Charging Li*gate Ba.eries Part 2 Seven Way Aux Pin Circuit Li*gate Ba.ery Charging Problems May 21, 2014 12:00 P.M. CDT Proprietary Informa/on
About the Presenter Bruce Purkey Founder & Chief Crea4ve Engineer 800-219- 1269 bpurkey@purkeys.net Bruce has over 40 years of experience servicing fleets electrical needs. Widely recognized as the authority on electrical issues in the heavy- duty trucking industry, Bruce has worked closely with some of the largest fleets in North America. Several of his invenyons have been awarded US patents and earned the Technology & Maintenance Council s Silver Spark Plug award, one of the highest honors awarded to members.
TC- 6 (P3000- K) Overview Li1gate Charging Webinar Part 2 TC- 6 (or P3000- K) A DC/DC charger that is only powered from the aux circuit of the seven way
ExisYng Charging Challenges Majority of truck load carriers have several trailers at every terminal that have li*gates These trailers cause operayon issues as they always require a tractor equipped with a synger cord to keep li*gate ba.eries charged If there are no tractors with synger cords available before routes, the trailer does not receive charge and li*gate failures could result
TC- 6 (P3000- K) SoluYon The TC-6 (or P3000-K) is the solution No synger cord is required Every tractor matches every trailer
P3000- K Diagram From Tractor Seven Way The power to the Trail Charger is provided via the aux (blue wire or middle pin) of the seven way cable
P3000- K Diagram This can be accomplished because the current load of the DC/DC converter is limited to 20+ amp Tractor s aux circuit is normally circuit protected to 30 amps
How It Works Trailer Seven Way Cable Tractor Output Ground TRAIL CHARGER Brake Aux Ground ABS MODULE Tractor ba.eries When the igniyon is in the run posiyon, the aux is powered it powers the trail charger
How It Works Trailer Seven Way Cable Tractor Output Ground TRAIL CHARGER Brake Aux Ground ABS MODULE Tractor ba.eries Shared Circuit The tractor and seven way cord is shared as it powers both the trailer ABS and trail charger
How It Works Trailer Seven Way Cable Tractor Output Ground TRAIL CHARGER Brake Aux Ground ABS MODULE Tractor ba.eries Not Shared Circuit Shared Circuit The trailer has two completely separate circuits that start at the aux pin
How It Works Trailer Seven Way Cable Tractor Output Ground TRAIL CHARGER Brake Aux Ground ABS MODULE Tractor ba.eries Not Shared Circuit Shared Circuit When the brakes are applied, the trail charger turns off and allows all power to go to trailer ABS module
TesYng Verifying the OperaYon
How to Test Step 1 (tractor off) with a voltmeter, test the li*gate ba.ery voltage
How to Test Step 2 Make sure the seven way is plugged into the trailer Now start the tractor
How to Test Step 3 Green LED light of DC/DC converter should turn on
How to Test Step 4 With a voltmeter, test the li*gate ba.ery voltage You should see an increase in voltage
How to Test Step 5 With an ammeter, test the amp flow from the #2 pin of the DC/DC converter that connects to the circuit protecyon lead to the li*gate ba.eries
How to Test Step 6 If you see an increase in voltage and amp flow, the system is working In this example, voltage increased from 12.5 to 14.02 amp flow increased from 0 to 23.61
Possible Issues TroubleshooYng
Possible Issues with Tractor DC/DC Indicator Light: No Light Condi4on: No Voltage from Tractor Test and Repair/Fix: With Voltmeter, test the seven way receptacle (at trailer end). Replace tractor fuse or circuit breaker, repair or replace seven way cord, or repair wiring in tractor.
Possible Issues with Trailer DC/DC Indicator Light: No Light Condi4on: No Voltage from Trailer Test and Repair/Fix: Check input in li*gate ba.ery box. Replace the fuse in the nose box or repair the trailer wiring as needed.
Possible Issues with Load DC/DC Indicator Light: Green light then two red lights, (then it repeats) Condi4on: Excessive voltage drop within the system Test and Repair/Fix: Check voltage while under load at seven way nose box. Repair or replace as needed. Test trailer wiring and repair as necessary.
Possible Issues with DC/DC Converter DC/DC Indicator Light: Green light on, but no voltage increase at li*gate ba.eries or any current flow Condi4on: Blown fuse or tripped circuit Breaker on output lead from DC/DC Converter Test and Repair/Fix: Make sure the output lead is not grounded, then replace fuse or reset the circuit breaker
Possible Issues with Li*gate Ba.eries DC/DC Indicator Light: Green light on with low voltage and high current Condi4on: Deeply discharged or defecyve li*gate ba.eries Test and Repair/Fix: Charge, then test each of the li*gate ba.eries and replace as needed
Possible Issues with Brake Circuit DC/DC Indicator Light: Solid green LED light Condi4on: No signal from brake circuit Test and Repair/Fix: Blown fuse in seven way nose box or damaged brake wire Test and Repair/Fix:
Possible Issues with Brake Signal DC/DC Indicator Light: Green LED light slowly blinking Condi4on: ConYnue signal to brake lockout pin Test and Repair/Fix: Brake signal connected wrong. Check to see where the wire is connected.
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