).

Function Test for (km/h) Measuring Range):

• Set the function selection switch (4) to km/h.
• Turn the set-point knob (6) until a value of approx. 100 km/h appears.
• Before calibrating the device, let it warm up for 10 minutes.
• Turn the set-point knob to the right until the limit stop. A value of at least 180.0 must
be shown on the display.
• Turn the set-point knob back to the left-hand limit stop. 000.0 must be shown on the
display (5).

Function Test for (1/min) Measuring Range:

• Set the function selection switch (4) to 1/min.
• Turn set-point knob slowly to the right and check whether the three right-hand digit
displays show the values 0 to 9 or whether the left-hand digit displays shows the va-
lues 0 to 3. After the right hand- limit stop has been reached, a value of at least 3000
must be shwon on the display.
• Finally, turn the set-point knob (6) back to the left-hand limit stop.

BA00-1602-322002 © Continental Automotive GmbH Page 7

Test Set-Up: Calibration of k Pulse

4 Test Set-Up: Calibration of k Pulse

Before setting up the test, make sure that the mains switch of the calibrator and the cali-
bration test stand is at the „0“ (= mains off) position.

A Calibration unit 1 Shift key for speed = 3.2 km/h or 50 km/h

B Ground line (calibration test 2 Shift key for autom. or manual mode
stand component) 4 Shift key for ATC or MTC
C Jack plug line (calibration test 5 Shift key for LS1 or LS2 light barrier
stand component)
D Calibration test stand 14 Shift key (grey) for switching over from
E Mains switch counter-mode to frequency-mode
F Set-point knob
G Function selection key
H k setting switch
I Jack bush
K Diode bush
L Display

Page 8 © Continental Automotive GmbH BA00-1602-322002

 Measurement Preparations of the Calibration Unit

4.1 Measurement Preparations of the Calibration Unit

• Switch 1, 50 km/h position

• Switch 2, autom. position
• Switch 4, MTC position
• Switch 5, LS2 position

4.2 Measurement Preparations of the Calibration Test Stand

• Insert the ground line (calibration test stand) into the diode bush „K“ of the calibration
test stand. Insert the side of the ground line with the banana plug (black) into the ba-
nana socket (black) of the calibration unit labelled „output“.
• Insert the jack plug line into the „I“ jack bush of the calibration test stand. Insert the
other side of the jack plug line into the „E1“ jack bush of the calibration unit.
• Turn the „k setting“ switch „H“ upwards to „k setting“.
• Press „G“ switch (key lights).
• Turn set-point to the left until the limit stop.
• Connect the calibration unit and the claibration test stand to 230V. Switch on the vol-
tage of the calibration unit by means of the mains switch (do not yet turn on the ca-
libration test stand).
• The value 0.00 must be shwon on the frequency display of the calibration unit. If this
is not the case, the grey key (14) must be pressed two times in order to activate the
frequency display.
• Switch on the voltage of the calibration test stand by means of the „E“ mains switch.

4.3 Calibration Sequence for k Pulse

• After the calibration test stand is switched on, it outputs the measuring frequency for
the k measurement.
• The measured frequency appears on the frequency display of the calibration unit.
• The measured k value appears on the measured value display of the calibration test
stand.
• The LED , of the calibration unit must light during the k measurement.
• Enter measured values in certificate:
1. Measured value of frequency display
2. Level size: yes/no (level size = yes when the LED is lit up)
3. k value display of calibration test stand.
• At the end of the calibration sequence, the testing cable (jack plug line) and the
ground line must be removed.

BA00-1602-322002 © Continental Automotive GmbH Page 9

Test Set-Up: Calibration of the Mechanical Drive for km/h

5 Test Set-Up: Calibration of the Mechanical Drive for km/h

A Calibration unit 1 Shift key for speed = 3.2 km/h or 50 km/h

B Calibrating cable1602-78-123 2 Shift key for autom. or manual mode
D Calibration test stand
F Set-point knob 4 Shift key for ATC or MTC mode
G Function selection switch 5 Shift key for LS1 or LS2 light barrier
H k setting switch
L Display 14 Shift key (grey) for switching over from
X Test sensor counter-mode to frequency-mode.

Page 10 © Continental Automotive GmbH BA00-1602-322002

 Measurement Preparations of the Calibration Unit

5.1 Measurement Preparations of the Calibration Unit

• Switch 1, 3.2 km/h position

• Switch 2, manual position
• Switch 4, MTC position
• Switch 5, LS2 position

5.2 Measurements Preparations of the Calibration Test Stand

• Turn „H“ „k setting“ switch downwards.

• Function selection switch „G“ may not be pressed (key must not light up).
• The value 0.00 must be shown on the „L“ display of the calibration test stand.
• The „F“ set-point knob must be at the left-hand limit stop.
• Screw the 1602-0118-000-000 test sensor onto the back of the calibration test stand
to the mech-anical drive.
• Connnect the 1602-78-123 calibrating cable to the test sensor and to the calibration
unit.
• The value 0.00 must be shown on the frequency display of the calibration unit. If this
is not the case, the grey key (14) must be pressed two times in order to activate the
frequency display.

5.3 Calibration Sequence of mechanical drive for km/h

• Turn the set-point knob „F“ of the calibration test stand to the right until 20.0 km/h is
shown on the measured value display of the calibration test stand.
• The follwing speeds are to be selected and the corresponding frequency is to be
checked: 20, 50, 80, 100, 125, 150 and 180 km/h. The corresponding frequency dis-
play of the calibration unit must be entered in the certificate (see calibration certi-
ficate)
• When the test of the mechanical drive for km/h has been completed, turn the set-
point knob of the calibration test stand to the left until limit stop.

BA00-1602-322002 © Continental Automotive GmbH Page 11

Test Set-Up: Calibration of Mechanical Drive for 1/min

6 Test Set-Up: Calibration of Mechanical Drive for 1/min

The test can be set up as described under Section 5. In addition, the „G“ key must be
pressed (key is lit up).

6.1 Calibration sequence of the Mechanical Drive for 1/min

• Turn the set-point knob of the calibration test stand to the right until 1000 min-1 is
shown on the measured vlaue display of the calibration test stand.
• Select the following engine speeds one after the other and check the corresponding
frequency: 1000, 2000, 3000 min-1.
• The frequency is shownon the frequency display of the calibration unit must be en-
tered in the certificate.
When the test of the mechanical drive for min-1 has been completed, turn the set-point
knob to the left until the limit stop.

Page 12 © Continental Automotive GmbH BA00-1602-322002

 Test Set-Up: Calibration of the Mechanical Drive for

7 Test Set-Up: Calibration of the Mechanical Drive for rev.

The test can be set up as described under Section 6. In addition, the strart/stop key (ca-
libration test stand component) must be connected to the calibration test stand.

7.1 Calibration Sequence for Mechanical Drive for rev.

• The frequency display of the calibration unit must be switched to the counter mode
by pressing the grey key (14) twice. 0 must be on the display.
• If 0 is not on the display, set counter to 0 by means of the red key.
• Press the start/ stop key until it locks into place.
• After that, a value of 0000 appears on the „L“ display of the calibration test stand.
• Turn the set-point knob slowly to the right until the couting procedure on the mea-
sured value display begins.
• Observe the measured value display of the calibration test stand and when a mea-
sured value of 1000 has been reached, turn the set-point knob to the left until the
limit stop.
• Enter the measured value into the certificate.
1. Measured calibration test stand value as desired value.
2. Measured value of calibration unit as actual value.
The actual value is greate by a factor of 1.25, as a test sensor with 10 pulses/rev. is
used (standard = 8 pulses/rev.).

BA00-1602-322002 © Continental Automotive GmbH Page 13

Concluding Tasks

8 Concluding Tasks
After the calibration procedure has been completed, the voltage of the calibration unit
must be switched off and the calibrating cable must be removed. The certificate must be
filled out completely with the signature of the inspector and his/her company stamp.
Any recognised defects, such as damage, missing parts, etc. must be entered in the cer-
tificate under „Comments“.
After calibration, the respective measuring device receives a calibration label, on which
the duration of calibration validity is marked.

Year Month
The date of validity is marked by cutting out (marking) the corresponding month and year
fields on the calibration label.

The calibration label must be attached to the front of the calibration test stand. The surface
onto which the calibration label is to be attached must first be cleaned.

Calibration label

Page 14 © Continental Automotive GmbH BA00-1602-322002

 Sample Certificate

9 Sample Certificate

A sample certificate for the 1601.17/0 calibration test stand is located in the Appendix. All
measured values are in italics and bold print (4000). The certificate must be filled out com-
pletely, including the signature of the inspector and his/ her company stamp. If a measu-
red value is not within the acceptable tolerance, no certificate my be issued. The date of
validity entered in the certificate must correspond to the date of validity on the calibration
label attached to the testing device.

BA00-1602-322002 © Continental Automotive GmbH Page 15

Sample Certificate

CALIBRATION CERTIFICATE
Calibration Test Stand
(Design with Nixie Display)

Device type : Calibration Test Stand Certificate no. : M2008/06/001

(Nixi) 1601.17

Serial no. : 123456 Valid until : 04.06.2009

Date : 04.06.2008

The proper function of the above-mentioned testing device has been tested and
calibrated. The measuring devices used for calibration meet national standards.

Calibration Unit Device no.:

1602.32 0066

1.) k pulse test (optional)

Desired value Tolerance Actual value

135 Hz r 15 Hz 128,45
Level display correct yes/no yes
100 pulses/km r 1 pulses/km 100

2.) Test of mechanical drive with digital km/h display

Desired value Tolerance Actual value

20 km/h 55,55 Hz r 1 Hz 058,48

50 km/h 138,88 Hz r 1 Hz 138,76
80 km/h 222,22 Hz r 1 Hz 222,25
100 km/h 277,77 Hz r 1 Hz 277,95
125 km/h 347,22 Hz r 1 Hz 347,34
150 km/h 416,66 Hz r 1 Hz 416,57
180 km/h 500,00 Hz r 1 Hz 499,86

Page 1 of 2

Page 16 © Continental Automotive GmbH BA00-1602-322002

 Sample Certificate

CALIBRATION CERTIFICATE
Calibration Test Stand
(Design with Nixie Display)

3. ) Test of mechanical drive with digital rpm display

Desired value Tolerance Actual value

1000 rpm 166,66 Hz r 1 Hz 166,69

2000 rpm 333,33 Hz r 1 Hz 333,39
3000 rpm 500,00 Hz r 1 Hz 499,86

4.) Test of mechanical drive with digital rev. display

Desired value Tolerance Actual value

at least 1000 rev.

test stand display calibration unit dispay x 1.25

1000 r 2 rev. 1250

Comments:

Continental Automotive GmbH is a

company certified according to
DIN EN ISO 9001: 2000 Company stamp/Signature of inspector

Page 2 of 2

BA00-1602-322002 © Continental Automotive GmbH Page 17

Sample Certificate

Page 18 © Continental Automotive GmbH BA00-1602-322002

Calibration Test Stand (LED)

EAP/5 1601-17/5
Calibration Instructions (Design with LED)
Seite 2 © Continental Automotive GmbH BA00-1602-322002
Table of Contents
1 Brief Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3 Calibration Test Stand Function Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
4 Test Set-Up: Calibration of k Pulse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
4.1 Measurement Preparations of the Calibration Unit . . . . . . . . . . . . . . 9
4.2 Measurement Preparations of the Calibration Test Stand . . . . . . . . . 9
4.3 Calibration Sequence for k Pulse . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5 Test Set-Up: Calibration of the Mechanical Drive for km/h . . . . . . . . . . . . . . . .10
5.1 Measurement Preparations of the Calibration Unit . . . . . . . . . . . . . 11
5.2 Measurement Preparations of the Calibration Test Stand . . . . . . . . 11
5.3 Calibration Sequence for Mechanical Drive for km/h . . . . . . . . . . . . 11
6 Test Set-Up: Calibration of Mechanical Drive for 1/min . . . . . . . . . . . . . . . . . . .12
6.1 Calibration Sequence for the Mechanical Drive for 1/min . . . . . . . . 12
7 Test Set-Up: Calibration of Mechanical Drive for rev. . . . . . . . . . . . . . . . . . . . .13
7.1 Calibration Sequence for Mechanical Drive for revolutions . . . . . . . 13
8 Concluding Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
9 Sample Certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

BA00-1602-322002 © Continental Automotive GmbH Page 3

Page 4 © Continental Automotive GmbH BA00-1602-322002
 Brief Description

1 Brief Description

1 Main switch, 230 V

2 Fuse T 1A
3 Rotary function selection switch
4 Display unit
5 Set-point knob
6 Start/stop switch
7 pulse/km bush

Additional, i.e., detailed, descriptions can be found in the respective operating instruc-
tions.

BA00-1602-322002 © Continental Automotive GmbH Page 5

Technical Data

2 Technical Data
Display: 4-digit numerical LED
Digit height = 15 mm
Interfaces: Frequency output (k pulse)
fmax 150 Hz, max. 15 V, max. 30 mA
Mains connection: 230 V, 50 - 60 Hz
Operating temperature: + 5°C to + 40°C
Measuring ranges: 0 - 9999 revolutions
10 - 180 km/h
160 - 3000 1/min
Device constant: fixed, k = 1000 rev./km
Mechanical drive:
One revolution of the shaft corresponds to one meter pulse at k = 1000.

1 km/h = 2.777 m/s = 2.777 shaft revolutions.

Test of drive by means of 1602-0118-000 test sensor shows 10 pulses per revolution.
min. 10 km/h 27.77 Hz +/- 1 Hz
max.180 km/h 500.00 Hz +/- 1 Hz

3 Calibration Test Stand Function Test

The following items must be carried out to perform a function test.

Page 6 © Continental Automotive GmbH BA00-1602-322002

 Calibration Test Stand Function Test

Display Test:

• Turn set-point knob (5) to the left until the limit stop.
• Set the rotary function selection switch (3) to km/h.
• Switch on calibration test stand by means of mains switch (1).
• 000.0 must be shown on the display (4). A decimal point must light up between the
3rd and 4th digit of the display.

Internal Crystal Control:

• Set the rotary function selection switch (3) to 4608 quartz.

• The value 4608 ± 2 must be shown on the display (4).

Function Test for (km/h) Measuring Range:

• Set the rotary function selection switch (3) to km/h.

• Turn the set-point knob (5) until a value of approx. 100 km/h appears.
• Before calibrating the device, let it warm up for 10 minutes.
• Turn the set-point knob to the right until the limit stop. A value of at least 180.0 must
be shown on the display (4).
• Turn the set-point knob back to the left-hand limit stop. 000.0 must be shown on the
display (4).

Function Test for (1/min) Measuring Range:

• Set the rotary function selection switch (3) to 1/min.

• Turn set-point knob (5) slowly to the right and check whether the three right-hand
digit displays show the values 0 to 9 or whether the left-hand digit display shows the
value 0 to 3. After the right-hand limit stop has been reached, a value of at least 3000
must be shown on the display.
• Finally, turn the set-point knob (5) back to the left-hand limit stop.

LED Test:

• Set rotary function selection switch to 8888.

• A value of 8888 must be shown on the display (4).

BA00-1602-322002 © Continental Automotive GmbH Page 7

Test Set-Up: Calibration of k Pulse

4 Test Set-Up: Calibration of k Pulse

Before setting up the test, make sure that the mains switch of the calibrator and the cali-
bration test stand is at the „0“ (=mains off) position.

A Calibration unit 1 Shift key for speed = 3.2 km/h or 50 km/h

B Ground line and 2 Shift key for autom. or manual mode
Jack plug line (calibration test 4 Shift key for ATC or MTC
stand component) 5 Shift key for LS1 or LS2 light barrier
D Calibration test stand 14 Shift key (grey) for switching over from
E Mains switch counter-mode to frequency-mode
F Set-point knob
G Function selection key
H Start / stop key

K Diode bush
L Display

Page 8 © Continental Automotive GmbH BA00-1602-322002

 Measurement Preparations of the Calibration Unit

4.1 Measurement Preparations of the Calibration Unit

• Switch 1, 50 km/h position

• Switch 2, autom. position
• Switch 4, MTC position
• Switch 5, LS2 position

4.2 Measurement Preparations of the Calibration Test Stand

• Insert the test wire (calibration test stand component) into the diode bush "K" of the
calibration test stand.
• Insert the ground wire with the banana plug (black) into the banana socket (black)
of the calibration unit labelled "output".
• Insert the jack plug line into the E1 jack bush of the calibration unit.
• Set "G" switch to pulses/km.
• Turn set-point knob to the left until the limit stop.
• Connect the calibration unit and the calibration test stand to 230 V. Switch on the
voltage of the calibration unit by means of the mains switch (do not yet turn on the
calibration test stand).
• The value 0.00 must be shown on the frequency display of the calibration unit. If this
is not the case, the grey key (14) must be pressed two times in order to activate the
frequency display.
• Switch on the voltage of the calibration test stand by means of the "E" mains switch.

4.3 Calibration Sequence for k Pulse

• After the calibration test stand is switched on, it outputs the measuring frequency for
the k measurement.
• The measured frequency appears on the frequency display of the calibration unit.
• The measured k value appears on the measured value display of the calibration test
stand.
• The LED of the calibration unit must light up during the k measurement.
• Enter the measured values in certificate:
1. Measured value of frequency display
2. Level size: yes/no (level size = yes when the LED is lit up)
3. k value display of calibration test stand.
• At the end of the calibration sequence, the testing cable (jack plug line) and the
ground wire must be removed.

BA00-1602-322002 © Continental Automotive GmbH Page 9

Test Set-Up: Calibration of the Mechanical Drive for km/h

5 Test Set-Up: Calibration of the Mechanical Drive for km/h

A Calibration unit 1 Shift key for speed = 3.2 km/h or 50 km/h

B Calibrating cable1602-78-123 2 Shift key for autom. or manual mode
D Calibration test stand
F Set-point knob 4 Shift key for ATC or MTC mode
G Function selection switch 5 Shift key for LS1 or LS2 light barrier
H Start / stop key
L Display 14 Shift key (grey) for switching over from
X Test sensor counter-mode to frequency-mode.

Page 10 © Continental Automotive GmbH BA00-1602-322002

 Measurement Preparations of the Calibration Unit

5.1 Measurement Preparations of the Calibration Unit

• Switch 1, 3.2 km/h position

• Switch 2, manual position
• Switch 4, MTC position
• Switch 5, LS2 position

5.2 Measurement Preparations of the Calibration Test Stand

• Set "G" function selection switch to km/h.

• The value 0.00 must be shown on the "L" display of the calibration test stand.
• The "F" set-point knob must be at the left-hand limit stop.
• Screw the 1602-0118-000-000 test sensor onto the back of the calibration test stand
to the mechanical drive.
• Connect the 1602-78-123 calibrating cable to the test sensor and to the calibration
unit.
• The value 0.00 must be shown on the frequency display of the calibration unit. If this
is not the case, the grey key (14) must be pressed two times in order to activate the
frequency display.

5.3 Calibration Sequence for Mechanical Drive for km/h

• Turn set-point knob "F" of the calibration test stand to the right until 20.0 km/h is
shown on the measured value display of the calibration test stand.
• The following speeds are to be selected and the corresponding frequency is to be
checked: 20, 50, 80, 100, 125, 150, and 180 km/h. The corresponding frequency is
shown on the frequency display of the calibration unit and must be entered in the
certificate (see calibration certificate).
• When the test of the mechanical drive for km/h has been completed, turn the set-
point knob of the calibration test stand to the left until the limit stop.

BA00-1602-322002 © Continental Automotive GmbH Page 11

Test Set-Up: Calibration of Mechanical Drive for 1/min

6 Test Set-Up: Calibration of Mechanical Drive for 1/min

The test can be set up as described under Section 5. The rotary function selection switch
„G“ must be set to the 1/min switch position.

6.1 Calibration Sequence for the Mechanical Drive for 1/min

• Turn the set-point knob of the calibration test stand to the right until 1000 1/min is
shown on the measured value display of the calibration test stand.
• Select the following engine speeds one after the other and check the corresponding
frequency: 1000, 2000, 3000 1/min.
• The frequency is shown on the frequency display of the calibration unit and must be
entered in the certificate.
When the test of the mechanical drive for 1/min has been completed, turn the set-point
knob to the left until the limit stop.

Page 12 © Continental Automotive GmbH BA00-1602-322002

 Test Set-Up: Calibration of Mechanical Drive for rev.

7 Test Set-Up: Calibration of Mechanical Drive for rev.

The test can be set up as described under Section 5. The rotary function selection switch
„G“ must be set to the revolution switch position.

7.1 Calibration Sequence for Mechanical Drive for revolutions

• The frequency display of the calibration unit must be switched to the counter mode
by pressing the grey key (14) two times. 0 must be on the display.
• If 0 is not on the display, set the counter to 0 by means of the red key.
• Press the "H" start/stop key until it locks into place.
• After that, a value of 0000 appears on the "L" display of the calibration test stand.
• Turn set-point knob slowly to the right until the counting procedure on the measured
value display begins.
• Observe the measured value display of the calibration test stand and when a measu-
red value of 1000 has been reached, turn the set-point knob to the left until the limit
stop.
• Enter the measured value in the certificate.
1. Measured calibration test stand value as desired value
2. Measured value of calibration unit as actual value.
The actual value is greater by a factor of 1.25, as a test sensor with 10 pulses/rev. is used
(standard = 8 pulses/rev.).

BA00-1602-322002 © Continental Automotive GmbH Page 13

Concluding Tasks

8 Concluding Tasks
After the calibration procedure has been completed, the voltage of the calibration unit
must be switched off and the test encoder must be removed. The certificate must be filled
out completely with the signature of the inspector and his/her company stamp.
Any recognised defects such as damage, missing parts, etc. must be entered in the cer-
tificate under "Comments".
After calibration, the respective measuring device receives a calibration label, on which
the duration of calibration validity is marked.

Year Month
The date of validity is marked by cutting out (marking) the corresponding month and year
fields on the calibration label.

The calibration label must be attached to the front side of the calibration test stand. The
surface onto which the calibration label is to be attached must first be cleaned.

Page 14 © Continental Automotive GmbH BA00-1602-322002

 Sample Certificate

9 Sample Certificate

A sample certificate for the 1601.17/5 calibration test stand is located in the Appendix. All
measured values are in italics and bold print (4000). The certificate must be filled out com-
pletely, including the signature of the inspector and his/her company stamp. If a measured
value is not within the acceptable tolerance, no certificate may be issued. The date of va-
lidity entered in the certificate must correspond to the date of validity on the calibration la-
bel attached to the testing device.

BA00-1602-322002 © Continental Automotive GmbH Page 15

Sample Certificate

CALIBRATION CERTIFICATE
Calibration Test Stand
(Design with LED)

Device type : Calibration Test Stand Certificate no. : M/2008/06/001

(LED) 1601.17/5

Serial no. : 123456 Valid until : 04.06.2009

Date : 04.06.2008

The proper function of the above-mentioned testing device has been tested and
calibrated. The measuring devices used for calibration meet national standards.

Calibration Unit Device no.:

1602.32 0066

1.) k pulse test

Desired value Tolerance Actual value

135 Hz r 15 Hz 128,45
Level display correct yes/no yes
100 pulses/km r 1 pulses/km 100

2.) Test of mechanical drive with digital km/h display

Desired value Tolerance Actual value

20 km/h 55,55 Hz r 1 Hz 055,58

50 km/h 138,88 Hz r 1 Hz 138,76
80 km/h 222,22 Hz r 1 Hz 222,25
100 km/h 277,77 Hz r 1 Hz 277,95
125 km/h 347,22 Hz r 1 Hz 347,34
150 km/h 416,66 Hz r 1 Hz 416,57
180 km/h 500,00 Hz r 1 Hz 499,86

Page 1 of 2

Page 16 © Continental Automotive GmbH BA00-1602-322002

 Sample Certificate

CALIBRATION CERTIFICATE
Calibration Test Stand
(Design with LED)

3. ) Test of mechanical drive with digital rpm display

Desired value Tolerance Actual value

1000 rpm 166,66 Hz r 1 Hz 166,69

2000 rpm 333,33 Hz r 1 Hz 333,39
3000 rpm 500,00 Hz r 1 Hz 49986

4.) Test of mechanical drive with digital rev. display

Desired value Tolerance Actual value

at least 1000 rev.

test stand display calibration unit dispaly x 1.25

1000 r 2 rev. 1250

Comments:

Continental Automotive GmbH is a

company certified according to
DIN EN ISO 9001: 2000 Company stamp/Signature of inspector

Page 2 of 2

BA00-1602-322002 © Continental Automotive GmbH Page 17

Diagnoser with Additional I/O Module

DIG 1602-02
Calibration Instructions
Table of Contents
1 Brief Description of Diagnoser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.1 Brief Description of Additional I/O Module (Rear View) . . . . . . . . . . . 5
2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3 Diagnoser Function Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
4 Test Set-Up: Calibration of Manual Distance7
4.1 Measuring Preparations of the Calibration Unit . . . . . . . . . . . . . . . . . 8
4.2 Measuring Preparations of the Diagnoser . . . . . . . . . . . . . . . . . . . . . 8
4.3 Calibration Sequence for the Manual Measuring Track . . . . . . . . . . . 9
5 Calibration Sequence for Automatic Distance Pulse Measurement11
5.1 Measuring Preparations of the Calibration Unit . . . . . . . . . . . . . . . . 12
5.2 Measuring Preparations of the Diagnoser with I/O Module . . . . . . . 12
5.3 Calibration Sequence for Automatic Distance Pulse Measurement. 13
6 Test Set-Up: Calibration of Automatic Distance Pulse Measurement (I/O)15
6.1 Calibration Sequence for Automatic Distance Pulse Measurement. 16
7 Test Set-Up: Calibration of the k Pulse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
7.1 Calibration Sequence for the k Pulse . . . . . . . . . . . . . . . . . . . . . . . . 17
8 Concluding Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
9 Sample Certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

BA00-1602-322002 © Continental Automotive GmbH Page 2

 Brief Description of Diagnoser

1 Brief Description of Diagnoser

1 Pushbutton key for supply voltage, ON/OFF

2 Reset button
3 Start pushbutton key
4 LED
5 Rotary switch program selection
6 Display

10Mounting plug 1, supply voltage (sixfold AMP)

11Mounting plug 2, supply voltage (fourfold AMP)
12Mounting plug 3, sensor connection
13Mounting plug 4, sensor connection (taximeter)

Additional, i.e., detailed, descriptions can be found in the respective operating instruc-
tions.

BA00-1602-322002 © Continental Automotive GmbH Page 4

Brief Description of Additional I/O Module (Rear View)

1.1 Brief Description of Additional I/O Module (Rear View)

15 Mounting plug 5, supply voltage

16 Jack bush for W/k pulses
17 Connection for light barrier
18 Sensor connection
19 Start 4 key
20 Rotary switch program selection

Page 5 © Continental Automotive GmbH BA00-1602-322002

 Technical Data

2 Technical Data
Display: 4-digit numerical display
Digit height = 13 mm

Interfaces: 8 V sensor supply, max 25 mA

Frequency input fmax = 1 kHz
U - low = 0 - 2 Volts, U - high = 2.5 - 20 Volts
Frequency output fmax = 150 Hz
max. 20 V, max. 30 mA

Voltage supply: 10.8 V - 30 V DC voltage with reverse voltage protection

Power consumption: approx. 200 mA

Operating temperature: +5°C to +40°C

Measuring ranges: w= 500 - 25000 pulses/km

k= 2400 - 25000 pulses/km

3 Diagnoser Function Test

The following items must be carried out to perform a function test:

Display Test:
• Supply diagnoser with voltage (output +/- of calibrator).
• Press "On" key until it locks into place.
• "Start" key may not be locked into place.
• Set program selection switch of the diagnoser to "1".
• A decimal point must appear between the 2nd and 3rd digit.
• Set program selection switch of the diagnoser to "4".
• The decimal point between the 2nd and 3rd digit must disappear.

I/O Expansion Module:

• Turn switch 20 to pos. 6 of I/O Modul.
• Press "Reset" key and keep it pressed. The numbers 0 through 9 appear consecu-
tively in all decades.
• Press the "Start" key until it locks into place.
• After approx. 5 sec. 2500 +/- 1 must appear on the display.
• The red LED in the front of diagnoser must light up.

BA00-1602-322002 © Continental Automotive GmbH Page 6

Test Set-Up: Calibration of Manual Distance

4 Test Set-Up: Calibration of Manual Distance

Before setting up the test, make sure that the mains switch is at the „0“ (=mains off)
position.

A Calibration unit 1 Shift key for speed = 3.2 km/h or 50 km/h

B Calibr. cable 1602-78-121
C Voltage supply cable 2 Shift key for autom. or manual mode
(diagnoser component) 4 Shift key for ATC or MTC
E Diagnoser 5 Shift key for LS1 or LS2 light barrier
14 Shift key (grey key) for switching over
from counter-mode to frequency-mode

Page 7 © Continental Automotive GmbH BA00-1602-322002

 Measuring Preparations of the Calibration Unit

4.1 Measuring Preparations of the Calibration Unit

• Switch 1, 3.2 km/h position

• Switch 2, manual position
• Switch 4, MTC position
• Switch 5, LS2 position

4.2 Measuring Preparations of the Diagnoser

• Connect the diagnoser to the voltage supply jack of the calibration unit labelled "Out-
put" by means of the "C" voltage supply line.

Note!
Insert the red banana plug into the red banana socket of the calibration unit.
Insert the black banana plug into the black banana socket.

• Connect the diagnoser to the calibration unit by means of the 1602-78-121 calibra-
ting line. Insert the AMP bush into the "3" AMP plug. The "3" AMP plug is located on
the back of the diagnoser.

• Set the selector switch to program selection "6".

• Press the "On" key until it locks into place.
• Press the "Start" key until it locks into place.
• Connect the calibration unit to 230 V by means of the voltage cable and switch on
the voltage by means of the mains switch of the calibration unit.
• The value 0.00 must be shown on the frequency display of the calibration unit. If this
is not the case, grey key (14) must be pressed two times in order to activate the fre-
quency display.
• Press the „Reset“ key of the diagnoser. After that, 0000 must be shown on the dis-
play.

BA00-1602-322002 © Continental Automotive GmbH Page 8

Calibration Sequence for the Manual Measuring Track

4.3 Calibration Sequence for the Manual Measuring Track

Page 9 © Continental Automotive GmbH BA00-1602-322002

 Calibration Sequence for the Manual Measuring

• Press the "Start" key of the calibration unit.

• 100 pulses are outputted from the calibration unit and counted on the display of the
diagnoser.
• Observe the counting frequency. The red LED on the front panel of the diagnosers
must blink for each digit counted.
• When no more pulses are counted, the measuring procedure has come to an end.
• Enter the measured value in the certificate.
• Press the "Reset" key.
• The measurement must be carried out 3 times.
• When the calibration procedure has come to an end, switch off the voltage of the ca-
libration unit.
• Remove the voltage supply line to the diagnoser and the calibrating line at the dia-
gnoser side.

• If the diagnoser has no expansion module (I/O) module, continue with Chapter 8
"Concluding Tasks".

BA00-1602-322002 © Continental Automotive GmbH Page 10

Calibration Sequence for Automatic Distance Pulse Measurement

5 Calibration Sequence for Automatic Distance Pulse

Measurement
Before setting up the test, make sure that the mains switch is at the „0“ (= mains off)
position.

A Calibration unit 1 Shift key for = 3.2 km/h or 50 km/h

B Calibr. cable 1602-78-121
C Voltage supply cable 2 Shift key for autom. or manual mode
(diagnoser component) 4 Shift key for ATC or MTC mode
E Diagnoser 5 Shift key for LS1 or LS2 light barrier
F Additional module (I/O mo- 14 Shift key (grey key) for switching over
dule) from counter-mode to frequency-mode
G Selector switch

Page 11 © Continental Automotive GmbH BA00-1602-322002

 Measuring Preparations of the Calibration Unit

5.1 Measuring Preparations of the Calibration Unit

• Switch 1, 50 km/h position

• Switch 2, autom. position
• Switch 4, MTC position
• Switch 5, LS1 position

5.2 Measuring Preparations of the Diagnoser with I/O Module

• Connect the diagnoser to the voltage supply jack of the calibration unit labelled "Out-
put" by means of the "C" voltage supply line.

Note!
Insert the red banana plug into the red banana socket of the calibration unit.
Insert the black banana plug into the black banana socket.

• Connect the diagnoser to the calibration unit by means of the 1602-78-121 calibra-
ting line. Insert the AMP bush into the "7" AMP plug. The "7" AMP plug is located on
the back of the I/O module.
• Insert the diode plug into the "8" diode bush. The "8" diode bush is located on the
back of the I/O module.
• Set the selector switch located on the back of the I/O module to program selection
"2".

• Set the selector switch to program selection "6".

• Press the "On" key until it locks into place.
• Press the "Start" key until it locks into place.
• Connect the calibration unit to 230 V by means of the voltage cable and switch on
the voltage by means of the mains switch of the calibration unit.
• The value 0.00 must be shown on the frequency display of the calibration unit. If this
is not the case, grey key (14) must be pressed two times to activate the frequency
display.

BA00-1602-322002 © Continental Automotive GmbH Page 12

Calibration Sequence for Automatic Distance Pulse Measurement

5.3 Calibration Sequence for Automatic Distance Pulse

Measurement

Page 13 © Continental Automotive GmbH BA00-1602-322002

 Calibration Sequence for Automatic Distance Pulse

• Press the "Clear" key of the calibration unit and keep it pressed.
• After that, the diagnoser emits a beep.
• Press the "Reset" key of the diagnoser twice. After that, 0000 must appear on the
display of the diagnoser.
• Release the "Clear" key of the calibration unit.
• After approx. 5 seconds, the diagnoser begins counting up the incoming pulses.
• Observe display.
• After approx. 5 seconds, the first measured value is reached and shown on the dis-
play of the diagnoser.
First measured value = 2000
• After approx. 5 seconds, the diagnoser continues counting and reaches the second
measured value after an additional 5 seconds.
Second measured value = 4000
• After the second measured value has been reached, the diagnoser continues coun-
ting to the third measured value after a pause of approx. 5 seconds.
Third measured value = 6000
• Enter all three measured values into the certificate.
• At the end of the calibration procedure, remove the "7" AMP plug of the I/O module
from the AMP bush. Switch off the voltage of the calibration unit.
• The diagnostic bush and the "C" voltage cable are required for the following test set-
up and may not be removed.

BA00-1602-322002 © Continental Automotive GmbH Page 14

Test Set-Up: Calibration of Automatic Distance Pulse Measurement (I/O)

6 Test Set-Up: Calibration of Automatic Distance Pulse

Measurement (I/O)
The test can be set up as described under Section 5. In addition, however, the jack plug
line (diagnoser component) must be connected. Insert the jack plug line into the A2 jack
bush of the calibration unit and into the "6" jack bush of the I/O module.

A Calibration unit 1 Shift key for = 3.2 km/h or 50 km/h

B Calibr. cable 1602-78-121
C Voltage cable (diagnoser 2 Shift key for autom. or manual mode
component) 4 Shift key for ATC or MTC mode
D Jack plug line (diagnoser 5 Shift key for LS1 or LS2 light barrier
component)
E Diagnoser
F Additional module (I/O mo- 14 Shift key (grey key) for switching over
dule) from counter-mode to frequency-mode
G Selector switch

Page 15 © Continental Automotive GmbH BA00-1602-322002

 Calibration Sequence for Automatic Distance Pulse

6.1 Calibration Sequence for Automatic Distance Pulse

Measurement

• Switch on the voltage of the calibration unit.

• Press the "Clear" key of the calibration unit and keep it pressed.
• After that, the diagnoser emits a beep.
• Press the "Reset" key of the diagnoser twice.
• Release the "Clear" key of the calibration unit.
• After approx. 5 seconds the diagnoser begins counting up the incoming pulses.
• Observe display.
• After approx. 5 seconds, the first measured value is reached and shown on the dis-
play of the diagnoser.
First measured value = 2000
• After approx. 5 seconds the diagnoser continues counting and reaches the second
measured value after an additional 5 seconds.
Second measured value = 4000
• After the second measured value has been reached the diagnoser continues coun-
ting to the third measured value after a pause of approx. 5 seconds.
Third measured value = 6000
• Enter all three measured values into the certificate.

BA00-1602-322002 © Continental Automotive GmbH Page 16

Test Set-Up: Calibration of the k Pulse

7 Test Set-Up: Calibration of the k Pulse

The test can be set up as described under Section 6. The selector switch of the diagnoser
which is located on the front panel must be set to program selection "4". The selector
switch of the I/O module which is located on the back must be set to program selection
"3". The jack plug line must be removed from the A2 jack bush and inserted into the E1
jack bush.

7.1 Calibration Sequence for the k Pulse

• The k measurement is started by means of the selector switch.

• The measured frequency appears in the frequency display of the calibration unit.
• The measured k value appears on the display of the diagnoser.
• The LED of the calibration unit must light up during the k measurement.
• Measured values:
1. Measured value of frequenc display
2. Display of level height, yes/no
3. Enter k value display of diagnoser into the certificate.

Page 17 © Continental Automotive GmbH BA00-1602-322002

 Concluding Tasks

8 Concluding Tasks
After the calibration procedure has been completed, the voltage of the calibration unit
must be switched off and the calibrating cable must be removed. The certificate must be
filled out completely with the signature of the inspector and his/her company stamp.
Any recognised defects such as damage, missing parts, etc. must be entered in the cer-
tificate under "Comments".
After calibration the respective measuring device receives a calibration label, on which the
duration of calibration validity is marked.

Year Month
The date of validity is marked by cutting out (marking) the corresponding month and year
fields on the calibration label.

The calibration label must be attached to the back of the diagnoser. The surface onto
which the calibration label is to be attached must first be cleaned.

BA00-1602-322002 © Continental Automotive GmbH Page 18

Sample Certificate

9 Sample Certificate

A sample certificate for the diagnoser and I/O module is located in the Appendix. All
measured values are in italics and bold print (4000). The certificate must be filled out com-
pletely, including the signature of the inspector and his/her company stamp. If a measured
value is not within the acceptable tolerance, no certificate may be issued. The date of va-
lidity entered in the certificate must correspond to the date of validity on the calibration la-
bel attached to the testing device.

Page 19 © Continental Automotive GmbH BA00-1602-322002

 Sample Certificate

CALIBRATION CERTIFICATE
Diagnoser / E/A - Module

Device type : Diagnoser-EA/Mod. EA/Mod. – Ser. - no. : 123456

1602.02-1602.01.16

Diagno. - Ser. - no. : 123456 Certificate no. : M/2008/06/001

Date : 04.06.2008 Valid until : 04.06.2008

The proper function of the above-mentioned testing device has been tested and
calibrated. The measuring devices used for calibration meet national standards.

Calibration Unit Device no.:

1602.32 0066

1.)Test for manual distance pulse measurement of diagnoser (generator input)

The distance pulse measurement test was carried out 3 times.

Desired value Tolerance Actual value

1. 100 pulses/km r 1 pulses/km 100

2. 100 pulses/km r 1 pulses/km 100
3. 100 pulses/km r 1 pulses/km 100

2. ) Test for automatic distance pulse measurement of diagnoser with E/A module
(generator input)
The distance pulse measurement test was carried out 3 times.

Desired value Tolerance Actual value

1. 2000 pulses/km r 1 pulses/km 2000

2. 4000 pulses/km r 2 pulses/km 4000
3. 6000 pulses/km r 3 pulses/km 6000

Page 1 of 2

BA00-1602-322002 © Continental Automotive GmbH Page 20

Sample Certificate

CALIBRATION CERTIFICATE
Diagnoser / E/A - Module

3. ) Test for automatic distance pulse measurement of diagnoser with E/A module
(E/A input)
The distance pulse measurement test was carried out 3 times.

Desired value Tolerance Actual value

1. 2000 pulses/km r 1 pulses/km 2000

2. 4000 pulses/km r 2 pulses/km 4000
3. 6000 pulses/km r 3 pulses/km 6000

4.) k pulse test

Desired value Tolerance Actual value

135 Hz r 20 Hz 128,45
Level display correct yes/no yes
100 pulses/km r 1pulses/km 100

Comments:

Continental Automotive GmbH is a

company certified according to
DIN EN ISO 9001: 2000 Company stamp/Signature of inspector

Page 2 of 2

Page 21 © Continental Automotive GmbH BA00-1602-322002

Distance RPM Constant Testing Device
(WK-Tester)

WK 1602-10
Calibration Instructions
Seite 2 © Continental Automotive GmbH BA00-1602-322002
Table of Contents
1 Brief Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3 Function Test for WK Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
4 Test Set-Up: Calibration of the k Pulse . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
4.1 Measuring Preparations of the Calibration Unit. . . . . . . . . . . . . . . . . . . . . 8
4.2 Measuring Preparations of the WK Tester . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3 Calibration Sequence for the k Pulse . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5 Test Set-Up: Calibration of Manual Distance Pulse Measurement . . . . . . .9
5.1 Calibration Sequence for Manual Distance Pulse Measurement . . . . . . 10
6 Concluding Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
7 Sample Certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

BA00-1602-322002 © Continental Automotive GmbH Page 3

 Brief Description

1 Brief Description

1 Start/stop switch
2 K/W switch
3 Switch for supply voltage, ON/OFF
4 4-digit display LCD
5 Plus supply voltage (red line)
6 Minus supply voltage (black line)
7 Testing line, jack plug
8 Testing line, sensor connection

Additional, i.e. detailed descriptions can be found in the respective operating instructions.

BA00-1602-322002 © Continental Automotive GmbH Page 5

Technical Data

2 Technical Data
Display: 4-digit LCD
Digit height = 10 mm

Interfaces: 8 V sensor supply, max 25 mA

Frequency input fmax = 1 kHz

U - low = 0 - 2 Volts, U - high = 2.5 - 20 Volts

Frequency output fmax = 150 Hz

max. 20 V, max. 30 mA

Voltage supply: 10.8 V - 30 V DC with reverse voltage protection

Power consumption: approx. 70 mA

Operating temperature: +5°C to +40°C

Measuring ranges: w = 500 - 25000 pulses/km

k = 2400 - 25000 pulses/km

3 Function Test for WK Tester

The following items must be carried out to perform a function test.

Display Test:

• Supply WK tester with voltage.

• A 0 will be shown on all decades of the display.

Page 6 © Continental Automotive GmbH BA00-1602-322002

 Test Set-Up: Calibration of the k Pulse

4 Test Set-Up: Calibration of the k Pulse

Before setting up the test, make sure that the mains switch is at the "0" (= mains off)
position.

A Calibration unit 1 Shift key for speed = 3.2 km/h or 50 km/h

B Measuring line (red) 2 Shift key for autom. or manual
mode
C Ground wire (black) 4 Shift key for ATC or MTC mode
D WK Tester 5 Shift key for LS1 or LS2 light barrier
E Jack plug line 14 Shift key (grey) for switching over from
counter-mode to frequency-mode
F Measured value display
G Switch for voltage, ON/OFF
H Shift key for K or W
I Stop/start shift key

BA00-1602-322002 © Continental Automotive GmbH Page 7

Measuring Preparations of the Calibration Unit

4.1 Measuring Preparations of the Calibration Unit

• Switch 1, 3.2 km/h position

• Switch 2, manual position
• Switch 4, MTC position
• Switch 5, LS2 position

4.2 Measuring Preparations of the WK Tester

• Insert the jack plug line of the WK tester into the „E1“ test jack of the calibration unit.
• Put the "H" slide switch of the WK tester into the K (pulses/km) switch position.
• Put the "I" slide switch of the WK tester in the START switch position.
• Insert the "B" (red) measuring line into the banana socket "+" (red) of the calibration
unit labelled "Output".
• Connect the other end of the "B" measuring line to the voltage terminal (red).
• Insert the "C" ground wire (black) into the banana socket (black) of the calibration
unit labelled "Output".
• Connect the other end of the "C" ground wire to the earth terminal (black) of the WK
tester.
• Before switching on the voltage, make sure that no short circuit can result between
the ground terminal and the voltage terminal of the WK tester.
• Connect the calibration unit to 230 V by means of the voltage cable and switch on
the voltage by means of the mains switch of the calibration unit.
• The value 0.00 must be shown on the frequency display of the calibration unit. If this
is not the case, the grey key (14) must be pressed two times in order to activate the
frequency display.
• Switch on the voltage of the WK tester by means of the "G" switch.

4.3 Calibration Sequence for the k Pulse

• After the WK tester is switched on, it outputs the measured frequency, and the
measured value is shown on the frequency display of the calibration unit.
• The measured k value appears on the display of the WK tester.
• The LED of the calibration unit must light up during the k measurement.
• Enter the measured values into the certificate.
1. Measured value of frequency display
2. Level size: yes/no (level size = yes when the LED is lit up)
3. k value display of WK tester
• Switch off the WK tester by means of the "G" switch.

Page 8 © Continental Automotive GmbH BA00-1602-322002

 Test Set-Up: Calibration of Manual Distance Pulse

5 Test Set-Up: Calibration of Manual Distance Pulse Measu-

rement
The test can be set up as described under Section 4. Only the jack plug line must be re-
moved from the "E1" jack plug bush and inserted into the A2 jack plug bush. The "H" slide
switch of the WK tester should be set to Wpulses.

A Calibration unit 1 Shift key for speed = 3.2 km/h or 50 km/h

B Measuring line (red) 2 Shift key for autom. or manual
mode
C Ground wire (black) 4 Shift key for ATC or MTC mode
D WK Tester 5 Shift key for LS1 or LS2 light barrier
E Jack plug line 14 Shift key (grey) for switching over from
counter-mode to frequency-mode
F Measured value display
G Switch for voltage, ON/OFF
H Shift key for K or W
I Stop/start shift key

BA00-1602-322002 © Continental Automotive GmbH Page 9

Calibration Sequence for Manual Distance Pulse Measurement

5.1 Calibration Sequence for Manual Distance Pulse Measure-

ment

• Turn on the WK tester by means of the "G" switch. After that, a value of 0000 ap-
pears on the display of the WK tester.
• Press the "Start" key of the calibration unit.
• The distance pulses are counted up on the display of the WK tester.
• At the end of the calibration procedure, a measured value of 100 is shown on the
display of the WK tester.
• Enter the measured value in the certificate.
• Switch off the WK tester by means of the "G" switch.
• The measurement is to be carried out three times.

Page 10 © Continental Automotive GmbH BA00-1602-322002

 Concluding Tasks

6 Concluding Tasks
After the calibration procedure has been completed, the voltage of the calibration unit
must be switched off and the calibrating cable must be removed. The certificate must be
filled out completely with the signature of the inspector and his/her company stamp.
Any recognised defects such as damage, missing parts, etc. must be entered in the cer-
tificate under "Comments".
After calibration, the respective measuring device receives a calibration label, on which
the duration of calibration validity is marked.

Year Month
The date of validity is marked by cutting out (marking) the corresponding month and year
fields on the calibration label.

The calibration label must be attached to the front of the WK-Tester. The surface onto
which the calibration label is to be attached must first be cleaned.

Calibration label

BA00-1602-322002 © Continental Automotive GmbH Page 11

Sample Certificate

7 Sample Certificate
A sample certificate for the WK Tester is located in the Appendix . All measured values
are in italics and bold print (4000). The certificate must be filled out completely, including
the signature of the inspector and his/her company stamp. If a measured value is not
within the acceptable tolerance, no certificate may be issued. The date of validity entered
in the certificate must correspond to the date of validity on the calibration label attached
to the testing device.

Page 12 © Continental Automotive GmbH BA00-1602-322002

 Sample Certificate

CALIBRATION CERTIFICATE
WK Tester

Device type : WK Tester 1602.10 Certificate no. : M/2008/06/001

Serial no. : 123456 Valid until : 04.06.2009

Date : 04.06.2008

The proper function of the above-mentioned testing device has been tested and
calibrated. The measuring devices used for calibration meet national standards.

Calibration Unit Device no.:

1602-32 0066

1.) k pulse test

Desired value Tolerance Actual value

135 Hz r 15 Hz 128,45
Level display correct yes/no yes
100 pulses/km r 1 pulses/km 100

2.) Test of manual distance pulse measurement

The distance pulse measurement test was carried out 3 times.

Desired value Tolerance Actual value

1. 100 pulses/km r 1 pulses/km 100

2. 100 pulses/km r 1 pulses/km 100
3. 100 pulses/km r 1 pulses/km 100

Comments :

Continental Automotive GmbH is a

company certified according to
DIN EN ISO 9001: 2000 Company stamp/Signature of inspector

Page 1 of 1

BA00-1602-322002 © Continental Automotive GmbH Page 13

Rotary Frequency Constant Testing Device
(DFK Tester)

DFK 1602-12
Calibration Instructions
Table of Contents
1 Brief Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3 Function Test of DFK Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
4 Test Set-Up: Calibration of Engine Speed Test . . . . . . . . . . . . . . . . . . . . .6
4.1 Measuring Preparations of the Calibration Unit. . . . . . . . . . . . . . . . . . . . . 7
4.2 Measuring Preparations of the DFK Tester. . . . . . . . . . . . . . . . . . . . . . . . 7
4.3 Calibration Sequence for DI (Engine Speed Pulse) Measurement . . . . . . 7
4.4 Calibration Sequence for Pulse Width. . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.5 Calibration Sequence for Engine Speed . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5 Concluding Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
6 Sample Certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

BA00-1602-322002 © Continental Automotive GmbH Page 2

Page 3 © Continental Automotive GmbH BA00-1602-322002
 Brief Description

1 Brief Description

1 Rotary switch program selection

2 Switch for supply voltage, ON/OFF
3 5-digit LCD
4 Connection for light barrier
5 Connection for voltage supply
6 Testing line for jack plug

Additional, i.e. detailed descriptions can be found in the respective operating instructions.

BA00-1602-322002 © Continental Automotive GmbH Page 4

Technical Data

2 Technical Data
Display: 5-digit numerical LCD
Digit height = 10 mm

Interfaces: Frequency input (engine speed pulse)

U - low = 0 - 2 Volts, U - high = 2.5 - 20 Volts
fmax = 10 kHz
Frequency input (light barrier)
U - low = 0 - 2 Volts, U - high = 2.5 - 20 Volts
fmax = 10 kHz
12 V light barrier supply max. 200 mA

Voltage supply: 10.8 V - 30 V DC with reverse voltage protection

Power consumption: approx. 50 mA

Operating temperature: +5°C to +40°C

Measuring ranges: n = 50 - 5000 1/min

I = 300 - 4000 µS
DI = 200 - 3000 pulses / 100 rev.

3 Function Test of DFK Tester

The following items must be carried out to perform a function test:

Display Test :
• Supply DFK tester with voltage
• A 0 will be shown in all 5 decades of the display.

Page 5 © Continental Automotive GmbH BA00-1602-322002

 Test Set-Up: Calibration of Engine Speed Test

4 Test Set-Up: Calibration of Engine Speed Test

Before setting up the test, make sure that the mains switch is at „0“ (= mains off) position.

A Calibration unit 1 Shift key for speed = 3.2 km/h or 50 km/h

B Calibr. cable 1602-78-121 2 Shift key for autom. or manual mode
C DFK tester measuring line 4 Shift key for ATC or MTC mode
D DFK voltage supply line 5 Shift key for LS1 or LS2 light barrier
E Voltage supply line (DFK tester) 14 Shift key (grey) for switching over from counter
F DFK tester -mode to frequency-mode
G ON/OFF switch
H Selector switch

BA00-1602-322002 © Continental Automotive GmbH Page 6

Measuring Preparations of the Calibration Unit

4.1 Measuring Preparations of the Calibration Unit

• Switch 1, 50 km/h position

• Switch 2, autom. position
• Switch 4, MTC position
• Switch 5, LS2 position

4.2 Measuring Preparations of the DFK Tester

• The value 0.00 must be shown on the frequency display of the calibration unit. If this
is not the case, the grey key (14) must be pressed two times in order to activate the
frequency display.
• Connect the DFK tester to the calibration unit by means of the "B" 1602-78-121 ca-
librating line.
• Connect the "C" measuring line of the DFK tester to the "A1" test jack of the calibra-
tion unit.
• Connect the DFK tester to the calibration unit by means of the voltage supply line,
which is a DFK tester component.

Caution!
Do not confuse plus (red) and minus (black) of the voltage cable.

• Set „H“ selector switch to DI

• Switch on voltage of calibration unit.
• Turn on the voltage of the DFK tester by means of the ON/OFF switch.

4.3 Calibration Sequence for DI (Engine Speed Pulse) Measu-

rement

• After the DFK tester has been switched on, the measurement will start automatically
and a value of 00000 will be shown on the display.
• A DI measurement requires approx. 25 sec.
• At least three measurements must be made.
• After three measurements, the following DI value will be shown on the display of the
DFK tester: 5760 pulses/100 rev.
• Enter the measured value of the third measurement into the certificate.

4.4 Calibration Sequence for Pulse Width

• Set selector switch to "I".

• After that, a value of 2000 µs appears on the display of the DFK tester.
• Enter the measured value into the certificate.

Page 7 © Continental Automotive GmbH BA00-1602-322002

 Calibration Sequence for Engine Speed

4.5 Calibration Sequence for Engine Speed

• Set selector switch to "n".

• After that, a value of 22 1/min appears on the display of the DFK tester.
• Enter the measured value in the certificate.

5 Concluding Tasks
After the calibration procedure has been completed, the voltage of the calibration unit
must be switched off and the calibrating cable must be removed. The certificate must be
filled out completely with the signature of the inspector and his/her company stamp.
Any recognised defects such as damage, missing parts, etc. must be entered in the cer-
tificate under "Comments".
After calibration, the respective measuring device receives a calibration label, on which
the duration of calibration validity is marked.

Year Month

The date of validity is marked by cutting out (marking) the corresponding month and year
fields on the calibration label.

BA00-1602-322002 © Continental Automotive GmbH Page 8

Sample Certificate

The calibration label must be attached to the front side of the DFK tester. The surface onto
which the calibration label is to be attached must first be cleaned.

6 Sample Certificate
A sample certificate for the DFK Tester is located in the Appendix. All measured values
are in italics and bold print (4000). The certificate must be filled out completely, including
the signature of the inspector and his/her company stamp. If a measured value is not
within the acceptable tolerance, no certificate may be issued. The date of validity entered
in the certificate must correspond to the date of validity on the calibration label attached
to the testing device.

Page 9 © Continental Automotive GmbH BA00-1602-322002

 Sample Certificate

CALIBRATION CERTIFICATE
DFK Tester

Device type : DFK - Tester 1602.12 Certificate no. : M/2008/06/001

Serial no. : 123456 Valid until : 04.06.2009

Date : 04.06.2008

The proper function of the above-mentioned testing device has been tested and
calibrated. The measuring devices used for calibration meet national standards.

Calibration Unit Device no.:

1602.32 0066

1.) Test of engine speed pulse ratio (DI)

Desired value Tolerance Actual value

5760 pulses. / 100 rev. r 2 pulses. / 100 rev. 5760

2.) Test of pulse width

Desired value Tolerance Actual value

2000 µs r 5 µs 1999

3.) Test of engine speed measurement

Desired value Tolerance Actual value

22 x 10 rpm-1 r 1 x 10 rpm-1 22

Comments:

Continental Automotive GmbH is a

company certified according to
DIN EN ISO 9001: 2000 Company stamp/Signature of inspector

Page 1 of 1

BA00-1602-322002 © Continental Automotive GmbH Page 10

Power Supply Unit (9 voltages)

NT 18 1601-18
Calibration Instructions
Table of Contents
1 Brief description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3 Function Test for Power Supply Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
4 Test Set-Up: Calibration of Output Voltage . . . . . . . . . . . . . . . . . . . . . . . . .7
4.1 Measuring Preparations of the Calibration Unit. . . . . . . . . . . . . . . . . . . . . 8
4.2 Measuring Preparations of the Power Supply Unit . . . . . . . . . . . . . . . . . . 8
4.3 Calibration Sequence for Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5 Concluding Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
6 Sample Certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

BA00-1602-322002 © Continental Automotive GmbH Page 3

 Brief description

1 Brief description

1 Mains switch 230 V

2 Fuse 230 V/0.5 A
3-11 Voltage selection (4.5 V - 30 V) press switches
12 Short circuit display
13 Jack for output voltage, U+
14 Jack for output voltage, ground

Additional, i.e. detailed descriptions can be found in the respective operating instructions.

BA00-1602-322002 © Continental Automotive GmbH Page 5

Technical Data

2 Technical Data
Mains connection: 230 V, 50 Hz

Power supply unit: 4.5 V, 6 V, 8 V, 10 V, 12 V, 16 V,

20 V, 24 V, 30 V
max. 0.5 A

3 Function Test for Power Supply Unit

The following items must be carried out to perform a function test:
• Switch on power supply unit and check whether the corresponding lamp lights up.
• Switch through the individual voltages from 4.5 V to 30 V one after the other and
check whether the pressed switch locks into place and whether the previous switch
disengages.
• Short circuit the jacks for U+ and ground output voltage and check whether the short
circuit lamp lights up.

Page 6 © Continental Automotive GmbH BA00-1602-322002

 Test Set-Up: Calibration of Output Voltage

4 Test Set-Up: Calibration of Output Voltage

Before setting up the test, make sure that the mains switch is at the "0" (= mains off)
position.
The voltage of the power supply unit must also be switched off.

A Calibration unit 1 Shift key for speed = 3.2 km/h or 50 km/h

B Testing cable, red 2 Shift key for autom. or manual mode
C Testing cable, black4 Shift key for ATC or MTC mode
D Power supply unit 5 Shift key for LS1 or LS2 light barrier
E Mains switch 14 Shift key (grey) for switching over from
F-NFunction keys counter-mode to frequency-mode

BA00-1602-322002 © Continental Automotive GmbH Page 7

Measuring Preparations of the Calibration Unit

4.1 Measuring Preparations of the Calibration Unit

• Switch 1, 50 km/h position

• Switch 2, manual position
• Switch 4, MTC position
• Switch 5, LS2 position

4.2 Measuring Preparations of the Power Supply Unit

• Insert red testing cable into the red "+" banana socket of the power supply unit. Insert
the other side of the testing cable into the red "V" banana socket of the calibration
unit labelled "Input".
• Insert black testing cable into the black "-" banana socket of the power supply unit.
Insert the other side of the testing cable into the black "-" banana socket of the cali-
bration unit labelled "Input".
• Press "F" 4.5 V function key (locked into place).
• Switch on the voltage of the calibration unit and the power supply unit.

4.3 Calibration Sequence for Voltage Test

• After the calibration unit and the power supply unit have been switched on, the
measured value appears on the voltage display of the calibration unit.
• Enter the measured value into the certificate.
• Select all other voltage values "6 - 30 V" one after the other by means of the function
keys. Enter the respective measured value into the certificate

Page 8 © Continental Automotive GmbH BA00-1602-322002

 Concluding Tasks

5 Concluding Tasks
After the calibration procedure has been completed, the voltage of the calibration unit
must be switched off and the calibrating cable must be removed. The certificate must be
filled out completely with the signature of the inspector and his/her company stamp.
Any recognised defects such as damage, missing parts, etc. must be entered in the cer-
tificate under "Comments".
After calibration, the respective measuring device receives a calibration label, on which
the duration of calibration validity is marked.

Year Month
The date of validity is marked by cutting out (marking) the corresponding month and year
fields on the calibration label.

The calibration label must be attached to the front of the power supply unit. The surface
onto which the calibration label is to be attached must first be cleaned.

BA00-1602-322002 © Continental Automotive GmbH Page 9

Sample Certificate

6 Sample Certificate
A sample certificate for the 1601.18 power supply unit is located in the Appendix. All
measured values are in italics and bold print (4000). The certificate must be filled out com-
pletely, including the signature of the inspector and his/her company stamp. If a measured
value is not within the acceptable tolerance, no certificate may be issued. The date of va-
lidity entered in the certificate must correspond to the date of validity on the calibration la-
bel attached to the testing device.

Page 10 © Continental Automotive GmbH BA00-1602-322002

 Sample Certificate

CALIBRATION CERTIFICATE
Power Supply Unit 1601.18

Device type : Netzteil 1601.18 Certificate no. : M2008/06/001

Serial no. : 123456 Valid until : 04.06.2009

Date : 04.06.2008

The proper function of the above-mentioned testing device has been tested and
calibrated. The measuring devices used for calibration meet national standards.

Calibration Unit Device no.:

1602.32 0066

1.) Voltage test ( Fixed voltage 4.5V, 6V, 8V, 10V, 12V, 16V, 20V, 24V, 30V )

Desired value Tolerance Actual value

4.5 Volt r 0,3 Volt 04,52

6 Volt r 0,5 Volt 06,13
8 Volt r 0,7 Volt 08,05
10 Volt r 1,0 Volt 10,03
12 Volt r 1,2 Volt 12,12
16 Volt r 1,6 Volt 16,07
20 Volt r 2,0 Volt 20,13
24 Volt r 2,4 Volt 24,21
30 Volt r 3,0 Volt 30,14

Comments:

Continental Automotive GmbH is a

company certified according to
DIN EN ISO 9001: 2000 Company stamp/Signature of inspector

Page 1 of 1

BA00-1602-322002 © Continental Automotive GmbH Page 11

Sample Certificate

Page 12 © Continental Automotive GmbH BA00-1602-322002

Power Supply Unit (3 voltages)

NT 14 1601-14
Calibration Instructions
Seite 2 © Continental Automotive GmbH BA00-1602-322002
Table of Contents
1 Brief Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3 Function Test for Power Supply Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
4 Test Set-Up: Calibration of Output Voltage . . . . . . . . . . . . . . . . . . . . . . . . .7
4.1 Measuring Preparations of the Calibration Unit. . . . . . . . . . . . . . . . . . . . . 8
4.2 Measuring Preparations of the Power Supply Unit . . . . . . . . . . . . . . . . . . 8
4.3 Calibration Sequence for Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5 Concluding Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
6 Sample Certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

BA00-1602-322002 © Continental Automotive GmbH Page 3

Page 4 © Continental Automotive GmbH BA00-1602-322002
 Brief Description

1 Brief Description

1 Mains switch 230 V

2 Fuse 230 V / 0.5 A
3 Rotary switches voltage (6 V, 12 V, 24 V) selection
13 Jack for output voltage, U+
14 Jack for output voltage, ground

Additional, i.e. detailed descriptions can be found in the respective operating instructions

BA00-1602-322002 © Continental Automotive GmbH Page 5

Technical Data

2 Technical Data
Mains connection: 230 V, 50 Hz

Power supply unit: 6 V, 12 V, 24 V

max. 0.8 A

3 Function Test for Power Supply Unit

• Switch on power supply unit and check whether the corresponding lamp lights up.

Page 6 © Continental Automotive GmbH BA00-1602-322002

 Test Set-Up: Calibration of Output Voltage

4 Test Set-Up: Calibration of Output Voltage

Before setting up the test, make sure that the mains switch is at the "0" (= mains off)
position.
The voltage of the power supply unit must also be switched off.

ACalibration unit 1 Shift key for speed = 3.2 km/h or 50 km/h

BTesting cable, red 2 Shift key for autom. or manual mode
CTesting cable, black4 Shift key for ATC or MTC mode
DPower supply unit 5 Shift key for LS1 or LS2 light barrier
EMains switch 14 Shift key (grey) for switching over from
counter-mode to frequency-mode
FVoltage selector switch

BA00-1602-322002 © Continental Automotive GmbH Page 7

Measuring Preparations of the Calibration Unit

4.1 Measuring Preparations of the Calibration Unit

• Switch 1, 50 km/h position

• Switch 2, manual position
• Switch 4, MTC position
• Switch 5, LS2 position

4.2 Measuring Preparations of the Power Supply Unit

• Insert red testing cable into the red "+" banana socket of the power supply unit. Insert
the other side of the testing cable into the red "V" banana socket of the calibration unit
labelled "Input".
• Insert black testing cable into the black "-" banana socket of the power supply unit.
Insert the other side of the testing cable into the black "-" banana socket of the calibration
unit labelled "Input".
• Turn "F" selector switch to "6 V".
• Switch on the voltage of the calibration unit and the power supply unit.

4.3 Calibration Sequence for Voltage Test

• After the calibration unit and the power supply unit have been switched on, the
measured value appears on the voltage display of the calibration unit.
• Enter the measured value into the certificate.
• Select all other voltage values "12 and 24 V" one after the other by means of the
function keys. Enter the respective measured value into the certificate.

Page 8 © Continental Automotive GmbH BA00-1602-322002

 Concluding Tasks

5 Concluding Tasks
After the calibration procedure has been completed, the voltage of the calibration unit
must be switched off and the calibrating cable must be removed. The certificate must be
filled out completely with the signature of the inspector and his/her company stamp.
Any recognised defects such as damage, missing parts, etc. must be entered in the cer-
tificate under "Comments".
After calibration, the respective measuring device receives a calibration label, on which
the duration of calibration validity is marked.

Year Month
The date of validity is marked by cutting out (marking) the corresponding month and year
fields on the calibration label.

The calibration label must be attached to the front of the power supply unit. The surface
onto which the calibration label is to be attached must first be cleaned.

BA00-1602-322002 © Continental Automotive GmbH Page 9

Sample Certificate

6 Sample Certificate
A sample certificate for the 1601.14 power supply unit is located in the Appendix. All
measured values are in italics and bold print (4000). The certificate must be filled out com-
pletely, including the signature of the inspector and his/her company stamp. If a measured
value is not within the acceptable tolerance, no certificate may be issued. The date of va-
lidity entered in the certificate must correspond to the date of validity on the calibration la-
bel attached to the testing device.

Page 10 © Continental Automotive GmbH BA00-1602-322002

 Sample Certificate

CALIBRATION CERTIFICATE
Power Supply Unit 1601.14

Device type : Netzteil 1601.14 Certificate no. : M/2008/06/001

Serial no. : 123456 Valid until : 04.06.2009

Date : 04.06.2008

The proper function of the above-mentioned testing device has been tested and
calibrated. The measuring devices used for calibration meet national standards.

Calibration Unit Device no.:

1602.32 0066

1.) Voltage test (Fixed voltage 6V, 12V, 24V )

Desired value Tolerance Actual value

6Volt r 0,6 Volt 06,13

12Volt r 1,2 Volt 12,12
24Volt r 2,4 Volt 24,14

Comments:

Continental Automotive GmbH is a

company certified according to
DIN EN ISO 9001: 2000 Company stamp/Signature of inspector

Page 1 of 1

BA00-1602-322002 © Continental Automotive GmbH Page 11

Rolling Road Test System APS

APS 1601-21
Calibration Instructions (APS with Double Roller)
Table of Contents
1 Brief Description of Rolling Road Test System (Front View). . . . . . . . . . . .3
1.1 Brief Description of Rolling Road Test System (Rear View) . . . . . . . . . . . .4
1.2 Brief Description of Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3 Function Test for Rolling Road Test System. . . . . . . . . . . . . . . . . . . . . . . .7
4 Test Set-Up: Calibration of k Pulse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
4.1 Measuring Preparations of the Calibration Unit. . . . . . . . . . . . . . . . . . . . . .9
4.2 Measuring Preparations of the Wheel Rotation Test System . . . . . . . . . . .9
4.3 Connection of Calibrating Line to Rolling Road Test System . . . . . . . . . .10
4.4 Calibration Sequence for k Pulse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
5 Test Set-Up: Calibration of Tyre Circumference
and Distance Pulse Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
5.1 Roller Correction / Speed Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
5.2 Calibration Sequence for Tyre Circumference Measurement . . . . . . . . . .13
5.3 Calibration Sequence for Distance Pulse Measurement. . . . . . . . . . . . . .13
6 Inspection of Entire Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
6.1 Wheel Rotation Test System Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . .14
6.2 Vehicle Function Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
7 Concluding Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
8 Sample Certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

BA00-1602-322002 © Continental Automotive GmbH Page 2

 Brief Description of Rolling Road Test System (Front

1 Brief Description of Rolling Road Test System (Front View)

1 Computer insert module

2 Printer insert module
3 Mains switch
4 LED for voltage supply
5 LED for "Apply brake"
6 LED for "Release brake"
7 LED for voltage supply
8 LED for print enable
9 8-digit alphanumerical LED
10 Label printer

BA00-1602-322002 © Continental Automotive GmbH Page 4

Brief Description of Rolling Road Test System (Rear View)

1.1 Brief Description of Rolling Road Test System (Rear View)

15 Plug board for computer insert module

16 Plug board for printer insert module
17 Input for roller pulse
18 Input for negative roller pulse
19 Input for light barrier pulse

Page 5 © Continental Automotive GmbH BA00-1602-322002

 Brief Description of Remote Control

1.2 Brief Description of Remote Control

20 Keypad (function keys)

21 Display for measured values (W, L, distance)
22 Display for measured values (km/h, k)
23 Function display (LED)
24 Decade switch for correction values
25 Connecting cable for testing line
26 Connecting cable for remote control

Additional, i.e. detailed descriptions can be found in the respective operating instructions.

BA00-1602-322002 © Continental Automotive GmbH Page 6

Technical Data

2 Technical Data
Display, remote control: 4-digit numerical LCD
Digit height = 13 mm (km/h, k display)
5-digit numerical LCD
Digit height = 13 mm
(W, L, distance display)
10 red LEDs for function display
Display, computer insert module: 2 red LEDs for function display
3 red LEDs for voltage display
Display, printer insert module: 2 red LEDs for function display
8-digit alphanumerical LCD
Digit height = 13 mm
Keypad, remote control: 12 function keys
Keypad, computer insert module: 2 function keys
Keypad, printer insert module: alphanumerical keyboard
Interfaces, remote control: Frequency input (W, k pulse)
fmax 3 kHz
U - low = 0 - 2 Volts,
U - high = 2.5 - 20 Volts
Frequency output (k pulse)
fmax 150 Hz, max. 15 V, max. 30 mA
Interfaces, computer insert module: Frequency input (roller pulse)
fmax 6 kHz
U - low = 0 - 2 Volts,
U - high = 2.5 - 20 Volts
Frequency input (light barrier)
fmax 1 kHz
U - low = 0 - 2 Volts,
U - high = 2.5 - 20 Volts
Power supply unit: External voltage supply
+12 V +/- 10 %, max 1A
Electronics supply 5 V +/- 5 %,
max. 500 mA
Mains connection: 187 V - 242 V, 50 Hz
Power consumption: approx. 600 mA
Operating temperature: + 5°C to + 40°C
Measuring ranges: 0 - 120 km/h
2000 - 25000 pulses/km
Device constant: 2400 - 25000 pulses/km

Page 7 © Continental Automotive GmbH BA00-1602-322002

 Function Test for Rolling Road Test System

3 Function Test for Rolling Road Test System

The following items must be carried out to perform a function test:

Display Test (Computer Insert Module):

• Switch on voltage of APS by means of mains switch.
• Check mains switch lamp.
• The LED for voltage supply (+5 V, +12 V, -12 V) must light up.
The LED for "Lös" (= release brake) must light up.
• Press "Arr" key on the remote control.
• LED for "Lös" (= release brake) must go out.
The LED for "Arr" (= apply brake) must light up.
• Press "Lös" key on the remote control.
• The LED for "Lös" (= release brake) must light up again.
LED for "Arr" (= apply brake) must go out.

Display Test (Printer Insert Module):

Some APS designs have no printer insert module. Skip this test if no printer insert module
exists.
• The LED for voltage supply (12 V) must light up.
• "DATE"? must be shown on the 8 digit display.
• Enter the current date by means of the keypad. Assume the date by means of the
"Return" key.
• After that, the LED for "Print enable" must light up.
• Start test printout by means of the "Print" key.
• The entered date and the set correction value (remote control) are printed out.

Display Test (Remote Control):

• Set correction value to -15 by means of decade switch.
• Press the "CL" key.
• A value of 000.0 must be shown on the upper LCD. A decimal point must appear
between the 1st and 2nd digits.
• A value of 00000 must be shown on the lower LCD.
• An automatic display test is started by pressing the "Test" key.
• All LED (function display) will be actuated one after the other and must light up
briefly.
• Then all decades of the upper and lower 5-digit LCDs will display an 8. A point will
be visible between the 2nd and 3rd digit of the upper display and between the 1st
and 2nd digit on the lower LCD.
• At the end of the display test the set correction value (3-digit decade switches), -15,
will be shown briefly on the upper display.

BA00-1602-322002 © Continental Automotive GmbH Page 8

Test Set-Up: Calibration of k Pulse

4 Test Set-Up: Calibration of k Pulse

Before setting up the test, make sure that the mains switch is at the "0" (= mains off)
position. The voltage of the APS must also be switched off.

A Clabration unit 1 Shift key for speed = 3.2 km/h or 50 km/h

B Clabr. cable 1602-78-120 2 Shift key for autom. or manual mode
C APS computer cabinet 4 Ahift key for ATC or MTC mode
D Ground connection 5 Shift key for LS1 or LS2 light barrier
E APS connecting signal line 14 Shift key (grey) for switching over from
counter-mode to frequency-mode
F APS cable for remote control
G APS remote control
H APS I/O cable

Page 9 © Continental Automotive GmbH BA00-1602-322002

 Measuring Preparations of the Calibration Unit

4.1 Measuring Preparations of the Calibration Unit

• Switch 1, 50 km/h position

• Switch 2, autom. position
• Switch 4, ATC position
• Switch 5, LS2 position
(see section 4)

4.2 Measuring Preparations of the Wheel Rotation Test Sy-

stem

• Unsolder signal lines 17 (R pulses), 18 (R pulses), and 19 (L pulses) from the plug
board.
• Mark the signal lines in such a way that they can be soldered to the same pin again
with-out being mixed up after the calibration procedure.
• Tape up the ends of the lines with insulating tape to avoid short circuits.

BA00-1602-322002 © Continental Automotive GmbH Page 10

Connection of Calibrating Line to Rolling Road Test System

4.3 Connection of Calibrating Line to Rolling Road Test Sy-

stem

• Clamp the 0 V line (grey) to ground terminal.

• Clamp the R pulse signal line (white) to item 17 of the A connecting plug.
• Clamp the R pulse 0 V line (yellow) to item 18 of the A connecting plug.
• Clamp the L pulse line (green) to item 19 of the A connecting plug.
• The +24 V line (brown) is not required.

Note!
The connection of the signal lines by means of the clamps of the 1602-78-120 cable
must be performed very carefully and correctly.
Incorrect connection to the rolling road test system results in short circuits, which can
lead to defects in the rolling road system or the calibration unit.

Page 11 © Continental Automotive GmbH BA00-1602-322002

 Calibration Sequence for k Pulse

• Connect the I/O line, which is an APS component, to the remote control of the APS
and the E1 test jack of the calibration unit (see Section 4).
• Connect the calibration unit to 230 V by means of a voltage cable and activate the
voltage by means of the mains switch (see Section 4).
• The value 0.00 must be shown on the frequency display of the calibration unit. If this
is not the case, the grey key (14) must be pressed twice in order to activate of the
frequency display.
• Switch on the voltage of the rolling road test system.
• Set the correction value +0.0 % by means of the decade switch of the remote control.

4.4 Calibration Sequence for k Pulse

• Press the "CLEAR" key of the calibration unit and keep it pressed.
• Wait until a value of 0.00 km/h is shown on the upper display of the remote control.
K
• The k measurement is started by means of the E of the remote control. Release
the "CLEAR" key of the calibration unit.
• The LED for "k measurement" must light up.
• The measured k value appears on the upper display of the remote control.
• The LED for "Clock pulse" must light up.
• The LED of the calibration unit must light up during the k measurement.
• Enter measured values into the certificate.
1. Measured value of frequency display
2. Level size: yes/no (level size = yes when the LED is illuminated)
3. k value display of remote control
• Cancel the k measurement by means of the "CL" key of the remote control.

5 Test Set-Up: Calibration of Tyre Circumference

and Distance Pulse Measurement
The test can be set up as described under Section 4. The APS test line (H) must be re-
moved from the "E1" jack bush and inserted into the "A2" jack bush.

BA00-1602-322002 © Continental Automotive GmbH Page 12

Roller Correction / Speed Display

5.1 Roller Correction / Speed Display

• Check the speed display.

• If the 50 km/h speed display deviates by + 0.3 km/h, a roller correction calculation is

Page 13 © Continental Automotive GmbH BA00-1602-322002

 Calibration Sequence for Tyre Circumference Measu-

necessary.
Calculation of roller correction (test stand roller adaptation)

Desired value Tolerance Actual value

50.0 km/h ± 0.3 km/h

If the desired value and the actual value are both equal to 50 km/h = + 0.3 km/h, the
test stand needs no roller correction value. The constant is RC = 1.00 (calculation to
2 decimal places). If the actual value is greater than or lesser than 50 km/h, the roller
set of the test stand has a roller correction value. This value is calculated by means
of the following formula:
Desired value The actual value of the distance pulse and the tyre cir-
RC = = cumference must be corrected by means of this RC
Actual value
constant.
• Enter the roller correction value into the certificate.

5.2 Calibration Sequence for Tyre Circumference Measure-

ment

• Start the tyre circumference measurement by pressing the "L" key of the remote con-
trol. The LED for "mm" of the remote control lights up.
• Wait until the measured value is shown on the lower display of the remote control.
• Enter the measured value into the certificate.
• Cancel the tyre circumference measurement by means of the "CL" key of the remote
control.
• The tyre circumference measurement must be carried out twice.

5.3 Calibration Sequence for Distance Pulse Measurement

• Check whether the "Sensor appl." key of the remote control has been pressed.
• Start the distance pulse measurement by pressing the "W" key of the remote control.
The LED for "p/km" of the remote control lights up.
• Wait until the measured value is shown on the lower display of the remote control.
• Enter the measured value into the certificate.
• Cancel the distance pulse measurement by means of the "CL" key of the remote
control.
• The distance pulse measurement must be carried out twice.

6 Inspection of Entire Installation

BA00-1602-322002 © Continental Automotive GmbH Page 14

Wheel Rotation Test System Settings

At the end of the calibration procedure the voltage of the calibration unit must be switched
off and the calibrating cable must be removed. The unsoldered lines must be resoldered
to the connections provided.

Standard APS signal line assignment

Signal lines: yellow 17 (R pulses), green 18 (R pulses), and yellow 19 (L pulses).

6.1 Wheel Rotation Test System Settings

• Set tyre correction value by means of the decade switch of the remote control.

6.2 Vehicle Function Test

• Automatic test
• Enter vehicle identification number
• Print out installation plate and make sure that the printout is error-free.
• Compare the measured values in the installation plate with those on the display of
the remote control.

7 Concluding Tasks
The certificate must be filled out completely with the signature of the inspector and his/her
company stamp. Any recognised defects such as damage, missing parts, etc. must be en-
tered in the certificate under "Comments".
After calibration the respective measuring device receives a calibration label on which the
duration of calibration validity is marked.

Year Month

Page 15 © Continental Automotive GmbH BA00-1602-322002

 Sample Certificate

The date of validity is marked by cutting out (marking) the corresponding month and year
fields on the calibration label.

The calibration label must be attached to the front of the APS unit. The surface onto which
the calibration label is to be attached must first be cleaned.

8 Sample Certificate

A sample certificate for the wheel rotation test system is located in the Appendix. All
measured values are in italics and bold print (4000). The certificate must be filled out com-
pletely, including the signature of the inspector and his/her company stamp. If a measured
value is not within the acceptable tolerance, no certificate may be issued. The date of va-
lidity entered in the certificate must correspond to the date of validity on the calibration la-
bel attached to the testing device.

BA00-1602-322002 © Continental Automotive GmbH Page 16

Sample Certificate

CALIBRATION CERTIFICATE
Rolling Road Test System APS
(Double Roller, Kienzle Roller, Performance Test Stands)

Device type : APS 1601.21 Certificate no. : M2008/06/001

Serial no. : 0021 Valid until : 04.06.2009

Date : 04.06.2008

The proper function of the above-mentioned testing device has been tested and
calibrated. The measuring devices used for calibration meet national standards.
.

Calibration Unit Device no.:

1602.32 0066

1.) k pulse test

Desired value Tolerance Actual value

135 Hz r 20 Hz 149,23

Level display correct yes/no yes

100 pulses/km r 1 pulses/km 100

2.) Calculation of roller correction (RC) and check of

speed display
Calculation of roller correction (test stand roller adaptation)

Soll - Wert Toleranz Ist - Wert

50.0 km/h r 0,3 km/h 49,9

If the desired value and the actual value are both equal to 50 km/h ± 0,3 km/h, the test stand
has no roller correction value. The constant is RC = 1.000 (calculation to 3 decimal places).
If the actual value is greater than or lesser than 50 km/h, the roller set of the test stand has a
roller correction value. This value is calculated by means of the following formula:

Page 1 of 2

Page 17 © Continental Automotive GmbH BA00-1602-322002

 Sample Certificate

CALIBRATION
CALIBRATION CERTIFICATE
CERTIFICATE
Rolling
Rolling Road
Road Test
Test System
System APS
APS
(Double
(DoubleRoller,
Roller,Kienzle
KienzleRoller,
Roller,Performance
PerformanceTest
TestStands)
Stands)

Desired
Desiredvalue
value
RC=
RC= RC
RC==1,000
1,000
Actual
Actualvalue
value

The
Theactual
actualvalues
valuesofofthe
thedistance
distancepulse
pulseand
andthe
thetyre
tyrecircumference
circumferencemust
mustbe
becorrected
corrected
by
bymeans
meansofofthis
thisRC
RCconstant.
constant.
Example:
Example:Measured
Measureddistance
distancepulse
pulse==7500
7500pulses/km.
pulses/km.Tyre
Tyrecircum.
circum.==2666
2666mm.
mm.RCRC==1.5
1.5
Measured
Measureddistance
distancepulse
pulse==7500
7500pulses/km
pulses/km1.5
1.5==5000
5000pulses/km
pulses/km(actual
(actualvalue)
value)
Measured
Measuredtyre
tyrecircumference
circumference==2666
2666mmmm* *1.5
1.5==4000
4000mm
mm(actual
(actualvalue)
value)

3.)
3.)Automatic
Automatictest
testof
ofdistance
distancepulse
pulseand
andtyre
tyrecircumference
circumferencemeasurement
measurement
The
Thetest
testofofthe
thedistance
distancepulse
pulseand
andtyre
tyrecircumference
circumferencemeasurement
measurementwas
wascarried
carriedout
outtwice.
twice.

Desired
Desiredvalue
value Tolerance
Tolerance Actual
Actualvalue
value

Tyre
Tyrecircumference
circumferencemeasurement
measurement

1.1. 4000
4000mm
mm rr40
40mm
mm Measured
Measuredvalue RC== 4001
value* *RC 4001
2.2. 4000
4000mm
mm rr40
40mm
mm Measured
Measuredvalue RC== 4001
value* *RC 4001

Distance
Distancepulse
pulsemeasurement
measurement

1.1. 5000
5000pulses/km
pulses/km rr50 pulses/km Measured
50pulses/km Measuredvalue RC== 5001
value RC 5001
2.2. 5000
5000pulses/km
pulses/km rr50
50pulses/km
pulses/km Measured
Measuredvalue
value RC
RC== 5001
5001

IfIfthe
thetest
testhas
hasaaroller
rollercorrection
correctionfunction,
function,the
thetolerance
toleranceincreases
increasesbyby±±22 pulses/km
pulses/kmfor
for
the
thedistance
distancepulse
pulsemeasurement
measurementand andbyby±±22mm
mmforforthe
thetyre
tyrecircumference
circumferencemeasurement.
measurement.

Comments:
Comments:

Continental
ContinentalAutomotive
AutomotiveGmbH
GmbHisisaa
company
companycertified
certifiedaccording
accordingtoto
DIN
DINEN
ENISO
ISO9001:
9001:2000
2000 Company
Companystamp/Signature
stamp/Signatureofofinspector
inspector

Page
Page22ofof22

BA00-1602-322002 © Continental Automotive GmbH Page 18

Rolling Road Test System APS

APS/ Bremse 1601-21

Calibration Instructions (Adaptation to Brake Test Stands)
Table of Contents
1 Brief Description of Rolling Road Test System (Front View). . . . . . . . . . . .3
1.1 Brief Description of Rolling Road Test System (Rear View) . . . . . . . . . . . 4
1.2 Brief Description of Remote Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3 Function Test for Rolling Road Test System. . . . . . . . . . . . . . . . . . . . . . . .7
4 Test Set-Up: Calibration of k Pulse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
4.1 Measuring Preparations of the Calibration Unit. . . . . . . . . . . . . . . . . . . . . 9
4.2 Measuring Preparations of the Rolling Road Test System . . . . . . . . . . . . 9
4.3 Connection of Calibrating Line to Rolling Road Test System . . . . . . . . . 10
4.4 Calibration Sequence for k Pulse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5 Test Set-Up: Calibration of Tyre
Circumference and Distance Pulse Measurement . . . . . . . . . . . . . . . . . .12
5.1 Calibration Sequence for Tyre Circumference Measurement . . . . . . . . . 13
5.2 Calibration Sequence for Distance Pulse Measurement (Single Axle) . . 13
5.3 Calibration Sequence for Distance Pulse Measurement (Double Axle) . 13
6 Inspection of Entire Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
6.1 Wheel Rotation Test System Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6.2 Vehicle Function Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
7 Concluding Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
8 Sample Certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

BA00-1602-322002 © Continental Automotive GmbH Page 2

 Brief Description of Rolling Road Test System (Front

1 Brief Description of Rolling Road Test System (Front View)

1 Computer insert module

2 Printer insert module
3 Mains switch
4 LED for voltage supply
5 LED for "Apply brake"
6 LED for "Release brake"
7 LED for "Release brake"
8 LED for print enable
9 8-digit alphanumerical LED
10 Label printer
11 Shift key for single or double back axle

BA00-1602-322002 © Continental Automotive GmbH Page 4

Brief Description of Rolling Road Test System (Rear View)

1.1 Brief Description of Rolling Road Test System (Rear View)

15 Plug board for computer insert module

16 Plug board for printer insert module
17 Input for roller pulse
18 Input for negative roller pulse
19 Input for light barrier pulse

Page 5 © Continental Automotive GmbH BA00-1602-322002

 Brief Description of Remote Control

1.2 Brief Description of Remote Control

20 Keyboard (function keys)

21 Display for measured values (W, L, distance)
22 Display for measured values (km/h, k)
23 Function display (LED)
24 Decade switch for correction values
25 Connecting cable for testing line
26 Connecting cable for remote control

Additional, i.e. detailed descriptions can be found in the respective operating instructions.

BA00-1602-322002 © Continental Automotive GmbH Page 6

Technical Data

2 Technical Data
Display, remote control: 4-digit numerical LCD
Digit height = 13 mm (km/h, k display)
5-digit numerical LCD
Digit height = 13 mm
(W, L, distance display)
10 red LEDs for function display
Display, computer insert module: 2 red LEDs for function display
3 red LEDs for voltage display
Display, printer insert module: 2 red LEDs for function display
8-digit alphanumerical LCD
Digit height = 13 mm
Keyboard, remote control: 12 function keys
Keyboard, computer insert module: 2 function keys
Keyboard, printer insert module: alphanumerical keyboard
Interfaces, remote control: Frequency input (W, k pulse)
fmax 3 kHz
U - low = 0 - 2 Volts,
U - high = 2.5 - 20 Volts
Frequency output (k pulse)
fmax 150 Hz, max. 15 V, max. 30 mA
Interfaces, computer insert module: Frequency input (roller pulse)
fmax 6 kHz
U - low = 0 - 2 Volts,
U - high = 2.5 - 20 Volts
Frequency input (light barrier)
f max 1 kHz
U - Low = 0 - 2 Volts,
U - High = 2.5 - 20 Volts
Power supply unit: External voltage supply
+ 12 V +/- 10 %, max 1A
Electronics supply 5V +/- 5%,
max. 500 mA
Mains connection: 187 V - 242 V, 50 Hz
Power consumption: ca. 600 mA
Operating temperature: +5 °C to + 40 °C
Measuring ranges: 0 - 120 km/h
2000 - 25000 pulses/ km
Device constant: 2400 - 25000 pulses/ km

Page 7 © Continental Automotive GmbH BA00-1602-322002

 Function Test for Rolling Road Test System

3 Function Test for Rolling Road Test System

The following items must be carried out to perform a function test:
Display Test (Computer Insert Module):
• Switch on voltage of APS by means of mains switch.
• Check mains switch lamp.
• The LED for voltage supply (+5 V, +12 V, -12 V) must light up.
The LED for "Lös" (= release brake) must light up.
• Press "Arr" key on the remote control.
• LED for "Lös" (= release brake) must go out.
The LED for "Arr" (= apply brake) must light up.
• Press "Lös" key on the remote control.
• The LED for "Lös" (= release brake) must light up again.
LED for "Arr" (= apply brake) must go out.

Display Test (Printer Insert Modulel):

Some APS designs have no printer insert module. Skip this test if no printer insert module
exists.
• The LED for voltage supply (12 V) must light up.
• "DATE"? must be shown on the 8 digit display.
• Enter the current date by means of the keypad. Assume the date by means of the
"Return" key.
• After that, the LED for "Print enable" must light up.
• Start test printout by means of the "Print" key.
• The entered date and the set correction value (remote control) are printed out.

Display Test (Remote Control):

• Set correction value to -15 by means of decade switch.
• Press the "CL" key..
• A value of 000.0 must be shown on the upper LCD. A decimal point must appear
between the 1st and 2nd digits.
• A value of 00000 must be shown on the lower LCD.
• An automatic display test is started by pressing the "Test" key.
• All LED (function display) will be actuated one after the other and must light up
briefly.
• Then all decades of the upper and lower 5-digit LCDs will display an 8. A point will
be visible between the 2nd and 3rd digit of the upper display and between the 1st
and 2nd digit on the lower LCD.
• At the end of the display test the set correction value (3-digit decade switches), -15,
will be shown briefly on the upper display.

BA00-1602-322002 © Continental Automotive GmbH Page 8

Test Set-Up: Calibration of k Pulse

4 Test Set-Up: Calibration of k Pulse

Before setting up the test, make sure that the mains switch is at the "0" (= mains off)
position. The voltage of the APS must also be switched off.

A Calibration unit 1 Shift key for speed = 3.2 km/h or 50 km/h

B Calibration cable 1602-78-120 2 Shift key for autom. or manual mode
C APS computer cabinet 4 Shift key for ATC or MTC
D Ground connection 5 Shift key for LS1 or LS2
E APS connecting signal line 14 Shift key (grey) for switching over from
counter-mode to frequency-mode
F APS cable for remote control
G APS remote control
H APS I/O cable

Page 9 © Continental Automotive GmbH BA00-1602-322002

 Measuring Preparations of the Calibration Unit

4.1 Measuring Preparations of the Calibration Unit

• Switch 1, 3.2 km/h position

• Switch 2, autom. position
• Switch 4, ATC position
• Switch 5, LS2 position
(see section 4)

4.2 Measuring Preparations of the Rolling Road Test System

• Unsolder signal lines 17 (R pulses), 18 (R pulses), and 19 (L pulses) from the plug
board.
• Mark the signal lines in such a way that they can be soldered to the same pin again
with-out being mixed up after the calibration procedure.
• Tape up the ends of the lines with insulating tape to avoid short circuits.

BA00-1602-322002 © Continental Automotive GmbH Page 10

Connection of Calibrating Line to Rolling Road Test System

4.3 Connection of Calibrating Line to Rolling Road Test Sy-

stem

• Clamp the 0 V line (grey) to ground terminal.

• Clamp the R pulse signal line (white) to item 17 of the A connecting plug.
• Clamp the R pulse 0 V line (yellow) to item 18 of the A connecting plug.
• Clamp the L pulse line (green) to item 19 of the A connecting plug.
• The +24 V line (brown) is not required.

Note!
The connection of the signal line by means of the clamps of the 1602-78-120 cable
must be performed very carefully and correctly.
Incorrect connection to the rolling road test system results in short circuits which can
lead to defects in the rolling road test system or calibration unit.

Page 11 © Continental Automotive GmbH BA00-1602-322002

 Calibration Sequence for k Pulse

• Connect the I/O line, which is an APS component, to the remote control of the APS
and the E1 test jack of the calibration unit (see Section 4).
• Connect the calibration unit to 230 V by means of a voltage cable and activate the
voltage by means of the mains switch (see Section 4).
• The value 0.00 must be shown on the frequency display of the calibration unit. If this
is not the case, the grey key (14) must be pressed two times in order to activate the
frequency display.
• Switch on the voltage of the rolling road test system.
• Set the correction value +0.0 % by means of the decade switch of the remote control.

4.4 Calibration Sequence for k Pulse

• Press the "CLEAR" key of the calibration unit and keep it pressed.
• Wait until a value of 0.00 km/h is shown on the upper display of the remote control.
K
• The k measurement is started by means of the E of the remote control. Release
the "CLEAR" key of the calibration unit.
• The LED for "k measurement" must light up.
• The measured k value appears on the upper display of the remote control.
• The LED for "Clock pulse" must light up.
• The LED of the calibration unit must light up during the k measurement.
• Enter measured values into the certificate.
1. Measured value of frequency display
2. Level size: yes/no (level size = yes when the LED is illuminated)
3. k value display of remote control
• Cancel the k measurement by means of the "CL" key of the remote control.

5 Test Set-Up: Calibration of Tyre

Circumference and Distance Pulse Measurement
The test can be set up as described under Section 4. The APS test line (H) must be re-
moved from the "E1" jack bush and inserted into the "A2" jack bush.

BA00-1602-322002 © Continental Automotive GmbH Page 12

Test Set-Up: Calibration of Tyre Circumference and Distance Pulse Measurement

Page 13 © Continental Automotive GmbH BA00-1602-322002

 Calibration Sequence for Tyre Circumference Measu-

5.1 Calibration Sequence for Tyre Circumference Measure-

ment

• Start the tyre circumference measurement by pressing the "L" key of the remote
control. The LED for "mm" of the remote control lights up.
• Wait until the measured value is shown on the lower display of the remote control.
• Enter the measured value into the certificate.
• Cancel the tyre circumference measurement by means of the "CL" key of the remote
control.
• The tyre circumference measurement must be carried out twice.

5.2 Calibration Sequence for Distance Pulse Measurement

(Single Axle)

Vehicle with Single Rear Axle

• The selector switch for "Vehicle back axle" (see Section 1) must be set to
"Single rear axle".
• Check whether the "Sensor appl." key of the remote control has been pressed.
• Start the distance pulse measurement by pressing the "W" key of the remote control.
The LED for "p/km" of the remote control lights up.
• Wait until the measured value is shown on the lower display of the remote control.
• Enter the measured value into the certificate.
• Cancel the distance pulse measurement by means of the "CL" key of the remote
control.
• The distance pulse measurement must be carried out twice.

5.3 Calibration Sequence for Distance Pulse Measurement

(Double Axle)

Vehicle with Double Back Axle

• The selector switch for "Vehicle rear axle" (see Section 1) must be set to
"Double back axle".
• Start the distance pulse measurement by pressing the "W" key of the remote control.
The LED for "p/km" of the remote control lights up.
• Wait until the measured value is shown on the lower display of the remote control.
• Enter the measured value in the certificate.
• Cancel the distance pulse measurement by means of the "CL" key of the remote
control.
• The distance pulse measurement must be carried out twice.

BA00-1602-322002 © Continental Automotive GmbH Page 14

Inspection of Entire Installation

6 Inspection of Entire Installation

At the end of the calibration procedure the voltage of the calibration unit must be switched
off and the calibrating cable must be removed. The unsoldered lines must be resoldered
to the connections provided.

Standard APS signal line assignment

Signal lines: yellow 17 (R pulses), green 18 (R pulses), and yellow 19 (L pulses).

6.1 Wheel Rotation Test System Settings

• Set tyre correction value by means of the decade switch of the remote control.

6.2 Vehicle Function Test

• Automatic test
• Enter vehicle identification number
• Print out installation plate and make sure that the printout is error-free.
• Compare the measured values in the installation plate with those on the display of
the remote control.

7 Concluding Tasks
The certificate must be filled out completely with the signature of the inspector and his/her
company stamp.
Any recognised defects such as damage, missing parts, etc. must be entered in the cer-
tificate under "Comments".
After calibration the respective measuring device receives a calibration label on which the
duration of calibration validity is marked.

Page 15 © Continental Automotive GmbH BA00-1602-322002

 Sample Certificate

Year Month
The date of validity is marked by cutting out (marking) the corresponding month and year
fields on the calibration label.

The calibration label must be attached to the front of the APS unit. The surface onto which
the calibration label is to be attached must first be cleaned.

8 Sample Certificate

A sample certificate for the wheel rotation test system is located in the Appendix. All
measured values are in italics and bold print (4000). The certificate must be filled out com-
pletely, including the signature of the inspector and his/her company stamp. If a measured

BA00-1602-322002 © Continental Automotive GmbH Page 16

Sample Certificate

value is not within the acceptable tolerance, no certificate may be issued. The date of va-
lidity entered in the certificate must correspond to the date of validity on the calibration la-
bel attached to the testing device.

Page 17 © Continental Automotive GmbH BA00-1602-322002

 Sample Certificate

CALIBRATION CERTIFICATE
Rolling Road Test System APS
(Double Roller, Kienzle Roller, Performance Test Stands)

Device type : APS 1601.21 Certificate no. : M2008/06/001

Serial no. : 0021 Valid until : 04.06.2009

Date : 04.06.2008

The proper function of the above-mentioned testing device has been tested and
calibrated. The measuring devices used for calibration meet national standards.

Calibration Unit Device no.:

1602.32 0066

1.) k pulse test

Desired value Tolerance Actual value

135 Hz r 20 Hz 149,23

Level display correct yes/no yes

100 pulses/km r 1 pulses/km 100

2.) Calculation of roller correction (RC) and check of

speed display
Calculation of roller correction (test stand roller adaptation)

Soll - Wert Toleranz Ist - Wert

50.0 km/h r 0,3 km/h 49,9

If the desired value and the actual value are both equal to 50 km/h ± 0,3 km/h, the test stand
has no roller correction value. The constant is RC = 1.000 (calculation to 3 decimal places).
If the actual value is greater than or lesser than 50 km/h, the roller set of the test stand has a
roller correction value. This value is calculated by means of the following formula:

Page 1 of 2

BA00-1602-322002 © Continental Automotive GmbH Page 18

Sample Certificate

CALIBRATION CERTIFICATE
Rolling Road Test System APS
(Double Roller, Kienzle Roller, Performance Test Stands)

Desired value
RC= RC = 1,000
Actual value

The actual values of the distance pulse and the tyre circumference must be corrected
by means of this RC constant.
Example: Measured distance pulse = 7500 pulses/km. Tyre circum. = 2666 mm. RC = 1.5
Measured distance pulse = 7500 pulses/km 1.5 = 5000 pulses/km (actual value)
Measured tyre circumference = 2666 mm * 1.5 = 4000 mm (actual value)

3.) Automatic test of distance pulse and tyre circumference measurement

The test of the distance pulse and tyre circumference measurement was carried out twice.

Desired value Tolerance Actual value

Tyre circumference measurement

1. 4000 mm r 40 mm Measured value * RC = 4001

2. 4000 mm r 40 mm Measured value * RC = 4001

Distance pulse measurement

1. 5000 pulses/km r 50 pulses/km Measured value RC = 5001

2. 5000 pulses/km r 50 pulses/km Measured value RC = 5001

If the test has a roller correction function, the tolerance increases by ± 2 pulses/km for
the distance pulse measurement and by ± 2 mm for the tyre circumference measurement.

Comments:

Continental Automotive GmbH is a

company certified according to
DIN EN ISO 9001: 2000 Company stamp/Signature of inspector

Page 2 of 2

Page 19 © Continental Automotive GmbH BA00-1602-322002

Clock-Tester

CLK 1602-13
Calibration Instructions
Table of Contents
1 Brief Description of Clock-Tester (Front View) . . . . . . . . . . . . . . . . . . . . . .4
1.1 Brief Description of Clock-Tester (Back Side) . . . . . . . . . . . . . . . . . . . . . . 5
2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3 Function Test of Clock-Tester . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
4 Test Set-Up: Calibration of Clock Tester. . . . . . . . . . . . . . . . . . . . . . . . . . .7
4.1 Measuring Preparations of the Calibration Unit. . . . . . . . . . . . . . . . . . . . . 8
4.2 Measuring Preparations of the Clock-Tester. . . . . . . . . . . . . . . . . . . . . . . 8
4.3 Calibration Sequence for Clock-Testers . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5 Concluding Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
6 Sample Certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

BA00-1602-322002 © Continental Automotive GmbH Page 2

Page 3 © Continental Automotive GmbH BA00-1602-322002
 Brief Description of Clock-Tester (Front View)

1 Brief Description of Clock-Tester (Front View)

1 ON/OFF key
2 2-digit display (cycle time)
3 1-digit display (standard cycle display)
4 3-digit display (cycle control)
5 Signal display
6 Select key (test program)
7 Reset key (measuring sequence)
8 Select key (cycle time)

BA00-1602-322002 © Continental Automotive GmbH Page 4

Brief Description of Clock-Tester (Back Side)

1.1 Brief Description of Clock-Tester (Back Side)

10 Mains connection, 230 V, internally switchable to 115 V

11 25-pole test jack
12 5-pole test jack

Additional, i.e., detailed description can be found in the respective operating instructions.

Page 5 © Continental Automotive GmbH BA00-1602-322002

 Technical Data

2 Technical Data
Display: 2-digit numerical LCD
12-mm charater height
1-digit numerical LCD
12-mm character height
3-digit numerical LCD
12-mm character height

Keyboard: 4 function keys

Clock accuracy required: < +/- 0.05 s/day

+/- 10 s/day
Voltage supply: 230 V, switchable to 115 V
Power consumption: max. 100 mA

3 Function Test of Clock-Tester

• Check clock-tester for damage.
• After the keys are pressed, they must switch audibly.
• The LCDs must not be damaged.
• Warm up the clock-tester for approx. 5 minutes before the calibration procedure, as
the internal crystal is thus stabilised.

BA00-1602-322002 © Continental Automotive GmbH Page 6

Test Set-Up: Calibration of Clock Tester

4 Test Set-Up: Calibration of Clock Tester

Before setting up the test, make sure that the mains seitch is at the „0“ (=mains off)
position.

A Calibration unit 1 Shift key for speed = 3.2 km/h or 50 km/h

B Calibration cable 1602.78.122 2 Shift key for autom. or manual mode
C Clock tester: rear view 4 Shift key for ATC or MTC mode
D Test jack 5 Shift key for LS1 or LS2 light barrier
E Clock tester 14 Shift key (grey) for switching over from
counter-mode to frequency-mode
F LED function (DIS)
G Select key
H Power key
J Cycle time display
K Cycle error display

Page 7 © Continental Automotive GmbH BA00-1602-322002

 Measuring Preparations of the Calibration Unit

4.1 Measuring Preparations of the Calibration Unit

• Switch 1, 50 km/h position

• Switch 2, autom. position
• Switch 4, ATC position
• Switch 5, LS2 position

4.2 Measuring Preparations of the Clock-Tester

• Insert the 1602-78-122 calibrating line with the DIN bush into the "D" test jack.
• Connect the other side of the calibrating cable into the calibration unit.
• Connect the clock-tester to 230 V by means of a mains line and turn on the voltage
by means of the "H" button.
• The number 2 appears on the "J" cycle time display.
• Set the measuring function by means of the "G" key. The red "F" LED labelled DIS
must light up.
• Switch on the 230 V of the calibrator.

4.3 Calibration Sequence for Clock-Testers

• After the calibration unit is switched on, it outputs a measuring frequency of 1 sec.
• The clock error appears in seconds per 24 hours on the left-hand "K" display of the
clock-tester (for the operation of the clock-tester, see the Clock-Tester 1602-13 ope-
rating instructions).
• The standard setting of the measuring time cycle of the clock-tester is 2 sec.
• The left-hand display must be observed for approx. 20 seconds and the cycle error
must not be greater than +/- 5.0 sec/24 h.
• Enter the maximum cycle error into the certificate.

BA00-1602-322002 © Continental Automotive GmbH Page 8

Concluding Tasks

5 Concluding Tasks
After the calibration procedure has been completed, the voltage of the calibration unit and
the clock tester must be switched off and the calibrating cable must be removed. The certi-
ficate must be filled out completely with the signature of the inspector and his/her com-
pany stamp.
Any recognised defects such as damage, missing parts, etc. must be entered in the certifi-
cate under "Comments".
After calibration, the respective measuring device receives a calibration label, on which
the duration of calibration validity is marked.

Year Month
The date of validity is marked by cutting out (marking) the corresponding month and year
fields on the calibration label.

The calibration label must be attached to the front of the clock-tester. The surface onto
which the calibration label is to be attached must first be cleaned.

Page 9 © Continental Automotive GmbH BA00-1602-322002

 Sample Certificate

6 Sample Certificate
A sample certificate for the clock tester is located in the Appendix. All measured values
are in italics and bold print (4000). The certificate must be filled out completely, including
the signature of the inspector and his/her company stamp. If a measured value is not
within the accept-able tolerance, no certificate may be issued. The date of validity entered
in the certificate must correspond to the date of validity on the calibration label attached
to the testing device.

BA00-1602-322002 © Continental Automotive GmbH Page 10

Sample Certificate

CALIBRATION CERTIFICATE
Clock Tester

Device type : Clock-Tester 1602-13 Certificate no. : M/2008/06/001

Serial no. : 877003352 Valid until : 04.06.2009

Date : 04.06.2008

The proper function of the above-mentioned testing device has been tested and
calibrated. The measuring devices used for calibration meet national standards.

Calibration Unit Device no.:

1602.32 0066

1.) Test of clock accuracy

Desired value Tolerance Actual value

r 0,00 sec / 24 h r 5.00 sec / 24 h 0,00

Comments:

Continental Automotive GmbH is a

company certified according to
DIN EN ISO 9001: 2000 Company stamp/Signature of inspector

Page 1 of 1

Page 11 © Continental Automotive GmbH BA00-1602-322002

PA 2000

Calibration Instructions
Seite 2 © Continental Automotive GmbH BA00-1602-322002
Table of Contents
1. Short Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
1.1 Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
1.2 Back View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2. Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3. Test Set-up Calibration of Output Voltage. . . . . . . . . . . . . . . . . . . . . . . . . .7
3.1 Measurement Preparations of Calibrating Unit . . . . . . . . . . . . . . . . . . . . . 8
3.2 Measurement Preparations for PA2000 . . . . . . . . . . . . . . . . . . . . . . . . . . 8
3.3 Calibrating Procedure for Output Voltage . . . . . . . . . . . . . . . . . . . . . . . . . 8
4. Test Set-up Calibration of Mechanical Drive km/h . . . . . . . . . . . . . . . . . . .9
4.1 Measurement Preparations of Calibrating Unit . . . . . . . . . . . . . . . . . . . . 10
4.2 Measurement Preparations for PA2000 . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.3 Calibrating Procedure for Mechanical Drive km/h . . . . . . . . . . . . . . . . . . 10
5. Test Set-up Calibration of Set km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
5.1 Measurement Preparations of Calibrating Unit . . . . . . . . . . . . . . . . . . . . 12
5.2 Measurement Preparations for PA2000 . . . . . . . . . . . . . . . . . . . . . . . . . 12
5.3 Calibrating Procedure for Set km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6. Concluding Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

BA00-1602-322002 © Continental Automotive GmbH Page 2

Page 3 © Continental Automotive GmbH BA00-1602-322002
 Short Description

1. Short Description
1.1 Front View

1 Display
2 Mains control
3 Voltage selection switch
4 Control display 12 V
5 Control display 24 V
7-9 Function switch
10 Positioning of working time group switch

BA00-1602-322001 © Continental Automotive GmbH Page 4

Back View

1.2 Back View

1 Type plate
2 Mains connector
3 Power switch
4 Drive output
for mechanical shaft connection

Please refer to the respective instructions for additional detailed descriptions.

Page 5 © Continental Automotive GmbH BA00-1602-322001

 Technical Data

2. Technical Data

Standard Version

Display: LCD

Mains connection: 187 - 242 V, 50 Hz

Operating temperature: +5°C + 40°C

Device constant: fixed k = 1000 rev/km

Mains unit 12 V, 24 V

BA00-1602-322001 © Continental Automotive GmbH Page 6

Test Set-up Calibration of Output Voltage

3. Test Set-up
Calibration of Output Voltage

A Calibrating unit 1 Shift key speed 3,2 km or 50 km/h

B Measuring cable red 2 Shift key for mode automatic or manual
C Earth cable black 4 Shift key for mode ATC or MTC
D PA2000 5 Shift key for light barrier LS1 or LS2
15 Grey key = switchover display / counter / frequency

Page 7 © Continental Automotive GmbH BA00-1602-322001

 Measurement Preparations of Calibrating Unit

3.1 Measurement Preparations of Calibrating Unit

• Switch 1, position 50 km/h

• Switch 2, position automatic
• Switch 4, position ATC
• Switch 5, position LS2

3.2 Measurement Preparations for PA2000

• Set voltage selection switch to 12 V (LED 12 V lights up).

• Connect ground wire of calibrating unit to ground wire of PA2000.
• Stick the measuring cable (red) into the banana plug + of the PA2000 and into the ba-
nana plug + (red) with the additional lettering "Input" of the calibrating unit (measuring
cable included in the delivery).

3.3 Calibrating Procedure for Output Voltage

• After test set-up the measured value for 12 V appears on the voltage display of the ca-
librating unit.
• Enter measured value in the certificate.
• Set voltage selection switch to 24 V (LED 24 V lights up).
• Enter measured value in the certificate.
• After the test remove the measuring cable (red) from the STC and the calibrator. The
earth cable must not be removed.

BA00-1602-322001 © Continental Automotive GmbH Page 8

Test Set-up Calibration of Mechanical Drive km/h

4. Test Set-up
Calibration of Mechanical Drive km/h

A Calibrating unit 1 Shift key for speed 3,2 km or 50 km/h

B Calibrating cable 1602.78.123 2 Shift key for mode automatic or manual
D PA2000 4 Shift key for mode ATC or MTC
E Function keys 5 Shift key for light barrier LS1 or LS2
X Test generator 15 Grey key = switchover display
1602-0118-000-000 (10 pulses) counter / frequency

Page 9 © Continental Automotive GmbH BA00-1602-322001

 Measurement Preparations of Calibrating Unit

4.1 Measurement Preparations of Calibrating Unit

• Switch 1, position 50 km/h

• Switch 2, position automatic
• Switch 4, position ATC
• Switch 5, position LS2

4.2 Measurement Preparations for PA2000

• Switch on the PA2000; "Menu start" appears on the display.

• Connect ground wire of calibrating unit to ground wire of PA2000.
• Connect the test generator 1602-0118-000-000 (10 pulses) to the drive shaft of the
PA2000 (shaft connector 1040-1300-009-001).
• Connect calibrating cable 1602-78-123 to the test generator and to the calibrating unit.
• The frequency display of the calibrating unit must show the value 0.00. Should this not
be the case, press grey key 2x in order to activate frequency display.

4.3 Calibrating Procedure for Mechanical Drive km/h

• Start the menu in the following order:

Display on PA2000 Confirm with key

Menu start Start

With operation No
Drive mech. Yes
Constant 1.0? Yes
EC-100 Standard No
EC-125 Automatic Yes
Test start Start

PA2000 starts with V-max; after an interval, speeds of 40, 80 and 120 km/h are set. Ple-
ase enter the measured values in the certificate and conclude the measurement by pres-
sing the "Stop" key on the PA2000.

BA00-1602-322001 © Continental Automotive GmbH Page 10

Test Set-up Calibration of Set km/h

5. Test Set-up
Calibration of Set km/h

A Calibrating unit 1 Shift key for speed 3,2 km or 50 km/h

B Calibrating cable 1602.78.122 2 Shift key for mode automatic or manual
C Test cable PA2000 4 Shift key for mode ATC or MTC
D PA2000 5 Shift key for light barrier LS1 or LS2
E Function keys 15 Grey key = switchover display
counter / frequency

Page 11 © Continental Automotive GmbH BA00-1602-322001

 Measurement Preparations of Calibrating Unit

5.1 Measurement Preparations of Calibrating Unit

• Switch 1, position 50 km/h

• Switch 2, position automatic
• Switch 4, position ATC
• Switch 5, position LS2

5.2 Measurement Preparations for PA2000

• Switch on the PA2000; "Menu start" appears on the display.

• Connect ground wire of calibrating unit to ground wire of PA2000.
• KTCO 1318 must be set parallel to the calibrating unit (level adaptation).
• Connect calibrating cable "B" 1602.78.122 to the calibrating unit.
• Connect test cable (component of PA2000) to PA2000.
• Connect calibrating cable (AMP plug) and test cable (AMP socket, 1314).
• The frequency display of the calibrating unit must show the value 0.00. Should this not
be the case, press grey key (15) 2x in order to activate frequency display.

5.3 Calibrating Procedure for Set km/h

• Start the menu in the following order:

Display on PA2000 Confirm with key

Menu start Start

With operation No
Drive mech. No
EC-100 Standard No
EC-125 Automatic No
KTCO-125 Yes
Test start Start

PA2000 starts with V-max; after an interval, speeds of 40, 80 and 120 km/h are set. Ple-
ase enter the measured values in the certificate and conclude the measurement by pres-
sing the "Stop" key on the PA2000.

BA00-1602-322001 © Continental Automotive GmbH Page 12

Concluding Tasks

6. Concluding Tasks
After the calibration procedure has been completed, the voltage of the calibration unit and
PA2000 must be switched off and the calibrating cable must be removed. The certificate
must be filled out completely with the signature of the inspector and his/her company
stamp.
Any recognised defects such as damage, missing parts, etc. must be entered in the cer-
tificate under "Comments".
After calibration, the respective measuring device receives a calibration label, on which
the duration of calibration validity is marked.

The date of validity is marked by cutting out (marking) the corresponding month and year
fields on the calibration label.

The calibration label must be attached to the left side of the PA2000 unit. The surface onto
which the calibration label is to be attached must first be cleaned.

Page 13 © Continental Automotive GmbH BA00-1602-322001

 Concluding Tasks

Sample Certificate
A sample certificate for the PA2000 unit is located in the Appendix. All measured values
are in italics and bold print (4000). The certificate must be filled out completely, including
the signature of the inspector and his/her company stamp. If a measured value is not
within the acceptable tolerance, no certificate may be issued. The date of validity entered
in the certificate must correspond to the date of validity on the calibration label attached
to the testing device.

BA00-1602-322001 © Continental Automotive GmbH Page 14

Concluding Tasks

CALIBRATION CERTIFICATE
PA2000

Device type : PA 2000 Certificate no. : M/2008/06/001

Serial no. : 123456 Valid until : 04.06.2009

Date : 04.06.2008

The proper function of the above-mentioned testing device has been tested and
calibrated. The measuring devices used for calibration meet national standards.

Calibration Unit Device no.:

1602.32 0066

1.) Voltage control

Desired value Tolerance Actual value

12 V r 0,6 Volt 12,05

24 V r 1,2 Volt 24,24

2.) Test of mechanical drive with digital display km/h

Desired value Tolerance Actual value

40 km/h 111,11 Hz r 2 Hz 111,32

80 km/h 222,22 Hz r 2 Hz 222,56
120 km/h 333,33 Hz r 2 Hz 333,75

Page 1 of 2

Page 15 © Continental Automotive GmbH BA00-1602-322001

 Concluding Tasks

CALIBRATION CERTIFICATE
PA2000

3. ) Test of mechanical drive with digital display min -1

Desired value Tolerance Actual value

40 km/h 88,88 Hz r 1 Hz 088,27

80 km/h 177,76 Hz r 1 Hz 177,52
120 km/h 266,66 Hz r 1 Hz 266,24

Comments :

Continental Automotive GmbH is a

company certified according to
DIN EN ISO 9001: 2000 Company stamp/Signature of inspector

Page 2 of 2

BA00-1602-322001 © Continental Automotive GmbH Page 16

Concluding Tasks

Page 17 © Continental Automotive GmbH BA00-1602-322001

Rolling Road Test Computer /
PC Version
ATC - PC 1601-29
Seite 2 © Continental Automotive GmbH BA00-1602-322002
Table of Contents
1 Test Set-up - Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
1.1 Measurement Preparations of Calibrating Unit . . . . . . . . . . . . . . . . . . . . . 6
1.2 Measurement Preparations for ATC-PC . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.3 Connection of Calibrating Cable to ATC-PC . . . . . . . . . . . . . . . . . . . . . . . 6
1.4 Roller Correction / Speed Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
1.5 Calibrating Procedure for Wheel Circumference Determination . . . . . . . . 7
1.6 Calibration of Distance Pulse Determination. . . . . . . . . . . . . . . . . . . . . . . 7
2 Checking the Entire System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
2.1 Settings of the ATC-PC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
2.2 Function Test Performance with Vehicle. . . . . . . . . . . . . . . . . . . . . . . . . . 8
3 Concluding Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
4 Sample Certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

BA00-1602-322001 © Continental Automotive GmbH Page 3

Page 4 © Continental Automotive GmbH BA00-1602-322001
 Test Set-up - Calibration

1 Test Set-up - Calibration

Before set-up please check if the mains switch is set at the symbol "0" = mains off. The
voltage of the ATC-PC must also be switched off.

1324 connector's flat Plug out 8-pin con-

side must point to the nector of roller sen-
lid. sor and light barrier
from the interface.

Connect calibration
cable of the calibra-
ting unit to the inter-
face.

A Calibrating unit 1 Shift key for speed 3,2 km or 50 km/h

B Calibrating cable X12-169-278-004 2 Shift key for mode automatic or manual
C Interface 1601-26-080-00 4 Shift key for mode ATC or MTC
D Measuring cable 1601-29-085-00 5 Shift key for light barrier LS1 or LS2
14 Grey key = switchover display
frequency / counter

BA00-1602-322001 © Continental Automotive GmbH Page 5

Measurement Preparations of Calibrating Unit

1.1 Measurement Preparations of Calibrating Unit

• Switch 1, position 50 km/h

• Switch 2, position automatic
• Switch 4, position ATC
• Switch 5, position LS2

1.2 Measurement Preparations for ATC-PC

• Plug out the 8-pin connector from the interface.

• Connect the 8-pin connector from the measuring cable of the calibrating
unit to the interface.

1.3 Connection of Calibrating Cable to ATC-PC

• The EA measuring cable which is part of the ATC-PC is connected to the interface
and to the calibrating adapter.
• Connect calibrating unit via voltage cable to 230 V and switch on the voltage by
means of the mains switch of the calibrating unit.
• Switch on the ATC-PC voltage.
• Setting of the correction value + 0,0 %.

Page 6 © Continental Automotive GmbH BA00-1602-322001

 Roller Correction / Speed Display

1.4 Roller Correction / Speed Display

• Checking the speed display.

• If the speed on the display (50 km/h) deviates by ± 0.3%, then a roller correction
calculation becomes necessary.
Determination of roller correction (test stand roller adaptation)

Set Value Tolerance Actual Value

50.0 km/h ± 0,3 km/h

Are both the set value and the actual value 50 km/h ± 0.3 km/h, then the test stand
does not have a roller correction value. The constant RC = 1.00 (calculation with 2
positions after the decimal point). If the set value is higher or lower than 50 km/h,
then the roller set of the test stand has a roller correction value. This must be
calculated according to the following formula:
Set Value
RC = =
Actual value

This RC constant must be used to correct the actual values of the distance pulse and
the wheel circumference.
• Enter the roller correction value into the certificate.

1.5 Calibrating Procedure for Wheel Circumference Determi-

nation

• The wheel circumference measurement starts by pressing key "F6" on the key-
board.
• Wait until the measured value appears on the screen.
• Enter the measured value into the certificate.
• Conclude the wheel circumference measurement by pressing the "Enter" key on the
keyboard.
• The wheel circumference measurement must be carried out twice.

1.6 Calibration of Distance Pulse Determination

• The distance pulse measurement starts by pressing key "F7" on the keyboard.
• Wait until the measured value appears on the screen.
• Enter the measured value into the certificate.
• Conclude the distance pulse measurement by pressing the "Enter" key on the key-
board.
• The wheel circumference measurement must be carried out twice.

BA00-1602-322001 © Continental Automotive GmbH Page 7

Checking the Entire System

2 Checking the Entire System

After the calibration has been completed the voltage of the ATC-PC and the calibrating
unit must be switched off and the calibrating cable removed. The connector of the roller
sensor and the light barrier which was plugged out must be reconnected to the interface.

2.1 Settings of the ATC-PC

• Enter the old correction value via function key "F1" on the keyboard.

2.2 Function Test Performance with Vehicle

• Automatic test
• Print out the installation plate and check if the printout is error-free.
• Compare the measured values of the installation plate with those on the ATC-PC.

Page 8 © Continental Automotive GmbH BA00-1602-322001

 Concluding Tasks

3 Concluding Tasks
The certificate must be filled out completely with the signature of the inspector and his/her
company stamp.
Any recognised defects, such as damage, missing parts, etc. must be entered into the cer-
tificate under „Comments“.
After calibration, the respective measuring device receives a calibration label, on which
the duration of calibration validity is marked.

Year 2007 - 2010 Month 1 - 12

The date of validity is marked by cutting out (marking) the corresponding month and year
field on the calibration label.

The calibration label must be attached to the ATC. The surface onto which the calibration
label is to be attached first be cleaned.

BA00-1602-322001 © Continental Automotive GmbH Page 9

Sample Certificate

4 Sample Certificate
A sample certificate for the ATC-PC is located in the Appendix. All measured values are
in italics and bold print (4000). The certificate must be filled out completely, including the
signature of the inspector and her/his company stamp. If a measured value is not within
the acceptable tolerance, no certificate may be issued. The date of validity entered into
the certificate must correspond to the date of validity on the calibration label attached to
the testing device.

Page 10 © Continental Automotive GmbH BA00-1602-322001

 Sample Certificate

CALIBRATION CERTIFICATE
ATC-PC

Device type : ATC-PC Unit no. : 1601-29

Serial no. : ATC_PC 05/200 Certificate no. : M/2008/06/001

Date : 04.06.2008 Valid until : 04.06.2009

The proper function of the above-mentioned testing device has been tested and
calibrated. The measuring devices used for calibration meet national standards.

Calibration Unit Device no.:

1602.32 0066

1.) Calculation of roller correction (RC) and check of speed display

Calculation of roller correction (test stand roller adaptation)

Desired value Tolerance Actual value

50.0 km/h ± 0,3 km/h 50,0

If the desired value and the actual value are both equal to 50 km/h ± 0,3 km/h, the test stand
has no roller correction value. The constant is RC = 1.000 (calculation to 3 decimal places).
If the actual value is greater than or lesser than 50 km/h, the roller set of the test stand has a
roller correction value. This value is calculated by means of the following formula:

Desired value
RC= RC = 1,000
Actual value

Page 1 of 2

BA00-1602-322001 © Continental Automotive GmbH Page 11

Sample Certificate

CALIBRATION CERTIFICATE
ATC-PC

The actual values of the distance pulse and the tyre circumference must be corrected
by means of this RC constant.
Example: Measured distance pulse = 7500 pulses/km. Tyre circum. = 2666 mm. RC = 1.5
Measured distance pulse = 7500 pulses/km 1.5 = 5000 pulses/km (actual value)
Measured tyre circumference = 2666 mm * 1.5 = 4000 mm (actual value)

3.) Automatic test of distance pulse and tyre circumference measurement

The test of the distance pulse and tyre circumference measurement was carried out twice.

Desired value Tolerance Actual value

Tyre circumference measurement

1. 4000 mm r 40 mm Measured value * RC = 4000

2. 4000 mm r 40 mm Measured value * RC = 4000

Distance pulse measurement

1. 5000 pulses/km r 50 pulses/km Measured value RC = 5000

2. 5000 pulses/km r 50 pulses/km Measured value RC = 5000

If the test has a roller correction function, the tolerance increases by ± 2 pulses/km for
the distance pulse measurement and by ± 2 mm for the tyre circumference measurement.

Comments :

Continental Automotive GmbH is a

company certified according to
DIN EN ISO 9001: 2000 Company stamp/Signature of inspector

Page 12 © Continental Automotive GmbH BA00-1602-322001

Tachograph Repair System TRS

TRS 1602-06
Calibrating Instructions
Table of Contents
1 Short Description TRS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
1.1 Short Description Calibrating Adapter 1602-78-150-00 for TRS . . . . . . . . 4
2 Technical Daten . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3 Functions Check TRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
4 Test Set-up Calibration TRS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
4.1 Measurement Preparations of Calibrating Unit . . . . . . . . . . . . . . . . . . . . . 7
4.2 Measurement Preparations for TRS Calibration . . . . . . . . . . . . . . . . . . . . 7
5 Calibrating Procedure for Output Voltage . . . . . . . . . . . . . . . . . . . . . . . . . .8
5.1 Calibrating of Sender Unit Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.2 Calibrating of Frequency Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.3 Calibrating of Pulse Width Measurement . . . . . . . . . . . . . . . . . . . . . . . . . 9
5.4 Calibrating of Voltage Measurement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6 Concluding Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .11
7 Sample Certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

BA00-1602-322002 © Continental Automotive GmbH Page 2

 Short Description TRS

1 Short Description TRS

Operating Elements of the Measuring Rack

1 Measuring output "H"+ 6 Digital voltmeter (DMV) 100

2 Measuring output "L" 0 Volt 7 On/off switch 230V for DMV 100
3 Frequeny counter 8 37-pin D-Sub connector
4 Measuring input "L" - 0 Volt 9 25-pin D-Sub connector for needle adapter
5 Measuring input “ H “ 10 9-pin D-Sub connector for programming cable

Operating elements of the Computer

1 Floppy disk drive 6 On/off switch 230V

2 Disk drive door 7 Reset switch
3 Key for disk drive door 8 Ventilation
4 Operating indicator 9 Connection keyboard
5 Running indicator hard disk

BA00-1602-322002 © Continental Automotive GmbH Page 3

Short Description Calibrating Adapter 1602-78-150-00 for TRS

1.1 Short Description Calibrating Adapter 1602-78-150-00 for

TRS

1 Calibrating adapter 6 37-pin D-Sub connector

2 Switch A 7 Jack connector
3 Switch B 8 Jack connector small
4 Voltage supply +/-
5 Adapter cable

The calibrating adapter contains an electronic system which enables you to carry
out the complete calibration of the TRS. The connecting cable (5) is delivered tog-
ether with the calibrating adapter (1). The voltage supply cables are delivered tog-
ether with the calibrating unit.

Please refer to the respective instructions for either additional or detailed descriptions.

Page 4 © Continental Automotive GmbH BA00-1602-322002

 Technical Daten

2 Technical Daten
Computer: Pentium 133 MHZ
4 serial interface
1 parallel interface
1 measuring interface
VGA connection
Tastatur alpha / nummerisch
Main connection: 187 Volt - 242 Volt / 50Hz
5 Amp.
Operating temperature: + 5º C bis + 40º C
Power supply: 12 Volt / 24 Volt (can be switched
over) max. 1 Amp.
Frequency output: K pulse
f max 150 Hz; max. 10Volt; max. 30mA
Speed / rpm
f max 500 Hz; max. 10Volt; max. 30mA
Pulse width measurement: Pulse width
500 µs - 3000 µs , max 24 Volt
Voltage measurement: 10 mVolt - 24 Volt
Power measurement: 1 mA - 750 mA
Measurements: Wigth = 570mm; Tiefe = 600mm;
Height = 440mm
Weight: approx. 30 Kg

3 Functions Check TRS

A functional check of the TRS is not necessary.

BA00-1602-322002 © Continental Automotive GmbH Page 5

Test Set-up Calibration TRS

4 Test Set-up Calibration TRS

Before set-up please check if the mains switch is set at the symbol "0" = mains off.

1
2

3
4
4 14

A
3

2
1
B

1a
1b

C 1 2 3

A Calibrating unit B Calibrating adapter

1 Shift key speed 3,2 or 50 km/h 1 Connecting cable 37-pin
2 Shift key mode automatic or manual 2 Voltage connection +/-
3 Shift key mode ATC or MTC 3 Jack connector
4 Shift key light barrier LS1 or LS2 4 Jack connector (small)
14 Grey key = switchover display C TRS
frequency / counter
1a Voltage supply FTCO 1 9-pin D-Sub connector for pro-
gramming FTCO
1b Programming cable FTCO 2 25-pin D-Sub connector for
needle adapter
3 37-pin D-Sub connector for
needle adapter

Page 6 © Continental Automotive GmbH BA00-1602-322002

 Measurement Preparations of Calibrating Unit

4.1 Measurement Preparations of Calibrating Unit

Please use the following switch setting:

• Switch 1, position 3,2 km/h
• Switch 2, position manual
• Switch 4, position MTC
• Switch 5, position LS2

4.2 Measurement Preparations for TRS Calibration

Note:
The system start described below must be carried out with a 24V, 125 km/h FTCO,
e.g. 1319-2700.

• Connect TCO 1319 to the TRS using the test cables (1a) and (1b)
• Switch on TRS and wait until the system has run up (continue with Enter)
• Enter VDO (Enter)
• Enter TCO voltage with "F4" (24 V)
• The system is now running in the host mask. Confirm parametrizing data with Enter
(status, date, TCO type, etc.)
• Disconnect connecting cable (1a) from TRS
• Connect cable (1) from the calibrating adapter 1602-78-150-00 to the TRS
(connector 3)
• Connect jack connector cable (3) to "E1" of calibrating unit
• Connect jack connector cable (4) to "A1" of calibrating unit
• Connect voltage supply cable (2) red/black to "Input" +/- of calibrating unit

Note:
All cables must be connected during testing so as to rule out error messages in the TRS
test program.

BA00-1602-322002 © Continental Automotive GmbH Page 7

Calibrating Procedure for Output Voltage

5 Calibrating Procedure for Output Voltage

• Connect calibrating unit via voltage cable to 230 V and switch on.
• The frequency display of the calibrating unit must show the value 0.00. Should this
not be the case, press grey key 2x in order to activate frequency display.

Checking the Output Voltage 24 V of the TRS

Switch Setting of Calibrating Adapter:

Switch A in position 2
Switch B in position 2

Actual value of output voltage is shown on the calibrator (VU meter, left)
Set point value = 24 V +/- 1,00 V
Enter voltage value in the calibrating certificate

5.1 Calibrating of Sender Unit Voltages

Switch Setting of Calibrating Adapter:

Switch A in position 1
Switch B in position 2

Choose function 02 of TRS testing program and trigger with Enter.

By pressing the space key, the individual measured values are activated.

Voltage measurement at B17000 mV+/- 100 mV

Voltage measurement at B37000 mV+/- 100 mV
Voltage measurement at B47000 mV+/- 100 mV

The respective actual values are shown on the screen.

Enter actual values in the calibrating certificate.

Page 8 © Continental Automotive GmbH BA00-1602-322002

 Calibrating of Frequency Output

5.2 Calibrating of Frequency Output

Switch setting of Calibrating Adapter:

Switch A in position 2

Switch B in position 2

Choose function 03 of TRS testing program and trigger with Enter.

By pressing the space key, the individual measured values are activated.

30 km/h = 066,66 Hz +/- 1Hz

110 km/h = 244,44 Hz +/- 1Hz
125 km/h = 277,75 Hz +/- 1Hz
110 km/h = 244,44 Hz +/- 1Hz
30 km/h = 066,66 Hz +/- 1Hz

The individual actual values (testing frequencies) are shown on the calibrator (right-hand
display). Enter actual values in the calibrating certificate.

5.3 Calibrating of Pulse Width Measurement

Switch setting of Calibrating Adapter:

Switch A in position 2

Switch B in position 2

Choose function 11 of TRS testing program and trigger with Enter.

By pressing the space key, the individual measured values are activated.

Measure pulse at B7 2000 µs +10us / -3 µs

Measure pulse at D3 2000 µs +10us / -3 µs

The respective actual values are shown on the screen.

Enter actual values in the calibrating certificate.

BA00-1602-322002 © Continental Automotive GmbH Page 9

Calibrating of Voltage Measurement

5.4 Calibrating of Voltage Measurement

Switch setting of Calibrating Adapter:

Switch A in position 2

Switch B in position 1

Choose function 47 of TRS testing program and trigger with Enter.

By pressing the space key, the individual measured values are activated.

Power consumption at A2 105 mA +/- 10 mA

Power consumption at A3 105 mA +/- 10 mA
Power consumption at A1 105 mA +/- 10 mA

The respective actual values are shown on the screen.

Enter actual values in the calibrating certificate.

Page 10 © Continental Automotive GmbH BA00-1602-322002

 Concluding Tasks

6 Concluding Tasks
After the calibration procedure has been completed, the voltage of the calibration unit
must be switched off and the calibrating cable must be removed. The certificate must be
filled out completely with the signature of the inspector and his/her company stamp.
Any recognised defects, such as damage, missing parts, etc. must be entered into the cer-
tificate under „Comments“.
After calibration, the respective measuring device receives a calibration label, on which
the duration of calibration validity is marked.

Year Month
The date of validity is marked by cutting out (marking) the corresponding month and year
field on the calibration label.

The calibration label must be attached of the TRS. The surface onto which the calibration
label is to be attached first be cleaned.

BA00-1602-322002 © Continental Automotive GmbH Page 11

Sample Certificate

7 Sample Certificate
A sample certificate for the TRS is located in the Appendix. All measured values are in
italics and bold print (4000). The certificate must be filled out completely, including the si-
gnature of the inspector and her/his company stamp. If a measured value is not within the
acceptable tolerance, no certificate may be issued. The date of validity entered into the
certificate must correspond to the date of validity on the calibration label attached to the
testing device.

Page 12 © Continental Automotive GmbH BA00-1602-322002

 Sample Certificate

CALIBRATION CERTIFICATE
Tachograph-Repair-System TRS
Device type : TRS 1601.06 Certificate no. : M/2008/06/001

Serial no. : 123456 Valid until : 04.06.2009

Date : 04.06.2008

The proper function of the above-mentioned testing device has been tested and
calibrated. The measuring devices used for calibration meet national standards.

Calibration Unit Device no.:

1602.32 0066

1.) Voltage Test (fixed voltage 24V)

Desired value Tolerance Actual value

24Volt r 1,20 Volt 24,20

Tests of the Voltage Measurement on B1 / B3 / B4

2.) Test Voltage Measurement

Desired value Tolerance Actual value

B1 = 7000 mV r 140 mV 7001

B3 = 7000 mV r 140 mV 7001
B4 = 7000 mV r 140 mV 7001

Page 1 of 2

BA00-1602-322002 © Continental Automotive GmbH Page 13

 Sample Certificate

CALIBRATION CERTIFICATE
Tachograph-Repair-System TRS
Test for Standard Model (Electronic drive)

3.) Test of Drive km/h (v = 8 pulses/rev.)

Desired value Tolerance Actual value

30 km/h 66,66 Hz r 1 Hz 066,67

110 km/h 244,44 Hz r 1 Hz 244,45
125 km/h 277,25 Hz r 1 Hz 277,29
110 km/h 244,44 Hz r 1 Hz 244,45
30 km/h 66,66 Hz r 1 Hz 066,67

Test of the Current Measurement A2 / A3 / A1

4.) Test of the Current Measurement

Desired value Tolerance Actual value

A2 = 105 mA r 5,25 mA 105

A3 = 105 mA r 5,25 mA 105
A1 = 105 mA r 5,25 mA 105

Test of the Pulse Width on B7 / D3

5.) Test of the Pulse Width

Desired value Tolerance Actual value

B7 = 2000 µs r 5 µs 1999
D3 = 2000 µs r 5 µs 1999

Comments:

Continental Automotive GmbH is a

company certified according to
DIN EN ISO 9001: 2000 Company stamp/Signature of inspector

Page 2 of 2

BA00-1602-322002 © Continental Automotive GmbH Page 15

Calibration Test Stand FTP 88

FTP 88 X12-052-000-005
Calibration Instructions
Table of Contents
1 Brief Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3 Functional Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
4 Test Set-Up: Calibration of Output Voltage . . . . . . . . . . . . . . . . . . . . . . . . .7
4.1 Measuring Preparations of the Calibration Unit. . . . . . . . . . . . . . . . . . . . . 8
4.2 Measuring Preparations of the FTP 88 . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.3 Calibration Seqeunce for Output Voltage . . . . . . . . . . . . . . . . . . . . . . . . . 8
5 Test Set-Up: Calibration of Mechanical Drive for km/h . . . . . . . . . . . . . . . .9
5.1 Measuring Preparations of the Calibration Unit. . . . . . . . . . . . . . . . . . . . 10
5.2 Measuring Preparations of the FTP 88 . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5.3 Calibration Sequence for Mechanical Drive for km/h . . . . . . . . . . . . . . . 10
6 Test Set-Up: Calibration of Mechanical Drive for 1/min . . . . . . . . . . . . . .11
6.1 Calibration Sequence for Mechanical Drive for 1/min . . . . . . . . . . . . . . . 12
7 Test set-Up: Calibration of Mechanical Drive for rev. . . . . . . . . . . . . . . . .13
7.1 Calibration Sequence for Mechanical Drive for rev. . . . . . . . . . . . . . . . . 14
8 Test Set-Up: Calibration of km/h Control. . . . . . . . . . . . . . . . . . . . . . . . . .15
8.1 Measuring Preparations of the Calibration Unit. . . . . . . . . . . . . . . . . . . . 16
8.2 Measuring Preparations of the FTP 88 . . . . . . . . . . . . . . . . . . . . . . . . . . 16
8.3 Calibration Sequence for km/h Control (2500 pulses/km). . . . . . . . . . . . 16
8.4 Calibration Sequence for Km/h Control (8000 pulses/km) . . . . . . . . . . . 16
8.5 Calibration Sequence for km/h Control (19000 pulses/km). . . . . . . . . . . 16
9 Test Set-Up: Switch-Over from km/h to mph. . . . . . . . . . . . . . . . . . . . . . .17
9.1 Calibration Sequence for Switch-Over from km/h to mph . . . . . . . . . . . . 18
10 Test Set-Up: Calibration of Odometer (Pulse) (k = 8000 pulses/km) . . . .19
10.1 Calibration Sequence for Odometer (Pulse) (k = 8000 pulses/km) . . . . 20
11 Concluding Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
12 Sample Certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

BA00-1602-322002 © Continental Automotive GmbH Page 2

 Brief Description

1 Brief Description

1 4-digit LCD (voltmeter/power supply unit, 4 - 28 V)

2 Potentiometer for voltmeter
3 Connecting jack of power supply unit
4 Drive shaft connection, M22 x 1.5 reed driver
5 Switch movement control right/ left
6 Mains switch with LED control
7 Set-point knob
8 Connecting jack for electronic tachograph and tachometer
9 Connecting jack for electronic tachometer
10 Function keys :

Stop = start/stop key

RES = zero setting (reset)
U = revolution
Umin = revolutions per minute
km/h = kilometres per hour (Black = mechanical and blue = electronic)
Imp = pulses
Hz = frequency
11 4-digit (pulses, rev., 1/min, km/h, mph, Hz)
12 5-stage coding switch for setting of distance revolution, distance pulse value, and
constant
13 Short circuit control
Additional, i.e. detailed description can be found in the respective operating instructions.

BA00-1602-322002 © Continental Automotive GmbH Page 4

Technical Data

2 Technical Data
Display : 3-digit numerical LCD
13 mm digit height
4-digit numerical LCD
13 mm digit height
Keyboard : 12 function keys
5-digit coding switch
Interfaces : Frequency output (w pulse)
f max = 1.5 kHz, 12 V, max. 30 mA
Power supply unit : Variable voltage, 5 V - 28 V
Voltage supply : 230 V, 50 Hz
Power consumption: ca. 600 mA
Operating temperature: + 5 °C to + 40°C
Varibale k setting: 2500 - 19000 pulses/km

Page 5 © Continental Automotive GmbH BA00-1602-322002

 Functional Test

3 Functional Test
The following items must be carried out to perform a functional test:

Display Test :
• Switch on device (set mains switch (6) to "ON") and check whether the yellow LED
(to the left of the mains switch) lights up.
• Turn set-point knob (7) to the left-hand limit stop. The black "km/h" function key must
be pressed.
• Set coding switch (12) to 01000.
• The meachanical drive (4) must not rotate.
• A decimal point lights up on the right-hand 4-digit display (11).
• Turn set-point knob (7) slowly to the right. All numbers on the display (11) must be
correct, complete and consecutive.
• Turn set-point knob back to the left-hand limit stop.
• Press the black "Umin" function key. The deciaml point on the right-hand 4-digit LCD
must no longer light up.
• Turn the potentiometer (2) for the voltmeter to the left-hand limit stop.
• Turn the potentiometer for the voltmeter slowly to the right. All numbers on the 3-digit
LCD (1) must be correct, complete and consecutive.

BA00-1602-322002 © Continental Automotive GmbH Page 6

Test Set-Up: Calibration of Output Voltage

4 Test Set-Up: Calibration of Output Voltage

Before setting up the test, make sure that the mains switch of the calibrator and the cali-
bration test stadn is at the "0" (= mains off) position.

A Calibration unit 1 Shift key for speed = 3.2 km/h or 50 km/h

B Connecting line (red) 2 Shift key for autom. or manual mode
C Ground wire (black) 4 Shift key for ATC or MTC mode
D FTP 88 5 Shift key for LS1 or LS2
E Connecting jack of power supply unit 14 Shift key (grey) for switching over from
F Mains switch, 230V counter-mode to frequency-mode
G Set-point knob
H Voltage regulator
I Voltage display
K Measured value display
L Function keys
M Coding switch
N Switch for direction of rotation

Page 7 © Continental Automotive GmbH BA00-1602-322002

 Measuring Preparations of the Calibration Unit

4.1 Measuring Preparations of the Calibration Unit

• Switch 1, 3.2 km/h position

• Switch 2, manual position
• Switch 4, MTC position
• Switch 5, LS2 position

4.2 Measuring Preparations of the FTP 88

• Turn the set-point knob (G) to the left until the limit stop.
• Turn the voltage regulator (H) to the left until the limit stop.
• None of the function keys (L) may be pressed (locked onto place).
• Insert the measuring line (red) into the "+" banana socket (red) of the FTP 88 and
into the "V" banana socket (red) of the calibration unit labbelled "Input".
• Insert the ground wire (black) into the "-" banana socket (black) of the FTP 88 and
into the "-" banana socket (black) of he calibration unit labelled "Input".
• Connect the calibraiton unit and the FTP 88 to 230 V by means of the voltage cable,
then switch on the voltage.

4.3 Calibration Seqeunce for Output Voltage

• After activation, the outputted voltage appears on the voltage display of the FTP 88
and the measured voltage appears on the voltage display of the calibration unit.
• Turn the voltage regulator to the right until a value of 5 V appears on the voltage dis-
play of the FTP 88.
• The measured value appears on the voltage display of the calibration unit.
• Enter the measured value into the certificate.
• Turn the voltage regulator to the right until a value of 12 V appears on the voltage
display of the FTP 88.
• The measured value appears on the voltag display of the calibration unit.
• Enter the measured value into the certificate.
• Turn the voltage regulator to the right until a vlaue of 24 V appears on the voltage
display of the FTP 88.
• The measured value appears on the voltage display of the calibration unit.
• Enter the measured value into the certificate.
• When the test has been completed, remove the measuring line (red) from the FTP
88 and the calibrator. The ground wire must not be removed.

BA00-1602-322002 © Continental Automotive GmbH Page 8

Test Set-Up: Calibration of Mechanical Drive for km/h

5 Test Set-Up: Calibration of Mechanical Drive for km/h

A Calibration unit 1 Shift key for speed = 3.2 km/h or 50 km/h

B Calibration cable 1602-78-123 2 Shift key for autom. or manual mode
D FTP 88 4 Shift key for ATC or MTC mode
E Connecting jack for power supply 5 Shift key for LS1 or LS2
F Mains switch, 230V 14 Shift key (grey) for switching over from
G Set-point knob counter-mode to frequency-mode
K Measured value display
L "km/h" function key
M Coding switch
N Switch for direction of rotation
X Test sensor 1602-0118-000-000

Page 9 © Continental Automotive GmbH BA00-1602-322002

 Measuring Preparations of the Calibration Unit

5.1 Measuring Preparations of the Calibration Unit

• Switch 1, 3.2. km/h position

• Switch 2, manual position
• Switch 4, MTC position
• Switch 5, LS2 position

5.2 Measuring Preparations of the FTP 88

• Press the black "km/h" function key (L) until it locks into place.
• Turn the switch for the direction of rotation (N) to the right towards the set-point knob.
• Set the coding switch (M) to 01000.
• Screw the test sensor (X) to the mechanical drive of the FTP 88.
• Connect the 1602-78-123 calibrating cable (B) to the test sensor and the calibration
unit.
• The value 0.00 must be shown on the frequency display of the calibration unit. If this
is not the case, the grey key (14) must be pressed two times in order to activate the
frequency display.

5.3 Calibration Sequence for Mechanical Drive for km/h

• Turn set-point knob (G) to the right until 20.0 km/h is shown on the measured value
display of the FTP 88.
• The following speeds are to be selected and the corresponding frequency is to be
checked: 020, 050, 080, 100, 125, 150 and 180 km/h. The corresponding frequency
is shown on the frequency display of the calibration unit and must be entered in the
certificate (see calibration certificate).
• When the test has been completed, turn the set-point knob to the FTP 88 to the left
until the limit stop.

BA00-1602-322002 © Continental Automotive GmbH Page 10

Test Set-Up: Calibration of Mechanical Drive for 1/min

6 Test Set-Up: Calibration of Mechanical Drive for 1/min

The test can be set up as described under Section 5. The black "Umin" key (L) must be
pressed until is locks into place.

A Calibration unit 1 Shift key for speed = 3.2 km/h or 50 km/h

B Calibration cable 1602-78-123 2 Shift key for autom. or manual mode
D FTP 88 4 Shift key for ATC or MTC mode
E Connecting jack for power supply 5 Shift key for LS1 or LS2
F Mains switch, 230V 14 Shift key (grey) for switching over from
G Set-point knob counter-mode to frequency-mode
K Measured value display
L "Umin" function key
M Coding switch
N Switch for direction of rotation
X Test sensor 1602-0118-000-000

Page 11 © Continental Automotive GmbH BA00-1602-322002

 Calibration Sequence for Mechanical Drive for 1/min

6.1 Calibration Sequence for Mechanical Drive for 1/min

• Turn the set-point knob (G) of the FTP 88 to the right until 1000 1/min is shown on
the measured value display.
• Select the following speeds one after the other: 1000, 2000, 3000 1/min. The fre-
quency is shown on the frequency display of the calibration unit and must be entered
into the certificate (see calibration certificate).
• When the test has been completed, turn the set-point knob of the FTP 88 to the left
until the limit stop.

BA00-1602-322002 © Continental Automotive GmbH Page 12

Test set-Up: Calibration of Mechanical Drive for rev.

7 Test set-Up: Calibration of Mechanical Drive for rev.

The test can be set up as described under Section 6. The black "U" key (L) must be
pressed until is locks into place.

A Calibration unit 1 Shift key for speed = 3.2 km/h or 50 km/h

B Calibration cable 1602-78-123 2 Shift key for autom. or manual mode
D FTP 88 4 Shift key for ATC or MTC mode
E Connecting jack for power supply 5 Shift key for LS1 or LS2
F Mains switch, 230V 14 Shift key (grey) for switching over from
G Set-point knob counter-mode to frequency-mode
K Measured value display
L "U" function key
M Coding switch
N Switch for direction of rotation
X Test sensor 1602-0118-000-000

Page 13 © Continental Automotive GmbH BA00-1602-322002

 Calibration Sequence for Mechanical Drive for rev.

7.1 Calibration Sequence for Mechanical Drive for rev.

• The frequency display of the calibration unit must be switched to the counter-mode
by pressing the grey key (14) two times. 0 must be on the display.
• If 0 is not on the display of the calibration unit, set the counter to 0 by means of the
red key.
• Press the black "U" function key (L).
• Press the white "RES" function key of the FTP 88.
• Turn set-point knob (G) slowly to the right until the counting procedure on the
measured value display begins.
• Observe the measured value display (K) of the FTP 88 and when a measured value
of 1000 has been reached, turn the set-point knob (G) to the left until the limit stop.
• Enter the measured value into the certificate.
1. Measured FTP 88 value as desired value
2. Measured value of calibration unit as actual value.
The actual value is greater by a factor of 1.25 as a test sensor with 10 pulses/rev. is
used (standard = 8 pulses/rev.)
• When the calibration sequence has come to an end, remove the calibrating cable
and the test sensor. The ground wire may not be removed.

BA00-1602-322002 © Continental Automotive GmbH Page 14

Test Set-Up: Calibration of km/h Control

8 Test Set-Up: Calibration of km/h Control

A Calibration unit 1 Shift key for speed = 3.2 km/h or 50 km/h

B Calibration cable 1602-78-122 2 Shift key for autom. or manual mode
C "Blue" testing line 4 Shift key for ATC or MTC mode
(FTP 88 component) 5 Shift key for LS1 or LS2
D FTP 88 14 Shift key (grey) for switching over from
G Set-point knob counter-mode to frequency-mode
K Measured value display
L "km/h" function key
M Coding switch
Z Test jack

Page 15 © Continental Automotive GmbH BA00-1602-322002

 Measuring Preparations of the Calibration Unit

8.1 Measuring Preparations of the Calibration Unit

• Switch 1, 3.2 km/h position

• Switch 2, manual position
• Switch 4, MTC position
• Switch 5, LS2 position

8.2 Measuring Preparations of the FTP 88

• Press blue "km/h" function key (L) until it locks into place.
• Set coding switch (M) of the FTP 88 to 02500 pulses/km.
• Connect the 1602-78-122 calibrating cable (B) to the calibration unit.
• Connect the "C" testing cable (FTP 88 component) to the "Z" test jack of the FTP 88.
• Attach the calibration cable (AMP plug) and the testing cable (AMP bush) to each
other.
• The value 0.00 must be shwon on the frequency display of the calibration unit. Is this
is not the case, the grey key (14) must be pressed in order to activate the frequency
display.

8.3 Calibration Sequence for km/h Control (2500 pulses/km)

• Turn the set-point knob (G) of the FTP 88 to the right until 20.0 km/h is shown on the
measured value display of the FTP 88.
• The following speeds are to be selected and the corresponding frequency is to be
checked: 020, 050, 080, 100, 125, 150 and 180 km/h. The corresponding frequency
is shown on the frequency display of the calibration unit and must be entered into
the certificate (see calibration certificate).
• Turn the set-point knob (G) of the FTP 88 to the left until the limit stop.

8.4 Calibration Sequence for Km/h Control (8000 pulses/km)

• Set coding switch (M) of the FTP 88 to 08000 pulses/km.

• Test the speeds between 20 and 180 km/h as described in Section 8.3.

8.5 Calibration Sequence for km/h Control (19000 pulses/km)

• Proceed as described in Section 8.4.

The coding switch (M) of the FTP 88 must be set to 19000 pulses/km.
• When the test has been completed, turn the set-point knob (G) of the FTP 88 to the
left until the limit stop.

BA00-1602-322002 © Continental Automotive GmbH Page 16

Test Set-Up: Switch-Over from km/h to mph

9 Test Set-Up: Switch-Over from km/h to mph

The test can be set up as decribed under Section 8. The black "mph" key (L) must be
pressed until it locks into place.

A Calibration unit 1 Shift key for speed = 3.2 km/h or 50 km/h

B Calibration cable 1602-78-122 2 Shift key for autom. or manual mode
C "Blue" testing line 4 Shift key for ATC or MTC mode
(FTP 88 component) 5 Shift key for LS1 or LS2
D FTP 88 14 Shift key (grey) for switching over from
G Set-point knob counter-mode to frequency-mode
K Measured value display
L "mph" function key
M Coding switch
Z Test jack

Page 17 © Continental Automotive GmbH BA00-1602-322002

 Calibration Sequence for Switch-Over from km/h to

9.1 Calibration Sequence for Switch-Over from km/h to mph

• Set the coding switch (M) of the FTP 88 to 0800 pulses/km.

• Turn the set-point knob (G) of the FTP 88 to the right until a value of 50 mph appears
on the measured value display (K) of the FTP 88.
• The frequency is shown in the frequency display of the calibration unit and must be
entered into the certificate.
• Turn the set-point knob (G) of the FTP 88 more to the right until a value of 100 mph
appears on the measured value display (K) of the FTP 88.
• The frequency is shown on the frequency display of the calibration unit and must be-
entered into the certificate.
• When the test has been completed, turn the set-point knob of the FTP 88 to the left
until the limit stop.

BA00-1602-322002 © Continental Automotive GmbH Page 18

Test Set-Up: Calibration of Odometer (Pulse) (k = 8000 pulses/km)

10 Test Set-Up: Calibration of Odometer (Pulse) (k = 8000 pul-

ses/km)
The test can be set up as described under Section 9. The blue "Imp" key (L) must be
pressed until it locks into place.

A Calibration unit 1 Shift key for speed = 3.2 km/h or 50 km/h

B Calibration cable 1602-78-122 2 Shift key for autom. or manual mode
C "Blue" testing line 4 Shift key for ATC or MTC mode
(FTP 88 component) 5 Shift key for LS1 or LS2
D FTP 88 14 Shift key (grey) for switching over from
G Set-point knob counter-mode to frequency-mode
K Measured value display
L "Imp" function key
M Coding switch

Page 19 © Continental Automotive GmbH BA00-1602-322002

 Calibration Sequence for Odometer (Pulse) (k = 8000

Z Test jack

10.1 Calibration Sequence for Odometer (Pulse)

(k = 8000 pul- ses/km)

• The frequency display of the calibration unit must be switched to the counter-mode
by pressing the grey key (14) two times. 0 must be on the display.
• If 0 is not on the display, set the counter to 0 by means of the red key.
• Set the coding switch (M) of the FTP 88 to 08000.
• Press the blue "Imp" switch.
• Press the white "RES" function key of the FTP 88.
• Turn the set-point knob (G) slowly to the right until the counting procedure on the
measured value display begins.
• Observe the measured value display (K) of the FTP 88 and when a measured value
of 8000 has been reached, turn the set-point knob (G) to the left until the limit stop.
• The counter input of the calibration unit has an eightfold scaler. This means that only
every eighth pulse of the FTP 88 is counted.
FTP 88 display = 8000 Calibration unit display = 1000

Desired value (8000):8 = Actual value 1000 ± 1 pulses

• Enter the measured value into the certificate:
1. Measured FTP 88 value as desired value
2. Measured value of calibration unit as actual vlaue.

BA00-1602-322002 © Continental Automotive GmbH Page 20

Concluding Tasks

11 Concluding Tasks
After the calibration procedure has been completed, the voltage of the calibration unit and
the FTP 88 must be switched off and the caibrating cable must be removed. The certi-
ficate must be filled out completely with the signature of the inspector and his/ her com-
pany stamp.
Any recognised defects such as damage, missing parts, etc. must be entered in the cer-
tifiacte under "Comments".
After calibration, the respecive measuring device receives a calibration label, on which the
duration of calibration validity is marked.

Year Month
The date of validity is marked by cutting out (marking) the corresponding month and year
fields on the claibration label.

The calibration labe must be attached to the front of the calibration test stand. The surface
onto which the calibration label is to be attached must first be cleaned.

Page 21 © Continental Automotive GmbH BA00-1602-322002

 Sample Certificate

12 Sample Certificate

A sample certificate for the FTP 88 is located in the Appendix. All measured values are
in italicy and bold print (4000). The certificate must be filled out completely, including the
signature of the inspecor and his/ her company stamp. If a measured value is not within
the acceptable tolerance, no certificate my be issued. The date of validity entered in the
certificate must correspond to the date of validity on the calibration label attached to the
testing device.

BA00-1602-322002 © Continental Automotive GmbH Page 22

Sample Certificate

Calibration Certificate
FTP 88
Device type : FTP 88 Certificate no. : M/2008/06/001

Serial no. : 123456 Valid until : 04.06.2009

Date : 04.06.2008

The proper function of the above-mentioned testing device has been tested and
calibrated. The measuring devices used for calibration meet national standards.

Calibration Unit Device no.:

1602.32 0066

Test for Mechanical Drive

1.) Voltage test (variable voltage 5V – 24V)

Desired value Tolerance Actual value

5 Volt r 0,25 Volt 05,05

12 Volt r 0,6 Volt 12,28
24 Volt r 1,2 Volt 24,05

2.) Test of mechanical drive with digital km/h display (k = 1000)

Desired value Tolerance Actual value

20 km/h 55,55 Hz r 2 Hz 055,71

50 km/h 138,88 Hz r 2 Hz 138,42
80 km/h 222,22 Hz r 2 Hz 222,57
100 km/h 277,77 Hz r 2 Hz 277,56
125 km/h 347,22 Hz r 2 Hz 347,15
150 km/h 416,66 Hz r 2 Hz 416,42
180 km/h 500,00 Hz r 2 Hz 499,87

Page 1 of 3

Page 23 © Continental Automotive GmbH BA00-1602-322002

 Sample Certificate

Calibration Certificate
FTP 88
3. ) Test of mechnaical drive with digital rmp display

Desired value Tolerance Actual value

1000 rmp 166,66 Hz r 2 Hz 166,87

2000 rmp 333,33 Hz r 2 Hz 333,21
3000 rmp 500,00 Hz r 2 Hz 499,86

4.) Test of mechanical drive with digital display

Desired value Tolerance Avtual value

At least 1000 rev.

(FTP 88 diplay) (calibration unit display x 1.25)

1000 r 2 Umdr. 1250

Test of Electronic Control System

5.) Test of km/h control (k value = 2500 pulses/km)

Desired value Tolerance Actual value

20 km/h 13,89 Hz r 1 Hz 013,87

50 km/h 34,71 Hz r 1 Hz 034,74
80 km/h 55,55 Hz r 1 Hz 055,53
100 km/h 69,44 Hz r 1 Hz 069,41
125 km/h 86,71 Hz r 1 Hz 086,77
150 km/h 104,15 Hz r 1 Hz 103,98
180 km/h 125,00 Hz r 1 Hz 124,92

6.) Test of km/h control (k value = 8000 pulses/km)

Desired value Tolerance Actual value

20 km/h 44,44 Hz r 1 Hz 044,45

50 km/h 111,11 Hz r 1 Hz 111,09
80 km/h 177,76 Hz r 1 Hz 177,77
100 km/h 222,22 Hz r 1 Hz 222,28
125 km/h 277,75 Hz r 1 Hz 277,73
150 km/h 333,33 Hz r 1 Hz 333,31
180 km/h 400,00 Hz r 1 Hz 400,01

Page 2 of 3

BA00-1602-322002 © Continental Automotive GmbH Page 24

Sample Certificate

Calibration Certificate
FTP 88

7.) Test of km/h control (k value = 19000 pulses/km)

Desired value Tolerance Actual value

20 km/h 105,54 Hz r 2 Hz 105,51

50 km/h 263,85 Hz r 2 Hz 263,90
80 km/h 422,16 Hz r 2 Hz 422,12
100 km/h 527,70 Hz r 2 Hz 527,86
125 km/h 659,62 Hz r 2 Hz 659,65
150 km/h 791,55 Hz r 2 Hz 791,60
180 km/h 949,86 Hz r 2 Hz 950,01

8.) Test of switch-over from km/h to mph (k = 8000 pulses/km)

Desired value Tolerance Actual value

50 mph 178,66 Hz r 1 Hz 178,68

100 mph 357,77 Hz r 1 Hz 357,15

9.) Test of odometer (pulse) (k = 8000 pulses/km)

Desired value Tolerance Actual value

(FTP 88 dispaly) (frequency display of calibration unit)

At least 8000 Imp

8000 :8 r 1 Imp 1000

Commments :

Continental Automotive GmbH is a

company certified according to
DIN EN ISO 9001: 2000 Company stamp/Signature of inspector

Page 3 of 3

Page 25 © Continental Automotive GmbH BA00-1602-322002

Pulse Counter ZG 20/84

ZG 20/84 X12-340-016-001
Calibration Instructions
Seite 2 © Continental Automotive GmbH BA00-1602-322002
Table of Contents
1 Brief Description of ZG 20/845
2 Technical Data6
3 ZG 20/84 Function Test6
4 Test Set-Up: Calibration of Manual Distance Pulse Measurement7
4.1 Measuring Preparations of the Calibration Unit . . . . . . . . . . . . . . . . . 8
4.2 Measuring Preparations of the ZG 20/84 . . . . . . . . . . . . . . . . . . . . . . 8
4.3 Calibration Sequence for Manual Distance Pulse Measurement . . . . 8
5 Concluding Tasks9
6 Sample Certificate10

BA00-1602-322002 © Continental Automotive GmbH Page 3

Page 4 © Continental Automotive GmbH BA00-1602-322002
 Brief Description of ZG 20/84

1 Brief Description of ZG 20/84

1 Measurement button
2 Reset button
3 Release/ stop switch for measurement
4 Measured value display
5 Pulse input

BA00-1602-322002 © Continental Automotive GmbH Page 5

Technical Data

2 Technical Data
Nominal voltage : 12 / 24 V
Display : 4-digit LCD

3 ZG 20/84 Function Test

No additional function test is required for the ZG 20/84 before calibration.

Page 6 © Continental Automotive GmbH BA00-1602-322002

 Test Set-Up: Calibration of Manual Distance Pulse

4 Test Set-Up: Calibration of Manual Distance Pulse Measu-

rement
Before setting up the test, make sure that the mains switch of the calibrator is set to the
"0" (= mains off) position.

A Calibration unit 1 Shift key for speed = 3.2 km/h or 50 km/h

B Jack plug cable (grey) 2 Shift key for autom. or manual mode
(ZG 20/84 component) 4 Shift key for ATC or MTC mode
C Voltage supply line 5 Shift key for LS1 or LS2 light barrier
(Workshop accessory) 14 Shift key (gry) for switching over from
D ZG 20/84 counter-mode to frequency-mode
E Selector switch for measurement
F LED
G Reset

BA00-1602-322002 © Continental Automotive GmbH Page 7

Measuring Preparations of the Calibration Unit

4.1 Measuring Preparations of the Calibration Unit

• Switch 1, 3.2 km/h position

• Switch 2, manual position
• Switch 4, MTC position
• Switch 5, LS2 position

4.2 Measuring Preparations of the ZG 20/84

• Connecet the ZG 20/84 to the calibration unit by means of the voltage supply line
(C), which is a ZG 20/84 component.

Caution:
Do not mix up the plus and minus voltage lines!

• Connecting plugs for the voltage of the ZG 20/84:

4 pol AMP - plug

6 pol AMP - plug

• Connect the ZG 20/84 to the "A2" jack plug bush of the calibration unit by means of
the jack plug line, which is a ZG 20/84 component.
• Connect the calibration unit to 230 V by means of the voltage cable and switch on
the voltage by means of the mains switch.

4.3 Calibration Sequence for Manual Distance Pulse Measure-

ment

• Press the measurement selector switch (E) until the LED for Tests 1a and 1b lights
up.
• Press the "Reset" key. After that, no segment of the display of the ZG20/84 may be
visible.
• Press the "Start“ key of the calibration unit.
• After that, the calibration unit outputs 100 pulses, which are slowly counted up by
the ZG 20/84.
• When the measurement has been completed, enter the measured value into the cer-
tificate.
• Press the "Reset" key and repeat the measurement three times.

Page 8 © Continental Automotive GmbH BA00-1602-322002

 Concluding Tasks

5 Concluding Tasks
After the calibration procedure has been completed, the voltage of the calibration unit
must be switched off and the ZG 20/84 must be removed. The certificate must be filled
out completely with the signautre of the inspector and his/ her company stamp.
Any recognised defects such as damage, missing parts, etc. must be entered in the cer-
tificate under "Comments".
After calibration, the respective measuring device receives a calibration label, on which
the duration of calibration validity is marked.

Year Month
The date of validity is marked by cutting put (marking) the corresponding month and year
fields on the calibration label.

The calibration label must be attached to the back of the pulse counter unit. The surface
onto which the calibration label is to be attached must first be cleaned.

BA00-1602-322002 © Continental Automotive GmbH Page 9

Sample Certificate

6 Sample Certificate

A sample certificate for the ZG 20/84 is located in the Appendix. All measured values are
in italics and bold print (4000). The certificate must be filled out completely, including the
signature of the inspector and his/ her company stamp. If a measured value is not within
the acceptable tolerance, no certificate may be issued. The date of validity entered in the
certificate must correspond to the date of validity on the calibration label attached to the
testing device.

Page 10 © Continental Automotive GmbH BA00-1602-322002

 Sample Certificate

Calibration Certificate
ZG20/84
Device type : Cetificate no. :

Order no. : Valid until :

Date :

The proper function of the above-mentioned testing device has been tested and
calibrated. The measuring devices used for calibration meet national standards.

Calibration Unit Device no.:

1602-32

1.) Pulse test ( f1 )

Desired value Tolerance Actual value

1. 100 pulses r 1 pulses

2. 100 pulses r 1 pulses
3. 100 pulses r 1 pulses

Comments :

Continental Automotive GmbH is a

company certified according to
DIN EN ISO 9001: 2000 Company stamp/Signature of inspector

Page 1 of 1

BA00-1602-322002 © Continental Automotive GmbH Page 11

Frequency Generator FG 94

FG 94 X12-397-045-001
Calibration Instructions
Table of Contents
1 Brief Description of FG 94 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3 FG 94 Function Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
4 Test Set-Up: Calibration of Frequency Output . . . . . . . . . . . . . . . . . . . . . .6
4.1 Measuring Preparations of the Calibration Unit. . . . . . . . . . . . . . . . . . . . . 7
4.2 Measuring Preparations of the FG 94 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4.3 Calibration Sequence for FG 94 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5 Concluding Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
6 Sample Certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

BA00-1602-322002 © Continental Automotive GmbH Page 2

 Brief Description of FG 94

1 Brief Description of FG 94

1 ON/OFF switch
2 Pilot lamp
3 Frequency range
4 Set-point knob
5 Connecting line for FG 94
6 Connecting plug for external voltage supply
7 Connecting plug for tachograph test jack

BA00-1602-322002 © Continental Automotive GmbH Page 4

Technical Data

2 Technical Data
Nominal voltage: 10 - 30 V

Power consumption: 35 mA

Operating temperature:- - 10° C to + 60° C

Dimensions (mm): 100 x 50 x 40 (H x W x D)

Weight: 0.23 kg

3 FG 94 Function Test
No additional function test is required for the FG 94 before calibration.

Page 5 © Continental Automotive GmbH BA00-1602-322002

 Test Set-Up: Calibration of Frequency Output

4 Test Set-Up: Calibration of Frequency Output

Before setting up the test, make sure that the mains switch of the calibrator is set to the
symbol "0" (= mains off).

A Calibration unit 1 Shift key for speed = 3.2 km/h or 50

B FG 94 km/h
C Jack plug cable 2 Shift key for autom. or manual mode
D Plus voltage supply 4 Shift key for ATC or MTC mode
E Minus voltage supply 5 Shift key for LS1 or LS2 light barrier
F Set-point knob 14 Shift key (grey) for switching over
G Pilot lamp from counter-mode to frequency
H ON/OFF switch mode
I Frequency range switch
X Testing cable (FG 94 component)

BA00-1602-322002 © Continental Automotive GmbH Page 6

Measuring Preparations of the Calibration Unit

4.1 Measuring Preparations of the Calibration Unit

• Switch 1, 3.2 km/h position

• Switch 2, manual position
• Switch 4, MTC position
• Switch 5, LS2 position

4.2 Measuring Preparations of the FG 94

• Connect the "X" testing cable to the FG 94.

• Insert the "C" jack plug line (yellow) into the E1 jack bush of the calibration unit.
• Insert the banana plug with the red/black line into the "+" banana socket (red) of the
calibration unit labelled "Output".
• Insert the banana plug with the black line into the "-" banana socket (black) of the
calibration unit labelled "Output".

Caution:
Do not mix up the plus (red/black) and minus (black) voltage lines!

• Set the "H" switch to "OFF".

• Turn the set-point knob to the left-hand limit stop.
• Connect the calibration unit to 230 V by means of a voltage cable and switch on the
voltage by means of the mains switch of the calibration unit.
• The value 0.00 must be shown on the frequency display of the calibration unit. If this
is not the case, the grey key (14) must be pressed twice to activate the frequency
display.

Page 7 © Continental Automotive GmbH BA00-1602-322002

 Calibration Sequence for FG 94

4.3 Calibration Sequence for FG 94

• Turn the "H" switch of the FG 94 to "ON".

• The "G" pilot lamp must light up.
• Set the "I" frequency range switch to f1.
• Turn the set-point knob slowly to the right until 3 Hz appears on the frequency dis-
play.
• The frequency of 3 Hz must be stable and may only fluctuate by maximum 1 Hz.
• Turn the set-point knob to the right-hand limit stop.
• A frequency of at least 1070 Hz must be shown on the frequency display.
• The frequency actually displayed must be stable and may only fluctuate by maxi-
mum +/-2 Hz.
• Enter the measured values into the certificate.
• Set frequency change-over switch to f2
• A frequency of at least 4300 Hz must be shown in the frequency display.
• The frequency actually displayed must be stable an may only fluctuate by maximum
+/- 5 Hz.
• Turn the set-point knob to the left until a value of 3 Hz is shown on the display of the
calibration unit.
• The frequency display must be stable and may fluctuate by a maximum of 1 Hz.
• Enter the measured values into the certificate.

BA00-1602-322002 © Continental Automotive GmbH Page 8

Concluding Tasks

5 Concluding Tasks
After the calibration procedure has been completed, the voltage of the calibration unit
must be switched off and the FG 94 must be removed. The certificate must be filled out
completely with the signature of the inspector and his/her company stamp.
Any recognised defects such as damage, missing parts, etc. must be entered in the cer-
tificate under "Comments".
After calibration, the respective measuring device receives a calibration label, on which
the duration of calibration validity is marked.

Year Month
The date of validity is marked by cutting out (marking) the corresponding month and year
fields on the calibration label.

The calibration label must be attached to the back of the frequency generator. The surface
onto which the calibration label is to be attached must first be cleaned.

Page 9 © Continental Automotive GmbH BA00-1602-322002

 Sample Certificate

6 Sample Certificate

A sample certificate for the FG 94 is located in the Appendix. All measured values are in
italics and bold print (4000). The certificate must be filled out completely, including the si-
gnature of the inspector and his/her company stamp. If a measured value is not within the
acceptable tolerance, no certificate may be issued. The date of validity entered in the cer-
tificate must correspond to the date of validity on the calibration label attached to the te-
sting device.

BA00-1602-322002 © Continental Automotive GmbH Page 10

Sample Certificate

Calibration Certificate
FG 94
Device type : Certificate no. :

Order no. : Valid until :

Date :

The proper function of the above-mentioned testing device has been tested and
calibrated. The measuring devices used for calibration meet national standards.

Calibration Unit Device no.:

1602-32

1.) Pulsse test ( f1 )

Desired value Tolerance Actual value

( min. ) 3 Hz - 1070 Hz

min. 3 Hz r 1 Hz
max. value ( min. 1070 Hz ) r 2 Hz

2.) Pulse test ( f2 )

Desired value Tolerance Actual value

( min. ) 3 Hz - 4300 Hz

min. 3 Hz r 1 Hz
max. value ( min. 4300 Hz ) r 5 Hz

Comments :

Continental Automotive GmbH is a

company certified according to
DIN EN ISO 9001: 2000 Company stamp/Signature of inspector

Page 1 of 1

Page 11 © Continental Automotive GmbH BA00-1602-322002

Calibrated Digital Test Stand DFG 1

DFG1 X12-052-000-004
Calibration instructions
Table of Contents
1 Test Device Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2 Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
3 Functional Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
4 Test Set-Up: Calibration of Output Voltage . . . . . . . . . . . . . . . . . . . . . . . . .8
4.1 Measuring Preparations of the Calibration Unit. . . . . . . . . . . . . . . . . . . . . 9
4.2 Measuring Preparations of the DFG1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
4.3 Calibration Sequence for 12 V Output Voltage . . . . . . . . . . . . . . . . . . . . . 9
4.4 Calibration Sequence for 24 V Output Voltage . . . . . . . . . . . . . . . . . . . . . 9
5 Test Set-Up: Calibration of Mechanical Drive for km/h . . . . . . . . . . . . . . .10
5.1 Measuring Preparations of the Calibration Unit. . . . . . . . . . . . . . . . . . . . 11
5.2 Measuring Preparations of the Calibrated Digital Test Stand . . . . . . . . . 11
5.3 Calibration Sequence for Mechanical Drive for km/h . . . . . . . . . . . . . . . 11
6 Test Set-Up: Calibration of Mechanical Drive for 1/min . . . . . . . . . . . . . .12
6.1 Calibration Sequence for Mechanical Drive for 1/min . . . . . . . . . . . . . . . 12
7 Test Set-Up: Calibration of Mechanical Drive for rev. . . . . . . . . . . . . . . . .13
7.1 Calibration Sequence for Mechanical Drive for rev. . . . . . . . . . . . . . . . . 13
8 Concluding Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
9 Sample Certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

BA00-1602-322002 © Continental Automotive GmbH Page 2

 Test Device Description

1 Test Device Description

1 Mains switch 9 Knobs (a, b, c)

2 Mains pilot lamp 10 Flip switches for switch-over of
potentiometer 9a to 9b/9c
3 Test key, when pressed - 11 Flip switch for switch-over of
LED 8888 (O.K.) potentiometer 9b to 9c
4 Test key, when pressed - 12 Flip switch, when pressed - number
no LED (O.K.) of revolutions (shift key 7 to
„rev.“ position)
5 Connecting jacks for 12-V direct 13 Reset button, when pressed -LED
voltage (load = max. 1 A) reset to zero
6 Connecting jacks for 24-V direct 14 Connecting jack for remote control
voltage (load = max. 1 A) switch (start/stop) - flip switch 12
must be set to „Start“
7 Shift key for revolutions, 15 Connection in accordance with DIN
1/min and km/h 75532 FormE2 (M 22x1.5-3mm reed)
8 Flip switch for changes in the 16 LED display
directon of device motor rotation

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Technical Data

2 Technical Data

Nominal voltage: 220 - 230 V/ 50 Hz

Operating temperature: + 10°C to + 40°C
Display: LED display
Measuring ranges: 150 - 3000 1/min infinitely variable,
10 - 180 km/h cw and ccw rotation
0 - 9999 revolutions
Device constant: fixed, k = 1000 rev./km
Dimensions: 300 mm x 135 mm x 230 mm (W x H
x D)
Weight: approx. 9.5 kg
Mechanical drive:

One revolution of the shaft corresponds to one meter pulse at k = 1000.

1 km/h = 2.77 m/s = 2.77 shaft revolutions.
Test of drive by means of 1602-0118-000-000 test sensor shows 10 pulses per revolution.

(Min. 10 km/h = 27.77 Hz ± 2 Hz)

(Max. 180 km/h = 500,00 Hz ± 2 Hz)

Page 5 © Continental Automotive GmbH BA00-1602-322002

 Functional Test

3 Functional Test
The following items must be carried out to perform a functional test:

Display Test:
• Turn knobs [9a, b, c] to the left-hand limit stop.
• Set shift key [7] to "km/h".
• Turn on the digital test stand by means of the mains switch [1]. The mains pilot lamp
[2] lights up.
• 0.0 must be shown on the LED display [16], A decimal must appear between both
numbers.
LED:
• Press test key [3]. LED display = 888.8
• Press test key [4]. No LED display (dark)
km/h Measuring Range [cckw Rotation]:
• Turn knobs [9a, b, c] to the left-hand limit stop.
• Set shift key [7] to "km/h".
• Turn flip switch for changing the direction of device motor rotation [8] to the left.
• Turn the [10] and [11] flip switches to the left.
• Set a value of 100 km/h by means of knob [9a].
• Before calibration let the test stand warm up for approx. 10 minutes.
• Turn knob [9a] to the right-hand limit stop. A value of at least 180.0 must appear on
the LED display [16].
• Turn knob [9a] back to the left-hand limit stop. A value of 0.0 must appear on the
LED display [16].

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Functional Test

• Turn the flip switch [10] to the right.

• Turn knob [9b] to the right-hand limit stop. A value of at least 180.0 must appear on
the LED display [16].
• Turn knob [9b] back to the left-hand limit stop. A value of 0.0 must appear on the
LED display [16].
• Turn the flip switch [11] to the right.
• Turn knob [9c] to the right-hand limit stop. A value of at least 180.0 must appear on
the LED display [16].
• Turn knob [9c] back to the left-hand limit stop. A value of 0.0 must appear on the
LED display [16].
km/h Measuring Range [cw Rotation]:
• Proceed as described for ccw rotation test, but turn the flip switch for changing the
direction of device motor rotation [8] to the right.
• The device motor must not be warmed up.
1/min Measuring Range [ccw Rotation]:
• Turn knobs [9a, b, c] to the left-hand limit stop.
• Set shift key [7] to "U/min".
• Turn flip switch for changing the direction of device motor rotation [8] to the left.
• Turn the [10] and [11] flip switches to the left.
• Turn knob [9a] slowly to the right and make sure that the 3 right-hand digits on the
LED display [16] show the values between 0 and 9 or that the left-hand digit display
shows the values 1 through 3. When the right-hand limit stop is reached, a value of
at least 3000 must appear on the LED display [16].
• Turn knob [9a] back to the left-hand limit stop. A value of 000 must appear on the
LED display [16].
• Turn the flip switch [10] to the right.
• Turn knob [9b] slowly to the right and make sure that the 3 right-hand digits on the
LED display [16] show the values between 0 and 9 or that the left-hand digit display
shows the values 1 through 3. When the right-hand limit-stop is reached, a value of
least 3000 must appear on the LED display [16].
• Turn knob [9b] back to the left-hand limit stop. A value of 000 must appear on the
LED display [16].
• Turn the flip switch [11] to the right.
• Turn knob [9c] slowly to the right and make sure that the 3 right-hand digits on the
LED display [16] show the values between 0 and 9 or that the left-hand digit display
shows the values 1 through 3. When the right-hand limit stop is reached, a value of
at least 3000 must appear on the LED display [16].
• Turn knob [9c] back to the left-hand limit stop. A value of 000 must appear on the
LED display [16].
1/min Measuring Range [cw Rotation]:
• Proceed as described for ccw rotation test, but turn the flip switch for changing the
direction of device motor rotation [8] to the right.

Page 7 © Continental Automotive GmbH BA00-1602-322002

 Test Set-Up: Calibration of Output Voltage

4 Test Set-Up: Calibration of Output Voltage

Before setting up the test, make sure that the mains switch of the calibration unit is at the
"0" (= mains off) position and that the mains switch of the DFG 1 at the "OFF" (= mains
off) position.

1 Mains switch 9 Knobs (a, b, c)

2 Mains pilot lamp 10 Flip switches for switch-over of
3 Test key, when pressed - potentiometer 9a to 9b/9c
LED 8888 (O.K.) 11 Flip switch for switch-over of
4 Test key, when pressed - potentiometer 9b to 9c
no LED (O.K.) 12 Flip switch, when pressed - number
of revolutions (shift key 7 to
5 Connecting jacks for 12-V direct „rev.“ position)
voltage (load = max. 1 A) 13 Reset button, when pressed -LED
6 Connecting jacks for 24-V direct reset to zero
voltage (load = max. 1 A) 14 Connecting jack for remote control
switch (start/stop) - flip switch 12
7 Shift key for revolutions, must be set to „Start“
1/min and km/h 15 Connection in accordance with DIN
8 Flip switch for changes in the 75532 FormE2 (M 22x1.5-3mm reed)
directon of device motor rotation 16 LED display

1* Shift key for speed = 3.2 km/h or 50 km/h A Calibration unit

2* Shift key for autom. or manual mode B Connecting line (red)
4* Shift key for ATC or MTC C Ground wire (black)
5* Shift key for LS1 or LS2 light barrier D DFG 1
14* Shift key (grey) for switching over from counter-mode to
frequency-mode

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Measuring Preparations of the Calibration Unit

4.1 Measuring Preparations of the Calibration Unit

• Switch 1*, 3.2 km/h position

• Switch 2*, manual position
• Switch 4*, MTC position
• Switch 5*, LS2 position

4.2 Measuring Preparations of the DFG1

• Insert the measuring line (red) into the 12 V=/1A banana socket (item 5) (red) of the
DFG1 and into the "V" banana socket (red) of the calibration unit labelled "Input".
• Insert the ground wire (black) into the "0" banana socket (item 5) (blue) of the DFG1
and into the "-" banana socket (black) of the calibration unit labelled "Input".
• Connect the calibration unit and the DFG1 to 230 V with one voltage cable each and
switch on the voltage.

4.3 Calibration Sequence for 12 V Output Voltage

• After activation, the outputted voltage appears on the voltage display of the calibra-
tion unit
• Enter the measured value in the certificate

4.4 Calibration Sequence for 24 V Output Voltage

• Remove the measuring line (red) from the 12V=/1A banana socket (item 5) (red) of
the DFG1 and insert it into the 24V=/1A banana socket (item 6) (red).
• Remove the ground wire (black) from the "0" banana socket (item 5) (blue) of the
DFG1 and insert it into the "0" banana socket (blue).
• The outputted voltage of the DFG1 appears in the voltage display of the calibration
unit.
• Enter the measured value into the certificate.
• Remove the measuring line and the ground wire from the DFG1 and the calibration
unit.

Page 9 © Continental Automotive GmbH BA00-1602-322002

 Test Set-Up: Calibration of Mechanical Drive for km/h

5 Test Set-Up: Calibration of Mechanical Drive for km/h

1 Mains switch 9 Knobs (a, b, c)

2 Mains pilot lamp 10 Flip switches for switch-over of poten-
3 Test key, when pressed - LED 8888 tiometer 9a to 9b/9c
(O.K) 11 Flip switch for switch-over of potentio-
4 Test key, when pressed - no LED meter 9b to 9c
(O.K.) 12 Flip switch, when pressed-number of
5 Connecting jacks for 12-V direct revolutions (shift key 7 to„rev.“position
voltage (load=max. 1A) 13 Reset button, when pressed-LED re-
6 Connecting jacks for 24-V direct set to zero
voltage (load=max. 1A) 14 Connecting jack for remote control
7 Shift key for revolutions, rpm, and kph switch (start/stop)-flip switch 12 must
8 Flip switch for changes in the direction be set to „Start“
of device motor rotation 15 Connection in accordance with DIN
1* Shift key for speed = 3.2 kph or 50 kph 75532 shape E2 (M 22x1.5-3mm
2* Shift key for autom. or manual mode reed)
4* Shift key for ATC or MTC mode 16 LED display
5* Shift key for LS1 or LS2 light barrier A Calibration unit
14* Shift key (grey) for switching over from B Connecting line
counter-mode to frequency-mode X Test sensor

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Measuring Preparations of the Calibration Unit

5.1 Measuring Preparations of the Calibration Unit

• Switch 1*, 3.2 km/h position

• Switch 2*, manual position
• Switch 4*, MTC position
• Switch 5*, LS2 position

5.2 Measuring Preparations of the Calibrated Digital Test

Stand

• Turn switch key [7] to "km/h".

• A value of 0.0 must appear on the LED display [16] of the calibrated digital test
stand.
• Turn knobs [9a, b, c] to the left-hand limit stop.
• Set flip switch for changing the direction of device motor rotation [8] and flip switches
[10, 11] to the left.
• Screw the 16020118-000-000 test sensor on the front of the calibrated digital test
stand to the mechanical connection [15].
• Connect the calibrating cable 1602-78-123 to the test sensor and the calibration unit.
• The value 0.00 must be shown on the frequency display of the calibration unit. If this
is not the case, the grey key (14) must be pressed two times in order to activate the
frequency display.

5.3 Calibration Sequence for Mechanical Drive for km/h

• Turn knob [9a] of the calibrated digital test stand to the right until a value of 20.0 ap-
pears on the LED display [16] of the calibrated digital test stand.
• The following speeds are to be selected and the corresponding frequency is to be
checked: 20, 50, 80, 100, 125, 150, and 180 km/h. The corresponding frequency is
shown on the frequency display of the calibration unit and must be entered into the
certificate (see calibration certificate). Turn the flip switch for changing the direction
of device motor rotation [8] to the right. Actuate the speeds listed above and enter
the frequencies into the certificate.
• This procedure must also be performed for knobs [9b, c] and for ccw and cw rotation
(for guidelines, see description of the km/h measuring ranges, ccw and ccw rota-
tion).
• When the test of the mechanical drive for km/h has been completed, turn knobs [9a,
b, c] to the left-hand limit stop. Set flip switches [8, 10, 11] to the left.

Page 11 © Continental Automotive GmbH BA00-1602-322002

 Test Set-Up: Calibration of Mechanical Drive for 1/

6 Test Set-Up: Calibration of Mechanical Drive for 1/min

The test can be set up as described under Section 4. Shift key [7] must be set to the
"1/min" switch position.

6.1 Calibration Sequence for Mechanical Drive for 1/min

• Set shift key [7] to "U/min".

• A value of 000 must be shown on the LED display [16] of the calibrated digital test
stand.
• Turn knobs [9a, b, c] to the left-hand limit stop.
• Turn flip switch for changing the direction of device motor rotation [8] to the left.
• Turn knob [9a] of the calibrated digital test stand to the right until a value of 1000
appears on the LED display [16] of the calibrated digital test stand.

Select the following engine speeds one after the other and enter the corresponding fre-
quency in the certificate: 1000, 2000, 3000 1/min.
This procedure must also be performed for knobs [9b, c] and for ccw and cw rotation (for
guidelines, see description of the rpm measuring ranges, cckw and ckw rotation).

BA00-1602-322002 © Continental Automotive GmbH Page 12

Test Set-Up: Calibration of Mechanical Drive for rev.

7 Test Set-Up: Calibration of Mechanical Drive for rev.

The test can be set up as described under Section 4. Shift key [7] must be set to the
"Umdr." switch position.

7.1 Calibration Sequence for Mechanical Drive for rev.

• The frequency display of the calibration unit must be switched to the counter mode
by pressing the grey key two times. 0 must be on the display .
• If 0 is not on the display, set the counter to 0 by means of the red key.
• Set flip switch [12] of the digital test stand to "Start". Press the reset button [13]. After
that, no display appears on the LED display [16] of the digital test stand (display is
dark).
• Turn knob [9a] slowly to the right until the counting procedure begins on the LED dis-
play [16].
• Observe the LED display [16] of the digital test stand and turn the knob to the left-
hand limit stop when a measured value of 1000 is reached.
• Enter the measured value into the certificate.
1.Measured calibrated digital test stand value as desired value
2.Measured value of calibration unit as actual value.
The actual value is greater by a factor of 1.25, as a test sensor with 10 pulses/rev.
is used (standard = 8 pulses/rev.).
• This procedure must also be performed for knobs [9b, c] and for ccw and cw rotation
(for guidelines, see description of the 1/min measuring ranges, ccw and cw rotation).

Page 13 © Continental Automotive GmbH BA00-1602-322002

 Concluding Tasks

8 Concluding Tasks
After the calibration procedure has been completed, the voltage of the calibration unit and
the digital test stand must be switched off and the calibrating cable and the
1602-0118-000-000 test sensor must be removed. The certificate must be filled out com-
pletely with the signature of the inspector and his/her company stamp. Any recognised de-
fects such as damage, missing parts, etc. must be entered in the certificate under
"Comments".
After calibration, the respective measuring device receives a calibration label, on which
the duration of calibration validity is marked.

Year Month

The date of validity is marked by cutting out (marking) the corresponding month and year
fields on the calibration label.

The calibration label must be attached to the front of the digital test stand. The surface
onto which the calibration label is to be attached must first be cleaned.

BA00-1602-322002 © Continental Automotive GmbH Page 14

Sample Certificate

9 Sample Certificate

A sample certificate for the DFG1 is located in the Appendix. All measured values are in
italics and bold print (4000). The certificate must be filled out completely, including the si-
gnature of the inspector and his/her company stamp. If a measured value is not within the
acceptable tolerance, no certificate may be issued. The date of validity entered in the cer-
tificate must correspond to the date of validity on the calibration label attached to the te-
sting device.

Page 15 © Continental Automotive GmbH BA00-1602-322002

 Sample Certificate

Calibration Certificate
Calibrated Digital Test Stand
Device type : DFG 1 Certificate no. : M/2008/06/001

Serial no. : 0123456 Valid until : 04.06.2009

Date : 04.06.2008

The proper function of the above-mentioned testing device has been tested and
calibrated. The measuring devices used for calibration meet national standards.

Calibration Unit Device no.

1602.32 0066

1.) Voltage test (fixed voltage.12V/ 24V)

Desired value Tolerance Actual value

12 V r 1,2 V 12,5V
24 V r 2,4 V 24,8V

2a.) Test of mechanical drive for km/h [9a]

Desired value Tolerance Actual value

cckw ckw
20 km/h 55,55 Hz r 2 Hz 055,00 056,00
50 km/h 138,88 Hz r 2 Hz 138,00 139,00
80 km/h 222,22 Hz r 2 Hz 222,00 223,00
100 km/h 277,77 Hz r 2 Hz 277,00 278,00
125 km/h 347,22 Hz r 2 Hz 347,00 348,00
150 km/h 416,66 Hz r 2 Hz 416,00 417,00
180 km/h 500,00 Hz r 2 Hz 499,00 500,00

Page 1 of 3

BA00-1602-322002 © Continental Automotive GmbH Page 16

Sample Certificate

Calibration Certificate
Calibrated Digital Test Stand
2b.) Test of mechanical drive for km/h [9b]

Desired value Tolerance Actual value

cckw ckw
20 km/h 55,55 Hz r 2 Hz 055,00 056,00
50 km/h 138,88 Hz r 2 Hz 138,00 139,00
80 km/h 222,22 Hz r 2 Hz 222,00 223,00
100 km/h 277,77 Hz r 2 Hz 277,00 278,00
125 km/h 347,22 Hz r 2 Hz 347,00 348,00
150 km/h 416,66 Hz r 2 Hz 416,00 417,00
180 km/h 500,00 Hz r 2 Hz 499,00 500,00

2c.) Test of mechanical drive for km/h [9c]

Desired value Tolerance Actual value

cckw ckw
20 km/h 55,55 Hz r 2 Hz 055,00 056,00
50 km/h 138,88 Hz r 2 Hz 138,00 139,00
80 km/h 222,22 Hz r 2 Hz 222,00 223,00
100 km/h 277,77 Hz r 2 Hz 277,00 278,00
125 km/h 347,22 Hz r 2 Hz 347,00 348,00
150 km/h 416,66 Hz r 2 Hz 416,00 417,00
180 km/h 500,00 Hz r 2 Hz 499,00 500,00

3a.) Test of mechnaical drive for rmp [9a]

Desired value Tolerance Actual value

cckw ckw
1000 rmp 166,66 Hz r 1 Hz 166,00 167,00
2000 rmp 333,33 Hz r 1 Hz 333,00 334,00
3000 rmp 500,00 Hz r 1 Hz 499,00 500,00

3b.) Test of mechanical drive for rmp [9b]

Desired value Tolerance Actual value

cckw ckw
1000 rmp 166,66 Hz r 1 Hz 166,00 167,00
2000 rmp 333,33 Hz r 1 Hz 333,00 334,00
3000 rmp 500,00 Hz r 1 Hz 499,00 500,00
Page 2 of 3

Page 17 © Continental Automotive GmbH BA00-1602-322002

 Sample Certificate

Calibration Certificate
Calibrated Digital Test Stand
3c.) Test of mechanical drive for rmp [9c]

Desired value Tolerance Actual value

cckw ckw
1000 rmp 166,66 Hz r 1 Hz 166,00 167,00
2000 rmp 333,33 Hz r 1 Hz 333,00 334,00
3000 rmp 500,00 Hz r 1 Hz 499,00 500,00

4a.) Test of mechanical drive for rev. [9a]

Desired value Tolerance Actual value

At least 1000 rev. Calibration unit display x 1.25

Test stand display
cckw ckw cckw ckw
1200 1200 r 2 rev. 1500 1501

4b.) Test of mechanical drive for rev. [9b]

Desired value Tolerance Actual value

At least 1000 rev. Calibration unit display x 1.25

Test stand display
cckw ckw cckw ckw
1200 1200 r 2 rev. 1500 1501

4c.) Test of mechanical drive for rev. [9c]

Desired value Tolerance Actual value

At least 1000 rev. Calibration unit display x 1.25

Test stand display
cckw ckw cckw ckw
1200 1200 r 2 rev. 1500 1501

Comments :

Continental Automotive GmbH is a

company certified according to
DIN EN ISO 9001: 2000 Company stamp/Signature of inspector

Page 3 of 3

BA00-1602-322002 © Continental Automotive GmbH Page 18

Sample Certificate

Page 19 © Continental Automotive GmbH BA00-1602-322002

Motometer HBG 10

Calibrating Instructions
Table of Contents
1 Short Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2 Functional Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
2.1 Test Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2.2 Functional Testing HBG 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3 Test Set-up - Calibration of Function "Automatic Distance Pulse Determination"
5
3.1 Measurement Preparations of Calibrating Unit . . . . . . . . . . . . . . . . . . . . . 6
3.2 Measurement Preparations for HGB 10 Calibration . . . . . . . . . . . . . . . . . 6
3.3 Calibrating Procedure for Distance Pulse Measurement . . . . . . . . . . . . . 6
4 Test Setup - Calibration of Set km/h . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
4.1 Calibrating Procedure for Set km/h (k = 2500 Pulses/km) . . . . . . . . . . . . 8
4.2 Calibrating Procedure for Set km/h (8000 Pulses/km) . . . . . . . . . . . . . . . 8
4.3 Calibrating Procedure for Set km/h (24000 Pulses/km) . . . . . . . . . . . . . . 8
5 Concluding Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
6 Sample Certificate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10
7 Connecting Cable A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
8 Connecting Diagram for Calibrating Cable . . . . . . . . . . . . . . . . . . . . . . . .14

BA00-1602-322002 © Continental Automotive GmbH Page 2

 Short Description

1 Short Description

1
3
11
4

10
5 9
7 6

The manual operating device HBG 10 is a testing and calibrating device for Motometer
tachographs of the model series EGK 100.

Important:
As a rule an operative EGK 100 for the calibration of the HBG 10 is requiered!

1 HBG 10
2 Connecting cable
3 Display (7-segment / 5-digit)
4 Functional LED's
5 Numerical keys
6 "Enter" key
7 "Clear" key
8 "Continue" key
9 Input key
10 Memory key
11 Function indicator

BA00-1602-322002 © Continental Automotive GmbH Page 3

Functional Testing

2 Functional Testing
2.1 Test Port

Before set-up please check if the mains switch is set at the symbol "0" = mains off.

1 Calibrating unit 2 Motometer EGK 100 3 Manual operating device HBG 10

4 Connecting cable A for EGK 100 5a Calibrating cable with 5b Calibrating cable with connector
connector

5c Calibrating cable with stereo jack 6 Test terminal EGK 100 7 Line coupling

8 25-pole connector 9 Functional LED's 10 Display

11 Cable HBG 10 with connector

Supply with calibrating unit with 230 V. Connect the EGK 100 via the connecting cable A
(4) with the 24 V connection of the calibrating unit. Connect the calibrating unit, the EGK
100 and the manual operating device HBG 10 via the calibrating cable (5). Switch on the
calibrating unit via the power switch (reverse side).

2.2 Functional Testing HBG 10

1 All functional LED's must light up for a few seconds, the display (10) shows 8888.8.
2 After a short time only the 2nd functional LED must light up and in the display (10)
the constant of the EGK 100 appears.

Page 4 © Continental Automotive GmbH BA00-1602-322002

 Test Set-up - Calibration of Function "Automatic Di-

3 Test Set-up - Calibration of Function "Automatic Distance

Pulse Determination"

A Calibrating unit 1 Shift key for speed 3,2 or 50 km/h

B EGK 100 2 Shift key for mode automatic or manual
C HGB 10 3 Start key
4 Shift key for light barrier LS1 or LS2
5 Shift key for mode ATC or MTC
6 Shift key (grey) for switching over from
counter-mode to frequency-mode

BA00-1602-322002 © Continental Automotive GmbH Page 5

Measurement Preparations of Calibrating Unit

3.1 Measurement Preparations of Calibrating Unit

• Switch 1, position 50,0 km/h

• Switch 2, position manual
• Switch 4, position MTC
• Switch 5, position LS2

3.2 Measurement Preparations for HGB 10 Calibration

• Connect the EGK 100 via the connecting cable (4) with the 24 V connection of the
calibrator.
• Connect the calibrating unit, the EGK 100 and the HGB 10 test cable (5).
• Connect the calibrating unit via voltage cable to 230 V and switch on the calibrating
unit using mains switch.
• The frequency display of the calibrating unit must show the value 0.00. Should this
not be the case, press grey key 2x in order to activate frequency display.

3.3 Calibrating Procedure for Distance Pulse Measurement

• Press key on the HBG 10 (C) until the green LED under the symbol "Cal" lights
up.
• The frequency display of the calibrating unit must show the value 0.00. Should this
not be the case, press grey key 2x in order to activate frequency display.
• Press Start key (3) on the calibrating unit.
• On the display of the HBG 10 (C) pulses are to increase. Wait until a constant value
is displayed.
• Press key on the HBG 10 (C). On the display "d........20" appears and the first
LED (red) lights up.
• Press key on the HBG 10 (C).
• Read the result on the display of the manual operating device. Enter the measured
value in the certificate; set value = W5000 pulses/km +/- 1 pulse.
• This measurement must be carried out three times.

Page 6 © Continental Automotive GmbH BA00-1602-322002

 Test Setup - Calibration of Set km/h

4 Test Setup - Calibration of Set km/h

The test set-up can be adopted as described under point 3.1.

A Calibrating unit 1 Shift key for speed 3,2 or 50 km/h

B EGK 100 2 Shift key for mode automatic or manual
C HGB 10 3 Start key
4 Shift key for light barrier LS1 or LS2
5 Shift key for mode ATC or MTC
6 Shift key (grey) for switching over from
counter-mode to frequency-mode

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Calibrating Procedure for Set km/h (k = 2500 Pulses/km)

4.1 Calibrating Procedure for Set km/h (k = 2500 Pulses/km)

• Press key on the HBG 10 (C) until the second green LED under the symbol "ki"
lights up. The set K value appears on the display.
• After that, press key. The first and second LED must light up. Enter the value
2500 via keyboard and confirm with key.
• Press key on the HBG 10 (C) until the green LED under the symbol "v" lights up.
• After that, press key. The first and fifth LED must light up.
• Enter the value 200 (= 20 km/h) via the keyboard and confirm 2x with key. The
corresponding frequency appears on the frequency display of the calibrating unit
and must be entered in the certificate (see calibrating certificate).
• Press key, enter the next test speed and proceed as described above.
• The following speeds must be selected one after the other and the corresponding
frequencies are to be checked: 020, 050, 080, 100 and 125 km/h. The correspond-
ing frequency appears on the frequency display of the calibrating unit and must be
entered in the certificate (see calibrating certificate.

4.2 Calibrating Procedure for Set km/h (8000 Pulses/km)

• After the test set km/h with the K value 2500 pulses/km and 125 km/h has been con-
cluded, set the K value 8000 as described under point 4.1.
• Check the speed from 020 to 125 km/h and a K value of 08000 pulses/km as descri-
bed under point 4.1.

4.3 Calibrating Procedure for Set km/h (24000 Pulses/km)

• Same procedure as described under point 4.2. The K value of 8000 pulses/km must
be changed to 24000 pulses/km.

Page 8 © Continental Automotive GmbH BA00-1602-322002

 Concluding Tasks

5 Concluding Tasks
After the calibration procedure has been completed, the voltage of the calibration unit
must be switched off and the calibrating cable must be removed. The certificate must be
filled out completely with the signature of the inspector and his/her company stamp.
Any recognised defects, such as damage, missing parts, etc. must be entered into the cer-
tificate under „Comments“.
After calibration, the respective measuring device receives a calibration label, on which
the duration of calibration validity is marked.

Year Month
The date of validity is marked by cutting out (marking) the corresponding month and year
field on the calibration label.

The calibration label must be attached to rear side of the HBG. The surface onto which
the calibration label is to be attached first be cleaned.

Calibration label

Back side HBG 10

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Sample Certificate

6 Sample Certificate

A sample certificate for the HBG 10 is located in the Appendix. All measured values are
in italics and bold print (4000). The certificate must be filled out completely, including the
signature of the inspector and her/his company stamp. If a measured value is not within
the acceptable tolerance, no certificate may be issued. The date of validity entered into
the certificate must correspond to the date of validity on the calibration label attached to
the testing device.

Page 10 © Continental Automotive GmbH BA00-1602-322002

 Sample Certificate

CALIBRATION CERTIFICATE
Hand Terminal HBG 10

Device type : HBG 10 Certificate no. : M/2008/06/001

Serial no. : 123456 Valid until : 04.06.2009

Date : 04.06.2008

The proper function of the above-mentioned testing device has been tested and
calibrated. The measuring devices used for calibration meet national standards.

Calibration Unit Device no.:

1602.32 0066

1. ) Test of automatic distance pulse measurement

Desired value Tolerance Actual value

1. 5000 Imp/km r 2 Imp/km 5000

2. 5000 Imp/km r 2 Imp/km 5000
3. 5000 Imp/km r 2 Imp/km 5000

2.) km/h control test (k value = 2500 pulses/km)

Desired value Tolerance Actual value

20 km/h 13,89 Hz r 1 Hz 0013,88

50 km/h 34,71 Hz r 1 Hz 0034,72
80 km/h 55,55 Hz r 1 Hz 0055,57
100 km/h 69,44 Hz r 1 Hz 0069,44
125 km/h 86,71 Hz r 1 Hz 0086,77
150 km/h 104,15 Hz r 1 Hz 0104,15
180 km/h 125,00 Hz r 1 Hz 0124,95

Page 1 of 2

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Sample Certificate

KALIBRIERZERTIFIKAT
Handbediengerät HGB 10

3.) km/h control test (k value = 8000 pulses/km)

Desired value Tolerance Actual value

20 km/h 44,44 Hz r 1 Hz 0044,43

50 km/h 111,11 Hz r 1 Hz 0111,12
80 km/h 177,76 Hz r 1 Hz 0177,75
100 km/h 222,22 Hz r 1 Hz 0222,23
125 km/h 277,75 Hz r 1 Hz 0277,76
150 km/h 333,33 Hz r 1 Hz 0333,33
180 km/h 400,00 Hz r 1 Hz 0399,96

4.) km/h control test (k value = 24000 pulses/km)

Desired value Tolerance Actual value

20 km/h 133,33 Hz r 2 Hz 0133,32

50 km/h 333,33 Hz r 2 Hz 0333,34
80 km/h 533,28 Hz r 2 Hz 0533,28
100 km/h 666,67 Hz r 2 Hz 0666,68
125 km/h 833,25 Hz r 2 Hz 0833,23
150 km/h 1000,00 Hz r 2 Hz 0999,95
180 km/h 1200,00 Hz r 2 Hz 1199,85

Bemerkungen :

Continental Automotive GmbH is a

company certified according to
DIN EN ISO 9001: 2000 Company stamp/Signature of inspector

Page 2 of 2

Page 12 © Continental Automotive GmbH BA00-1602-322002

 Connecting Cable A

7 Connecting Cable A
(Voltage supply of EGK 100)

Blue red

brown

black

Illumination
Ignition

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Connecting Diagram for Calibrating Cable

8 Connecting Diagram for Calibrating Cable

Page 14 © Continental Automotive GmbH BA00-1602-322002