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    							Xenon/Halogen Headlamp Beam Comparison
    Bi-XenonAHalogenB
    The xenon low/high beam headlamps use ellipsoidal
    technology for the lens and reflector providing improved
    night time visibility compared to conventional halogen
    headlamps. The xenon headlamps provide the following
    benefits when compared to halogen headlamps:
    •Longer bulb life - Approximately 3 to 5 times longer
    than a halogen bulb
    •Increased light output - xenon headlamps output 3
    to 4 times more light on the road surface than
    halogen headlamps
    •Blue/White light which is closer to natural daylight
    - xenon lamps produce a blue/white light compared
    to a yellow light produced by a halogen bulb
    •Improved night time driving visibility - xenon lamps
    produce a wider and brighter beam in front of the
    vehicle than conventional halogen bulbs
    •Lower running temperatures
    •Lower power consumption.
    (G421288) Technical Training172
    Lesson 2 – ElectricalExterior Lighting 
    						
    							Xenon Headlamp Construction
    Bracket1
    DS2 xenon bulb2
    DS2 connector3
    Swivel actuator (AFS lamp only)4
    Solenoid5
    Aspheric lens6
    Shade7
    Shade8
    Lens support9
    Exterior LightingLesson 2 – Electrical
    173Technical Training (G421288) 
    						
    							The xenon headlamp is a self contained unit located
    within the headlamp assembly. The unit comprises a
    reflector, an adaptor ring, the lens, a shutter controller
    and the xenon bulb, which as an assembly is known as
    the projector module.
    The reflector is curved and provides the mounting for
    the xenon bulb. The bulb locates in a keyway to ensure
    correct alignment in the reflector and is secured by
    pushing and turning to lock. The bulb has a two pin
    connector which is also a push and turn to lock fitting.
    The shutter controller is a solenoid which operates, via
    a lever mechanism, to the shutter. The shutter is used
    to change the beam projection from low beam to high
    beam and visa versa.
    A tourist lever mechanism is located on the right hand
    side of the projector module. This mechanism moves
    to blank off a portion of the beam spread to enable the
    vehicle to be driven in opposite drive hand markets
    without applying blanking decals to the headlamp lens.
    The beam is changed by removing the access cover at
    the rear of the lamp assembly and moving a small lever
    located near the bulb holder, at the side of the reflector.
    Make sure that the headlamps are off before removing
    the access cover.
    The xenon bulbs illuminate when an arc of electrical
    current is established between two electrodes within the
    bulb. The xenon gas sealed in the bulb reacts to the
    electrical excitation and the heat generated by the current
    flow. The xenon gas reaction to the controlled current
    flow between the electrodes produces the blue/white
    light.
    To operate at full efficiency, the xenon bulb goes
    through three stages of operation before full output for
    continuous operation is achieved. The three phases are;
    start-up phase, warm-up phase and continuous phase.
    In the start-up phase, the bulb requires an initial high
    voltage starting pulse of 18000 to 28000 volts to
    establish the arc. This is produced by the igniters. The
    warm-up phase begins once the arc is established. The
    xenon control modules regulate the supply to the bulbs
    to 2.6A which gives a lamp output of 75W. During this
    phase, the xenon gas begins to illuminate brightly and
    the environment within the bulb stabilises ensuring a
    continual current flow between the electrodes. When
    the warm-up phase is complete, the xenon control
    modules change to continuous phase. The supply voltage
    to the bulb is reduced and the operating power required
    for continual operation is reduced to 35W.
    The xenon system is controlled by the CJB, the two
    xenon control modules and the two igniters. The xenon
    control modules (one per headlamp) receive an operating
    voltage from the CJB when the headlamps are switched
    on. The modules regulate the power supply required
    through the phases of start-up.
    The igniters (one per headlamp) generate the initial high
    voltage required to establish the arc. The igniters have
    integral coils which generate high voltage pulses
    required for start-up. Once the xenon bulbs are
    operating, the igniters provide a closed circuit for
    regulated power supply from the control modules.
    Turn Signal Lamp
    The turn signal lamp is incorporated into the outer part
    of the headlamp assembly. The lamp is located above
    the side lamp/cornering lamp. The turn signal lamp uses
    an 27W/7W S8W wedge bulb. The bulb is fitted into a
    holder which is connected via wires to the main
    connector on the headlamp housing. The holder is fitted
    into an aperture in the headlamp housing and rotated to
    lock into position. The bulb is accessible via a sealed
    cover which is attached to the rear of the headlamp
    housing. The cover is secured in the housing by rotating
    in a clockwise direction until locked. Access to the cover
    requires removal of the headlamp from the front carrier
    assembly and removal of the outer locking plate from
    the headlamp.
    (G421288) Technical Training174
    Lesson 2 – ElectricalExterior Lighting 
    						
    							The turn signal lamps are operated by the left hand
    steering column multifunction switch or by the hazard
    flasher switch. The steering column multifunction switch
    is only active with the ignition switch in the ignition
    position (II), the hazard flasher switch is active at all
    times. When active, the turn signal lamps will flash at
    a frequency cycle of 380ms on and 380ms off.
    If a bulb fails, the remaining turn signal lamps bulbs
    continue to flash at normal speed. The turn signal
    indicators in the instrument cluster will flash at double
    speed to indicate the bulb failure to the driver.
    Side Lamp
    The side lamp is incorporated into the outer part of the
    headlamp assembly and is located below the turn signal
    indicator lamp. The side lamp shares the same housing
    and reflector as the cornering lamp and static bending
    lamp (when fitted).
    The side lamp uses a 5W bayonet fitting bulb which
    locates into a holder which is connected via wires to the
    main connector on the headlamp housing. The holder
    is a push fit into a receptacle in the headlamp housing.
    The bulb is accessible via a removable cover at the rear
    of the headlamp housing. Access to the cover requires
    removal of the headlamp from the front carrier assembly
    and partial removal of the outer locking plate from the
    headlamp.
    The side lamps are operated by selecting side lamps or
    headlamps on the lighting control switch. The side lamps
    are operational at all times and are not dependant on the
    ignition switch position. The side lamps will also be
    illuminated when the lighting control switch is in the
    AUTO position and a lights on signal is received by
    the CJB from the rain/light sensor.
    Cornering Lamp
    NOTE: The cornering lamps are not fitted to NAS
    market vehicles
    The cornering lamps are an optional feature designed
    to illuminate the direction of travel when cornering at
    low speeds. The design of the lens projects a spread of
    light from the vehicle at approximately 45 degrees to
    the vehicle axis.
    The cornering lamp is incorporated into the outer part
    of the headlamp assembly and shares the same housing
    and reflector as the side lamp.
    The cornering lamp uses a 35W Halogen H8 bulb which
    locates in a holder which is connected on the headlamp
    housing. The holder is located in an aperture in the
    headlamp housing and rotated to lock. The bulb is
    accessible via a removable cover at the rear of the
    headlamp housing.
    The cornering lamps are controlled by the left hand
    steering column multifunction switch with the lighting
    control switch in the headlamp position and the ignition
    switch in position II. The cornering lamps are supplied
    power via the ignition switch to ensure that they do not
    function with the headlamp delay feature. The cornering
    lamps are deactivated if the vehicle speed exceeds 25
    mph (40 km/h).
    Only one cornering lamp will illuminate at any one time.
    If the left hand turn signal indicators are selected on,
    the left hand cornering lamp will be illuminated and
    visa versa, providing the vehicle speed and lighting
    control switch positions are correct. Cornering lamps
    are disabled when reverse gear is selected.
    Exterior LightingLesson 2 – Electrical
    175Technical Training (G421288) 
    						
    							ADAPTIVE FRONT LIGHTING SYSTEM (AFS)
    Xenon Headlamp Assembly with AFS
    Locking plate1
    Turn signal lamp2
    Side marker lamp (NAS only)3
    Side lamp4
    Static bending lamp (All except NAS)5
    Xenon low/high beam AFS lamp6
    Halogen high beam lamp7
    High beam lamp access cover8
    Xenon control module9
    Low/high beam lamp access cover10
    Side lamp and static bending lamp access cover
    (hidden)
    11
    (G421288) Technical Training176
    Lesson 2 – ElectricalExterior Lighting 
    						
    							Turn signal lamp access cover (hidden)12
    The AFS is a new system to improve driver visibility
    under differing driving conditions. AFS provides a larger
    visible area which is illuminated when cornering by
    adjusting the position of the beam distribution on the
    road. Horizontal adjustment is made automatically to
    the most suitable orientation for the driving conditions
    using steering angle and information from other vehicle
    sensors.
    AFS is only available with xenon headlamps and also
    includes the dynamic headlamp levelling system
    described in the Headlamp Levelling section of this
    document. The bi-xenon module within the headlamp
    is controlled by actuator motors which rotate the
    projector module on its vertical and horizontal axes to
    adjust the beam output to suit the cornering conditions
    and vehicle inclination. Only the bi-xenon lamp
    projector module swivels, the halogen high beam lamp
    unit remains static.
    The AFS system is controlled by an AFS control module
    which is located at the bottom of the A pillar, behind
    the CJB. The control module controls the vertical and
    horizontal alignment of the xenon projector module and
    the operation of the static bending lamp which is
    requested by the AFS control module but controlled by
    the CJB.
    AFS Concept
    Conventional headlamp beam distribu-
    tion
    A
    AFS swivel headlamp beam distributionB
    AFS Control Module
    The AFS control module is a dual functionality unit
    which also incorporates software to control the dynamic
    headlamp levelling. The AFS control module is
    connected to the high speed CAN bus and receives
    inputs from other vehicle systems on the status of the
    following parameters:
    Exterior LightingLesson 2 – Electrical
    177Technical Training (G421288) 
    						
    							•Steering angle
    •Vehicle speed
    •Headlamp status
    •Engine running
    •Reverse gear selected
    •Automatic lighting on.
    The AFS will only operate when the AFS control
    module receives an engine running signal on the CAN
    bus. When the engine running signal is received and the
    lighting control switch is in the headlamps position, the
    AFS control module performs an initialisation routine.
    The AFS will also function when the lighting control
    switch is in the AUTO position and the AFS control
    module receives a lights on signal from the rain/light
    sensor and an engine running signal.
    The AFS control module then monitors the inputs from
    the other vehicle systems to control the AFS
    functionality according to cornering angles and vehicle
    speed.
    AFS Control Module Connector C2193 Pin Details
    Input/OutputDescriptionPin No.
    InputGround1
    -Not used2 and 3
    Input/OutputCAN High4
    Input/OutputCAN Low5
    OutputRH Headlamp swivel actuator signal6
    OutputRH Headlamp swivel actuator signal7
    -Not used8
    OutputRH Headlamp levelling motor 1 - Positive +9
    InputRH Headlamp levelling motor 1 - Negative -10
    OutputRH Headlamp levelling motor 2 - Positive +11
    InputRH Headlamp levelling motor 2 - Negative -12
    Input12V Ignition feed13
    -Not used14 to 17
    OutputLH Headlamp swivel actuator signal18
    OutputLH Headlamp swivel actuator signal19
    -Not used20
    OutputLH Headlamp levelling motor 1 - Positive +21
    (G421288) Technical Training178
    Lesson 2 – ElectricalExterior Lighting 
    						
    							Input/OutputDescriptionPin No.
    InputLH Headlamp levelling motor 1 - Negative -22
    OutputLH Headlamp levelling motor 2 - Positive +23
    InputLH Headlamp levelling motor 2 - Negative -24
    Operating Modes
    The AFS has three modes of operation:
    •Manoeuvring mode
    •Normal driving mode
    •High speed mode
    •Reverse mode.
    Manoeuvring mode is used for speeds up to 18.6 mph
    (30 km/h). Manoeuvring mode only moves the xenon
    projector module on the side of the vehicle towards the
    direction of turn, e.g. Left hand projector module moves
    to the left during a left hand turn. The opposite projector
    module is fixed and does not move. This mode allows
    the maximum amount of swivel range of the projector
    module to 15 degrees.
    Normal driving mode is used for speeds between 18.6
    and 43.5 mph (30 and 70 km/h). Normal driving mode
    moves both xenon projector modules at a ratio of 3:1,
    e.g during a left hand turn, the left hand projector
    module moves 3 degrees and the right hand projector
    module moves 1 degree. This mode allows the
    maximum amount of swivel range of the projector
    module in the direction of the turn to 12 degrees.
    High speed mode is used for speeds above 43.5 mph
    (70 km/h). High speed mode moves both xenon
    projector modules at a ratio of 3:1, e.g during a left hand
    turn, the left hand projector module moves 3 degrees
    and the right hand projector module moves 1 degree.
    This mode allows the maximum amount of swivel range
    of the projector module in the direction of the turn to
    10 degrees.
    Reverse mode disables the swivel function when reverse
    gear is selected. The AFS projector modules move to
    their central straight ahead position and the static
    bending lamp, if active, will go off. When reverse gear
    is deselected, the AFS projector modules will move to
    a position to match the steering angle and the static
    bending lamp will illuminate if the operating conditions
    are correct (i.e. vehicle speed above 1.86 mph (3 km/h).
    Exterior LightingLesson 2 – Electrical
    179Technical Training (G421288) 
    						
    							Xenon Headlamp Assembly with AFS Construction
    Projector module horizontal pivot1Reflector2
    (G421288) Technical Training180
    Lesson 2 – ElectricalExterior Lighting 
    						
    							Access cover3
    DS2 xenon lamp connector4
    DS2 xenon lamp5
    AFS swivel horizontal actuator6
    Horizontal actuator drive7
    Projector module vertical pivots8
    AFS swivel vertical actuator9
    Xenon control module10
    Control module cover11
    Static bending lamp bulb (All except NAS)12
    Side lamp bulb13
    Turn signal lamp bulb14
    The AFS xenon headlamp construction is similar to the
    non-AFS xenon headlamp assembly. The AFS assembly
    contains an additional carrier frame which provides the
    location for the AFS components. The remaining lamps
    are as described previously for the Xenon headlamp
    assembly. The functionality of the static bending lamp
    on the AFS headlamp is different from the functionality
    of the cornering lamp on the xenon headlamp.
    The carrier frame has a radial bearing at the top and a
    thrust washer at the bottom which provide the horizontal
    pivot points for the xenon projector module. The lamp
    module lower pivot has a splined end which locates in
    the mating splines of the AFS horizontal actuator motor.
    The carrier frame is suspended on two flexible
    mountings at the top which provide for the vertical pivot
    points for the xenon projector module which allow for
    the vertical adjustment of the projector module. The
    bottom of the carrier frame is attached to the AFS
    vertical actuator motor.
    The AFS actuator motors are dc motors which are driven
    by a power output from the AFS control module. The
    AFS control module also provides the earth path for the
    motor.
    The actuators contain a potentiometer which is
    connected via wires with gold plated connector pins to
    the AFS control module. The two wires to each actuator
    provide a feedback signal to the AFS control module to
    give the precise position of the xenon projector module.
    The AFS control module receives front and rear
    suspension height data to provide dynamic headlamp
    levelling adjustment via the vertical actuator motor. The
    AFS control module also receives vehicle speed signals
    from the ABS module to adjust the projector module
    vertically to increase the beam range as the vehicle speed
    increases.
    Initialisation Procedure
    When the AFS control module receives an ignition on
    signal, the control module performs the initialisation
    procedure which ensures that the headlamps are
    correctly aligned on both their vertical and horizontal
    axes.
    The headlamp levelling initialisation takes less than 3
    seconds to complete. The headlamp levelling motors
    are powered from their current position, which can be
    either the upper or lower limit or somewhere in between,
    to their lower position and then back to the 0 degrees
    position.
    The AFS swivel initialisation starts less than 1 second
    after the headlamp levelling initialisation is activated
    to ensure that the headlamps are at or below the 0 degree
    position in the vertical axis, thus preventing glare to
    oncoming vehicles. The AFS swivel initialisation is
    completed in less than 2.5 seconds. The LH and RH
    AFS actuator motors are powered from the 0 degree
    position to their fully inboard position, then to their fully
    outboard position and then back to the 0 degree position.
    Exterior LightingLesson 2 – Electrical
    181Technical Training (G421288) 
    						
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