Montracon SanuControl User manual
MontraconTrailers
SanuControlDoubleDeckManual
December2015
Introduction
Thisdocumenthasbeenpreparedtooutlinethebasicoperationofthe
doubledecksystemthatcontrolsthemovingdecksystem
Thisdocumenthashadthehydraulicequipmentaddedasthis
completesthecontrolsystem.
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. Electrical Connections in the Hydraulic Power Pack
10. Hydraulic layouts
11. Maintenance / Fault Finding
12. (Re)Programming and program version
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.
The hydraulic operation is covered in a separate section but all the electrical interfaces to
the hydraulic system are covered in this section.
The main interconnections are all made in the boxes under the chassis.
Hydraulic Enclosure (Stainless steel box)
Electrical Enclosure (Plastic box)
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.
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.
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.
3. Safety Warning Devices
There are 3 different electrical safety warning devices on the trailer they are as follows:-
a. 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.
The final termination in the box is as follows:-
Brown Live Pin OUT04 Bank E, Pin 1
White Earth Pin GND Bank E, Pin 2
b. 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 Pin OUT05 Bank F, Pin 3
White Earth Pin GND Bank F, Pin 4
c. 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 Earth Pin GND Bank F, Pin 6
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.
The switches have covers fitted for protection:-
When the lock is on the proximity switch is made the LED on the barrel of the
proximity switch illuminates.
All the proximity Switches are powered directly to the PLC.
They are wired as follows:-
2 x Brown from FOS & FNS Proxy
Switch Live
Bank A,
Pin 8
Black from FNS Proxy Switch
Bank A,
Pin 6
Black from FOS Proxy Switch
Bank A,
Pin 7
2 x Blue from FOS & FNS Proxy
Switch Earth
Bank A,
Pin 5
2 x Blue from ROS & RNS Proxy
Switch Earth
Bank B,
Pin 4
Black from RNS Proxy Switch
Bank B,
Pin 2
Black from ROS Proxy Switch
Bank B,
Pin 3
2 x Brown from ROS & RNS Proxy
Switch- Live
Bank B,
Pin 1
Note:-
M12 Wiring Codes are as follows:-
Black = Output from the switch
Blue = Earth
Brown = Live in
All proximity switches are PNP
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.
The operation is identical to the flag sensors detailed above
It is wired as follows:-
Black from Deck in Roof Proxy
Switch
Bank B,
Pin 2
Blue from Deck in Roof Proxy
Switch
Bank B,
Pin 5
Brown from Deck in Roof Proxy
Switch- Live
Bank B,
Pin 8
b. Operational Buttons
The operational buttons are situated inside the UK N/S on the rear pillar, there
are 2 buttons (Up, Down)
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.
●As soon as the raise (up) button is released the deck will stop.
●If the deck is stopped at full height (by the deck in roof sensor) then the deck
locks will automatically engage and the motor will stop working.
To lower the deck.
●Press the down (green) button
●The plc will verify the position of the locks and if safe to lower then the
system will begin to operate.
●The buzzer and flasher will activate and the hydraulic valves will open
allowing the oil to return to tank thus allowing the deck to lower.
●As soon as the button is released the deck will stop.
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
●Do not operated the system on a voltage of less than 22v DC
●The system (plc) will not allow deck operation if the voltage is less than 18 volts.
●When operating the deck please always pay attention to the locks and ensure all
locks are retracted when the deck is moving
●The system is not designed for continuous running!
●Maximum advised duty is XXX per hour.
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)
Remove the cover
Remove the nuts retaining Mega Fuse
Remove and replace the failed fuse
Refit in reverse order.
b. 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
button.
Typical Circuit Breaker – mounted in box (visible)
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