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Montracon SanuControl Manual

Double deck
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Montracon Trailers 
 
SanuControl Double Deck Manual 
 
December 2015 
 
 

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Summary of Contents for Montracon SanuControl

  • Page 1           Montracon Trailers    SanuControl Double Deck Manual    December 2015     ...

  • Page 2: Table Of Contents

      Introduction    This document has been prepared to outline the basic operation of the  double deck system that controls the moving deck system  This document has had the hydraulic equipment added as this  completes the control system.      Contents 1. Introduction 2. Power Supply 3. Safety Warning Devices 4. On Board Switches 5. Specifics of Deck Operation 6. Fuses and protection devices 7. General Arrangement of the System 8. Motor Relay Logic 9.

  • Page 3: Introduction

    1. Introduction The deck is moved by an electro hydraulic power pack and is controlled by a PLC. These systems are both chassis mounted. The electric controls are contained in a plastic toolbox on the N/S of the trailer just to the rear of the landing legs. The hydraulic power pack is situated next to the electrical enclosure in a stainless steel enclosure.
  • Page 4 2. Power The system is 24v DC system and has a two input plugs, an Anderson socket mounted on the front bulkhead and another Anderson connector fitted under the body on the RNS.
  • Page 6 All Anderson connectors have fuses fitted, these are 175 Amp Mega fuses. These are fitted in the neck of the trailer and under the chassis at the rear as per the following photographs.
  • Page 7 Transformers (if used) must smoothed as AC current will damage the electronic systems on board and may cause false triggering of sensors An on board DC-DC converter can be specified to smooth the input voltage if required. If any welding is carried out please disconnect the power connectors to the PLC as failure to do so may damage the unit.

  • Page 8: Safety Warning Devices

    3. Safety Warning Devices There are 3 different electrical safety warning devices on the trailer they are as follows:- Warning Bleeper This device is fitted at the rear of the trailer The warning will sound whenever the deck is moving The alarm is wired onto the main feed from the PLC box, a joint is found at the rear.
  • Page 9 Amber Flashing Strobe This device is fitted to the top of the rear RH post The unit will strobe whenever the deck is moving The strobe is fitted on a 2 core extension cable, this comes out of the rear connector and is connected as follows:- Brown Live...
  • Page 10 Safe Access LED This light is fitted in the rear operational panel and illuminates when the deck is in the roof and all the flags (locks) are in the safe condition (under deck). The wiring is as follows:- Brown Live Pin OUT06 Bank F, Pin 5 White...

  • Page 11: On Board Switches

    4. On Board Switches There are 2 different switches used to operate the electrical system of the double deck. They give outputs the PLC to identify different conditions a. Proximity Switches i) Lock position proximity switches These units are mounted in the locks on each pillar and in the roof, these identify the conditions of the locks and the deck.
  • Page 12 The switches have covers fitted for protection:-...
  • Page 13 When the lock is on the proximity switch is made the LED on the barrel of the proximity switch illuminates.
  • Page 14 All the proximity Switches are powered directly to the PLC. They are wired as follows:- 2 x Brown from FOS & FNS Proxy Bank A, Switch Live Pin 8 Bank A, Black from FNS Proxy Switch Pin 6 Bank A, Black from FOS Proxy Switch Pin 7 Bank A,...
  • Page 15 i) Lock position proximity switches This is the same type of a proximity switch as used for the lock position switch. The switch is located at the top of the front UK N/S pillar and it is set to give an output when the deck is above the lock flags.
  • Page 16 b. Operational Buttons The operational buttons are situated inside the UK N/S on the rear pillar, there are 2 buttons (Up, Down)

  • Page 17: Specifics Of Deck Operation

    5. Specifics of deck operation To raise the deck ● Ensure safe to proceed (from operational manual) and you are trained / qualified to operate. ● Press the Raise (Red) button. ● Once pressed the buzzer and flasher will activate and if the plc detects the system is below the maximum stroke the motor will start and the deck will raise.
  • Page 18 ATTENTION ● Please ensure the deck is regularly checked for signs of wear ● Ensure there are no obstructions that would prevent / hinder the decks operation ● Do not operate as a passenger lift. ● When lowering the deck please pay attention there are no crushing hazards ●...

  • Page 19: Fuses And Protection Devices

    6. Fuses and Protection Devices The systems are all protected by various devices these are positioned as follows:- a. Front Input fuses – Unders chassis at neck FNS Beam b. Rear Input Fuse - Under chassis at rear RNS Beam These units are fitted on the front bulkhead and are 175 Amp Mega Fuses To replace:- Ensure the power has been removed from the vehicle (all possible sources)
  • Page 20 PLC Circuit Breakers The main PLC (control system) is protected by a set of circuit breakers. These are located on the side of the PLC control box inside the small black plastic enclosure. There are 3 breakers:- 1 protect the PLC 1 protects the inputs 1 protects the outputs All circuit breakers have dust caps fitted and are simply reset by pushing down the...
  • Page 21 c. Load Dump module This device is mounted inside the PLC control box It protects the PLC from external voltage spikes that may be generated by external switches and relays that induce small spikes into the supply voltage. Note: This is not a replacement for appropriate voltage regulation. Note: Constant overvoltage will damage the load dump module Load Dump Module before Fitment...

  • Page 22: General Arrangement Of The System

    7. General Arrangement of the System...

  • Page 23: Motor Relay Logic

    8. Motor Relay Logic...

  • Page 24: Electrical Connections In The Hydraulic Power Pack

    9. Electrical Connections in the Hydraulic Power Pack There is a interconnecting cable from the PLC enclosure to the hydraulic power pack enclosure. The photos show the cables inside the enclosure the functions and where they are wired:- A: Main Power to PLC This comes from the same terminal as the input power to the Motor Red to Load Dump Module (+ve) Black to Load Dump Module (-ve)
  • Page 25 Main +ve taken from the +ve on the motor solenoid...
  • Page 26 B: Motor Solenoid 2 x 6.3mm spades on Motor solenoid marked + and – 2 Core cable Live Pin OUT2 Bank E, Pin 5 Black Earth Pin GND Bank E, Pin 6 C: Lock Solenoid Moulded 2P+E Connector LED Illuminates when device is operated 3 Core cable Green / Yellow Not Used...
  • Page 27 D: Ram Solenoid This is a direct feed from the PLC enclosure Earth Pin GND Bank E, Pin 5 Black Live to coil from PLC Pin OUT03 Bank E, Pin 6...
  • Page 28 PLC Input / Output configuration                     VBBs VBBs VBBs     UP Button RNS Proxy     Down Button ROS Proxy             FNS Proxy Deck in roof Proxy IN10  ...
  • Page 29 10. Hydraulic system The following shows the hydraulic system layout:-...
  • Page 30 11. Maintenance / Fault finding information Plug in Power – No power Check input power (interior lights not on)   Check main input fuse   Check circuit breakers on PLC box   Deck will not move Check flag positions   Check the proxy switch setting (gap)  ...
  • Page 31 Emergency operational buttons On the lid of the plc enclosure there are 4 emergency use buttons These should only be used in case of maintenance or emergency operation. The buttons operate the following:- Locks on Locks off Deck up Deck Down These buttons should only be used by trained staff under supervised conditions as you do not have a sight of the inside of the deck while operating the buttons.
  • Page 32 12. (Re)Programming and program version The main plc is fitted with a programming cable that is accessible from just inside the main outer enclosure. this should be an IFM interface cable terminated in a 2 pin superseal (note: remember the terminal resistor) When looking at the program you must have the same program on the PC trying to log in.