SERVICE BULLETIN NO. SB-17-014 Issue Date: 07/05/06 SUBJECT: Phillips Permalogic Trailer Dome Lamp Controller Technical Bulletin Phillips Industries has released a technical bulletin related to installation and user instructions for their Permalogic trailer dome lamp controller. Please see the attached technical bulletin for full details. Any questions regarding the technical bulletin should be directed to Phillips Industries at 626-781-2121. Any questions regarding this service bulletin should be directed to Utility s Field Service Department at 800-423-6591. Field Service Department UTILITY TRAILER MANUFACTURING COMPANY SB-17-014
WE MAKE PRODUCTS THAT MAKE A DIFFERENCE PERMALOGIC Trailer Dome Lamp Controller Installation and User Instructions PERMALOGIC Technical Bulletin PERMALOGIC is a solid-state electronic controller designed to manage power to trailer dome lamps even automatically turning them off if they are left on accidentally. By simply stepping on the brake pedal, a driver can be assured that the trailer dome lamps are off and that all power from the blue wire is available for the ABS braking system. When installed with the LED Logic Switch, the controller has a multi-color LED light pattern that indicates multiple operating conditions (such as high/low voltage or a short circuit). The PERMALOGIC controller is unique in that it monitors and manages current and voltage directly at the nosebox. The controller piggybacks off the back of the J560 socket and hooks up directly to the Dark Blue (Power), White (Ground) and Red (Brake light) circuits. The PERMALOGIC controller monitors the voltage and current into the unit every 30 milliseconds (.030 of a second) and makes decisions with regard to output and display information. The current draw is monitored and controlled electronically, allowing the driver to be worry- free, in the event the driver forgets to turn OFF the power to the trailer dome lamps. Drivers can tell by looking at the units equipped with an LED Logic Switch as to the condition of the tractor batteries. The LED display in the switch will provide valuable information regarding the proper function of the trailer dome lighting system: if the driver needs to idle the truck, or if service / replacement of tractor batteries is needed. The PERMALOGIC controller has an integrated low voltage disconnect that disables trailer dome lamp operation when tractor batteries are drawn near the point of requiring a jumpstart. The PERMALOGIC controller with LED Logic Switch can tell you when there is a fault or short in the lighting circuit by displaying a fault color code. This can reduce time for troubleshooting electrical problems. The controller is completely maintenance free. 12012 Burke Street, Santa Fe Springs, CA 90670 Tel: 562-781-2121 Fax: 562-781-1166 www.phillipsind.com
WIRE GAUGE RECOMMENDATION Recommended wire gauge is 8 ga WIRE CONNECTION TABLE Below are wiring installation guides for the two types of units. The first is stand-alone PERMALOGIC which requires integration into an existing nosebox. The second is the PERMALOGIC integrated into the nosebox. In addition, PERMALOGIC can be ordered with dual output banks (allowing two banks of trailer dome lamps for multi-compartment trailers). Stand-alone PERMALOGIC : PERMALOGIC N osebox (existing) Description o Red (14 ga) Red Brake Light o White (14 ga) White Ground Return o Dark Blue (8 ga) Dark Blue Power Input o White/Grn. (14 ga) N/A See Below* Remote Switch 1 o Light Blue (8 ga) N/A See Below** Output to Bank 1 Dome Lamps Stand-alone PERMALOGIC with dual output banks (optional): o White/Ylw. (14 ga) Optional See Below* Remote Switch 2 o Gray (8 ga) Optional See Below** Output to Bank 2 Dome Lamps * Connect to momentary switch for dome lamps ** Connect to power for dome lamps Integrated PERMALOGIC Nosebox: PERMALOGIC Wire Connection Description o White (14 ga) White Ground Return o White/Green (14 ga) N/A See Below* Remote Switch 1 o Light Blue (8 ga) N/A See Below** Output to Bank 1 Dome Lamps Integrated PERMALOGIC Nosebox with dual output banks (optional): o White/Yellow (14 ga) Optional See Below* Remote Switch 2 o Gray (8 ga) Optional See Below** Output to Bank 2 Dome Lamps * Connect to momentary switch for dome lamps ** Connect to power for dome lamps OTHER CONNECTION INFORMATION Use momentary switches at the doors of the trailer o Normally open, wired to ground o One pulse On, next pulse Off o <DCA rating OK o 20F to +150F temperature rating 2
HOW TO RESET TIMER SETTINGS The PERMALOGIC is set to automatically turn off the output load to the trailer dome lamps after 60 minutes. This can be modified in the field to 45, 30 or unlimited minutes by following the instructions below. Note: If the PERMALOGIC has not been installed on the trailer, one person can complete the change. If the PERMALOGIC is mounted on the trailer, changing the timer will require two people (1 person to operate the truck brakes and 1 to trigger the door switch for the trailer dome lamps, see 2 nd Method). Table 1.1 Green Flash Red Flash Blue Flash White Flash = 60 Minutes = 45 Minutes = 30 Minutes = Unlimited Minutes 1 st Method: If the PERMALOGIC unit has not yet been installed 1) Connect White (14 ga) of PERMALOGIC to Ground Return Terminal. 2) Connect White/Green (14 ga) of PERMALOGIC to Red (14 ga) of PERMALOGIC 3) Connect Dark Blue (8 ga) of PERMALOGIC to +12VDC. 4) The LED Logic Switch will turn Solid Purple and then start to cycle through Red, Green, Blue and White. Each color will cycle for approximately 2 seconds. See Table 1.1 for the corresponding time/color interval you wish to select. 5) When the color flashes that corresponds to the time you want, immediately disconnect the White/Green wire from the Red wire. 6) This will select the new timer setting and reset the system. 2 nd Method: After the PERMALOGIC has been completely installed (Requires 2 people) 1) Turn the tractor OFF; keys are not in the ignition. 2) 1 st installer presses on brake pedal and holds it there. 3) 2 nd installer will HOLD momentary switch that is connected to White w/ Green stripe to GROUND. 4) 1 st installer will start the engine, which will engage the PERMALOGIC to start cycling Timer codes. 5) When the desired color appears on the PERMALOGIC, the 1 st installer can release the brake, or the 2 nd installer can release the momentary switch. This will select the new timer setting and reset the system. 3
HOW TO USE PERMALOGIC The PERMALOGIC is programmed to turn off the trailer dome lamps in one of three ways: Pressing any switch in the system (door switches or PERMALOGIC Logic Switch, if optioned) Allowing timer to fully cycle Depressing the tractor brake pedal (when red wire is connected to J560 stop lamp terminal) OPERATING INDICATORS (LED Logic Switch) Blue = Ready Red = Brake Lights On Green = Output Circuit 1 To Trailer Dome Lamps On Aqua = Output Circuit 2 To Trailer Dome Lamps On WARNING INDICATORS (LED Display / LED Logic Switch models) Red (Steady On) Low Voltage Warning Red (Slow Flash) Low Voltage Disconnect Red (Fast Flash) High Voltage Disconnect Purple (Steady On) Short Circuit Disconnect 1) On initial Power-up of the PERMALOGIC unit, the flashing LED will indicate the amount of time delay there is before the output to the Dome lights are turned OFF. 2) After the timer delay indicator flashes, the LED Display Switch will become Solid Purple for 1 to 2 seconds. Then it will switch to a Solid Blue light, indicating that the PERMALOGIC is READY and POWER to the Dome Lamps are turned OFF. 3) Press the LED Display Switch once. The Output load should now have 12VDC @ up to 20 Amps which will turn ON the Dome Lamps. The LED Display Switch will turn and remain Solid Green, until timer has elapsed. After timer has lapsed, the LED Display Switch will turn and remain Solid Blue. 4) If these are not the results that are received after setting up the PERMALOGIC, please see chart below to troubleshoot the installation and the PERMALOGIC unit. 4
PROBLEM DESCRIPTION SOLUTION Light is NOT on in trailer LED colors do not cycle through Green, Purple and Blue on the PERMALOGIC display during power-up Power is not properly connected to the PERMALOGIC unit. Use a DVM to measure approximately 12 ~ 14VDC between Dark Blue and White wires on PERMALOGIC unit PERMALOGIC display light is Solid Purple. PERMALOGIC display light is Blue. An over current condition has been detected (> 20 Amps). Indicates normal current conditions and dome lamps OFF. Check the output on the alternator or for a possible short in the trailer wiring Press the LED Logic Switch to engage dome lamps Display light is Solid Green (Solid Aqua for Circuit 2, Optional) Dome lamps have gone out and PERMALOGIC display is Blinking Red. Indicates Power ON to dome lamps. Use a DVM to measure 12VDC across the PERMALOGIC Controller output on the "Light Blue" wire to GROUND. Do the same for the Gray wire. Next check for +12VDC at the Output Load Input voltage to PERMALOGIC Start engine to charge batteries back controller has fallen below minimum to safe operating conditions dome lamps operating parameters. Light is ON but does not stay ON. Dome lamps blink ON & OFF continuously. The wrong switch type is installed. Must be a momentary switch to GROUND. Check to ensure the trigger wire (White/Grn or White/Ylw) is not making a continuous contact with GROUND. PERMALOGIC display is Blinking Red Input voltage to PERMALOGIC is too HIGH (> 16VDC) or input voltage is too LOW (<10.2VDC). Use a DVM to check alternator outputs to ensure approximately 11.2VDC~16.0VDC. PERMALOGIC display is Solid Voltage drop too great between Green, not all lamps on the PERMALOGIC and the dome connected circuit come ON in trailer. lamps, or too many lamps are connected while using the wrong wire gauge. The crimp connections to the flickering dome lamps are not making sufficient surface contact between wire and crimp connector. Ensure that proper wire gauge is used between PERMALOGIC controller and dome lamp input wire. Ensure that minimum voltage at the last lamp furthest from the PERMALOGIC controller is 9VDC. Re-crimp/re-solder wires that are connected to White/Grn and White/Ylw. PERMALOGIC display light is Solid Red and dome lamps flicker once every minute. This is the Low Voltage warning Engine idling may be necessary to indicator. The input voltage from the bring voltage back above 11.2VDC at alternator to the PERMALOGIC the nosebox. controller has dropped below 11.2VDC. The dome lamps may shut off soon. 5
Every PERMALOGIC controller features the following: 240 watt rating per circuit. Diagnostic code troubleshooting. Built in variable timer preset at 60 minutes (30, 45, 60, or Infinite intervals can be selected) Over-voltage, under-voltage, high current disconnect and low voltage warning detection. Appendix 1.1: PERMALOGIC Comparison Chart Part # Enclosure Circuits Timer Standalone 1 Nosebox 2 Activation Switch Status LED 60-2500 X X X X X 60-2502 X X X X X 60-2520 X X X X X 60-2522 X X X X X 60-2500 60-2520 60-2502 60-2522 6