• A whole array of benefits from safety to economy

  • 22 items outlining the merits of the model series

  • Innovative coach concept for environment-minded operators

Active and passive safety

The ComfortClass 500 demonstrates a foresighted approach. Active Brake Assist (BAS PLUS), a further development of the existing system, responds to stationary obstacles - a first in the coach sector which markedly reduces risks on the road. This system enables precarious situations to be avoided or the consequences of accidents to be reduced in severity. An acoustic warning by BAS PLUS enables the driver to defuse a critical situation on their own initiative. If the driver fails to react appropriate, BAS PLUS will automatically initiate emergency braking to avoid collisions with vehicles ahead and partial braking in response to stationary objects. When there is no vehicle ahead, the proximity-controlled cruise control operates like a conventional cruise control and shuts down automatically at a speed of under 15 km/h. On the ComfortClass 500, the proximity-controlled cruise control is also available with the additional Stop Assist system. This function remains active at lower speeds and in stop-and-go traffic it is able to bring the coach from a standing start into the desired proximity-controlled mode.

Setra has adopted the optionally available Attention Assist safety system from the passenger car segment, adapting it for the ComfortClass 500. This assistant continuously calls up information on the state of the driver by reference to specific criteria, such as steering movements and braking activities, activation of the direction indicator, vehicle speed and time of day. By correlating the obtained data and the adapted driver profile, Attention Assist is able to assess the driver's responsiveness or tiredness. When a defined model value is exceeded, an electronic signal initiations vibration of the driver's seat - without the passengers noticing anything.

The camera of the Lane Assistant and rain/light sensor are integrated in a box and installed at the bottom of the windscreen. The newly designed headlamp is equipped with a standard-fit LED daytime running lamp (optional with the MD) and an H7 low beam lamp. The reflectors provide for even more powerful illumination of the area in front of the vehicle, thus guaranteeing further enhanced safety, particularly during night-time travel.

The Front Collision Guard (FCG), a passive safety system to protect the driver and the tour guide, has undergone further development in the ComfortClass 500 and is integrated in the framework. The second-generation passive safety structure, which meets the requirements of the pendulum impact test in accordance with ECE-R29, for example, comprises a front underride guard, an integrated absorber structure as a crash element and a module which pushes the entire cockpit to the rear in the event of a collision.

Ambient lighting

Passengers are always able to find their way around the ComfortClass 500 with ease, even in the dark. In addition to the main lighting on the service sets, ambient lighting conjures up a unique feeling of space. These optionally available LED light strips illuminate the entire length of the passenger compartment in the form of two-dimensional, indirect, stepless lighting leading right up to the high front window.

Brakes

For the ComfortClass 500 the engineers have developed a brake system whose electronics are integrated into the vehicle's innovative electronics architecture in conjunction with an advanced version of the conventional, pneumatically/ mechanically controlled compressed-air system.

Advantages here are that the new electronically controlled compressed-air delivery system reduces fuel consumption and the maintenance intervals are extended. An intelligent control system uses the vehicle's overrun phases to generate pressure and enables regeneration of the air drier cartridge.

Cockpit

Swift and convenient access to the controls, an optimised seat position, an ergonomically improved, suspended pedal system and improved overall visibility make the driver's work easier.

The centrepiece of the newly designed cockpit is the high-resolution colour display with the four round pointer instruments which indicate the vehicle speed, the engine speed and the current fuel and AdBlue levels. An anti-glare, scratchproof  glass screen over the new display instrument exudes elegance and exclusivity.

The positioning of the buttons and the grouping of the individual switch elements on the cockpit dashboard have been reconfigured. The result is a cockpit boasting an easy-care surface, a clear, attractive appearance and intuitive handling.

Swift and smart control is guaranteed by the "Stacks&Cards" system, which enables efficient navigation between individual menu groups (stacks) via steering wheel buttons - such as route information or current vehicle data - together with submenus - the cards. As in a passenger car, the driver can call up various items of information about the vehicle on the central display while on the move and conveniently alter individual settings.

The development engineers have also considered the numerous items of equipment used by the driver and created space for additional user-oriented stowage facilities, e.g. for parking tickets, document folders or gloves. The stowage compartment in the centre console offers additional space. The fold-out cover of the refrigerator can be used as a surface for a laptop. The 67-litre refrigerator in the cockpit features circulating cooling of all the interior walls for swift and uniform lowering of the interior temperatures and offers the tour guide good access.

Coach Multimedia System

The standard-fit Coach Multimedia System (CMS) offers entertainment, information and functionality to the highest standard at the HD. It is based on two components - the integrated Bosch Coach Communications Center (CCC) and the Coach System Extension (CSX). The CSX is a coach-specific control unit which features as standard and controls the spatial separation of functions and audio output - for the purposes of volume control, for example - between the driver's area and the passenger compartment by means of control buttons. The radio designed in line with the new operating concept features a clearly laid-out display. A DVD drive is incorporated and permits playback of videos as well as mp3 formats.

The driver has a central unit at their disposal which features a clear control structure with arrow buttons, a 10-key control panel for telephony and navigation, a Bluetooth connection, an audio jack and a USB connection.

As standard the HD models of the ComfortClass 500 are also equipped with a commercial-vehicle-specific navigation system which enables manual entry of the vehicle's height, width and length and suggests appropriate routes based on this data. The ultimate in convenience. Unpleasant surprises en route which entail time-consuming detours are a thing of the past with the new system.

The steering column in the cockpit of the ComfortClass 500 is raised slightly by electro-pneumatic means and the driver's workplace is easily adjustable by 50 mm to 910 mm affords the driver a commanding view of the traffic situation.

Design

Forward-looking Setra is attractive from the rear, too. With the ComfortClass 500 the brand is presenting a further development of the design that points the way to the future on the basis of the brand values of economy, comfort and safety.

The main focus of attention is on the curved aluminium strip with the decorative element at the B-pillar. A gently rising and falling linear movement runs around the entire vehicle, lending the front area a friendly face which incorporates all the requirements of aerodynamics with bold lines and smooth surfaces. It is immediately apparent that this coach is a Setra.

The ComfortClass 500 is characterised by steep sides, a long flue on the roof at the front and the markedly rounder windscreen extending far down to the front logo trim with the three-dimensional Setra lettering.

Viewed from the side, the dynamically rising shoulderline is immediately noticeable, taking up the three-dimensional brand emblem with the brilliant silver Setra lettering and providing a base which supports the striking C-pillar. The ComfortClass 500 also acquires a special appearance with the so-called aero rear end, which improves the air-flow break-away, thereby reducing soiling problems, among other benefits. This is not the only feature contributing to a strong finish at the rear. As the installation of the Euro VI powertrain necessitated a new engine compartment ventilation system, the designers have deliberately placed an opening on the right-hand side only, thereby providing the tailgate with an asymmetric form and visualising the new engine compartment layout.

Entrance

The gentle lines of the exterior are continued in the cockpit area and the interior of the ComfortClass 500. The individual appointments combine to form a harmonious blend of comfort and class, form and colour. In the cockpit the entrance area of the HD vehicles is finished in "greige" - a colour composed of grey and beige which also lends a warm character to the entire passenger compartment.

It quickly becomes clear that the designers have adopted a holistic approach to creating space in the ComfortClass 500. This is evident in the three-step entrance area at the front, which has been widened noticeably. The tour guide's seat has been moved outwards by a few centimetres - freeing up even more space for the crossover into the passenger compartment.

Elegantly curved handrails guide the passengers safely and comfortably onto the coach. The tour operator's seat also offers even greater comfort with a height-adjustable 3-point seat belt. Under the seat, on the side wall of the entrance, the development engineers have found space for a new design element presenting the Setra lettering in a brilliant and classy chrome look.

Electronic keys

The Setra offers new options on board the ComfortClass 500 right from the off. Instead of a mechanical ignition lock, drivers can use an electronic lock. The mechanical steering wheel lock has had its day. This electronic drive authorisation system enhances anti-theft protection substantially, as the immobiliser is connected up to the on-board electronics in the same manner as in a passenger car. Depending on the selected scope of vehicle equipment, the new key generation with integrated Setra brand emblem comes in two variants. The coach operator can choose between the Low key with basic start and stop function and the Standard key. The latter ignition key incorporates two additional remote control buttons for vehicles with central locking.

Euro VI

The ComfortClass 500 is headed for an environment-friendly and economical future with the high-performance "Blue Efficiency Power" engine generation and the appurtenant emission control system from Mercedes-Benz.

With no compromises and no additional fuel consumption. The service life of these engines, which can be used in low-emission zones without requiring special approval, stands at a princely 1.2 million kilometres.

Transmission

The ComfortClass 500 employs the optional GO 250 8 PowerShift eight-speed manual transmission. This fully automated unit is based on the tried and tested GO 240 8 PowerShift transmission. Drivers benefit from the familiar progressive stepping and swift and comfortable gearshifts. The transmission ratios range as usual from 6.75 in first gear to 0.63 in top gear. The transmission is approved for maximum engine torque of 2500 Nm. A separate heat exchanger maintains the oil temperature at a constant operating temperature of approximately 80 degrees Celsius. The oil-change intervals for the transmission have been increased by 60,000 kilometres to 360,000 kilometres.

Intelligent electronics network

The hidden workings of the ComfortClass 500 are also of a very high calibre. The overall architecture of the electronics system has been completely revised, re-configuring the on-board system along more efficient lines. This ensures the necessary performance capabilities for the increased requirements pertaining to the vehicle's individual components and enables extended diagnosis options and increased maintenance-friendliness. The majority of electronics components and all fuses of relevance to the driver are readily accessible at two central installation locations on the right-hand side of the vehicle, facing away from the road. This positioning provides added safety for the driver in the event of a breakdown.

The front compartment with the main switch panel is installed in the stowage compartment above the front axle. The rear compartment with the auxiliary switch panel is located on the right side above the drive axle and can be pulled outwards.

Air conditioning concept

Wherever passengers sit in the comfortable touring coaches, the temperature is always pleasant, evenly distributed and controlled fully automatically. This has been made possible by the introduction of a front and rear floor mixing circuit for the heating, separation of the water circuits and zone-specific sensoring and blower control. Coach companies benefit from the new water circuit system, whose piping is produced in lightweight aluminium for the ComfortClass 500.

Steering characteristics

The ComfortClass 500 stands for substantially enhanced ride comfort for your passengers. This is ensured by shock absorber connections employing soft bearings, which comfortably absorb short, hard jolts. The transverse links on the front axle are provided with comfort-optimised elastomer bearings. A new design for the stabiliser bar reduces stiffness at the front axle and improves the coach's compression performance. The three-axle ComfortClass 500 coaches feature a more direct steering ratio, assuring the driver of even more precise steering characteristics which require less corrective movements of the steering wheel.

Multifunction steering wheel

Drivers in the ComfortClass 500 have a firm grip on proceedings. In the interests of a clear, uncluttered workplace, the multifunction steering wheel avoids the need for switches on the dashboard. This clearly enhances ergonomics and functionality in the cockpit. The buttons on the steering wheel provide the driver with a simple means of using the Stacks&Cards system to receive telephone calls, to operate the cruise control, to select programmes and control the volume of the radio and to operate all driver assistance systems, for example - without having to remove their hands from the steering wheel.

Level control system

Boarding the ComfortClass 500 is easy. To further facilitate boarding, especially for older passengers, the standard kneeling function can be applied to lower the entire right-hand side of the vehicle by up to 40 mm. In motorway use, the extremely sensitive electronic level control system on board the ComfortClass 500 comes into its own. This new generation features a wider sensor track at the rear axle and an additional level sensor at the front axle. In all, four sensors provide for even more precise level control on each individual wheel.This also has economic benefits. Electronic lowering of the vehicle's body by 20 mm from a speed of 95 km/h reduces aerodynamic drag by up to 20 percent - leading to fuel savings of around 0.7 percent at 100 km/h while maintaining smooth running characteristics.

Space concept

The ComfortClass 500 offers ample space. 2100 mm of headroom is available on board. This also enables the touring coach to be provided with a level floor and luxurious 2+1 seating. There is no danger of taller passengers in window seats banging their heads on the new touring coaches, as the contours of the air duct open up towards the side windows. This means more light inside the vehicle and a better view out of the side windows for passengers sitting on the aisle side.

Tyre pressure monitoring system

The ComfortClass 500 keeps tabs on tyre pressure as it cruises along. The optional tyre pressure monitoring system promises greater comfort, clarity and safety, showing the current tyre pressures on the cockpit display when requested by the driver.

The new position for the fuel tank in front of the front axle on the three-axle ComfortClass 500 coaches necessitated an increased load-bearing capacity for these vehicles. Consequently, tyres with a load rating of 7.5 t and reduced rolling resistance now feature as standard - resulting in lower fuel consumption.

Service sets

The ComfortClass 500 sounds great on board. The loudspeakers are installed on a track of their own in the air duct and integrated - separately from the service sets - in the air duct at the level of the window pillar. This provides for a soft transition between pillar and ceiling, guaranteeing a uniform sound throughout the entire passenger compartment.

The reading lamps are housed behind a closed panel and are aligned exactly with the respective passenger seats. The standard-fit LED reading lamps and air vents on the "service track" are modular in design. Optionally, the coach operator can order the service sets at a spacing of 450 mm, irrespective of the seat spacing. This enables simple and convenient conversion of the ComfortClass 500 from 4-star to 3-star seating in a "second life" for the vehicle - without requiring any modification measures on the ceiling.

Robustness

More stability, more safety, less weight. Aerodynamics engineers, designers and bodyshell construction engineers contributed their technical expertise at an early stage in the development of the ComfortClass 500 to ensure dynamically elegant lines and maximum robustness. The hybrid lightweight construction featuring a mix of steels, cast iron and forged parts and the body structure incorporates a whole range of weight-reducing measures to create an all-round economical and safe touring coach concept.

The 200 kg lighter bodyshell, designed using state-of-the-art 3D body engineering computer simulations, is based on the proven structure employing annular frame members, but is now markedly more rigid. This avoids unwanted vehicle vibrations and provides added safety for the passenger compartment. The coach is substantially more resistant to rolling over, despite the lighter bodyshell. The specific use of high-strength steels guarantees effective passenger protection, such that all ComfortClass 500 models already comply in full with the more stringent European regulation ECE R66/01 which is due to enter into force in 2017.

Fuel consumption

The aerodynamic lines provide the ComfortClass 500 with the necessary basis for attractively low fuel consumption. Aerodynamic drag has been reduced by 20 percent. This, together with other individual measures, results in an unprecedented Cd value of 0.33, which is without parallel in the sector.

The development engineers have provided the front section of the ComfortClass 500 with enlarged radii for the roof flue and redesigned the A-pillar such that the loss of air flow at the frontal area is substantially reduced with the curved windscreen and the air flow clings to the vehicle's body in this area. The previously rectangular profile of the mirror arm now also features aerodynamic lines on the new vehicles. The modified driver's window and the aerodynamic modifications to the doors and window reduce wind noise and intrinsic soiling. The aerodynamics engineers and designers have also contributed pioneering modifications in the rear area. The tapered roof and side area cause the air flow to hug the vehicle for as long as possible. The rear edge provides for defined flow separation behind the vehicle.

In a spectacular Record Run, the Setra ComfortClass 500 has demonstrated the utmost energy efficiency, with fuel consumption 8.2 percent lower than the thrifty reference model.

Consumer management

The Setra ComfortClass 500 is equipped with a management facility for the on-board electric system, employing an intelligent battery sensor. This sensor continuously measures the temperature, current and voltage of the batteries. These measurements enable an ideal battery charging voltage to be set on the generators at all times. In the event of a drained battery, when the vehicle is stationary the engine's idling speed is automatically raised in order to provide charging energy, thereby increasing the output of the three 150A long-life generators. In the event of a further loss of energy, the intelligent consumer management system will automatically reduce or shut down individual consumers on the vehicle, thereby increasing the service life of the batteries.

Maintenance intervals

The Setra ComfortClass 500 is kind on the environment - the new-generation BlueEfficiency Power engines not only boast excellent green credentials, they also enjoy longer service lives. The maintenance intervals for the ComfortClass 500 have also increased, from 90,000 km to as much as 120,000 km.

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