CONTROLLER DIAGNOSTIC GUIDE

Transcription

1 Proprietary tice: This document contains proprietary information which not to be reproduced, transferred, to other documents, disclosed to others, used for manufacturing or any other purpose without the prior written permission of The Braun Corporation. 9

2 Control Assembly Identification The control boards are marked with a white manufacturer s sticker which is about ¼ x.0 that carries information as to the assembly number, assembly revision, serial number and date code. The arrangement of information is depicted in the example below. Assembly Number Assembly Revision xxxxxx-xxx Rev. x /0 Serial Number Date Code Figure Serial Number and Date Code Tag OPERATION This interface module is designed to operate an RA00 Ramp System. This is done by interfacing to the three external connectors J to supply power, J for Ramp control, and J which is the vehicle connector for operator control and display. Refer to the figure below to locate the following components. Fuse F - Found on the board next to the power connector, F is the master fuse for the controller. This fuse is sized at amps. Fuse F This fuse is found next to the display connector in the lower left hand corner of the board. This fuse is sized at 7. amps and is used to limit the current for the alarm and indicator relays. Cycle Counter This 6-digit counter is in the upper right hand corner of the board and is used to keep a running tally of the ramp cycles. This counter has onboard non-volatile memory and is non-resettable. The counter will increment with the completion of each full-out and full-in cycle. Diagnostic Display This is a -/ digit LCD which displays the status of the controller during operation. Various codes will be displayed depending on the ramp s current operational status. The codes are defined as follows: of

3 CODE NUMBER RA00 FUNCTION 00 A power up reset has occurred 0 Ramp is fully retracted 0 Ramp is extending due to an active EXTEND. 0 Ramp is fully deployed 0 Ramp is retracting due to an active RETRACT. 0 Ramp is stopped between extents 06 Ramp is extending due to an active One-Touch. 07 Ramp is retracting due to an active One-Touch. 0 Manual Release Detected t operating due to Parking Brake. t operating due to Pressure Pad Retract movement stopped Obstruction detected Extend movement stopped Obstruction detected Switch Fault Full-in and Full-out both active 6 t operating due to Ramp Enable Indicator LEDs There are 6 LEDs in the lower left hand corner of the control board which locally display the current status of the indicator control. These LEDs are powered from an on-board + volt supply. The indicator circuitry is designed to allow the user to supply the reference. This will determine whether the indicator relay es power or ground. Since the on-board LEDs are powered from volts they will light up green if volts is used as the reference. Conversely, the indicators will light red if ground is supplied as the reference. Calibration System The calibration system is used to adjust the obstruction sensitivity of the platform by allowing a technician to replace the hard coded obstruction preset for extension and retraction movements The calibrate is a toggle function which means that pressing the is used to both enter and exit the calibration mode. A controller as supplied from the factory operates from its software default values for obstruction detection. Care must be taken when making these adjustments since entering the calibration mode will change both extend and retract presets to the values associated with the adjustment pots R0 and R. Upon entering calibration mode the initial position of these pots may effect significant changes in the platform so cycle testing is required for each change. of

4 As is discussed in the adjustment procedure, the digital value can be read through the serial diagnostic port if a computer is available. This greatly helps in making these adjustments. At any time the controller can be returned to the factory setting by using the Calibration reset button. Use the calibration button to enter calibration mode but to exit calibration mode use the Cal Reset button. This will cause the processor to ignore any changes due to R0 and R and return to the internal default values.. Figure Component Location Diagram A clear top is used on the module housing to allow visual access to the two displays built onto the control board. of

5 (Diagnostic) J (Power) J (Vehicle) J (Ramp) Figure Module Connector Location The top must be removed to access the calibrate buttons and the adjustment pots. Extend Adj. Pot Retract Adj. Pot Indicator LEDs Calibrate Reset Switch Calibrate LED Calibrate Switch Figure Calibration Component Locations of

6 CONNECTOR DEFINITIONS J Power Connector PIN PIN Figure Power Connector Pin # Description Vehicle System Power Vehicle Ground Table Power Connector Pinout J Ramp Connector This connector is actually three connectors in a combining shell including J which is a 6-pin signal connector, J which is a single pin power blade, and J which is also a single pin power blade. The signals on these pins are as defined below. PIN J PIN J J PIN PIN 6 J RAMP CONNECTOR Figure 6 Ramp Connector 6 of

7 J Ramp Signals CONTROLLER DIAGNOSTIC GUIDE Pin # Description Full Out limit Manual Release Limit Switch Switch Reference voltage Alarm Indicator Pressure Pad Switch 6 Full In limit Table Ramp Connector Pinout J Retract Motor This pin will be grounded in its inactive state. When the ramp motor is powered to retract the ramp, this pin will be ed to the input voltage. In this case J will supply the return path for the motor. J Extend Motor This pin will be grounded in its inactive state. When the ramp motor is powered to extend the ramp, this pin will be ed to the input voltage. In this case J will supply the return path for the motor. J Vehicle Connector This connector contains all signal lines required to interface with a vehicle with the exception of power. 7 Figure 7 Vehicle Connector 7 of

8 FAULT TREES Pin # Description Move Out Indicator Alarm Indicator EXTEND Switch ONE TOUCH Switch Indicator Power 6 Manual Release Indicator 7 Ramp Enable Switch Common 9 Full In Indicator 0 RETRACT Switch Parking Brake Negative Move In Indicator Full Out Indicator Parking Brake Positive Table Vehicle Connector Pinout The following fault trees are designed to allow diagnosis of ramp problems with only a volt/ohm meter and the onboard LED indicators. The first tree labeled Operational Check can be used to determine the area the fault may be found. Subsequent fault trees will be used to allow the faults to be specifically isolated and repaired. Some tests require the use of the Extend, Retract, or One-Touch buttons on the control es. Since ramp installations will use either Extend and Retract es or a single One-Touch motion, tests that require use of control es need to be interpreted according to the configuration being tested. The difference between the -00 and -00 versions of the RA00 controller have to do with the internal configuration of the diagnostic LEDs. Therefore the following diagnostic processes are segregated into three groups which are those which only address the -00 module, those which only address the -00 module, and those which apply to both modules. When following these diagnostic trees always be sure you are using the fault tree that addresses the module version of your particular ramp. PROCESSES for Modules ONLY The following diagnostic processes apply only to the module. The -00 unit has the diagnostic LEDs (D, D, D-D6 & D9) applied to the outputs of the indicator relays which allows them to be used to diagnose problems all the way out to and including the dash indicators in the vehicle. Since this configuration requires a trickle current through the dash indicator even when the indicator is off, it prohibits the of

9 use of LED type dash indicators. Only incandescent indicators can be used. This continuous indicator current is only present when the module is powered and not in its sleep mode. D9 ALARM D6 MOVE OUT D FULL OUT D FULL IN D MANUAL RELEASE D MOVE IN Figure Ramp Fully Stowed (-00) D9 ALARM D6 MOVE OUT D FULL OUT D FULL IN D MANUAL RELEASE D MOVE IN Figure 9 Ramp Extending (-00) D9 ALARM D6 MOVE OUT D FULL OUT D FULL IN D MANUAL RELEASE D MOVE IN Figure 0 Ramp Fully Extended (-00) D9 ALARM D6 MOVE OUT D FULL OUT D FULL IN D MANUAL RELEASE D MOVE IN Figure Ramp Retracting (-00) 9 of

10 Fully stow the ramp and cycle power to the controller OPERATIONAL CHECK (-00) Be sure the Manual Release is fully down and locked Do the LEDs match Figure? Perform Extend Test Verify the Parking Brake is set Verify the Ramp Enable interlock is active Press and hold the RETRACT Examine the LEDs D, D, D, D, D6, & D9 Does the ramp move into the cassette? Perform Retract Test 6 Do the LEDs match Figure? Perform Initialization Test 6 Do the LEDs match Figure? Perform Retract Test 7 7 Press and hold the EXTEND Continue to hold until ramp stops Does the ramp start out of the cassette? Perform Extend Test Does the ramp continue until fully retracted? Perform calibration adjustment 9 Do the LEDs match Figure? Perform Extend Test 9 Does the motor stop when the ramp stops? Perform Limit Switch Test 0 Continue to hold until ramp stops 0 Press and release the ONETOUCH Does the ramp continue until fully extended? Perform calibration adjustment Does the ramp start extending and continue until fully extended? Perform Harness Test Does the motor stop when the ramp stops? Perform Limit Switch Test Test Passed! Operational Check (-00) 0 of

11 Step Action Description Result 6 Fully stow the ramp and cycle power to the controller. Be sure the Manual Release is fully down and locked. Verify the Parking Brake Interlock is active Verify the Ramp Enable Interlock is active Compare the LEDs D, D, D, D, D6 & D9 to Figure Do the LEDs match Figure? (Assume J pin is volts) Resetting the system Setting external input to known value (not active) Setting external input to known value (active) Setting external input to known value (active) Figure shows the indicator conditions for a ramp that is fully retracted. If indicator power is volts LEDs will be green for active es and will be red for inactive es. Indicators other than D show Green or some are not lit. (FAULT) D is only green LED Perform Initialization Test 7 Press the EXTEND Switch Testing extend capability Does the ramp move out of the Moving cassette? t Moving (FAULT) Perform Extend Test 9 Do the LEDs match Figure 9? YES (Assume J pin is volts) NO Perform Extend Test 0 Continue to hold EXTEND until ramp stops. Does ramp continue until fully extended? Does the motor stop when the ramp stops Ramp should auto stop when fully extended. Obstruction detection can cause premature halt. Full_Out Limit tells the controller to stop If NO perform Calibration Adjustment If NO perform Limit Switch Test Do the LEDs match Figure 0? YES (Assume J pin is volts) NO Perform Extend Test Press the RETRACT Switch Testing retract capability Does the ramp move into the Moving If YES cassette? t Moving (FAULT) If NO Perform Retract Test 6 Do the LEDs match Figure? YES (Assume J pin is volts) NO Perform Retract Test 7 Continue to hold RETRACT until ramp stops. Does ramp continue until fully retracted? Ramp should auto stop when fully retracted. Obstruction detection can cause premature halt. If NO perform Calibration Adjustment of

12 9 Does the motor stop when the ramp stops Full_In Limit tells the controller to stop If NO perform Limit Switch Test 0 Press and release the ONETOUCH This function does not require the to be held active. Does the ramp start extending and continue until fully extended? Ramp should auto stop when fully extended. If NO Perform Harness test Press and release the ONETOUCH The Ramp should begin to retract Continue Apply lbs. pressure ( kg) on the pressure mat. This is the minimum weight required to activate the pressure Does the ramp stop once the pressure is applied? The pressure tells the controller to stop regardless of operational mode If YES Test Passes If NO perform Pressure Switch Test Table Operational Check of

13 Stow the ramp and cycle power INITIALIZATION TEST (-00) Examine LEDs D,,,, 6 & 9 A Are all LEDs lit? 6 Are any LEDs on? 6 FIGURE Do the LEDs match figure? 7 For all LEDs not lit check their corresponding dash lamp. 7 Measure voltage on J pin Is Vdc present? Check vehicle wiring from J to dash lamps and es 9 Replace Open ckt Lamps Are all LEDs lit now? 0 Do any lamps show open ckt. Are all LEDs lit? Verify dash lamps & vehicle wiring. 9 0 Are any LEDs on? Reseat the J7 connector inside the control module. Check voltage on J pins & 6 7 Is Vdc present? Replace F Are any LEDs on now? A Problem is with Vehicle fuses or wiring Do the LEDs match figure? Are any LEDs on? Test Passed! Are Problem LEDs D, D, or D? NO Replace Controller Proceed to Limit Switch Test of

14 INITIALIZATION TEST (-00) Step Action Description Result Fully stow the ramp and cycle power to the controller. Be sure the Manual Release is fully down and locked. (not active) Resetting the system Figure shows the indicator conditions for a ramp that is fully retracted. If indicator Compare the LEDs D, D, D, power is volts LEDs will be D, D6 & D9 to Figure green for active es and will be red for inactive es. Are all six LEDs lit? (either red or green) Do the LEDs match Figure? (Assume J pin is volts) All indicators must turn on. If NO go to step 6. All on indicates basic functionality Indicators other than D show active D is only green LED If NO go to step Initialization Test Passed! 6 Are any LEDs ON? Some still unlit If NO go to step 6 All are either red or green 7 For each unlit LED, check the associated dash lamp for infinite ohms. (open) Do any lamps show an open circuit? 9 Replace failed lamps 0 Are all LEDs lit? Check vehicle wiring from controller J to dash lamps and es. Are all LEDs lit now? LEDs use dash lamps to provide ground path. Lamp need not be turned on to cause problem. All Dash lamps are OK. If NO go to step 0 Open is the failure mode for an incandescent lamp. Replace all lamps that correspond to unlit LEDs All indicators must be lit either red or green Means all dash lamps are OK If YES go to step Look for poorly seated connectors & cut wires Bulbs and harness are good but some LEDs are still unlit All are working now continue with test Do the LEDs match Figure? Assumes J pin is volts Are the problem LEDs D, D or D? These LEDs are affected by ramp limit es If NO go to step If NO go to step If NO go to step of

15 Perform Limit Switch test Refer to Figure for limit locations Go to step 9 6 Using a voltmeter measure the voltage on J pin This is a volt power output from the controller which will show whether the on-board regulator is operating correctly 7 Is V ±0. volts DC present? Verify wiring from dash lamps to controller J is correct. 9 Are any LEDs ON now? 0 Reseat the J7 connector inside the controller module Are any LEDs ON now? Replace Controller Restart test Check voltage on J pins & Is V dc present? 6 Replace F 7 Are any LEDs ON now? power to controller LEDs cannot operate without v power. LED supply is good Look for poorly seated connectors & cut wires Problem still effects all the indicators with at least one working the problem is improving. J7 is the board's indicator connector LED operation is dependant on load presented by dash lamps. LED problem must reside in controller Rerun test after correcting detected problems This checks the main power supplied to controller from the vehicle thing works without vehicle power. Problem must be internal to the controller With good supply power the only interruption can be F Problem must be a component failure in the controller We now have some LEDs working continue with test. Problem must reside in vehicle wiring or fusing If NO go to step If YES go to step 7 If YES go to step 7 Go to step Go to step If NO go to step If NO go to step If YES go to step Go to step Table INITIALIZATION TEST (-00) of

16 Refer to figure for locations. LIMIT SWITCH TEST (-00) Unlock and pull the manual release handle Does D change color With ramp fully retracted does D show green? With ramp fully extended does D show green? Manually activate the Manual Release limit Manually activate the Full In limit Manually activate the Full Out limit Test Passed! Adjust Switch positioning Does D change color? Adjust Switch positioning Does D change color? Adjust Switch positioning Does D change color? Using an ohmmeter measure the resistance between contacts with the closed Using an ohmmeter measure the resistance between contacts with the closed 6 Using an ohmmeter measure the resistance between contacts with the closed 0 Replace 6 Is reading less than ohm? 0 Replace 6 Is reading less than ohm? Replace 7 Is reading less than ohm? 7 7 Using an ohmmeter measure the resistance between contacts with the open Using an ohmmeter measure the resistance between contacts with the open Using an ohmmeter measure the resistance between contacts with the open Does reading show infinite Does reading show infinite 9 Does reading show infinite Inspect the chassis wiring for an open and repair break Inspect the chassis wiring for an open and repair break Inspect the chassis wiring for an open and repair break 6 of

17 LIMIT SWITCH TEST (-00) Step Action Description Result Unlock and pull out the manual release handle Does the D (Manual Release) LED change color? Manually operate the manual release limit while observing D. Does the D (Manual Release) LED change color? Using an ohmmeter measure the resistance between the common and the normally open terminal of the limit. This action will disengage the motor and initiate the manual release signal Switch may be out of adjustment Switching working properly If YES go to step This tests the and harness There is a problem with the or the harness Switch is out of adjustment If YES go to step Be sure the is closed during the measurement Switch is bad! Stuck open! If NO go to step 0 6 Is the reading less than ohm Closed contacts will read less than ohm 7 9 Using an ohmmeter measure the resistance between the common and the normally open terminal of the limit. Does the meter read infinite Inspect the chassis wiring for an open ckt or the connectors for a poorly mated connection 0 Replace Limit Switch Adjust Limit position With the ramp fully retracted does the D LED show green? Manually operate the Full-In limit while observing D. Does the D (Full-In) LED change color? Using an ohmmeter measure the resistance between the common and the normally open terminal of the limit. Be sure the is open during the measurement Switch is bad! Stuck closed! If NO go to step 0 Closed contacts will read less than ohm Since the checks OK the problem must be in the harness. Part number found in Bill of Material Follow published adjustment procedures Switch may be out of adjustment Go to step Go to step Switching working properly If YES go to step This tests the and harness There is a problem with the or the harness Switch is out of adjustment If YES go to step Be sure the is closed during the measurement 7 of

18 Switch is bad! Stuck open! If NO go to step 0 6 Is the reading less than ohm Closed contacts will read less than ohm 7 9 Using an ohmmeter measure the resistance between the common and the normally open terminal of the limit. Does the meter read infinite Inspect the chassis wiring for an open ckt and the connectors for a poorly mated connection 0 Replace Limit Switch Adjust Limit position With the ramp fully extended does the D LED show green? Be sure the is open during the measurement Switch is bad! Stuck closed! If NO go to step 0 Closed contacts will read less than ohm Since the checks OK the problem must be in the harness. Part number found in Bill of Material Follow published adjustment procedures Switch may be out of adjustment Limit Switch Test Passed! 6 Manually operate the Full-Out limit while observing D. Does the D (Full-Out) LED change color? Using an ohmmeter measure the resistance between the common and the normally open terminal of the limit. Go to step Go to step Switching working properly If YES go to step This tests the and harness There is a problem with the or the harness Switch is out of adjustment If YES go to step Be sure the is closed during the measurement Switch is bad! Stuck open! If NO go to step 7 Is the reading less than ohm Closed contacts will read less than ohm 9 0 Using an ohmmeter measure the resistance between the common and the normally open terminal of the limit. Does the meter read infinite Inspect the chassis wiring for an open ckt and the connectors for a poorly mated connection Replace Limit Switch Adjust Limit position Be sure the is open during the measurement Switch is bad! Stuck closed! If NO go to step Closed contacts will read less than ohm Since the checks OK the problem must be in the harness. Part number found in Bill of Material Follow published adjustment procedures Go to step Go to step of

19 Table 6 LIMIT SWITCH TEST (-00) EXTEND TEST (-00) Move the ramp to its fully retracted position then depress and hold the EXTEND Do the LEDs match figure? 9 Is the Full-Out LED Green? Go to Limit Switch Test step 9 Do the LEDs match figure? B Disconnect J at the controller 0 Measure the voltage between Pin 7 and ground Is the Manual Release LED Green? Go to Limit Switch Test step 9 Does the ramp start extending? Continue holding the EXTEND button until the ramp is fully extended and movement stops Perform Motor Test Does the meter read approximately Vdc? Measure the voltage of Pins & wrt ground Does pin read 0 volts or Pin read volts? 6 yes The Ramp Enable must be above Vdc to allow operation Setting the parking brake must either ground pin or take pin above volys to allow operation Does the ramp motor stop? Check resistance between pins & while pressing the extend button 6 Go to Limit Switch Test step 9 7 Test Passed 9 7 Does the meter show less than ohm? Check the resistance between the NO and COM contacts of the EXTEND Replace the controller Perform Initialization Test Inspect the harness for a broken wire 0 Does the meter show less than ohm? Repair wire and restart the extend test Replace the EXTEND Switch and restart the extend test B 9 of

20 EXTEND TEST (-00) Step Action Description Result Ramp should be started in the fully stowed position. Depress and hold the EXTEND EXTEND and RETRACT are momentary functions and must be held on to remain active. First check to see if input was received by the Go to step Do the LEDs match Figure 9? controller Figure is proper indication for extending the ramp. Does the ramp start extending? Controller is not connecting to the motor Command was received and the operation was started. If NO perform the Motor Control Test Continue holding EXTEND until ramp movement stops. Checking to see if ramp operation stops automatically Ramp has stopped. Has the motor stopped running? 6 Check the Full-Out limit Motor shut off properly If NO go to 6 Controller does not see the full out limit Determine if is out of adjustment or broken. 7 Extend Test Passed! Perform the Limit Switch Test. A change was caused by the EXTEND os something If NO go to step else is wrong. Do the LEDs match figure? indicates that the EXTEND command was not received or an interlock is not satisfied. 9 Disconnect J at the controller First lets verify the interlocks 0 Measure the voltage between pin 7 and ground. Does the meter read above volts dc? This is the ramp enable signal. It must be above volts dc to guarantee operation. Below v will inhibit operation Above v will allow operation If YES go to step Correct the ramp interlock Restart this test Go to step Measure the voltage of pins and with respect to ground. Does pin read below volts or pin read above volts? These are the Parking Brake input pins At lease one must be active to allow operation If NO go to step 0 of

21 6 7 CONTROLLER DIAGNOSTIC GUIDE Fix the parking brake input and restart the test Check the resistance between pins and while pressing the EXTEND. PBrake (pin ) must be above Volts DC or PBrake-n (pin ) must be below volt DC to allow operation. Testing the and the harness in this step Greater than ohm would be Does the meter show less than a bad. ohm? Less than ohm is a good closed. Go to step If NO go to step 9 Replace the controller Rerun all tests Go to step 9 0 Check the resistance between the normally open (NO) and normally closed contacts of the while activating it. This will check the without including the wire Greater than ohm would be Does the meter show less than a bad. ohm? Less than ohm is a good closed. If YES go to step Replace the EXTEND Switch Restart this test Go to step Inspect the harness for a broken wire Since the is OK the problem has to be in the harness. Repair the harness Restart this test Go to step Is the Full-Out LED green? Is the manual Release LED green? The ramp should not show full out It appears the micro- is at fault. The manual release should not be engaged. It appears the micro- is at fault. Table 7 EXTEND TEST (-00) If YES, go to the Limit Switch test If NO go to step If YES, go to the Limit Switch test of

22 RETRACT TEST (-00) Move the ramp to its fully extended position then press and hold the retract button. 9 Do the LEDs match figure? Is the Full-In LED Green? Go to Limit Switch Test step 0 Do the LEDs match figure? C 0 Disconnect J at the controller Measure the voltage between Pin 7 and ground Is the Manual Release LED Green? Go to Limit Switch Test step 9 Does the ramp start retracting? Continue holding the RETRACT button until the ramp is fully retracted and movement stops Does the ramp motor stop? Perform Motor Test Does the meter read approximately Vdc? Measure the voltage of Pins & wrt ground 6 Does pin read 0 volts or Pin read volts? yes Check resistance between pins & 0 while pressing the RETRACT button The Ramp Enable must be above Vdc to allow operation Setting the parking brake must either ground pin or take pin above volys to allow operation Correct interlock problem and restart test 6 Go to Limit Switch Test step 9 7 Test Passed 7 Does the meter show less than ohm? 9 Check the resistance between the NO and COM contacts of the RETRACT Replace the controller Perform Initialization Test Inspect the harness for a broken wire 0 Does the meter show less than ohm? Repair wire and restart the RETRACT test Replace the RETRACT Switch and restart the extend test C of

23 RETRACT TEST (-00) Step Action Description Result Ramp should be started in the fully stowed position. Depress and hold the EXTEND and RETRACT are RETRACT. momentary functions and must be held on to remain active. First check to see if input was received by the Go to step Do the LEDs match Figure 9? controller Figure is proper indication for extending the ramp. Does the ramp start retracting? Controller is not connecting to the motor Command was received and the operation was started. If NO perform the Motor Control Test Continue holding RETRACT until ramp movement stops. Checking to see if ramp operation stops automatically Ramp has stopped. Has the motor stopped running? 6 Check the Full-In limit Motor shut off properly If NO go to 6 Controller does not see the full out limit Determine if is out of adjustment or broken. 7 Retract Test Passed! A change was caused by the RETRACT or something else is wrong. Do the LEDs match figure? indicates that the RETRACT command was not received or an interlock is not satisfied. Perform the Limit Switch Test. If NO go to step 9 Disconnect J at the controller First lets verify the interlocks This is the ramp enable 0 operation. Measure the voltage between signal. It must be above pin 7 and ground. volts dc to guarantee Below v will inhibit Does the meter read above operation volts dc? Above v will allow operation If YES go to step Correct the ramp interlock Restart this test Go to step Measure the voltage of pins and with respect to ground. Does pin read below volts or pin read above volts? These are the Parking Brake input pins At lease one must be active to allow operation If NO go to step of

24 6 7 CONTROLLER DIAGNOSTIC GUIDE Fix the parking brake input and restart the test Check the resistance between pins and while pressing the RETRACT. PBrake (pin ) must be above Volts DC or PBrake-n (pin ) must be below volt DC to allow operation. Testing the and the harness in this step Greater than ohm would be Does the meter show less than a bad. ohm? Less than ohm is a good closed. Go to step If NO go to step 9 Replace the controller Rerun all tests Go to step 9 0 Check the resistance between the normally open (NO) and normally closed contacts of the while activating it. This will check the without including the wire Greater than ohm would be Does the meter show less than a bad. ohm? Less than ohm is a good closed. If YES go to step Replace the RETRACT Switch Restart this test Go to step Inspect the harness for a broken wire Since the is OK the problem has to be in the harness. Repair the harness Restart this test Go to step Is the Full-In LED green? Is the manual Release LED green? The ramp should not show full out It appears the micro- is at fault. The manual release should not be engaged. It appears the micro- is at fault. If YES, go to the Limit Switch test If NO go to step If YES, go to the Limit Switch test Table RETRACT TEST (-00) of

25 PROCESSES for Modules ONLY The following diagnostic processes apply only to the module. The -00 unit differs from the -00 unit only as far as the diagnostic LEDs are concerned. There are no operational differences between the two units. The -00 unit has its diagnostic LEDs connected at the output of the indicator relays. Due to the fact that the Diagnostic indicators are illuminated in both the active and inactive states of the outputs, a small (approx. 0mA) current is always passing through the dash indicators even when they are not active. This current is not sufficient to illuminate an incandescent bulb but will illuminate an LED. If dashboard LED indicators are preferred over incandescent, by the installer, the -00 controller should be used. The -00 controller moves its diagnostic LEDs back to the inputs of the indicator relays (K-K). This means there is no longer any voltage or current present at the indicator output of the controller when a it is not active. This change in circuitry limits the effectivity of the LEDs to functions that are internal to the control module. They can no longer be used to validate connectivity to the dashboard indicators. D9 ALARM D6 MOVE OUT D FULL OUT D FULL IN D MANUAL RELEASE D MOVE IN Figure Ramp Fully Stowed (-00) D9 ALARM D6 MOVE OUT D FULL OUT D FULL IN D MANUAL RELEASE D MOVE IN Figure Ramp Extending (-00) of

26 D9 ALARM D6 MOVE OUT D FULL OUT D FULL IN D MANUAL RELEASE D MOVE IN Figure Ramp Fully Extended (-00) D9 ALARM D6 MOVE OUT D FULL OUT D FULL IN D MANUAL RELEASE D MOVE IN Figure Ramp Retracting (-00) 6 of

27 Fully stow the ramp and cycle power to the controller OPERATIONAL CHECK (-00) Be sure the Manual Release is fully down and locked Do the LEDs match Figure? Perform Extend Test Verify the Parking Brake is set Verify the Ramp Enable interlock is active Press and hold the RETRACT Examine the LEDs D, D, D, D, D6, & D9 Does the ramp move into the cassette? Perform Retract Test 6 Do the LEDs match Figure? Perform Initialization Test 6 Do the LEDs match Figure? Perform Retract Test 7 7 Press and hold the EXTEND Continue to hold until ramp stops Does the ramp start out of the cassette? Perform Extend Test Does the ramp continue until fully retracted? Perform calibration adjustment 9 Do the LEDs match Figure? Perform Extend Test 9 Does the motor stop when the ramp stops? Perform Limit Switch Test 0 Continue to hold until ramp stops 0 Press and release the ONETOUCH Does the ramp continue until fully extended? Perform calibration adjustment Does the ramp start extending and continue until fully extended? Perform Harness Test Does the motor stop when the ramp stops? Perform Limit Switch Test Test Passed! 7 of

28 Operational Check (-00) Step Action Description Result 6 Fully stow the ramp and cycle power to the controller. Be sure the Manual Release is fully down and locked. Verify the Parking Brake Interlock is active Verify the Ramp Enable Interlock is active Compare the LEDs D, D, D, D, D6 & D9 to Figure Do the LEDs match Figure? (Assume J pin is volts) Resetting the system Setting external input to known value (not active) Setting external input to known value (active) Setting external input to known value (active) Figure shows the indicator conditions for a ramp that is fully retracted. The LEDs will be red for active es and will be green for inactive es. Indicators other than D show Green or some are not lit. (FAULT) D is only green LED Perform Initialization Test 7 Press the EXTEND Switch Testing extend capability Does the ramp move out of the Moving cassette? t Moving (FAULT) Perform Extend Test 9 Do the LEDs match Figure? YES (Assume J pin is volts) NO Perform Extend Test 0 Continue to hold EXTEND until ramp stops. Does ramp continue until fully extended? Does the motor stop when the ramp stops Ramp should auto stop when fully extended. Obstruction detection can cause premature halt. Full_Out Limit tells the controller to stop If NO perform Calibration Adjustment If NO perform Limit Switch Test Do the LEDs match Figure? YES (Assume J pin is volts) NO Perform Extend Test Press the RETRACT Switch Testing retract capability Does the ramp move into the Moving If YES cassette? t Moving (FAULT) If NO Perform Retract Test 6 Do the LEDs match Figure? YES (Assume J pin is volts) NO Perform Retract Test 7 Continue to hold RETRACT until ramp stops. Does ramp continue until fully retracted? Ramp should auto stop when fully retracted. Obstruction detection can cause premature halt. If NO perform Calibration Adjustment of

29 9 Does the motor stop when the ramp stops Full_In Limit tells the controller to stop If NO perform Limit Switch Test 0 Press and release the ONETOUCH This function does not require the to be held active. Does the ramp start extending and continue until fully extended? Ramp should auto stop when fully extended. If NO Perform Harness test Press and release the ONETOUCH The Ramp should begin to retract Continue Apply lbs. pressure ( kg) on the pressure mat. This is the minimum weight required to activate the pressure Does the ramp stop once the pressure is applied? The pressure tells the controller to stop regardless of operational mode If YES Test Passes If NO perform Pressure Switch Test Table 9 Table 9 Operational Check (-00) 9 of

30 Stow the ramp and cycle power INITIALIZATION TEST (-00) Examine LEDs D,,,, 6 & 9 NO Are all LEDs Replace Controller lit? Do the LEDs match figure? 7 Is D red? YES Verify the Manual Release is disengaged 9 Is D still red? YES 6 Test Passed! Is D Red? 0 Proceed to Limit Switch Test Is D Red? YES Is D6 Red? YES Proceed to Extend Switch Harness Test Is D red? YES Proceed to Retract Switch Harness Test Is D9 Red? 0 of

31 INITIALIZATION TEST (-00) Step Action Description Result Fully stow the ramp and cycle power to the controller. Be sure the Manual Release is fully down and locked. (not active) Resetting the system Examine the LEDs D, D, D, D, D6 & D9. LEDs will be green for active es and will be red for inactive es. Are all six LEDs lit? (either red or green) Replace the controller Do the LEDs match Figure? All indicators must turn on. All on indicates basic functionality Diagnostic indicators are faulty Indicators other than D show active (red) D is only red LED 6 Initialization Test Passed! 7 Is D red? Green shows Manual Release inactive Red shows the Manual Release is active If YES go to step Restart tests. If NO go to step 7 If NO go to step Check the Manual Release lever and make sure it is disengaged. When Disengaged the LED should show green. 9 Is D still red? 0 Proceed to Limit Switch Test Is D red? Is D red? Green shows Manual Release inactive Red shows the Manual Release is active A bad or damaged harness can cause problem. Green indicates ramp partially extended. Red indicates Full-In status (Stowed) Green indicates ramp not fully extended Red indicates ramp is fully extended If NO go to step If NO go to step 0 If continue If go to step 0 of

32 Is D6 red? Is D red? Is D9 red? Green indicates ramp not moving out Red indicates ramp is moving out Green indicates ramp not moving in. Red indicates ramp is moving in Green indicates ramp not moving in. Red indicates ramp is moving in Table 0 Initialization Test (-00) If continue If go to Extend Switch Harness test. If continue If go to Retract Switch Harness test If go to step If go to step of

33 Refer to figure for locations. LIMIT SWITCH TEST (-00) Unlock and pull the manual release handle Does D change color With ramp fully retracted does D show red? With ramp fully extended does D show red? Manually activate the Manual Release limit Manually activate the Full In limit Manually activate the Full Out limit Test Passed! Adjust Switch positioning Does D change color? Adjust Switch positioning Does D change color? Adjust Switch positioning Does D change color? Using an ohmmeter measure the resistance between contacts with the closed Using an ohmmeter measure the resistance between contacts with the closed 6 Using an ohmmeter measure the resistance between contacts with the closed 0 Replace 6 Is reading less than ohm? 0 Replace 6 Is reading less than ohm? Replace 7 Is reading less than ohm? 7 7 Using an ohmmeter measure the resistance between contacts with the open Using an ohmmeter measure the resistance between contacts with the open Using an ohmmeter measure the resistance between contacts with the open Does reading show infinite Does reading show infinite 9 Does reading show infinite Inspect the chassis wiring for an open and repair break Inspect the chassis wiring for an open and repair break Inspect the chassis wiring for an open and repair break of

34 LIMIT SWITCH TEST (-00) Step Action Description Result Unlock and pull out the manual release handle Does the D (Manual Release) LED change color? Manually operate the manual release limit while observing D. Does the D (Manual Release) LED change color? Using an ohmmeter measure the resistance between the common and the normally open terminal of the limit. This action will disengage the motor and initiate the manual release signal Switch may be out of adjustment Switching working properly If YES go to step This tests the and harness There is a problem with the or the harness Switch is out of adjustment If YES go to step Be sure the is closed during the measurement Switch is bad! Stuck open! If NO go to step 0 6 Is the reading less than ohm Closed contacts will read less than ohm 7 9 Using an ohmmeter measure the resistance between the common and the normally open terminal of the limit. Does the meter read infinite Inspect the chassis wiring for an open ckt or the connectors for a poorly mated connection 0 Replace Limit Switch Adjust Limit position With the ramp fully retracted does the D LED show red? Manually operate the Full-In limit while observing D. Does the D (Full-In) LED change color? Using an ohmmeter measure the resistance between the common and the normally open terminal of the limit. Be sure the is open during the measurement Switch is bad! Stuck closed! If NO go to step 0 Closed contacts will read less than ohm Since the checks OK the problem must be in the harness. Part number found in Bill of Material Follow published adjustment procedures Switch may be out of adjustment Go to step Go to step Switching working properly If YES go to step This tests the and harness There is a problem with the or the harness Switch is out of adjustment If YES go to step Be sure the is closed during the measurement of

35 Switch is bad! Stuck open! If NO go to step 0 6 Is the reading less than ohm Closed contacts will read less than ohm 7 9 Using an ohmmeter measure the resistance between the common and the normally open terminal of the limit. Does the meter read infinite Inspect the chassis wiring for an open ckt and the connectors for a poorly mated connection 0 Replace Limit Switch Adjust Limit position With the ramp fully extended does the D LED show red? Be sure the is open during the measurement Switch is bad! Stuck closed! If NO go to step 0 Closed contacts will read less than ohm Since the checks OK the problem must be in the harness. Part number found in Bill of Material Follow published adjustment procedures Switch may be out of adjustment Limit Switch Test Passed! 6 Manually operate the Full-Out limit while observing D. Does the D (Full-Out) LED change color? Using an ohmmeter measure the resistance between the common and the normally open terminal of the limit. Go to step Go to step Switching working properly If YES go to step This tests the and harness There is a problem with the or the harness Switch is out of adjustment If YES go to step Be sure the is closed during the measurement Switch is bad! Stuck open! If NO go to step 7 Is the reading less than ohm Closed contacts will read less than ohm 9 0 Using an ohmmeter measure the resistance between the common and the normally open terminal of the limit. Does the meter read infinite Inspect the chassis wiring for an open ckt and the connectors for a poorly mated connection Replace Limit Switch Adjust Limit position Be sure the is open during the measurement Switch is bad! Stuck closed! If NO go to step Closed contacts will read less than ohm Since the checks OK the problem must be in the harness. Part number found in Bill of Material Follow published adjustment procedures Go to step Go to step of

36 Table Limit Switch Test (-00) EXTEND TEST (-00) Move the ramp to its fully retracted position then depress and hold the EXTEND 9 Do the LEDs match figure? Is the Full-Out LED red? Go to Limit Switch Test step 9 Do the LEDs match figure? B Disconnect J at the controller 0 Measure the voltage between Pin 7 and ground Is the Manual Release LED red? Go to Limit Switch Test step 9 Does the ramp start extending? Continue holding the EXTEND button until the ramp is fully extended and movement stops Perform Motor Test Does the meter read approximately Vdc? Measure the voltage of Pins & wrt ground Does pin read 0 volts or Pin read volts? 6 yes The Ramp Enable must be above Vdc to allow operation Setting the parking brake must either ground pin or take pin above volts to allow operation Does the ramp motor stop? Check resistance between pins & while pressing the extend button 6 Go to Limit Switch Test step 9 7 Test Passed 9 7 Does the meter show less than ohm? Check the resistance between the NO and COM contacts of the EXTEND Replace the controller Perform Initialization Test Inspect the harness for a broken wire 0 Does the meter show less than ohm? Repair wire and restart the extend test Replace the EXTEND Switch and restart the extend test B 6 of

37 EXTEND TEST (-00) Step Action Description Result Ramp should be started in the fully stowed position. Depress and hold the EXTEND EXTEND and RETRACT are momentary functions and must be held on to remain active. First check to see if input was received by the Go to step Do the LEDs match Figure? controller Figure is proper indication for extending the ramp. Does the ramp start extending? Controller is not connecting to the motor Command was received and the operation was started. If NO perform the Motor Control Test Continue holding EXTEND until ramp movement stops. Checking to see if ramp operation stops automatically Ramp has stopped. Has the motor stopped running? 6 Check the Full-Out limit Motor shut off properly If NO go to 6 Controller does not see the full out limit Determine if is out of adjustment or broken. 7 Extend Test Passed! Perform the Limit Switch Test. A change was caused by the EXTEND os something If NO go to step else is wrong. Do the LEDs match figure? indicates that the EXTEND command was not received or an interlock is not satisfied. 9 Disconnect J at the controller First lets verify the interlocks 0 Measure the voltage between pin 7 and ground. Does the meter read above volts dc? This is the ramp enable signal. It must be above volts dc to guarantee operation. Below v will inhibit operation Above v will allow operation If YES go to step Correct the ramp interlock Restart this test Go to step Measure the voltage of pins and with respect to ground. Does pin read below volts or pin read above volts? These are the Parking Brake input pins At lease one must be active to allow operation If NO go to step 7 of

38 6 7 CONTROLLER DIAGNOSTIC GUIDE Fix the parking brake input and restart the test Check the resistance between pins and while pressing the EXTEND. PBrake (pin ) must be above Volts DC or PBrake-n (pin ) must be below volt DC to allow operation. Testing the and the harness in this step Greater than ohm would be Does the meter show less than a bad. ohm? Less than ohm is a good closed. Go to step If NO go to step 9 Replace the controller Rerun all tests Go to step 9 0 Check the resistance between the normally open (NO) and normally closed contacts of the while activating it. This will check the without including the wire Greater than ohm would be Does the meter show less than a bad. ohm? Less than ohm is a good closed. If YES go to step Replace the EXTEND Switch Restart this test Go to step Inspect the harness for a broken wire Since the is OK the problem has to be in the harness. Repair the harness Restart this test Go to step Is the Full-Out LED red? Is the manual Release LED red? The ramp should not show full out It appears the micro- is at fault. The manual release should not be engaged. It appears the micro- is at fault. Table Extend Test (-00) If YES, go to the Limit Switch test If NO go to step If YES, go to the Limit Switch test of

39 RETRACT TEST (-00) Move the ramp to its fully extended position then press and hold the retract button. 9 Do the LEDs match figure? Is the Full-In LED Red? Go to Limit Switch Test step 0 Do the LEDs match figure? C 0 Disconnect J at the controller Measure the voltage between Pin 7 and ground Is the Manual Release LED Red? Go to Limit Switch Test step 9 Does the ramp start retracting? Continue holding the RETRACT button until the ramp is fully retracted and movement stops Perform Motor Test Does the meter read approximately Vdc? Measure the voltage of Pins & wrt ground 6 Does pin read 0 volts or Pin read volts? yes Check resistance between pins & 0 while pressing the RETRACT button The Ramp Enable must be above Vdc to allow operation Setting the parking brake must either ground pin or take pin above volys to allow operation Correct interlock problem and restart test 6 Go to Limit Switch Test step 9 7 Does the ramp motor stop? Test Passed 7 Does the meter show less than ohm? 9 Check the resistance between the NO and COM contacts of the RETRACT Replace the controller Perform Initialization Test Inspect the harness for a broken wire Repair wire and restart the RETRACT test 0 Does the meter show less than ohm? Replace the RETRACT Switch and restart the extend test C 9 of

40 RETRACT TEST (-00) Step Action Description Result Ramp should be started in the fully stowed position. Depress and hold the EXTEND and RETRACT are RETRACT. momentary functions and must be held on to remain active. First check to see if input was received by the Go to step Do the LEDs match Figure? controller Figure is proper indication for extending the ramp. Does the ramp start retracting? Controller is not connecting to the motor Command was received and the operation was started. If NO perform the Motor Control Test Continue holding RETRACT until ramp movement stops. Checking to see if ramp operation stops automatically Ramp has stopped. Has the motor stopped running? 6 Check the Full-In limit Motor shut off properly If NO go to 6 Controller does not see the full out limit Determine if is out of adjustment or broken. 7 Retract Test Passed! A change was caused by the RETRACT or something else is wrong. Do the LEDs match figure? indicates that the RETRACT command was not received or an interlock is not satisfied. Perform the Limit Switch Test. If NO go to step 9 Disconnect J at the controller First lets verify the interlocks This is the ramp enable 0 operation. Measure the voltage between signal. It must be above pin 7 and ground. volts dc to guarantee Below v will inhibit Does the meter read above operation volts dc? Above v will allow If YES go to step operation Correct the ramp interlock Restart this test Go to step Measure the voltage of pins and with respect to ground. Does pin read below volts or pin read above volts? These are the Parking Brake input pins At lease one must be active to allow operation If NO go to step 0 of

41 6 7 CONTROLLER DIAGNOSTIC GUIDE Fix the parking brake input and restart the test Check the resistance between pins and while pressing the RETRACT. PBrake (pin ) must be above Volts DC or PBrake-n (pin ) must be below volt DC to allow operation. Testing the and the harness in this step Greater than ohm would be Does the meter show less than a bad. ohm? Less than ohm is a good closed. Go to step If NO go to step 9 Replace the controller Rerun all tests Go to step 9 0 Check the resistance between the normally open (NO) and normally closed contacts of the while activating it. This will check the without including the wire Greater than ohm would be Does the meter show less than a bad. ohm? Less than ohm is a good closed. If YES go to step Replace the RETRACT Switch Restart this test Go to step Inspect the harness for a broken wire Since the is OK the problem has to be in the harness. Repair the harness Restart this test Go to step Is the Full-In LED red? Is the manual Release LED red? The ramp should not show full out It appears the micro- is at fault. The manual release should not be engaged. It appears the micro- is at fault. Table Retract Test (-00) If YES, go to the Limit Switch test If NO go to step If YES, go to the Limit Switch test of