nufa k702

Technical Manual Model series Nufa, CPU K201 N201-VZ Table of contents 14. September 2010 Page 1 of 2

© Copyright reserved WashTec 1997

3 - Brush Nufa 6 - 3395 2 - Brush Nufa 6 - 2495

4 - Brush Tandem Nufa 6 - 4595 6 - Brush Tandem Nufa 6 - 6595

High-pressure Nufa 6 - 0297 MaxiWash Combi 6 - 0302

2 - 3 Brush MaxiWash Pro 6 - 0303 2 - 3 Brush MaxiWash-Intro 6 - 0503

4 - 6 Brush MaxiWash Tandem 6 - 0903

Content Date Pages Identifier Table of contents ________________________________ 14.11.07 ___ 2 ___ N201-VZ P2 Modcon System Parameters 1.35 ________________ 13.11.07 ___ 49 __ N201-01-01-E Electronics: Displays, Code Switches_______________ 22.04.04 ___ 4 ___ N201-01-02-E-HW Special Bus – Mirror Program _____________________ 14.11.07 ___ 4 ___ N201-01-05-E Errors, Error Numbers, Error Classes _______________ 13.04.06 ___ 4 ___ N201-02-01-D Cable numbers for P4 Hardware Test _______________ 05.11.05 ___ 7 ___ N201-02-02-D P3 Monitor-Bytes ________________________________ 13.11.07 ___ 29 __ N201-02-03-D Torque Converter Board, Test Manual ______________ 08.05.01 ___ 3 ___ N201-02-05-D Frequency converter drives, Diagnostic: Omron, Lust _ 17.07.05 ___ 7 ___ N201-02-10-D Maintenance Checklist ___________________________ 22.03.06 ___ 2 ___ none (04-01) Commissioning Test Protocol _____________________ 12.12.00 ___ 5 ___ N201-05-01 Commissioning Option Antifreeze__________________ 02.07.04 ___ 1 ___ N201-05-05-I Commissioning Tandem system ___________________ 02.07.04 ___ 2 ___ N201-05-10-I Commissioning (Radio) Modem Port _______________ 07.07.04 ___ 2 ___ N201-05-15-I Utility program P2 Modcon Service _________________ 03.06.04 ___ 4 ___ N201-07-01-F Utility program P0 Operator _______________________ 14.04.06 ___ 4 ___ N201-07-02-F Utility program P1 ERPROS _______________________ 03.06.04 ___ 2 ___ N201-07-03-F Utility program P3 Monitor ________________________ 04.06.04 ___ 1 ___ N201-07-04-F Utility program P4 Hardware Test __________________ 17.04.01 ___ 1 ___ N201-07-05-F Utility program Call and Quit ______________________ 17.04.01 ___ 1 ___ N201-07-06-F Operating Instruction Quick reference guide _________ 22.02.01 ___ 2 ___ N201-07-07-F-BA Water Valves Control and Wash Programs___________ 12.07.04 ___ 3 ___ N201-07-08-F-Wa Software modification, Hints for upgrades from 1.13 __ 18.09.98 ___ 1 ___ N201-08-01-SW Software modification, Hints for upgrades from ______ 18.09.98 ___ 1 ___ N201-08-02-SW CPU Exchange __________________________________ 14.11.07 ___ 1 ___ N201-09-01-HW

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Technical Manual N201-VZ Model series Nufa, CPU K201 14. September 2010 Table of contents Page 2 of 2


Table of content, continuation Date Pages Identifier Changes from Edition 6-1677 _____________________ 23.04.04 ____ 2 ___ N201-11-01-A HP Nufa 6-0297 Differences to common Nufa ________ 12.07.04 ____ 3 ___ N201-11-02-A Frequency Converter: Conversion Lust to Omron / Fuji 14.04.05 ____ 3 ___ N201-12-01-UM RPD Power Measurement: Assembly Instructions ____ 19.05.04 ____ 6 ___ N201-12-02-UM Brush Profile: Conversion Instruction for Silo Trucks _ 19.05.04 ____ 1 ___ N201-12-03-UM Water System: Conversion to Fresh Water in reverse run19.05.04 ___ 1 ___ N201-12-04-UM Glossary ______________________________________ 15.07.04 ___ 18 ___ N201-Glossar

Explanation of identifiers:

The first part denotes the machine type (Nufa with controller K201 = N201, Nufa Allgemein = common Nufa = NuA)

The second part contains the number of the type description. The instructions in the manual are sorted by this number.

K - 0 = Important brief summaries E - 1 = Adjustments, setting instructions D - 2 = Diagnostic methods R - 3 = Repairs, troubleshooting W - 4 = Maintenance I - 5 = Commissioning M - 6 = Assembly

F - 7 = Function descriptions SW - 8 = Software, Changes HW - 9 = Hardware, Structure TD - 10 = Technical data A - 11 = General UM - 12 = Conversion, rework

Each description contains a serial number as a supplement to the group term. (E1-1, E1-2 ...). To leave space for more important manuals there are jumps in the numbering. Subject matter code letters:

The final supplement means that each description may be given as group of letters for further explanation.

BA = Operating manual BE = Operating unit DB = Roof brush

DD = Roof nozzle SB = Side brush ST = Controller

Wa = Water system Z = Additives and more

Created: Bernd Zeller Date: 04.03.1997 Approved: Bernd Zeller

Updated: Bernd Zeller Date: 14.11.2007 File: NU-TH-GB_N201-00-00-Content_c_14-11-07.docx

Updates made after 15.07.2004 are colored and marked by „|” at the left margin.

Technical Manual Model series Nufa, CPU K201 N201-01-01-E P2 Modcon system parameters 13. November 2007 Software K201: to version 1.35, SN 192 003 Page 1 of 49


This section describes the system parameters for the Nufa versions MaxiWash Pro, Intro, Tandem and Combi with controller K201. Some parameters are in pulses from the incremental generator. 1 pulse portal = 2.2 cm, 1 pulse SBs = 1 cm, 1 pulse DB = 1,48 cm (different with winding drive). Any parameters not listed have no meaning.

The "Recommended change step" indicates in what steps parameter changes are recommended and therefore sensible.

Contents, Module numbers and abbreviations Common Equipment Parameters _______________________ 2 000 POR Portal ___________________________________ 2

000 POR, continued, from Para 7 ____________________ 3 000 POR, Continued, from Para 13 __________________ 4

001 DB Roof brush __________________________________ 5 001 DB, continued, from Para 4 _____________________ 6 001 DB, continued, from Para 15 ____________________ 7 001 DB, continued, from Para 20 ____________________ 8 001 DB, continued, from Para 25 ____________________ 9

002 SBL Side brush left 003 SBR Side brush right ______ 10 002 SBL, 003 SBR, continued, from Para 9 ___________ 11 002 SBL, 003 SBR, continued, from Para 19 __________ 12 002 SBL, 003 SBR, continued, from Para 23 __________ 13 002 SBL, 003 SBR, continued, from Para 29 __________ 14

004 DD Roof nozzle (for MaxiWash Combi) from 1.31 ____ 14 004 DD, continued, from Para 9 ____________________ 15 004 DD, continued, from Para 21 ___________________ 16

005 UBW Under-body wash _________________________ 16 005 UBW, continued, from Para 10 _________________ 17

006 HP side (Y40 for wheels) ____________________ 007 Y1 FreWa VN arch 008 Y2 FreWa add. N arch 009 Y3 ProcWa brushes 010 Y4 ProcWa VN arch 011 Y6 CDA VN arch 012 Y7 CTH add. N arch 013 Y8 CVW 014 Y46 split arch 015 Y10 HP chemistry lower side 016 Y11 HP chemistry upper side 017 Y12 HP chemistry roof 018 Y13 HP roof 019 Y14 HP lower side 020 Y15 HP upper side 021-023 Y16-Y18 Reserve 024 Y19 Swivel HP side 025 Y20 Reserve ________________________________ 18

005 - 025 Valves, continued, from Para 14 ____________ 19 Basic setting of the valve parameters: _______________ 19

026 DOP Dosing pumps ___________________________ 20 027 PMP Water pumps ____________________________ 21

028 ANL System __________________________________ 22 028 ANL continued, from Para 9 ___________________ 23 028 ANL continued, from Para 13 __________________ 24

029 M 1 Machine 1 ________________________________ 25 030 M 2 Machine 2 ________________________________ 26 031 M 3 Machine 3 ________________________________ 26 032 CHK, Check/Monitor ____________________________ 26

032 CHK continued, from Para 12 _________________ 27 033 FUH Frequency converter lifting

034 FUP Frequency converter Portal 035 FUR Frequency converter Reserve ______________ 27

036 LT1 Auxiliaries table 1 __________________________ 28 037 LT2 Auxiliaries table 2 __________________________ 28 038 PRG Programs _______________________________ 29

038 PRG continued, from Para 4 __________________ 30 039 EFT Entry door 040 AFT Exit door _______________ 31 041 MKL Magnetic card reader ______________________ 32 042 CKL Chip card reader __________________________ 33 043 SER Serial interfaces __________________________ 34 044 BED Operating unit, parallel input _________________ 35

044 BED, continued, from Para 3 ___________________ 36 044 BED, continued, from Para 9 ___________________ 37

045 KFZ Vehicle position ___________________________ 37 045 KFZ, continued, from Para 14 ____________________ 38 046 TST Test ____________________________________ 38 047 SOF Special Functions _________________________ 39

047 SOF continued, from Para 2 ___________________ 40 047 SOF continued, Para 4 continued ______________ 41 047 SOF continued, Para 4 continued ______________ 42 047 SOF continued, from Para 5 continued __________ 43 047 SOF continued, from Para 8 ___________________ 44 047 SOF continued, Para 13 ______________________ 45 047 SOF Continued, Para 13 Continued_____________ 46

048 R 1 Reserve __________________________________ 47 Parameters for Soko Verkehrsbetriebe Endingen: _____ 47 General Parameters _____________________________ 47

048 R 1 continued ______________________________ 48 Parameter for trolley bus France:___________________ 48

049 RPD Real Power Device, power measurement _______ 48 050 LS Light barrier board __________________________ 49 051 to 057 R4 to R11 Reserve ______________________ 49

Technical Manual N201-01-01-E Model series Nufa, CPU K201 13. November 2007 P2 Modcon system parameters Page 2 of 49 Software K201: to version 1.35 Para- Default Unit Notes meter value


Common Equipment Parameters Para 15 001 value Module exists for Solo machine;

000 = the module does not exist. The default could also be 002 and define a different type (e.g. frequency converter FUH: 001 = Lust, 002 = Omron). Attention: activation of the module is only accepted after Reset (Power off-on)!

Para 16 001 value Module exists for Tandem machine 1; like Para15.

Para 17 001 value Module exists for Tandem machine 2; like Para15.

These parameters are valid for all modules. Here is predefined what is available in the different machines, e.g. for a 2 brush Nufa the para 15 of module DB and FUH has to be changed to 000 because these units do not exist.

000 POR Portal Para 1 00050 pulses Position semi-trailer start area

from 1.18: The brushes are locked from this no. of pulses after the front of the vehicle; up to 1.16i: The brushes are locked from this portal position(portal counter);

Para 2 00030 pulses Position spoiler start area from 1.18: The roof brush is locked from this no. of pulses after the front of the vehicle up to 1.16i: The roof brush is locked from this portal position(portal counter);

Para 3 00700 pulses Portal stop position for „short wash bay“, from 1.09f Attention: The parameter has to be smaller than the end of the wash bay (turn position)!!

Para 4 250 pulses Start position 2nd

Automatic parking of the machine with distance to the exit. (At the exit the vehicles has to go around a corner and will take a wide turn). If the function has been released (ANL para 9) the machine moves after the end of wash to this portal position (number of pulses); Default 250 = 5,5 m before begin of bay, Portal 1. Home position; Additionally the position can be increased by para 14, each digit for 256 pulses = 5.6 m: 2. IP = para 4 + (256 * para 14).

home position

Para 5 000 value Portal basic speed, from 1.28na From Rev. 1.29r2 not active in vehicle program run. The customer may change the portal basic speed in three steps (slow, medium, fast) in P0 operator. Does not apply for the vehicle program. 000 = Standard, no changes possible, menu item is hidden in P0; 001 = Portal slow (basic speed - 25 Hz) 002 = Portal medium (basic speed - 15 Hz) 003 = Portal fast (Standard basic speed according to the program matrix)

Para 6 000 pulses Pick-Up Function and area length, run change, from 1.28na The parameter is used to determine the function of the Pickup wash and simultaneously the length of the Pickup area and thereby the run change at the rear of the vehicle. 000 = Standard, the roof brush is locked when the portal reaches the value vehicle front +DB Para3. The side brushes continue with washing the side of the vehicle. The cycle is changed at the rear by the position of the side brushes inward or the towing bar. > 000 = here roof brush and side brush are locked. Simultaneously the parameter determines the cycle change (e.g. 250 pulses = approx. 5.5 m from the locking position) for tractor of semi-trailer or dumper from 1.29d: extended area with Para 11; cycle change at portal counter = (vehicle front + DB Para 3 + POR Para 6 + (POR Para 11 x 255))

Technical Manual Model series Nufa K201 6-0395 N201-01-01-E P2 Modcon system parameters 13. November 2007 Software K201: to version 1.35 Page 3 of 49 Para- Default Unit Notes meter value


000 POR, continued, from Para 7 Para 7 160 pulses Semi-trailer area length

For this section, the brushes remain locked from reaching para 1 From 1.24: additionally the area can be expanded with Para 11 for each 256 pulses = 5,5 m: Semitrailer length = Para 7 + (255 x Para 13).

Para 8 180 pulses Spoiler area length For this section, the DB remains locked from reaching para 2

Para 9 010 pulses Spoiler roof brush lowering after max vehicle height, from 1.29o Here you may determine for how many pulses the roof brush may lower after reaching the max. height in the spoiler area. For vehicles where the spoiler is higher than the roof. Only active in forward cycle.

Para 9 000 pulses only up to 1.16e, Wash start position for special bus, from 1.13 from 1.16f separate adjustable with DB para 3 and SB para 2 DB and SBs just begin washing from this portal counter, no front wash (because of the large mirrors) up to 1.16e default = 200.

Para 10 000 value Release for special portal positions, from 1.16 000 = standard 001 = SoKo Stadtwerke Wolfsburg: Parking behind initial position; with the keys „Portal backwards“ + „Release“ out of initial position the portal moves backwards until the limit switch „Tandem initial position“ (E040); 002 = Release wash start out of 2nd start position; will be activated with the key „special function“, LED on = 2nd start position. or activating with separate switch (E049: SOF Para 5 = 8) For 2 nd

Para 11 000 value Extended area for Pickup area length, from 1.29d

start position the portal is positioned on the limit switch „Tandem initial position“ (E040). It is wash begin and end. There is no moving backwards to the standard initial position 003 = SoKo RVA Obersdorf: move limit with opened entrance door, from 1.16f; additionally: EFT para 5 = 255 = limit switches active, SOF Para 8 = 8 = A113 = door may not open; (up to 1.16k: ANL para 12 = 008). If the door is opened the portal moves max. to the Tandem-IP E040. If the portal is behind the Tandem-IP the output A113 = 1 will be set, to block the opening of the door.

Extension for Para 6, Each number keeps the brushes locked for further 255 portal pulses (5.6m). Example: Para 6 = 080, Para 11 = 1 (= 1 x 5,6 m further) Pickup area = 80 + 1 x 255 = for 335 pulses (7.4 m) are the brushes locked; applies also for turn position at Pickup semitrailer (Para 6).

Para 12 000 pulses Short wash bay program: return cycle length, from 1.28na Function parameter 12 = 001 only from 1.32h. After the short wash bay program stops the portal at the rear the bus moves motor-driven forwards until the side brushes turn freely. The traffic light turns to red. If the bus does not stop in time the side brushes lose contact to the vehicle. The portal moves than backwards for the in Para 12 entered pulses until the side brushes have again contact to the vehicle. Then another 60 pulses (1.3 m), so that the side brushes are at the vehicle side. If Para 12 = 001 the portal does not move backwards the 60 pulses and the roof brush is locked and does not wash the rear (saves time). Afterwards the forward wash is released and the rear of the vehicle is finished.



000 POR, Continued, from Para 13 Para 13 000 value Extended area for semitrailer area - length, from 1.24

Extension for Para 7, each number keeps the machine locked for further 256 pulses (5,6 m). Example: Para 7 = 080, Para 13 = 1 (= 1 x 5,6 m further) Semitrailer area = 80 + 1 x 255 = for 335 pulses (7,4 m) the brushes are locked;

Para 14 000 value Extended area for 2nd initial position, from 1.13 Extension for Para 4, each number lets the machine run for another 255 pulses (5,6 m). 2. GS = Para 4 + (255 x Para 14) Example: Para 4 = 120, Para 14 = 2 (= 2 x 5,6 m further) 2. initial position = 120 + 2 x 255 = at 630 pulses = 12,8 m away from initial position.

P 15-17 001 value Portal exists; 001 = Portal active. must not be changed to 000!

Para 30 000 pulses Advanced 1st initial position after vehicle has left wash bay, from 1.32s2 Automatic parking of the machine with distance to exit with traffic light positioning and start light barrier at machine. for MaxiCombi; when simultaneously ANL Para 9 = 001 = 2. IP and SOF Para 4 = 003 is set. Machine moves into 2nd initial position after end of wash (Para 4), after the vehicle has left the wash bay into 1st initial position (Para 30). Reason: At start of wash the HP roof nozzle needs a sufficient distance towards the vehicle because otherwise the roof nozzle moves against the front. .



001 DB Roof brush Para 1 00225 pulses Washing position, lower limit switch

With reaching the lower limit switch the lift counter is set to the adjusted value. Has to be adjusted for the different washing heights (normally done in the factory). From 1.24 the wash position can be learned automatically. 1. Set DB para 1 = 0; 2. Activate the test program with Monitor DB Byte 2 = 007; During the test mode the DB first runs to top then slowly descends to the lower position. At the limit switch the counter is written into the parameter automatically. 3. Check DB Para 1, whether the value could be correct. Wash height cm: 330 360 390 420 450 495 Winding drive: new belt 188 197 206 219 231 250 Winding drive: 192 202 212 226 239 259 Tooth belt: 205 225 245 265 285 315

Up to 1.19m default = 267. Para 2 00200 pulses Wash start for special bus program, from 1.27g

or DB Portal position length mirror area If Para 20, 21, 22 = 0: The roof brush starts to wash the bus from this portal counter, without front wash (because of large outside mirrors) or mirror bypass: During the front wash the roof brush washes upwards up to Para 22, than the portal moves first by Para 20 pulses backwards, the roof brush is lifted up to Para 21, than the portal moves forwards by the Para 2 pulse before the roof brush moves back towards the vehicle. Para 2 has to be at least 15 larger than Para 20! Note: Para 2 and 3 for the roof brush have been exchanged so that the same parameters are used for roof brush and side brushes for special buses. The parameters are automatically rewritten during a software update.

00040 pulses only up to 1.27f: Pickup locking for dumpers, from 1.09d compare Para 3 from 1.18: from this number of pulses after the vehicle front the roof brush is switched off, it is cleared; up to 1.16i: from this portal position (portal counter) the roof brush is switched off; up to 1.16 default = 230.

Para 3 00040 pulses Pickup locking for dumper, from 1.27g from this number of portal pulses after the vehicle front the roof brush is switched off, it is cleared;

00200 pulses only up to 1.27f: Wash start for special bus program from 1.16f compare Para 2 (from 1.18: mirror bypass: Portal position end X2, compare Para 20 - 22) up to 1.17 default 080, much too low!



001 DB, continued, from Para 4 Para 4 080 % Truck, bus, etc. contact pressure for forwards washing

Higher values produce higher contact pressure, (up to 1.24a default = 100) Recommended change step 5 - 15;

Para 5 080 % Truck, bus, etc. contact pressure for backwards washing like para 4, recommended change step 5 - 15; (up to 1.24a default = 100)

Para 6 060 % Lift control properties, influences lifting/lowering speed, depending on torque, higher values go for faster lifting, but risk of swinging. During the longitudinal wash the roof brush should less lift and lower. (up to 1.24a default = 100)

Para 7 100 % Portal control properties, influences the portal speed, depending on toque, higher values = more influence = more braking force. During the front and rear wash the portal should less move forward and backwards.

Para 8 100 % Operating contact pressure of P0 operating program The value is shown here for ETT changes by customer in P0.

Para 9 170 pulses Drawbar height; For trucks and/or trailers the DB is only lowered to this height at the rear or between the tractor unit and the trailer. Approx. values for different wash heights: Wash height cm: 330 360 390 420 450 495 Winding drive: new belt 100 120 140 160 180 210 Winding drive: 110 130 150 170 190 220 Tooth belt: 130 150 170 190 210 240

Up to 1.16 default = 190. Para 10 110 pulses Position reverse rotation direction before the front, from 1.15 b

While washing backwards the rotation direction is reversed this number of pulses before the front. From 1.32s3 also turn-off position at 1x front wash during return cycle. Standard = 110 pulses before front. from 1.29e: for Tandem M2, if Para 10 > 000: DB in reverse wash uses the rotation of the forward cycle. M2 starts with reverse wash, therefore the position is unknown. The time for the rotation change can therefore not be determined. Therefore the start is always with rotation direction forward cycle. from 1.23: 000 = no reversed rotation,

Para 11 000 pulses Stationary passage wash height; The roof brush is locked at this height, not yet active

Para 12 080 % Contact pressure, cars, for forwards washing, from 1.09e like para 4, recommended change step 5 - 15, but for cars; The vehicle contact pressure should be at least 15 - 20 lower than the truck contact pressure up to 1.19m default = 100;

Para 13 080 % Contact pressure, cars, for backwards washing, from 1.09e Contact pressure, cars, for backwards washing, from 1.09e The vehicle contact pressure should be at least 15 - 20 lower than the truck contact pressure up to 1.19m default = 100;

Para 14 000 Hz Speed for searching the vehicle, from 1.12b With brushes ∅ of 800 mm the speed should be reduced to ca. 12 Hz (000 = Standard = 35 Hz).



001 DB, continued, from Para 15 P 15-17 001 value Roof brush fitted;

must be set to 0 for dual brush machine; Can also be switched in P0 operator system settings. 000 = not fitted, Attention: Brush is not operated anymore; it has to be removed manually out of the drive area if necessary; 001 = Brush active. In case of faulty frequency converter the para 15-17 of the module FUH must be set to 0! Attention: Activation of the module is only accepted after power off-on!

Para 18 000 value Truck + trailer, small gap between truck and trailer, from 1.29c; Usually the gap between the rear of the truck and the front of the trailer has tob sufficient so that the roof brush does not wash rear and front at the same time. For special trailer trucks with gaps lower than 100 cm (up to 70 cm) the roof brush can only be lowered manually into the small gap. The safety load limits are thereby increased. Attention: There is a risk of damaging at vehicle and brush if the gap is not reached exactly! 000 = Standard, small gaps cannot be washed; 001 = A small gap can be washed manually. Press the stop key when the brush reaches the gap. Move roof brush manually above the gap. Press the start key when the roof brush has reached the drawbar. Lift the brush manually out of the gap. Thereby front and rear are cleaned simultaneously. Now press the start key again and the remaining wash is continued automatically.

Para 19 000 value Function switch binary; The individual bits of the parameter are treated like a coding switch with 8 switches. The individual coding switches activate different functions or switch between different selections. To determine the parameter value the individual figures are added. Switch 1: Special bus, front wash during reverse wash, from 1.28b 000 = Standard, without front wash during reverse wash, if the portal counter reaches the value of Para 2 the brush is witched off; + 001 = Normal front wash during reverse wash, Due to the special form of the mirrors the mirror area has to be bypassed during forward cycle (the mirrors will be flapped to the windscreen). In reverse cycle the front may be washed normally. Switch 2: Roof brush rotation off at end of the wash, from 1.29g 000 = Standard, + 002 = Roof brush switches rotation off when the side brushes are outside, longer ejection of the roof brush At normal switch-off of the roof brush rotation the brush drops for some time. Here the rotation is on until the side brushes have reached the outer initial position. The roof brush is ejected until then. No dripping of the brush while the vehicle leaves the wash bay. Switch 3: Semitrailer: deactivate roof brush locking, from 1.32pk 000 = Standard, roof brush is locked in semitrailer area. + 004 = roof brush will not be locked in semitrailer area, The roof brush is not locked in the semitrailer program, makes sense when there is no gap or when “Spoiler” is active. Switch 4: Roof brush semitrailer rear wash extended, from 1.32pk 000 = Standard, + 008 = Roof brush washes rear in semitrailer program up to drawbar position + 20 pulses downward, In the semitrailer program the wash continues for 20 pulses downwards above drawbar position. Makes sense when the drawbar position at the rear of the semitrailer is not sufficient.



001 DB, continued, from Para 20 Para 20 000 pulses Mirror bypass, Portal distance away from the vehicle, from 1.27g

Position, start mirror area (X1), from 1.18 Not active if Para 20, 21, 22 = 0 The roof brush does not wash the front between the portal positions X1 and X2 (Para 2, 3). From 1.27g: After front wash the portal moves backwards for this number of pulses.

Para 21 000 pulses Mirror bypass, roof brush lifting position, end of mirror area (Y1), from 1.18 Not active if Para 20, 21, 22 = 0 The roof brush moves away from the vehicle between the lift positions Y1 and Y2 (Para 22) From 1.27g 001 = The roof brush moves to the upper limit switch, the rotation is witched off during forward move of the portal; > 001 = the roof brush moves upwards until the lift counter has been reached, the rotation remains on during the portal moves forward;

Para 22 000 pulses Mirror bypass, roof brush lifting, start at mirror area (Y2), from 1.27h to 1.27f: length of mirror area (Y2-Y1), from 1.18 Not active if Para 20, 21, 22 = 0 from 1.27h: Para 22 = Start mirror area; The lifting is finished when the lift counter reaches the value of Para 22 during the front wash. The portal moves backwards away from the front.

Changed sequence, from 1.27g, portal position depends on vehicle front: 1 = Roof brush lowers until lower limit switch 2 = Search for vehicle until vehicle front 3 = Wash upwards until lift counter = Para 22 below mirror 4 = Portal backwards for Para 20 pulses in front of mirror 5 = Lift roof brush until lift counter = Para 21 above mirror 6 = Portal forward by Para 2 pulses (= wash start) behind mirror 7 = Lower roof brush to vehicle and wash roof Experienced values for setting:

Para 2 = 060, Para 20 = 025, Para 21 = 080, Para 22 = 180; From 1.18 up to 1.27f:

If the lift counter reaches the values of Para 21 + Para 22 during the front wash the lifting is stopped and the portal moves backwards, away from the front. 1 = Roof brush lowers until lower limit switch 2 = Search for vehicle 3 = Wash upwards until lift counter 22 (Y1 + Y2) below mirror 4 = Portal backwards for Para 20 (X1) in front of mirror 5 = Lift roof brush until lift counter = Para 21 (Y1) above mirror 6 = Portal forward until Para 2 (3) (X2 = wash start) behind mirror 7 = Lower roof brush to vehicle and wash roof

Para 23 000 pulses Semitrailer: lowering between truck and trailer, from 1.28p1 During forward cycle the roof brush lowers behind the truck down to the set counter, the front of the trailer is washed. During reverse cycle the roof brush is locked as usually. Value = The roof brush is lowered in forward cycle down to the set counter in the semitrailer area.

Para 24 000 pulses Lowering at rear for ski basket/loading ramp, from 1.25k The parameter is used to determine how low (down to which lift counter) the roof brush lowers at the rear when ski basket/loading ramp has been selected. 000 = Standard = lower to drawbar; Value = it is lowered down to the set counter (e.g. 120).

P2 6 P21 7 1 5 P20 P22 4 3 2

Side view

1.18 to 1.27f X1 X2 6 Y1 7 1 5 Y2 4 3 2

Side view



001 DB, continued, from Para 25 Para 25 000 value Unbalance monitoring, from 1.24

During monitoring is checked whether the difference between minimal and maximum captured torque values exceeds the limit of 20. Larger values cause an error message. 000 = Standard = without unbalance - monitoring 001 = with unbalance - monitoring.

Para 26 000 value Idling correction for backwards wash, from 1.23o Standard = 000 = 100 = without idling correction; In case the rotation motor has larger differences to the reference value during forward and reverse cycle the parameter can be used to achieve a balance. Para 26 = 100 + reference value reverse - reference value forward; maximum may be corrected with +/- 10. For bigger differences the motor has to be changed. Example: Ref value forwards = 132, Ref value backwards = 138 Para 26 = 106; Determine the difference with P3 Monitor: Let the brush rotate for 2 minutes in each direction and read out Byte 3 (set value).

Para 27 000 value Tandem: Zero balance at wash start, from 1.22a Standard = 000 = roof brush makes no zero balance at wash start; 001 = no zero balance, if „DB off“ for Tandem M1 and automatic start; 002 = no zero balance, if „DB of“ for Tandem M2 and bus program.

Para 28 000 value Bus ski basket function, from 1.21e Standard = 000 = DB lowers at the rear until drawbar height; 001 = Ski basket not active, the DB lowers until wash position, the lower limit switch only admissable with hard case ski baskets.

Para 29 000 value Rear wash for truck + trailer or semitrailer, from 1.19 Standard = 000 = until drawbar height; 001 = the DB lowers until wash position, the lower limit switch only admissable if all vehicles have rear cladding.

Para 30 000 value Rotation change for passenger car, from 1.18t 000 = Standard = without; + 001 = only roof brush with rotation change at vehicle centre during reverse wash + 002 = SBL/R with rotation change at vehicle centre during reverse wash, from 1.27k + 003 = Roof and side brushes change rotation, from 1.27k + 004 = no rotation change of the roof brush for bus and special bus program, from 1.33r



002 SBL Side brush left 003 SBR Side brush right Para 1 00000 value Rotation change during reverse cycle, from 1.18t

00000 = Standard = without; 00110 = with rotation change at position vehicle front + 110 pulses (Para value) should always be set like Para 10 roof brush

Para 2 00160 pulses Wash start for special bus program, from 1.16f or side brush portal position length mirror area If Para 2 = 160 and Para 20, 21, 22 = 0: The side brushes start to wash the bus from this portal counter without front wash (because of the large outside mirrors) up to 1.19m default = 110, too tight (for mirror bypass: Portal position length mirror area only possible with special side brush frame!) 000 = without front wash, from 1.27g; The special bus is positioned in a way that the side brushes already reach the side of the bus while moving inwards while the portal is still in initial position. If the side brushes reach the inner limit switches when the bus is positioned not correctly the wash is aborted. 060 = Mirror bypass with front detection, from 1.27g; After the front has been detected (and center overlapping if SOF Para 13 = 001) the side brush washes outwards up to Para 22, than the portal moves backwards by 20 pulses, the side brushes move outwards up to Para 21, than the portal moves forwards by Para 2 (60) pulses, before the side brushes move back towards the vehicle; Para 2 has to be at least 15 larger than Para 20!

Para 3 00000 value Release rotation change at 1 x Washing at rear, from 1.13 00000 = Center overlapping at rear without rotation change (opposed) 00001 = the rotation is changed at the rear when the wash position has been reached to wash a complete center overlapping in the same direction. 00002 = from 1.30j: after reaching the wash position an opposed center overlapping is done, afterwards the rotation changes with a center overlapping, but this time in the same direction 00003 = from 1.30j: after reaching the wash position an opposed center overlapping is done, afterwards the rotation changes with a half center overlapping, in the same direction

Para 4 130 % Truck, bus, etc. contact pressure for forwards washing Larger values press stronger towards the vehicle, (up to 1.24a default = 100) recommended change steps 5 - 15;

Para 5 130 % Truck, bus, etc. contact pressure for backwards washing like Para 4; (up to 1.24a default = 100)

Para 6 180 % Adjusting controller Impacts the entry and exit duration depending on the torque larger values increase the movement, but risk of oscillating. During the side wash the side brushes should adjust just a little bit. At lower values the side brushes may not move around the corners; up to 1.19m default = 100

Para 7 100 % Portal controller, Impacts the portal speed depending on the torque, larger values = more impact = more breaking. During the front and rear wash the portal should move just a little bit.

Para 8 100 % Operator contact pressure from P0 operator program The value is displayed at changes by the customer.



002 SBL, 003 SBR, continued, from Para 9 Para 9 030 pulses Drawbar width

At trucks and/or trailers the side brushes move inwards only up to this width when washing the rear or between truck and trailer. Set to 50-60 for wide machine.

Para 10 030 pulses Ski basket/Loading ramp width Like drawbar width must not be smaller than drawbar width Para 9.

Para 11 020 pulses Stationary drive-through wash width Value < 255: For buses the rotating brushes will be locked in this width, The bus moves motor-driven through the stationary portal. Set to 35-40 for wide machine. From 1.29p7 Value = 255: The max. infeed distance is only defined by the side brush wash position. (for stationary drive-through washes and no portal drive fitted)

Para 12 080 % Contact pressure cars for forward wash, from 1.09e like para 4, recommended change step 5 - 15, but for cars; up to 1.19m default = 100;

Para 13 080 % Contact pressure cars for reverse wash, from 1.09e like para 12, recommended change step 5 - 15; up to 1.19m default = 100;

Para 14 030 pulses Distance for center overlapping, from 1.12 From the wash position the side brushes keep moving this number of pulses. . The distance may be increased in case of dirt stripes at rear or front. Depending on the setting of the inner limit switch, however pay attention to the mechanical stoppers!

P 15-17 001 value Side brush fitted; 001 = active. must not be changed to 000!

Para 19 000 value Function switch binary; from 1,28b The individual bits of the parameter are treated like a coding switch with 8 switches. The individual coding switches activate different functions or switch between different selections. To determine the parameter value the individual figures are added. Switch 1: Special bus, front wash during reverse wash, from 1.28b 000 = Standard, without front wash during reverse wash, if the portal counter reaches the value of Para 2 the brush is witched off; + 001 = Normal front wash during reverse wash, Due to the special form of the mirrors the mirror area has to be bypassed during forward cycle (the mirrors will be flapped to the windscreen). In reverse cycle the front may be washed normally. Switch 2: Stop at change of direction center overlapping at rear, from 1.30e 000 = standard, no stop during change of rotation at infeed + 002 = 3 seconds stop during change of rotation at infeed, Up to now the rotation was changed immediately during center overlapping in a way that front or rear have not been washed properly in this area. By stopping during the change of rotation these end positions will now be washed intensively for 3 seconds. Switch 3: Semitrailer: deactivate side brush locking, from 1.32pk 000 = Standard, the side brush is locked in the semitrailer area; + 004 = no locking of the side brush in the semitrailer area. The side brush is not locked in the semitrailer program. Makes sense when there is no gap. Thereby the side brushes wash the side of the driver cabin much better.



002 SBL, 003 SBR, continued, from Para 19 Para 19 000 value Function switch binary; from 1,28b, continued

Switch 4:

Para 20 000 pulses Mirror bypass, Portal distance away from the vehicle, from 1.27g Position, start mirror area (X1), from 1.18

Torque reference value generation at position = 20 pulses, from 1.33o5 000 = Standard, the reference is measured at wash start in initial position; + 008 = the side brush moves first 20 pulses inwards before the reference is calibrated: If the special bristles of the side brushes are very long and touch the frame in side brush initial position the side brushes move first 20 pulses inward at wash start. . There the reference is build. Additionally parameter 29 has to be adapted if necessary if the side brushes stripe too strongly.

Not active if Para 20, 21, 22 = 0; May only be activated with special side brush frame! The side brush does not wash the front between portal positions X1 and X2 (Para 2). From 1.27g: After center overlapping (only if SOF Para 13 = 001) and front wash the portal moves backwards by this number of pulses.

Para 21 000 pulses Mirror bypass, side brush set position, end of mirror (Y1), from 1.18 Not active if Para 20, 21, 22 = 0; May only be activated with special side brush frame! The side brush moves away from the vehicle between positions Y1 and Y2 (Para 22). From 1.27g 001 = the side brush moves until the outer limit switch is reached, while the portal moves forwards (between X1 and X2) the rotation is switched off; > 001 = the side brush moves outwards until this side brush counter is reached, the rotation remains on during portal forwards;

Para 22 000 pulses Mirror bypass, side brush set, , start of mirror (Y2), from 1.27h up to 1.27f: mirror width (Y2-Y1), from 1.18 Not active if Para 20, 21, 22 = 0; May only be activated with special side brush frame! from 1.27h: Para 22 = start mirror, if the set counter reaches the value of Para 22 during the front wash the outward movement is stopped and the portal moves backwards.. Changed procedure, from 1.27g, Portal position depending on vehicle front: 1 = Side brush inwards until inner limit switch 2 = Search for vehicle until vehicle front 3 = Center overlapping (only if SOF Para 13 = 001; Para 22 or 14 are the max. limit for center overlapping, depending which value is reached first) and wash outwards up to set counter = Para 22 besides mirror 4 = Portal backwards for Para 20 pulses in front of mirror 5 = Side brush outwards up to set counter = Para 21 outside mirror 6 = Portal forward by Para 2 pulses (= wash start) behind mirror, besides vehicle 7 = Side brush inwards to vehicle and side wash Experienced values for setting: Para 2 = 060, Para 20 = 025, Para 21 = 001, Para 22 = 100; From 1.18 to 1.27f: If the set counter reaches the values of Para 21 + Para 22 during the front wash the outward movement is stopped and the portal moves backwards, away from the front; Center coverage is not possible. 1 = Side brush inwards until inner limit switch 2 = Search for vehicle until load 3 = Wash outwards up to Para 22 (Y1 + Y2) besides mirror 4 = Portal backwards up to Para 20 (X1) in front of mirror 5 = Side brush outwards up to Para 21 (Y1) outside mirror 6 = Portal forward up to Para 2 (X2 = Wash start) behind mirror, besides vehicle 7 = Side brush inwards to vehicle and side wash

P2 6 P21 7 1 5 P20 P22 4 3 2

Top view, mirror image for SBL

1.18 bis 1.27f X1 X2 6 Y1 7 1 5 Y2 4 3 2

Topr view, mirror image for SBL



002 SBL, 003 SBR, continued, from Para 23 Para 23 000 pulses Offset for side brush portal position mirror length, from 1.33r5

000 = no offset > 000 = Offset, portal position for decreasing the value of Para 2 in pulses, the side brushes are switched on earlier by the offset Para 23 and are moved towards the vehicle. If the portal has to be moved back again because the roof brush bypasses the mirror, the side brushes are switched off when the portal moves below the value of Para 2 without the offset of Para 23. Thereby is can be avoided that the side brushes are continuously switched off and on during mirror bypass of the roof brush.

Para 24 000 pulses Offset for side brush portal position start mirror, from 1.33rn 000 = no offset >000 = Offset, Portal position in wash reverse cycle for Tandem machine 2 for increasing the value of Para 21 in pulses. In mirror bypass procedure of the Tandem 2 the side brushes may move inwards up to wash position if the portal position is lower them the value (Para 21 + Para 22). Attention:

Para 26 000 value Idling correction for backwards wash, from 1.23o

The vehicle front has always be positioned in the same distance to the machine to avoid damage to the mirror.

Standard = 000 = 100 = without idle correction; If the rotation motor has larger differences to the reference value between forward and reverse cycle this parameter may be used to achieve a balance. Para 26 = 100 + reference value reverse cycle – reference value forward cycle maximum corrections +/- 10. At larger differences the motor has to be exchanged. Example: reference value forward cycle = 132, reference value reverse cycle = 138 Para 26 = 106; Determine the difference with P3 Monitor: Let the brush rotate in each direction for approx. 2 minutes and read off Byte 3 nominal value.

Para 27 000 value Wash position, inner limit switch, from 1.24e As for the roof brush now the inner limit switch is used for synchronisation of the counters (only if the value is not 000). Automatic teaching of the wash position. 1. Set SBL/R Para 27 = 0; 2. In P3 Monitor set SBL/R Byte 2 = 007, activate the test program; during the test program the SB first moves outwards to the limit switch, then inwards. With reaching the inner limit switch the counter is written into the parameter automatically. 3. Check SBL/R Para 27, weather the value could be correct.

Wash width cm: 260 290 Counter inside (row value) 120 125

Para 28 000 value Trailer rear wash, from 1.24c For a trailer can be put in the bay forwards or backwards the side brushes only wash until the drawbar width at front and rear. 000 = Standard = at front and rear only until drawbar width; 001 = Wash at the rear until inner position, centre overlap possible too. The draw-bar of the trailer is always at the front; 002 = from 1.29b; at front and rear the side brushes wash up to inner side, center overlapping is possible for change bridges.



002 SBL, 003 SBR, continued, from Para 29 Para 29 000 value Torque lowering, from 1.23o

Some SB rotation motors have an inflated reference value (over 150). Therefore the range up to the maximum value of 255 becomes to small, There are very often overload errors. With para 29 (0 up to max. 8) the read in torque value can be decreased.

Para 30 000 value Torque Offset for profiled bristles (Holland), from 1.18t 000 = Standard = no offset; adjust from 010 to 020; (nominal value = nominal value – para 30) For this value the read torque value of the side brush is decreased. Thereby the contact pressure of the brush will increase for truck, bus etc. For the brush has contact to the vehicle over the total height in spite of the profiling.

004 DD Roof nozzle (for MaxiWash Combi) from 1.31 At the standard Nufa the module DD has no function and thereby no parameters. MaxiWash Combi = Combination of brushed and high-pressure Nufa, with adjustable high-pressure roof nozzle, scanning of vehicle contour with light barriers . The IO boards integrated into the controller detect the type. Para 1 00002 pulses admissible difference between roof nozzle and stored vehicle contour

The light barriers capture the vehicle contour. The portal stops if the difference between roof nozzle position and captured contour is larger than Para 1 (no matter if the roof nozzle is higher or lower than the contour). In roof nozzle pulses (one pulse approx. 1.5 cm).

Para 2 00000 pulses Distance roof nozzle to contour light barriers for forward cycle, portal track Here the distance between roof nozzle frame and light barrier frame is entered, in portal pulses (one pulse = 2.2 cm). It is the offset between roof nozzle and light barriers.

Para 3 00018 pulses Distance roof nozzle to contour light barriers for reverse cycle, portal track Like Para 2 distance between roof nozzle and light barriers, to move a slightly different contour during reverse cycle, more distance at the vehicle front.

Para 4 020 pulses Position of the most upper contour light barrier B20 in roof nozzle pulses Distance in height between the most upper light barrier to roof nozzle initial position, in roof nozzle pulses (one pulse approx. 1.5 cm).

Para 5 060 pulses Position of the 2nd

Distance in height between the light barrier B21 to roof nozzle initial position, in roof nozzle pulses (one pulse approx. 1.5 cm).

contour light barrier from top (B21) in roof nozzle pulses

Para 6 030 pulses Minimal distance of a gap in which can be lowered If there is sufficient space in a gap (e.g. between truck and trailer) the roof nozzle may be lowered into this gap, in portal pulses (one pulse = 2.2 cm). Determines simultaneously the distance of the roof nozzle to the contour behind a vertical or sloping surface

Para 7 030 pulses Delay portal distance, from uncovered light barrier, from 1.32 If the light barrier becomes uncovered (other lower light barriers may still be covered) by the contour (or an edge) the portal track will be driven on before the roof nozzle lowers.

Para 8 090 pulses Position of the 3rd


contour light barrier from top (B22) , from 1.32



004 DD, continued, from Para 9 Para 9 120 pulses Position of the 4th


contour light barrier from top (B23) , from 1.32

Para 10 030 pulses Trail portal track, from uncovered light barrier, from 1.32 If all light barriers are uncovered at the rear this portal track is driven on, only the cycle is changed.

Para 11 015 pulses Height until light barrier lifts at front, from 1.32 As soon as the light barrier is actuated at the front during forward cycle the portal stops and the roof nozzle is lifted tot he set position.

Para 12 000 pulses Portal position for front wash of the roof nozzle, from 1.32L As soon as the front of the portal has reached the set position during forward cycle or if previously a light barrier has been actuated the portal stops. Thereby a sufficient distance to the vehicle front can be set for the HP/CVW roof nozzle front wash. Standard = 000 = 60 portal pulses.

Para 13 000 pulses Wash position lower limit switch, from 1.32k When the lower limit switch is reached the lift counter is set to the pre-set value. Reference value = 187. The wash position can be teached automatically. 1. Enter DD Para 13 = 0; 2. Activate test program in Monitor DD Byte 2 = 007; In test program: first the roof nozzle moves possibly upwards, than slowly downwards. At the limit switch the counter is automatically entered into the Parameter 3. Check DD Para 13 if the identified value is correct. At wash height 4.1 m the value should be approx. 187 lift pulses.

Para 14 140 pulses Drawbar position, from 1.32m At truck and/or trailer program the roof nozzle is only lowered down to this position between truck and trailer. Reference value = 140 Standard = 000 = Function not active.

Para 15 000 value Roof nozzle fitted; Has to be set to 001 for Combi and 000 for standard!

Para 18 040 pulses Minimal width of a gap for debouncing the light barrier, from 1.32p1 Minimal portal track for which the light barrier has to be uncovered. After uncovering the light barrier the signal of the light barrier is analyzed time-delayed for the set rack. Is used for debouncing the light barrier. 000 = Standard = 10 pulses, experience value for parameter 29 = 1 is 050

Para 19 040 pulses Offset for contour in front of a rising surface, from 1.32pk Determines the distance of the roof nozzle in front of a rising or vertical surface. 000 = Standard = 0 pulses, experience value = 035

Para 20 000 value Service keys instead of select switches for CVW roof and HP roof; from 1.32po Determines if the contour controlled cycle for CVW roof or HP roof or HP cycle is activated by select switch or service key. 000 = Standard = Contour controlled cycle via select switch CVW-/ HP roof. 001 = Contour controlled cycle via service key CVW, HP active. (Service keys CVW, HP, additional arch) Thereby the CVW/HP contour cycle can be activated by wash cards or parallel entry without extra pre-setting of the select keys. The select keys for CVW roof and HP roof have to be off or deactivated.



004 DD, continued, from Para 21 Para 21 025 value Lift speed at front and rear for high-pressure wash; from 1.32s2

Here the lift speed of the roof nozzle at front and rear can be set. Serves for intensive cleaning with high-pressure.

Para 22 000 pulses Activate drawbar position for high-pressure rear wash; from 1.33h 001 = at truck and/or trailer program the roof nozzle is only lowered down to this drawbar position (value see parameter 13). Standard = 000 = roof nozzle lowers to wash position at the rear.

Para 28 000 pulses Release and search vehicle length for chain wash, from 1.33o; During chain wash several vehicles can be washed subsequently during a chemical wash. The portal moves further for this number of pulses. If no new front can be detected the cycle is reversed. For the chemical wash

Selection by key special function see SOF parameter 2 value = 008.

: > 000 pulses: behind the rear of a vehicle a new vehicle is searched for the set value in pulses. (recommended value = 040) approx.1,5 to 2 m)

Selection by select key see SOF parameter 5 to 7 value = 016. Release of chain wash for the brush wash see ANL para 5

Para 29 000 value Automatic further movement of the vehicle contour in cycle 1; from 1.32s 000 = Function locked. Roof nozzle remains at the highest point locked until all light barriers are uncovered at the rear. 001 = Roof nozzle continuous to move after the contour in the 1st

Para 30 000 value Automatic correction at vehicle contact; from 1.32s

cycle. Presumed that the parameters 6, 7, 18 and 19 are set correctly. Experience values for 6 = 030, 7 = 030, 18 = 40 und 19 = 40,

Standard = 000 = Function not active. 001 = Machine tries to move around the obstruction by itself when the roof nozzle has touched the vehicle. Lift height max.100 pulses. 001 to 025 roof nozzle lifts after contact for 100 pulses. > 025 = roof nozzle lifts for the set value in pulses after contact. After contact with the vehicle the portal moves away from the obstacle for approx. 30 cm. Afterwards the roof nozzle is lifted for the value set in Parameter 30 and locks. Afterwards the portal moves further for 1 m (controlled). Then the locking ends.

005 UBW Under-body wash Para 1 00000 pulses for segment UBW: switch point at front, from 1.33h2

Determines the minimum vehicle length at which the segment UBW is activated. Para 2 02000 pulses for segment UBW: latest switch-off point, from 1.33h2

If no rear is detected; this witch point usually never appears. Para 4 003 value Kind of pump, which pump is switched with the UBW

Preset values, normally no change required 000 = no pump 003 = high-pressure pump

Para 6 000 pulses Switch point in front of rear (off during forward, on during reverse) Switch point at rear of the vehicle. Determines how many segments are switched on, depending on the vehicle length.

Para 7 000 pulses Switch point after rear (off during forward, on during reverse) like Para 6



005 UBW, continued, from Para 10 Para 10 002 0.1 sec. Switch-on delay for stationary spray system, from 1.14

for UBW, delay after dark light barrier (E031 = 0) The parameter must not be 0 or 1, otherwise the valve does not switch on!

Para 11 002 0.1 sec. Switch-off delay for stationary spray system, from 1.14 for UBW, delay after light barrier (E031 = 1) The parameter must not be 0 or 1!

Para 12 000 0.1 sec for segment UBW: switch-on time for each segment, from 1.33h2 > 000 = spray time each UBW segment

Para 13 000 value Activate segment UBW, Kemi Finland, from 1.33h2 000 = Standard, stationary or no UBW; 001 = Segment UBW sequence active, only possible for HP Combi-Nufa w/o brushes. The UBW consist of 4 segments which are individually subsequently controlled. The outputs A128 to A131 (from the valves Y01 to Y04) are used. The vehicle length determines how many UBW segments are controlled. Para 2 of the modules Y1 to Y4 determines the end of the respective segment. The UBW has to be activated with para cycle 2 = 11 in the wash program matrix (35). With P3 Monitor SOF Byte 2 = 013 the UBW para will be set to standard values for the segment UBW. Sequence: Cycle 1 = Applying chemistry, Determination vehicle length; Cycle 2 = Start UBW, Portal waits at rear; segment controlling of the UBW; afterwards reverse cycle with high-pressure.

Para 14 001 value Stationary spray system, from 1.14 Is activated with input 031 „UBW light barrier“ For module 005 UBW and 013 Y8 CVW; from 1.27a also for 006 HP (Y40) and 014 Y46 possible; from 1.28d also several stationary arches can be activated; 000 = Standard, no stationary system, portal spray arch; 001 = Stationary system: After switching on of the key „UBW“ or „HP“ or „HP add. arch“ at the terminal the arch will only be activated until the end of the next wash. After the light barrier has been covered the arch switches on. Attention: The key LED remains on after the wash. from 1.27 to 1.28 function 001 did not work! 002 had to be used. 002 = Stationary system: After switching on the UBW key the light barrier is still active and activates the arch.

P 15-17 001 value UBW fitted 000 = does not exist 001 = is fitted in the system for the function anti-freeze, Para 15-17 have to be changed to 000 like for all other non-existing valves. Therewith the controller does not try to blow out the non-existing valves.

Para 29 030 0.1 sec. for segment UBW: switch-off delay for each segment; from 1.33h2 030 = 3 sec. Switch-off delay, when spray time according to para 12 is elapsed. Overlapping from segment to segment, should avoid that the HP pump is switched off shortly between the segments and before start of the HP cycle.

Para 30 000 value for segment UBW: rear offset, from 1.33h2 Adaptation to the vehicle length for short vehicles (for the last UBW segment). If the last UBW segment sprays against the roof because of the vehicle length it can be switched off earlier.



006 HP side (Y40 for wheels) 007 Y1 FreWa VN arch 008 Y2 FreWa add. N arch 009 Y3 ProcWa brushes 010 Y4 ProcWa VN arch 011 Y6 CDA VN arch 012 Y7 CTH add. N arch 013 Y8 CVW 014 Y46 split arch 015 Y10 HP chemistry lower side 016 Y11 HP chemistry upper side 017 Y12 HP chemistry roof 018 Y13 HP roof 019 Y14 HP lower side 020 Y15 HP upper side 021-023 Y16-Y18 Reserve 024 Y19 Swivel HP side 025 Y20 Reserve VN = Pre-/Post-rinse arch, add. N = additional post spray arch

Para 1 00??? pulses Switch point at front The valve switches at this portal counter. During forward wash the valve is switched on here During reverse wash the valve is switched off here

Para 2 02000 pulses Latest switch-off point If no rear is found, usually never occurs

Para 4 00? value Pump type, which pump is actuated with the valve Preset value, no change required 000 = no pump 001 = fresh water pump 002 = process water pump 003 = HP pump 006 = additional HP pump (Reserve)

Para 5 0?? 0.1 sec. Waiting time after switch-on with portal stop For building up pressure in the pipes.

Para 6 ??? pulses Switch point in front of rear (Off during forward, On during reverse) Switch point at rear of the vehicle. When the portal is in front of rear this number of pulses (machine is over the vehicle) the valve is witched off.

Para 7 ??? pulses Switch point behind rear (Off during forward, On during reverse) like Para 6, but machine is behind the vehicle.

Para 8 00? value Dosing pump Preset value, no change required 000 = no pump 001 = M20 Shampoo 002 = M21 CDA 003 = M22 CVW 004 = M23 HP chemicals

Para 9 0?? 0.1 sec. Post spray time at switch-off position with portal stop

000 value only for Y1: Release rinse with 2nd

for additional rinsing; 000 = no rinsing; 001 = continue rinsing after end of wash, during movement in 2nd initial position.

initial position, from 1.15d

Para 10 002 0.1 sec. Switch-on delay for stationary spray system, from 1.14 for UBW, delay after dark light barrier (E031 = 0) The para must not be set to 0 or 1 else the valve will not be activated!

Para 11 002 0.1 sec. Switch-on delay for stationary spray system, from 1.14 for UBW, delay after light barrier (E031 = 0) The para must not be set to 0 or 1 else the valve will not be activated!

Para 12 000 0.1 sec. Reaction time at stop after end of cycle 1, from 1.31b Portal stops for this time to allow the detergent to react after CVW cycle



005 - 025 Valves, continued, from Para 14 Para 14 00? value Stationary spray system, from 1.14

is activated by the input 031 „UBW light barrier“ For module 005 UBW and 013 Y8 CVW; from 1.27a also for 006 HP (Y40) and 014 Y46 possible; from 1.28d also several stationary arches may be activated; 000 = Standard, no stationary system the valve is switched with the portal switch points (Para 1, 5 und 6); 001 = Stationary system: After switching on the key „UBW“ at the arch will only be activated until the end of the next wash, after the light barrier has been covered the arch switches on. Attention: The key LED remains on after the wash from 1.27 to 1.28 function 001 did not work! 002 had to be used. 002 = Stationary system: After switching on the UBW key the light barrier is still active and activates the arch.

P 15-17 001 value Valve fitted 000 = Valve does not exist 001 = Valve is fitted in the system for the function anti-freeze, Para 15-17 have to be changed to 000 like for all other non-existing valves. Therewith the controller does not try to blow out the non-existing valves.

Basic setting of the valve parameters: Parameter number

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

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005 UBW 3 2 2 1 1 1 1 006 HP 60 2000 3 60 1 1 1 007 Y1 FreWa VN arch 2000 1 40 2 1 1 1 008 Y2 FreWa add. N arch 2000 1 2 1 1 1 009 Y3 ProcWa brushes 2000 2 50 1 1 1 1 010 Y4 ProcWa VN arch 2000 2 50 1 1 1 1 011 Y6 CDA VN arch 2000 1 1 2 1 1 1 012 Y7 CDA add. N arch 2000 1 1 2 1 1 1 013 Y8 CVW 2000 1 10 3 1 1 1 014 Y46 split arch top 60 2000 3 60 1 1 1 015 Y10 HP chem. lower side 170 2000 2 45 4 1 1 1 016 Y11 HP chem. upper side 170 2000 2 45 4 1 1 1 017 Y12 HP chem. roof 058 2000 2 10 4 1 1 1 018 Y13 HP roof 053 2000 3 1 1 1 019 Y14 HP lower side 150 2000 3 1 1 1 020 Y15 HP upper side 150 2000 3 1 1 1 024 Y19 HP side swivelling 300 2000 1 1

up to 1.13: basic values Y1 to Y8 Para 1 = 50 up to 1.16i: basic values Y10 to Y20 Para 1 = 50 up to 1.17: basic values Y8 Para 5 = 100 up to 1.18r: basic values UBW Para 10 and Para 11 = 0 up to 1.19m: basic values Y1 Para 6 = 80



026 DOP Dosing pumps Para 4 000 value Dosing cycles per minute M20 shampoo

Value = 0 = Permanent signal (for all dosing pumps) Para 5 000 value Dosing cycles per minute M21 CDA Para 6 000 value Dosing cycles per minute M22 CPW Para 7 000 value Dosing cycles per minute M23 high pressure chemicals Para 8 000 value Dosing cycles per minute Reserve Para 9 000 value Dosing cycles per minute Reserve Para 10 000 value Dosing cycles per minute Reserve Para 11 000 value Dosing cycles per minute Reserve Para 20 000 value Dosing Shampoo, switchable in P0 operator program, from 1.18t

000 = Standard, with dosing 001 = Shampoo off, the dosing pump is not active during the wash.

Para 21 000 value Dosing chemical dry agent, switchable in P0 operator program, from 1.18t 000 = Standard, with dosing 001 = CDA off, the dosing pump is not active during the wash.



027 PMP Water pumps Para 4 050 0.1 sec. Pressure build-up time for water pumps

Delay time until error shut down during active pump after error input becomes 0; Para 5 010 0.1 sec. Pressure build-up and relief time water pumps, from 1.13

After the valves are switched on the pump is switched on delayed by this time. After the pumps are switched off the valves remain opened by this time. Avoids water hammers when switching the valves on and off. up to 1.32n only in wash sequence, not in stationary sequence. up to 1.32n also in stationary sequence. up to 1.33h2 only for fresh water and process water pump (for HP pumps see para 13).

000 value only up to 1.12, flow monitor process water, release, from 1.10; 001 = active, after Y3 on (pump on) the flow monitor must switch. Input 036 = 1 = water flows; E = 0 = Error, no water.

Para 6 000 value Flow monitor pump 1 (fresh water), release, from 1.13 000 = not active 001 = active, after „pump on“ the flow monitor must be activated Input 032 = 1 = water flowing; E = 0 = Error, no water.

010 0.1 sec. Only up to 1.12, Pressure build-up time water pumps;

Para 7 000 value Flow monitor pump 2 (process water), release, from 1.13 Input 033 is controlled;

Para 8 000 value Flow monitor pump 3 (HP), release, from 1.13 Input 034 is controlled;

Para 9 000 value Flow monitor pump 4 (Reserve), release, from 1.13

Para 10 040 0.1 sec Run up time pump 3 for star delta, from 1.13

Para 11 010 1 Min Start interlock for HP pump 3, only for HP Nufa , from 1.15 The large HP pump (75kW) must be started not more than 6 times within one hour. After the pump is switched off it cannot be switched on again for the time set in Para 11. For a 55 kW pump a 6 minutes interlock is sufficient.

Para 12 000 value Start interlock for HP pump 3, activates for all machines, from 1.32pk After the pump is switched off it cannot be switched on again for the time set in Para 12. 000 = Standard = only for HP Nufa active, (see Parameter 11), 001 = for all machine versions active.

Para 13 010 0.1 sec. Pressure build-up and relief time HP water pumps (pump 3 + 4), from 1.33h2 After the valves are switched on the pump is switched on delayed by this time. After the pumps are switched off the valves remain opened by this time. Avoids water hammers when switching the valves P 15-17

Para 15 001 value Module exists; 001 = active. must not be changed to 000!



028 ANL System Para 4 000 value Kind of pulse counter for roof brush and portal; from 1.18

000 = one single counter for roof brush and portal, 001 = two counters for portal, 002 = two counters for roof brush, 003 = two counters for roof brush and portal,

000 value only up to 1.16k, Function of special input E049; from 1.11 Replaced by 047 SOF Para 5 000 = switch Solo (E049 = 0) / Tandem (1). 001 = operating unit released (0) / locked (1)

Para 5 002 pulses Release and length of searching vehicle for chain wash, from 1.18r; During chain wash several vehicles can be washed subsequently during one wash. The portal moves further for this number of pulses, if no new vehicle can be found the cycle is reversed. 000 to 015 = without chain wash, the portal move further for the number of pulses; 060 = 60 pulses: after the rear of a vehicle a new vehicle is searched for 60 pulses (approx. 1.3m). up to 1.23o: only 000 = no chain wash up to 1.19m: basic value = 060;

000 value only up to 1.16k (replaced by 047 SOF Para 10) special output A159; replaced by 047 SOF para 10 Depending on the para, A159 may be activated and can be used as per its function; 000 = On, when program running; 001 = On if wash is completed until machine is free (as long as exit light flashes); 002 = On, if magnetic card rear is released (MCR light); 003 = On, if magnetic card rear is not released; 004 = On if frost guard is active. 007 = On, if ready for operation; 008 = SoKo RVA Obersdorf: On, if „door may not open“, because the portal is too near (the door opens in the moving area of the portal), from 1.16f; additionally: 000 POR para 10 = 3, 039 EFT para 5 = 255.

Para 6 001 value Roof brush initial position (and lights forward/backward) Switchable in P0 operator program. With chosen option „2nd

Para 7 000 value Positioning lights

IP“ (from 1.18) this menu point will not appear and automatically set to „DB start pos top“. 000 = Start position bottom and lights backward at the end of washing, time saving, since the brush does not have to move downwards at the start of washing; 001 = Start position top, passage is normally clear; lights forward at end of washing (see para 11);

000 = no positioning light fitted, the menu for switching does not appear in operator program P0; from 1.18t; 002 = positioning light off; 003 = positioning light on; up to 1.19m basic value = 002.

Para 8 000 value Machine properties 000 = Manual start, by swiping card or pressing program key 001 = Automatic start, first start program, then position vehicle, Wash starts automatically after a delay (045 KFZ para 7); The lights has to be activated (ANL para 7 = 003)!



028 ANL continued, from Para 9 Para 9 000 value Release 2nd

Changeable by the operator in P0. 2

initial position nd IP = after the end of wash the machine moves tot he according portal counter. With

active „2nd

Para 10 000 value System language

IP“ the roof brush start position is automatically set to initial position top and the menu for changing in P0 disappears (from 1.18t). 000 = off, start from initial position (S14) 001 = on, start from 2nd initial position (POR para 4)

000 = German 001 = English, from 1.12 002 = French 003 = Danish, from 1.09d 004 = Dutch, from 1.16 005 = Spanish 006 = Italian, from 1.32p3 007 = Finnish, from 1.32p3 008 = Norwegian, from 1.09d 009 = Swedish, from 1.32p3 010 = Polish, from 1.32.p3 011 = Slovenian, from 1.32p3

Para 11 000 value Posit. light backwards after end of wash, in spite of DB IP top, from 1.21 a See Para 6; 000 = Standard, lights show forward 001 = after the end of the wash the lights show backward, although the DB start position is top

000 value only up to 1.16k (replaced by 047 SOF Para 6) special input E050, from 1.13 000 = ext. Switch for switching between manual and automatic start 001 = EFT: „close door“ push button 002 = Lights light barrier „backwards“ at the wall of the hall (instead of E028)

Para 12 000 value Tandem: Pos. Light off for Solo operation and car, from 1.25 j 000 = Standard, Positioning light controller active, (depending on ANL Para 7) 001 = In Solo operation, for car programs the light is off the positioning light barriers are installed too high for cars; only possible without automatic start. 002 = from 1.29l: In Solo operation the positioning light is off for all cars; e.g. when the start light barrier is covered by M1 in Solo operation.

000 value only up to 1.16k (replaced by 047 SOF Para 8) special output A113, from 1.16 Values like Para 5

Para 13 000 value Function switch binary The individual bits of the parameter are treated like a coding switch with 8 switches. The individual coding switches activate different functions or switch between different selections. To determine the parameter value the individual figures are added. Switch 1: Delete wash program after end of wash, from 1.25 r + 001 = Soko Strohhofer Geiselwind The wash program is deleted after end of wash. The message “Please select program” appears. The next wash can only be started after the new vehicle type (wash program) has been selected. Switch 2: Program entry only via parallel inputs E076-E092, from 1.29o + 002 = only parallel input possible. The program entry is only possible as serial input via the entries E076 to E092. Services can only be changed from the terminal. Switch 3: Activate mirror bypass with input E211, from 1.29p + 004 = one pulse at E211 (button) activates the mirror bypass. <> 004 = continuous signal at E211 (switch, light barrier) activates the function The mirror bypass can also be selected from a button at input 211. The button has to be pressed shortly before the start of the wash program, each other function deletes the key again!



028 ANL continued, from Para 13 Para 13 000 value Function switch binary; continued

Switch 4: End of wash in 2nd initial position during 1 x wash, from 1.30d + 008 = early end of wash in last cycle 4 during 1 x wash activated. During 1 x wash and pre-selection 2nd initial position (ANL Para 9 =001) the wash program will already be finished in cycle 4 (reverse cycle without brush wash) in the 2nd initial position. The vehicle will not be completely rinsed, but it can drive out in advance (time-saving). Switch 5: Portal stop at rear during 1x wash, from 1.30j + 016 = Portal stop at rear until vehicle is driven out. During 1 x wash the portal stops after cycle 3 (1. brush wash) at the rear until the start light barrier is uncovered and the vehicle has left the wash bay. Then the portal moves into initial position. Switch 4 + Switch 5: During 1 x wash and deactivated pre-selection 2nd initial position (ANL Para 9 = 000), the wash program is finished early in the 2nd initial position during cycle 4 (reverse cycle without brush wash).. The portal remains in this position until the start light barrier is uncovered and the vehicle has left the wash bay. Then the portal moves back into 1st initial position. The vehicle will not be completely rinsed, but it can drive out in advance (time-saving). Switch 6: Delay for wash program start, from 1.30L1 normal start immediately after program selection; + 032 = start only after a time delay (045 KFZ Para 7) for French systems with terminal at the machine; Start delay for the wash program start to allow the operator to move away from the machine before the water starts sprinkling. Switch 7:

000 value only up to 1.16k (replaced by 047 SOF Para 9) special output A155, from 1.16

Start light barrier at portal, from 1.33h + 064 = the start light barrier is installed at the frame of the portal and moves together with the system. Thereby it is possible to start the machine also from the 2nd initial position. Mainly used for the HP-Combi-Nufa. For outdoor machines the increased onsite effort for installing external start light barriers can be avoided.

Values like Para 5 Para 14 000 value Brush material, from 1.28 a

Attention: SofTecs only for busses! Not allowed for trucks, semitrailers, etc. because of damaging the SofTecs material. From 1.29e -1.29n: car wash not possible, Program selection for cars suppressed; from 1.29n: also car wash possible 000 = Standard, PE brushes; 001 = SofTecs, more sensitive regulation, from 1.29n: only roof brush in SofTecs 002 = from 1.29n: only side brushes in SofTecs, 003 = from 1.29nroof brush and side brushes in SofTecs Prerequisite for car wash with SofTecs, from. 1.29n: SBL/R at least the lower two rows have to be assembled with strengthened PE and no slow rotation drives should be installed.



029 M 1 Machine 1 Para 1 00150 pulses Assumed vehicle middle, after the front, for truck, bus...

For truck program: up to the middle the DB does not wash rear Tandem M1 starts to wash from this counter; With the old default the service vehicle could not be washed as truck. up to 1.16 basic value = 270; to 1.19m = 220; to 1.33h = 190.

Para 2 00999 pulses Tandem start position M1, from 1.09d The distance between the initial position (S14) and the tandem start position (S18) is saved here. After loading ROM data: Para 2 = 999 and the Tandem initial position has to be determined, up to 1.33n default = 000. From 1.23l: Tandem operation: 1. Verify that both Para 2 of the modules M1 and M2 are set to 999 for both machines. 2. Move both machines manually into Tandem initial position (S18); 3. Star bus program, both machines move first into Solo initial position and back again into Tandem initial position. Then the Para 2 of the modules M1 and M2 are entered automatically. Afterwards the wash starts. Up to 1.23l: 1. Move both machines manually into initial position (start of wash bay, S14); 2. Move both machines manually into Tandem initial position (S18); 3. In machine 1: Read off 000 POR Word 1 in P3 Monitor; enter this value into both machines to 29 M1 Para 2; 4. In machine 2: Read off 000 POR Word 1 in P3 Monitor; enter this value into both machines to 30 M1 Para 2;

Para 3 00173 pulses Displacement M1, for Tandem, from 1.09d Distance between both machines in initial position; The distance of the switching cams in Tandem and solo initial position has to be the same! The displacement parameter has to be entered in both machines in 029 M1 Para 3. The Para is calculated from: Para 3 = (distance / 2,2) - 50; or read off the distance with the portal counters: 1. Move both machines into initial position manually (begin of bay, S14); 2. Mark position of M1 on the floor (e.g. front end of the drive base); 3. Move M1 4 - 5 m forwards; 4. Move M2 onto the previous position of M1 (marking); 5. Read off portal counter M2 (P3 Monitor POR Word 1); 6. Module 029 M1 Para 3 = portal counter M2 -50; Example: P3 Monitor M2 Word 2 = 223 029 M1 Para 3 = 223 - 50 = 173.

Para 4 120 pulses Overlapping M1 in Tandem operation, from 1.09d M1 washes this number of pulses towards the front, to overlap

Para 13 000 value For 1 x wash: door open and traffic light green, from 1.28g Up to 1.29e only for Tandem, from 1.29f also for Solo machine; 000 = Standard, door opens and traffic light is green after end of wash (M1+M2 in initial position); 001 = already at the end of wash the door opens and traffic light is green. Thereby buses can leave the wash bay earlier. (M2 in Tandem initial position and M1 ready at the rear)



030 M 2 Machine 2 Para 1 00060 pulses Assumed vehicle middle, after the front, for cars, from 1.18r

like M1 Para 1 but for cars up to 1.33 default = 00090

Para 2 00999 pulses Tandem start position M1, from 1.09d like M1 Para 2

Para 6 000 value Centre overlapping, from 1.22a It is adjustable witch machine will wash the area between M1 and M2. In standard the M1 washes first to the front of the vehicle (distance = M1 para 4 pulses) and then to the rear, and again back to tandem initial position. 000 = Overlapping is done by M1 (distance = M1 Para 4); 001 = Overlapping is done by M2 (distance = M1 Para 4);

Para 7 000 pulses Tandem M2 offset mirror bypass, from 1.28n3 Because M2 has not determined a front at start of wash the mirror bypass program cannot run as usual in the special bus program. In addition to the normal SBL/R Para 2 now the value of M2 Para 7 is added to finish the reverse wash in time. During the following forward wash the mirrors are bypassed as usual.

031 M 3 Machine 3 No parameters

032 CHK, Check/Monitor Para 4 100 0.1 min. Waiting time until the water system is drained, from 1.06

In frost (input = 1) the system waits for this time to find whether another wash is to be completed. Up to 1.24c default = 010

Para 5 150 value Blow out time per valve, from 1.06 In frost each valve is blown out or drained in sequence for this time. The full cycle is repeated once.

Para 6 000 value SoKo: Kups drain hoses of recycling water, from 1.18r 001 = if the switch at the entrance E038 is set on (= 1), all valves will be activated. The input of frost is used for this function, therefore both functions are not available at the same time.

Para 7 000 value Anti-freeze sequence is not terminated by emergency-off, from 1.32s3 001 = if anti-freeze is active the blow out of the valves is not interrupted at emergency-off. A wiring change is required because the valves are connected to potential 4 which is interrupted by emergency-off. In this case the valves have to be supplied by potential 3.

Para 10 001 value Belt monitoring version, from 1.29j Affects the inputs 208, 209 for the roof brush, or 074, 075 at HP Nufa 6-0297 and 067, 068 for the roof nozzle at MaxiWash Combi 6-0302. 000 = old version until fall 2003: switch free = error 001 = new version from fall 2003: switch actuated (input = 0) = error. Thereby also a cable break is detected as an error .

Para 11 000 value Compressed air monitoring, from 1.33L6 000 = air monitoring off 001 = air monitoring active: when input 062 for 3 seconds = 0, than follows error 046 compressed air too low.



032 CHK continued, from Para 12 Para 12 000 value Voltage monitoring torque board

Voltage compensation brush control, from 1.34 000 = Voltage monitoring not active; 002 = Voltage compensation for the roof brush, 004 = Compensation for the side brushes, 006 = Compensation for the roof brush and side brushes. The voltage compensation compensates voltage fluctuations in the main and stabilizes thereby the brush control. Input E006 monitors phase L2 after the motor protection switch Q3 and verifies that the board works without fail, the voltage value is digitally displayed. If the value is below 20 for more than 6 seconds the system is switched off with error 47 „Error torque board“. In case of error pay attention: test instruction torque board N201-02-05-D Attention: Check if wiring and cables are up to date: The voltage measurement must be connected directly at the motor protection switch and not at the power contactor. Correct is: a. torque board U4 plug X3 pin 1, 3, 5 to motor protection Q3 terminal 2, 4, 6 b. torque board U4 plug X1 pin 5 to K201-CPU A3 X4 pin 1 Wrong is: a. torque board U4 X3 Pin 1, 3, 5 to contactor K3R terminal 1, 3, 5 b. for system with flat belts U4 X1 pin 4 to A1 X4 pin 1. c. for system with tooth belts U4 X1 pin 5 to A1 X3 pin 2. Report changes in the wiring diagram!

033 FUH Frequency converter lifting 034 FUP Frequency converter Portal 035 FUR Frequency converter Reserve Para 4 050 0.1 sec. Waiting time to switch on frequency converter after emerg.-off or after a trip

After the FC supply has been switched off (as a result of an emergency-off or trip), the supply is not switched on again until after this waiting time. from 1.18m changed calculation because of Omron FC (needs about 30 sec.) waiting time = 10 sec. + para 4 (+ 10 sec. for Omron) up to 1.18m default = 150

Para 5 060 Hz Maximum frequency, from 1.16k Independent of the program parameters the maximum speed of the motor is limited. FUH with winding drive: To avoid a swing of the roof brush on the top of a truck the parameter should be reduced to 45 or 40 Hz FUP from 1.19n: default = 068;

P 15-17 002 value Frequency converter fitted; For a faulty FC the para is to set to 0 Attention: Activating the module is only accepted after power off-on! 000 = no FC fitted or Intro machine, for Maxi Wash Intro without FC (from 1.29k), instead contactors are controlled; 001 = Lust FU active; the FC is controlled by a serial interface; 002 = Omron FU active, from 1.18b; the FC is controlled by an additional board on the CPU with one error input and three control outputs (SN 200 681); For field tests or when more than 2 serial interfaces are required an 8FC board (SN 192 066 , Hex-switch = D) from the wash tunnel is used. Up to 1.22 default = 001.



036 LT1 Auxiliaries table 1 Using the auxiliaries table modules it is possible to define which program or which auxiliaries are activated as the default program or auxiliaries when the main switch is turned on.

Para 1 00000 value Wash program after power on 000 = Truck 001 = Truck + trailer 002 = Semi-trailer 003 = Bus 004 = Car 005 = Trailer 006 = Stat. drive through wash 007 = Short hall 008 = Pick-Up 009 = Pick-Up truck + trailer 010 = Reverse wash 011 = Special bus with mirrors 012 = HP program, from 1.27n 013 = Pick-Up semitrailer, from 1.29d 014 = Van + trailer, from 1.33k 015 = Trolley bus, from 1.33r1 only active with 047 SOF Para 14 = + 002

Para 2 03184 binary Auxiliaries selection for solo or M1 after power on, from 1.09e + 16 = Wash twice 2 x / 1 x + 32 = Centre overlap 2 x / 1 x + 64 = DB Wash front 2 x / 1 x + 128 = Special function on / off + 256 = Spoiler on / off + 512 = Ski basket/Loading ramp on / off + 1024 = DB on / off + 2048 = SBs on / off + 4096 = UCW on / off + 8192 = CPW on / off + 16384 = HP side on / off + 32768 = Additional HP side arch on / off

Para 3 00000 binary Manual key pre-selection Solo or. M1 at power on, from 1.09e + 64 = lock roof brush + 512 = lock side brushes other values make no sense

By adding the various number values, it is possible to obtain the auxiliaries combination which appears after the main switch on the terminal has been switched on as the default settings. For tandem mode the auxiliaries selection of M1 has priority. Only DB, SB operation and DB, SB lock may be different. The auxiliaries marked with are already set as defaults.

037 LT2 Auxiliaries table 2 Para 2 03184 binary Auxiliaries selection M2 at power on, from 1.09d

like LT1 Para 3 00000 binary Manual key pre-selection Solo or. M2 at power on, from 1.09e

like LT1



038 PRG Programs The parameters from module PRG are for the wash program allocation for the inputs of the parallel operating units (E076 to 091). The individual bits of the parameter are treated like a coding switch with 8 switches. Each input requires 16 bits (switches), 1 - 4 for the wash program and 5 - 16 for the auxiliaries. By adding the individual figures the program/auxiliary of each input are determined. A complete input (E076 to 078) can be defined with parameter 1 to 3, because these parameters are words or dual bytes. Each parameter has 16 bits (switches). The other parameters now require 2 parameters to reach the 16 bits (switches), i.e. E079 consists of Para 4 (switch 1 - 8) + Para 5 (switch 9 - 16), E080 consists of Para 6 + Para 7 etc. Defaults for French Nufa with 8 program selection keys at CAN terminal: E076, Prog. 1: Para 1 = 03188 = car with 2x wash, CO, DB front 2 x, DB, SB E077, Prog. 2: Para 2 = 03195 = special bus with 2x wash, CO, DB front 2 x, DB, SB E078, Prog. 3: Para 3 = 03440 = truck with 2x wash, CO, DB front 2 x, DB, SB, Spoiler E079, Prog. 4: Para 4 = 113 + Para 5 = 013 = truck + trailer with 2x wash, CO, DB front 2 x, DB, SB, Spoiler E080, Prog. 5: Para 6 = 114 + Para 6 = 013 = semitrailer with 2x wash, CO, DB front 2 x, DB, SB, Spoiler E081, Prog. 6: Para 8 = 125 + Para 7 = 012 = ST-tractor with 2x wash, CO, DB front 2 x, DB, SB

Para 1 00000 value Wash program 1, input 076 switch 1 - 4: wash program = vehicle type + 000 = truck + 001 = truck + trailer + 002 = semitrailer + 003 = bus + 004 = car + 005 = trailer only + 006 = Stationary drive-through wash + 007 = short wash bay + 008 = pick-Up + 009 = pick-Up with trailer + 010 = reverse wash + 011 = special bus with mirror + 012 = HP program + 013 = Pick-up semitrailer + 014 = Transporter + trailer + 015 = Trolley bus only active with 047 SOF Para 14 = + 002 switch 5: + 016 = 2 x wash switch 6: + 032 = center overlapping switch 7: + 064 = roof brush front wash 2x switch 8: + 128 = special function switch 9: + 00256 = spoiler switch 10: + 00512 = ski basket/loading platform switch 11: + 01024 = roof brush switch 12: + 02048 = side brush switch 13: + 04096 = UBW switch 14: + 08192 = CVW switch 15: + 16384 = HP switch 16: + 32768 = HP additional arch

Para 2 00000 value Wash program 2, input 077 Setting like Para 1

Para 3 00000 value Wash program 3, input 078 Setting like Para 1



038 PRG continued, from Para 4 Para 4 000 value Wash program 4, input 079, switch 1 to 8

Setting like Para 1, switch 1 - 8; switch 1 - 4: wash program = vehicle type switch 5: + 016 = 2 x wash switch 6: + 032 = center overlapping switch 7: + 064 = roof brush front wash 2x switch 8: + 128 = special function

Para 5 000 value Wash program 4, input 079, switch 9 to 16 Setting like Para 1, switch 9 - 16, however other values; switch 9: + 001 = Spoiler switch 10: + 002 = ski basket/loading platform switch 11: + 004 = roof brush switch 12: + 008 = side brush switch 13: + 016 = UBW switch 14: + 032 = CVW switch 15: + 064 = HP switch 16: + 128 = HP additional arch

Para 6+7 000 value Wash program 5, input 080 Setting like Para 4/5














039 EFT Entry door 040 AFT Exit door Para 2 00200 pulses Portal position for "Door open"

If the portal reaches this position in the last run, the open pulse is given after a delay (para 10).

Para 4 020 0.1 sec. Length door open/close pulse

Para 5 000 1 sec. Time until door opened/closed Enter the time required to open/close the door here; if para 8 = 1: Waiting time until start of wash after closed pulse. up to 1.15c in 0.1 sec. If limit switch is connected, „255“ has to be set; from 1.32e traffic light switches to green at end of wash only when door switch open is actuated.

Para 6 000 value EFT: Winter door: Door open Push Button; from 1.13 000 = Door opens at once; 001 = Door opens if machine is ready and free (induction loop).

Para 7 000 value Door pulse type 000 = Pulse length from para 4; 001 = Continuous pulses for old doors.

Para 8 000 value System waits until door closed 000 = System does not wait, close pulse and start of wash at the same time; 001 = para 5 time must have elapsed after the output of close pulse before the first run can start.

Para 10 000 1 sec. Open delay after reaching the portal position After reaching the portal counter (para 2) the delay for the open pulse starts. up to 1.17 in 0.1 sec.

Para 11 003 0.1 sec. AFT: Winter door: Actuation time for door light barrier The light barrier must be dark for this time to recognise that the vehicle has left the hall. Measured as from leasing the stop area. No light barrier monitor if para 11 = 0.

Para 12 030 0.1 sec. AFT: Winter door: "Door close" delay after free door light barrier Para 13 000 value Door open at emergency-off; from 1.33h

000 = open doors at emergency-off. 001 = door remain closed at emergency-off.

P 15-17 001 value Module fitted; Must not be set to 000



041 MKL Magnetic card reader Para 4 000 value Number of CAN terminals, from 1.15

000 / 001 = Standard = one CAN terminal 002 = two CAN terminals, for HP-Nufa inside the cabin; Both terminals are totally running parallel (divided by the coding switches). For both terminals the same software release is required.

Para 5 000 value Release for deleting the counter in operator prog. P0 000 = Counters can be deleted with keys "+/-" and "Safety key" 001 = Counters cannot be deleted, the "Delete" menu point does not appear.

Para 6 001 value Hide MCR in the menu of P0 operator, from 1.19b 000 = the menu point „MCR on/off“ appears 001 = the menu point „MCR on/off“ is hidden, MCR not existing. up to 1.19m default = 000

Para 13 000 value Inverted A-B signals, from 1.29o 000 = Standard, A-B-signals for Kleindienst MCR; 001 = A signal inverted, for foreign operating units; 002 = B signal inverted, for foreign operating units; 003 = A and B signal inverted, for foreign operating units.

Para 14 000 value Type operating unit, from 1.29o 000 = WashTec or CK-MCR; 001 = Codax reader; 002 = Coin validator; 003 = Kienzle reader; 004 = UK-Chip reader with parallel program transfer. The outputs of the A-B signals are modified: A signal = A180 = blocker signal, B signal = A181 = error inverted; + 100 = program selection with parallel manual input unit; from 1.30K8 instead „Insert card“ appears „Select program“. (with BED Para 5 = 002 the CAN terminal can be locked (no program selection).



042 CKL Chip card reader Up to 1.14: module name: „IO module“, without function

Para 4 000 value Release CKL and accounting system, from 1.14 000 = without CKL 001 = with CKL and accounting system AWA-Manager All washes with chip cards are memorised, after latest 1000 washes an accounting by the AWA-Manager has to be done (the data have to be called) 002 = with CKL and without AWA-Manager (the chip washes are not memorised). 003 = SoKo.: with CKL, accounting system AWA-Manager and time detection with the help of the special inputs E049 and E050; from 1.16 E049 counts the HP lance time (contact of the lance pump); E050 counts the hall occupancy time (light barrier in the hall) with the AWA-Manager the times can be read out. 005 = with CAN- CKL 6-0799 with AWA-Manager, from 1.23 The CAN- CKL or SB-CCR is a chip card reader with the terminal of the CK45/30 Datamat M4, but with reduced functions. The operation of the service programs is not possible. 006 = with CAN- CKL 6-0799 without AWA-Manager, from 1.23 Card washes are not memorised. 012 = WashTec transponder reader with CP2, CAN unit, from 1.33r; WTT address 4 (bridge X11/6-4), P0 system settings/MCR=on create cards with Profit or AWA-Manager 013 = Transponder reader with CP1, with AWA-Manager, from 1.33r; like 012 014 = Datamat M4 transponder reader (Lithuania, Switzerland), from 1.34;

Para 5 000 value Release for capturing wash data during manual operation, from 1.33r2 000 = without separate wash data capture 001 = Wash data capture with time and date for accounting system; Maximum 1000 washes can be stored, the data can be transferred with the accounting program Profit. 002 = Vehicle length or wash time capturing with time / date; from 1.34L for accounting program Profit if SOF Para 14 = + 008 the wash time is captured instead of the vehicle length.



043 SER Serial interfaces up to 1.14: module „IO-Module“, without function

Para 2 00010 value Release serial interface RS 232 at plug X2, from 1.14 000 = not active 002 = Ticket printer; 003 = Chip card reader; 006 = Protocol printer (for printing of parameters, counters a.s.o.); 010 = PC with AWA Manager 011 = PC with AWA-Manager for direct connection, when simultaneously a modem is connected to another interface, from 1.33o4

Para 3 00000 value Release interface RS 232 at plug X3, from 1.14 like para 2 not existing with serial interface board for Omron-FC.

Para 4 006 value Release interface RS 232 at plug X4, from 1.14 like para 2 not existing with serial interface board for Omron-FC.

Para 5 000 value Release interface RS 232 at plug X5, from 1.14 like Para 2

Para 8 000 value Machine reports an error, from 1.18r If in addition for this error in P1 Erpros menu point „ SMS Error classes“ the item is „Mld (J)“ (reports = yes = J; doesn’t report = no = N). up to 1.27j: „Mld“ (Meldung = report) instead of „SMS“ 000 = report at direct connected PC, AWA-Manager; 001 = report via modem with SMS, dial numbers will be set in P2 Modcon "Station Parameters".

Para 9 000 value Modem-Type, from 1.18r 000 = analogue modem 001 = radio modem, Siemens M20 or TC35.



044 BED Operating unit, parallel input Para 1 61568 binary Auxiliaries selection release

+ 1 = Truck program can be selected + 2 = Truck + trailer program can be selected + 4 = Semi-trailer program can be selected + 8 = Bus program can be selected + 16 = Wash twice 2 x / 1 x + 32 = Centre overlap 2 x / 1 x + 64 = Front wash 2 x / 1 x + 128 = Special function on / off + 256 = Spoiler on / off + 512 = Ski basket/Loading ramp on / off + 1024 = DB on / off + 2048 = SBs on / off + 4096 = UCW on / off + 8192 = CPW on / off + 16384 = HP side on / off + 32768 = Additional HP side arch on / off Up to 1.27m default = 61440, Special function key was not disabled up to 1.19m default = 61486, „Centre overlap“ and „Front wash 2x“ were lockable too.

Using this parameter it is possible to define which keys the owner can disable in the P0 operator program with „Auxil. selection on/off“. The disabled functions () can then not be used by the washing customers. The non-disabled auxiliaries can be changed by the washing customers at any time, such as spoiler, for example.

The value of the parameters is calculated by adding the individually required functions. The total of those marked produces the default setting of 611568.

To disable all keys enter the value 65535.

Para 2 00000 binary Manual control keys release, from 1.07 (+ 1 = Start key, cannot be disabled) + 2 = Portal forwards + 4 = Portal backwards + 8 = Stop + 16 = Lift roof brush + 32 = Lower roof brush + 64 = Lock roof brush + 128 = Side brushes out + 256 = Side brushes in + 512 = Lock side brushes

Disable all except „Start“ = Para 2 = 1022 Using this parameter it is possible to define which manual control keys the owner can disable (like para 1 for the auxiliaries keys). The start key cannot be disabled. The value of the parameter results from the addition of the individual desired functions.



044 BED, continued, from Para 3 Para 3 46304 binary Disable wash programs, from 1.16

+ 1 = truck + 256 = Pick-Up + 2 = truck + trailer + 512 = Pick-Up with trailer + 4 = semitrailer + 1024 = Reverse wash + 8 = bus + 2048 = special bus with mirror + 16 = car + 4096 = HP program, from 1.27n + 32 = trailer only + 8192 = semitrailer Pick-Up from 1.29d + 64 = Stationary drive-through wash + 16384 = transporter + trailer, from 1.33k + 128 = short wash bay + 32768 = trolley bus, from 1.33r1 only active with 047 SOF Para 14 = + 002 up to 1.33r default = 13536, trolley bus was not disabled; up to 1.29d default = 5344, semitrailer pickup was not disabled; up to 1.27m default = 1216, trailer and HP program was not disabled; up to 1.19m default = 1728, Pick-Up with trailer was also disabled

Use these parameters to determine which wash programs should not be selectable from the terminal. They do not appear in the display. Para 5 000 value Operating unit operation mode

switchable in P0 operator system settings 000 = Manual operation, without card reader (together with 041 MKL Para 6 = 1); 001 = Card operation, for parallel MCR or foreign devices P0 system settings MCR = on; Display: „Insert card“ Operating mode is determined by the operating unit at CAN-MCR or CKL operation, 002 = automatic detection of the operating mode with CAN-MCR; the switchover manual-card operation is done within the MCR (041 MKL Para 6 = 1). When no CAN-MCR is connected automatically it is manual mode.

Para 6 000 value Auxiliaries selection switchable in P0 operator system settings 000 = auxiliary selection on, the customer can change programs and auxiliaries at any time. 001 = off; only dedicated wash program changes are possible (BED Para 1, Para 2).

Para 7 000 value Change wash program at end of wash, from 1.23d For sometimes the staff forgot to reactivate auxiliaries after the end of wash this will be done now automatically 000 = standard, no change of the auxiliaries 001 = at end of wash „DB on", „SB on" and „ski basket/loading platform" are switched off; from 1.27n: all auxiliaries are set to „Power On“

000 value only up to 1.16k (replaced by 047 SOF Para 4) change of operating mode via the inputs 49, 50, 51, from 1.11 000 = no switchover 001 = E049 = switchover Solo (when input = 0) or Tandem (1) = E050 = switchover manual (0) / automatic (1) = E051 = switchover MCR- (0) / manual operation (1) Attention: conflicts with ANL Para 4/11

Para 8 000 value Start disable (E037) if E037 = 1: 000 = no wash program start; 001 = all machine movements disabled. if E037 = 0: 002 = no wash program start; 003 = all machine movements disabled.



044 BED, continued, from Para 9 Para 9 000 value Function „external start key“ (E047), from 1.15

000 = Start of the wash program; 001 = Start only after previous program start for winter door control (for Hauser, Rottweil).

Para 10 000 value Setting POWER ON via P0 auxiliary selection on/off; from 1.33h6 000 = Setting for POWER ON via P0 auxiliary selection on/off is locked 001 = Setting for POWER ON via P0 auxiliary selection on/off is active.

045 KFZ Vehicle position Para 4 000 0.5 sec. Delay drive out vehicle in winter door operation, from 1.29p;

After the end of wash the vehicle stays in the wash bay for this period until the start light barrier is queried again. Leaving the stop area is delayed. Necessary when the distance from the start light barrier to the drive through light barrier is larger than the vehicle length (e.g. car). Otherwise the exit door does not close again afterwards. Attention: can only be set in KFZ Para 8 = 000 or 001. If KFZ Para 8 = 002 then the default is automatically = 255.

Para 5 000 0.1 sec. Short wash bay, delay traffic light Stop after rear reached, from 1.30m; If the brushes do not reach the vehicle rear while the vehicle moves forward the traffic light is switched to Stop with a delay.

Para 7 030 0.1 sec. Waiting time until wash start; The wash start is delayed, after program start the system waits for this period before the wash is started; (see also Parameter 13 value+013)

Para 8 000 value Traffic light positioning, from 1.10 000 = 2 light barriers (CVW- + Start light barrier) for positioning; 001 = only Star light barrier for positioning (no backwards) if without CVW input 028 has to be 0! 002 = from 1.29k: positioning with mechanical floor switches; while driving out the vehicle the system waits for 25,5 seconds before the positioning is active again. 003 = from 1.32pa: only CVW light barrier for positioning instead of start light barrier. The inputs E028 and E030 must be switched in parallel. Makes only sense with 2nd initial position (ANL Para 9 = 001) and automatic start. Recommended for 2nd initial position POR Parameter 4 = 090

Para 9 010 0.1 sec. Warning signal switch-on time during wash start, from 1.33r1; During wash start a warning signal is given for this time. only active with 047 SOF Para 8 = 014

Para 10 000 value CVW light barrier E028 (as positioning light barrier) installed in wash bay, from 1.34b; 000 = Standard, CVW light barrier at machine or without CVW light barrier; 001 = CVW light barrier installed in wash bay. Is required when during traffic light operation the start and the CVW light barrier are both installed in the wash bay and when after the brush cycle a chemistry cycle should run (e.g. osmosis spry cycle). No vehicle length measurement with the CVW light barrier.



045 KFZ, continued, from Para 14 Para 14 000 value Wash width, automatic parameter adaptation, from 1.29o;

For different wash widths several parameters have to be adapted.. 000 = wash width 2.60 m Standard; SBs Para 9/10 drawbar/ski box = min. 40, Para 27 inside = max. 120 001 = wash width 2.90 m; SBs Para 9/10 drawbar/ski box = min. 60, Para 27 inside = max. 120 002 = wash width 3.20 m; no center overlapping possible! SBs Para 9/10 drawbar/ski box = min. 75, Para 27 inside = max. 150; 004 = wash width 3.50 m; no center overlapping possible! SBs Para 9/10 drawbar/ski box = min. 90, Para 27 inside = max. 150 After setting of Para 14 a Setup has to be done for the side brushes: P2 Modcon SBL/R Para 27 = 000 set, P3 Monitor SBL/R Byte 2 = 007 start test program, the side brushes measure the distance to the inner limit switch and enter the value into Parameter 27, additionally Para 9 drawbar width and Para 10 ski box / loading platform are adapted.

046 TST Test Para 4 000 value Printing

000 = Standard, no printing 001 = Just as an error appears the monitor bytes of the most important modules are printed automatically. Or a print out of monitor bytes is started using the "Special function + Safety" keys. 002 = with ticket printer, at the end of wash a bill is printed.

Para 8 000 value only up to 1.19a, Torque offset for profiled (Holland) bristles, from 1.12 Replaced by SBR/L para 30; set to 10 - 20; The read in torque values of the side brushes are decreased by this parameter to increase the contact pressure for truck, bus ... By this operation the contact of the brush to the car is over the complete height but of the profiling.



047 SOF Special Functions up to 1.16k: Module Name: „R1 - Reserve“, without function

Para 1 00650 pulses Latest end of coupling areas for truck + trailer, from 1.23 From 1.24 measured from the vehicle front. Up to 1.24 default 750. From this point the washing phase is switched from the truck to the trailer (in case of the gap was not recognised, from now on the rear of the trailer will be searched) For trams (Stadtwerke Bielefeld) the value has to be increased extremely (over 1000), for the tractor of the tram is much more longer but a truck.

Para 2 00000 value Function switch binary: Function of the special function key; The individual bits of the parameter are treated like a coding switch with 8 switches. The individual coding switches activate different functions or switch between different selections. Several functions may be assigned to the special function key simultaneously. To determine the parameter value the individual figures are added. 000 = Standard, key is without function, Switch 1: Truck+trailer: Loading platform function only active for truck, from 1.30d replaces SOF Para 4 = 012 + 001 = Loading platform at rear of the trailer not activated; The key „special function“ can be used to select if the trailer rear should be washed normally even when the auxiliary „ski box / loading platform“ has been selected. (LED = on = no loading platform at rear of the trailer = normal wash). i.e. the locking for the loading platform is only active at the rear of the truck. (makes only sense when the limits for loading platform and drawbar position are different, can be set with DB Para 24, SB Para 10). Switch 2: Short wash bay sequence, from 1.30d + 002 = activate short wash bay for all wash programs; Use the key “special function” at the terminal to activate the short wash bay sequence for all wash programs (replaces SOF Para 4 = 015) Switch 3: SoKo, 2. CVW arch, from 1.30K3 + 004 = switchover between normal and additional CVW; Use the key “special function” at the terminal to activate a 2nd Chemical arch, With switchover either the normal CVW arch (Y08) or the additional arch (special output) is switched on during CVW cycle. The additional arch is activated with a special output, simultaneously SOF Para 8 = 012 has to be set. Switch 4: Chain wash, from 1.30L2 + 008 = activate chain wash; Use the key “special function” at the terminal to activate the chain wash. The machine searches for the next front after the rear of a vehicle. The search distance is entered in 028 ANL Para 5. If the chain wash is switched off the cycle is reversed afte the rear is washed (without search distance). Switch 5: Anti-freeze, from 1.32J + 016 = activate anti-freeze; Use the key “special function” at the terminal to activate the anti-freeze. The key works like the contact of a temperature monitor of the anti-freeze. Switch 6: 2nd initial position, from 1.32K + 032 = activate 2nd initial position; LED = off = normal initial position, LED = on = 2nd initial position; (replaces SOF Para 4 = 004)



047 SOF continued, from Para 2 Para 2 000 value Function switch binary: Function of the special function key

Switch 7: Automatic wash interruption during brush wash, from 1.32L + 064 = wash interruption after cycle 3 (first brush cycle). To assure that problem areas of the vehicle can be cleaned manually the machine is stopped after the end of the rear wash in forward wash. By pressing the start button the wash will be continued; (replaces SOF Para 4 = value + 100) Switch 8: Automatic wash interruption after chemistry cycle, from 1.32p6 + 128 = wash interruption after cycle 1 (first chemistry cycle); To assure that problem areas of the vehicle can be cleaned manually and the chemical agent reacts the machine is stopped after the end of the rear in chemistry cycle. By pressing the start button the wash will be continued. Switch 9:

Para 3 00000 pulses Portal turn position, limit switch end of wash bay, from 1.33t7

Activate mirror bypassing, from 1.33r + 256 = Activate mirror bypassing for all programs; Therewith the mirror bypass can be allocated to each vehicle before the wash starts.

Serves to ensure that the portal moves with a ramp into the limit switch instead of bumping into the stopper with high speed. Also it allows the brushes to wash the rear until wash position is reached which would not be the case at high speed. Automatic teaching of the turn position. 1. Enter SOF Para 3 = 0; 2. In Monitor POR Byte 2 = 007, activate test program; The portal moves eventually into initial position, than into portal turn position. The counter is automatically entered into the parameter at the limit switch. 3. Check SOF Para 3 weather the value could be correct.

Para 4 000 value Special constructions machine behaviour, from 1.17 000 = no special behaviour 001 = SoKo Stadtwerke Remscheid: On switchover switches 3 special inputs together: E049 = switchover Solo M1 (0) / Tandem operation (1); E050 = switchover manual (0) / automatic operation (1); E051 = switchover MCR (0) / manual operation (1). 002 = SoKo Schierle Aalen: - After end of wash the portal moves into 2nd initial position and after the vehicle has left the wash bay the portal moves back to wash bay entry (external signals E090, E091); - One key (E050) activates CVW for the next wash; - Kienzle MCR. 003 = Driving out with 2nd initial position, from 1.18r; After end of wash the portal moves into 2nd initial position and after the vehicle has left the wash bay (positioning light barriers uncovered) the portal moves back to wash bay entry. The 2nd

004 = Key special function at terminal for 2 initial position must not be activated in P0!

nd initial position, from 1.18r; LED = off = normal initial position, LED = on = 2nd

005 = Program/auxiliary on default Power-on, from 1.23; after end of wash, wash program and auxiliaries are set to default like after Power-On.

initial position. (from 1.32k better use SOF Para 2)

Attention: better use BED Para 7.



047 SOF continued, Para 4 continued Para 4 000 value Special constructions machine behaviour, continued

006 = US version, from 1.23 the car program cannot be selected anymore and the input control voltage control voltage E052 is not queried. From 1.25k: Change for Pick-Up program: The roof brush will not be cleared after reaching the Pick-up locking (Para 2 or 3) It remains locked in this height with rotation. Change for bus program: instead of „bus“ now „bus or van prog“ will be displayed, and the display „Vehicle length“ will be suppressed. 007 = SoKo Beer, Nürnberg, from 1.24g stationary CVW and UBW; Parallel operating unit (foreign reader) with 2 power inputs: Inputs 076 to 089 for wash program, E090 + 091 for auxiliaries (CVW, HP side and UBW) At program allocation for E091 + E092 the wash program (truck,...) is not used, only the selected auxiliaries will be added to the other selected input. The foreign reader activates for example simultaneously E091 + E078. 008 = SoKo: Verkehrsbetriebe Endingen Train wash for Regio-Shuttle and railcar NE81, from 1.27e These trains are washed instead of the trailer program. Roof brush and side brushes are limited inwards by the drawbar position. Additionally the roof brush is lifted at dedicated areas (can be set with 048 R1 Para 1 to 6). The key special function switches between NE81 (LED off, roof brush is lifted once in the center) and Regio-Shuttle (LED on, roof brush is lifted twice, at front and rear). From 1.27r: The display shows depending on the position of key „Special function“ the program text „Railcar“ or „Regio-Shuttle“; during program cycle appears „Program TRI running“ (or REG) 009 = Soko: ESA Switzerland: very short wash bay, from 1.27i Very short portal track between the limit switches; (a system with 70 cm track, several with 380 cm) only program „Short wash bay“ and „Stationary drive-through“ possible. The machine washes up to the turn position, then the vehicle moves forwards until the brushes rotate freely, then follows the rear wash. The following parameters have to be changed additionally: 000 POR Para 3 = 000700, Forward wash stop short wash bay, This position must not be reached; 029 M1 Para 1 = 020, default middle of vehicle, 034 FUP Para 5 = 020, maximum frequency, „Change programs“ - matrix 15 and 31 - cycle 3 - Y2 = 004 post-spray arch active from 1.27l also all other wash programs possible from a portal track of approx.. 2,5 m also the mirror bypass may be activated (DB, SB Para 2, 20, 21, 22) 010 = Soko Esa Switzerland: autom. stop after 1. Cycle at HP program, from 1.27n The machine stops at the rear after the first CVW cycle. By pressing the start key the wash is continued with HP cycle reverse. 011 = SoKo Strohofer Geiselwind: Rinse with fresh water after end of wash, from 1.27n The keys „additional arch“ + „safety key“ are used to control the valve Y01fresh water with CDA for the VN arch (instead of Y46). „additional arch“ again switches off. Therewith the vehicle is rinsed additionally while driving out of the wash bay.



047 SOF continued, Para 4 continued Para 4 000 value Special constructions machine behaviour, continued

012 = Soko, truck + trailer: loading platform only at truck, from 1.27y (from 1.30d better use SOF Para 2) With the key „special function“ you may select if the rear of the trailer should be washed normally even if auxiliary “Ski basket / loading platform” has been selected (LED = on = no loading platform at trailer rear = normal wash). i.e. the locking for the loading platform is only active at the rear of the truck (makes only sense when the limits for the loading platform and the drawbar are, different, can be set with DB Para 24, SB Para 10). 013 = Soko Silbermann, Hermsdorf: from 1.28n HP roof arch is controllable (with Joy-Stick, like HP Nufa) and swivelling HP side arches with outer limit switch left E050, right E051; Select switch 1./2. initial position E049 1. Start position = Portal initial position, E025, outside the wash bay and 2. Start position, E040, inside the wash bay; Door control AFT upper limit switch E046; the machine may be moved out of the wash bay only when the door is open (1. Start position) further parameters: SOF Para 5 = 008, Para 6 = 000, Para 7 = 000. Brush wash is only possible when HP side arches are in initial position; otherwise HP initial position error. 014 = CAN terminal with 8 program keys (for France), from 1.28p New program foil (French) required; instead of the upper 4 keys now two rows of keys (8) are used for the program selection (Program 1 to 8); the program allocation is done with the parameter of 038 PRG; from 1.28r the LEDs of the upper three key rows are suppressed. 015 = Special function key for short wash bay sequence, from 1.29e (better use from 1.30d SOF Para 2 = + 002) The short wash bay sequence can be activated for all wash programs with the special function key at the terminal. Value + 100 = wash interruption after first brush wash, from 1.28c To clean problem areas of the vehicle manually the machine is stopped at the end of the rear wash during forward wash. The machine is stopped after the rear wash is finished. The wash is continued by pressing the start key.

Para 5 000 value Function of the special input E049, from 1.17 000 = no function 001 = switchover Solo (0) / Tandem (1); 002 = operating unit released (0) / locked (1); 003 = switchover manual- (0) / automatic operation (1), from 1.30L1; 004 = switchover MCR (0) / manual operation (1); 005 = key for closing the entrance door 006 = traffic light reverse light barrier in wash bay (instead of CVW light barrier) 007 = switchover from 1. (0) to 2nd initial position (1); from 1.19g 008 = switchover from 1. (0) to 2nd start position (1); from 1.19g only if additionally 000 POR Para 10 = 2 009 = feedback contact wire switch-off; from 1.22 for Stadtwerke Bielefeld, washing of trams; as long as E049 = 0 the contact wire is switched on, start locking, no machine movement possible; from 1.29f: no automatic start of the system possible; 010 = SoKo Stürzer, Landsberg: external HP arch with start locking; from 1.23s Input = 1 = HP on (with star/delta) and start locking; Input = 0 = HP off, machine ready



047 SOF continued, from Para 5 continued Para 5 000 value Function of the special input E049, continued

011 = from 1.29n: selection switch „maximum portal speed “; depending on the setting of the maximum speed in P0 (POR Para 5 = 2 or 3) the speed is reduced by one step with the switch (at input = 1), 012 = from 1.29o: Light barrier for short wash bay with truck + trailer, After the portal has reached the short wash bay stop position (POR Para 3) the truck + trailer move forward. The brushes remain locked as long as the light barrier is covered (vehicle covers the light barrier). The brushes are locked in the gap between truck and trailer; 013 = from 1.30L1: switch off auxiliary CVW at start, external key switch, so that the CVW cannot be activated during rush hours. If input = 0 the CVW key at the terminal is without function, CVW is off. 113 = from 1.33s: (= 13+100) if input = 0 = auxiliary CVW = off if input = 1 = auxiliary CVW = on 014 = from 1.32n: Wash the gap between truck + trailer for short wash bay sequence, After the portal has reached the front position + 110 the truck + trailer move forwards. The brushes remain locked until the light barrier is uncovered. As soon as the vehicle covers the light barrier the traffic light switches to stop and the brush locking is released. Now the vehicle is washed normally including the gap between truck and trailer. If the short wash bay stop position is reached (POR Para 3) or if the portal turn position is reached the brushes are locked again ant the traffic light switches to green. The vehicle will be moved forward until the brushes loose the load at the rear. Now the traffic light shows stop and the rear wash is finished. 015 = from 1.32o: Wash of semitrailers in short wash bay sequence, After the portal has reached the portal turn position or the short wash bay position (POR para 3) the roof brush is lifted in initial position in program semitrailer. Now the traffic light switches to green and the vehicle can be moved forward. As soon as the light barrier after the exit is actuated the roof brush can lower again or is released. This avoids damages when the roof brush is in front of the trailer while moving out. (trailer higher than drivers cabin). 016 = from 1.33o: Selection of chain wash by selection switch. If input = 1, then a so called chain wash is executed. Now several vehicles can be positioned and washed one after the other. Setting of search distance at chemistry cycle via module 004 DD Parameter 28 (recommended value = 40), for brush cycle via module ANL Parameter 5 (recommended value = 60). Distance between vehicles for positioning approx. 1, 5 to 2 meters. 017 = from 1.33r: Recognition of trolley busses via light barrier. If the light barrier is covered (input = 0) a trolley bus (with collector) is washed instead of a normal bus. The trolley bus is recognized by the vehicle height (alternatively to the separate wash program 15 trolley bus). Only active with 047 SOF Para 14 = + 002. 018 = from 1.33s: select auxiliary ski basket / loading platform at start, external switch to select the auxiliary ski basket / loading platform at a parallel card reader before program start. if input = 0 = auxiliary ski basket / loading platform = Off if input = 1 = auxiliary ski basket / loading platform = On.

Para 6 000 value Function of the special input E050, from 1.17; Setting like Para 5

Para 7 000 value Function of the special input E051, from 1.17; Setting like Para 5



047 SOF continued, from Para 8 Para 8 000 value Function of the special output A113, from 1.17

Potential P3, 230 V before emergency-off 000 = on, when program runs 001 = on, when wash is finished, until vehicle is moved out 002 = on, when MCR is released 003 = on, when MCR is not released 004 = on, when anti-freeze is active 005 = on, when machine is defect or system not ready, from 1.27z 006 = on, for 1 sec. at end of program, e.g. for wash counting; 007 = on, when ready for operation 008 = on, when SoKo RVA Obersdorf, door must not open because the portal is to close (additionally 000 POR Para 10 = 3 and 039 EFT Para 5 = 255) 009 = on when: request for connector switch-off, from 1.22 for Stadtwerke Bielefeld, tram. The vehicle is positioned, the electric connector must be switched off. 010 = on when: locking parallel operating unit, from 1.27y at error, „System not ready“ or „Program running“; 011 = on, as long as special bus program is selected, from 1.30b for controlling the control light; 012 = on, output for 2. CVW arch, active, when special function key = on, from 1.30K3; SoKo: for controlling an additional CVW arch; simultaneously SOF Para 2 + 004 must be entered; 013 = on, when machine interrupted or system not ready and no car program active, from 1.33h5 014 = on, warning signal at wash start for adjustable time, from 1.33r1 time = 045 KFZ Para 9. Value + 100 = inverse function, from 1.19e

Para 9 000 value Function of the special output A155, from 1.17 Potential P4, 230 V after emergency-off Setting like Para 8

Para 10 000 value Function of the special output A159, from 1.17 Potential free NOC Setting like Para 8

Para 12 000 value Function output A182 „lock parallel program entry“, from 1.27y The output locks the wash program entry in case of error, „System not ready“ or „Wash program running“ at the inputs of the parallel operating units (WCR …); „Entry locked“ at output = 1; 000 = Standard, only possible when traffic light is switched on; 001 = independent of traffic light; Value + 100 = inverse function; „ Entry locked“ at output = 0.



047 SOF continued, Para 13 Para 13 000 value Function switch binary;

The individual bits of the parameter are treated like a coding switch with 8 switches. The individual coding switches activate different functions or switch between different selections. To determine the parameter value the individual figures are added. Switch 1: Mirror bypass with center overlapping at front for special bus, from 1.27g 000 = Standard, without center overlapping; + 001 = with center overlapping, only possible with new side brush frame!, The center overlapping can only be activated if there is sufficient space between the large mirrors. Attention: the side brush frame limits the distance! Switch 2: Lock stationary manual operation, from 1.29o 000 = Standard, manual operation is started with the keys UBW, HP, CVW and safety key; + 002 = no stationary manual operation possible. If an auxiliary like CVW, UBW, HP or additional HP is activated for a wash program and the release key is actuated before the start key the manual operation is switched on instead of starting a wash. Switch 3: Very short wash bay, from 1.30L6 000 = Standard, normal wash bay length; + 004 = Very short wash bay, rail length below 4 m. like SOF Para 4 = 9 Very short portal track length between the limit switches; The machine washes until turn position, than the vehicle moves forward until the brushes rotate freely, than follows the rear wash. From portal track of approx. 2.5 m the mirror bypass can be activated. (DB, SB Para 2, 20, 21, 22). The following parameters have to be changed also: 000 POR Para 3 = 000700, forward wash stop short wash bay, this position must never be reached; 029 M1 Para 1 = 020, default vehicle middle, 034 FUP Para 5 = 020, maximum frequency, „Change program“ matrix 15 and 31 - cycle 3 - Y2 = 004 post-spray arch active; Switch 4: UBW Exception for card operation, from 1.31a 000 = Standard, at card operation the auxiliary UBW cannot be changed; + 008 = at card operation the auxiliary UBW can be changed. Nevertheless the auxiliary UBW can be switched on and off during card operation. The auxiliary key UBW is not influenced by card operation. Switch 5: Early cycle change for Pickup truck + trailer; from 1.32d 000 = Standard, no early cycle change for Pickup truck + trailer; + 016 = early cycle change for Pickup truck + trailer, If this switch is set the machine switches early into wash reverse cycle for the Pickup truck + trailer program. The portal cycle change positioned is calculated by: Vehicle front + DB Para 3 + POR Para 6 + (POR Para 11 x 255). Switch 6: At POWER ON always short wash bay program; from 1.32d 000 = Standard, POWER ON after LT1 Para 1 to 3; + 032 = the short wash bay program is automatically selected at POWER ON. If the sequence short wash bay is activated for all vehicles by selection switch or special function key this can also be set for Power-ON. (together with SOF Para 2 = + 002 or Para 5 = 12, 14 or 15) If additionally Para 7 = 001 in BED, then short wash bay is selected also after end of program.



047 SOF Continued, Para 13 Continued Para 13 000 value Function switch binary;

Switch 7: Short wash bay program without brush wash at rear; from 1.32g 000 = Standard, at short wash bay program the roof brush washes the rear; + 064 = at short wash bay program the roof brush does not wash the rear. The roof brush is locked at the rear. If this switch is set the roof brush does not wash the rear of the vehicle. The roof brush is locked shortly before the rear. (Alternative to 000 POR Para 12 = 001) Switch 8

Para 14 000 value Function switch binary;

: Emergency operation for SOKO from 1.33m 000 = Standard, wash only in combination with chip card reader operation; + 128 = emergency operation at failure of the chip card reader. A wash can also be carried out without chip card reader. Normally the chip card reader issues the authorization for the wash start. If the chip card reader fails no wash could be started without emergency operation because the authorization is missing. The automatic procedure for „Open door“, „Position vehicle“, etc. will be switched off and the wash can be executed as usual.

The individual bits of the parameter are treated like a coding switch with 8 switches. The individual coding switches activate different functions or switch between different selections. To determine the parameter value the individual figures are added. Switch 1: for US: Exchange of the keys SAZ and L+H, from 1.25k 000 = Standard, normal key assignment + 001 = the keys SAZ and L+H are switched. The key SAZ activates the program truck+ trailer, key L+H activates the semitrailer; In the US “truck + trailer” corresponds with the European semitrailer. Switch 2: Trolley bus France, bypassing collector, from 1.33r1 000 = Standard, no reversing of the collector; + 002 = Reversing of the collector in trolley bus program. If trolley bus has been selected (bus with collector on the roof) the roof brush washes only the front and the rear and bypasses the collector at the rear. The wash procedure depends on module 048 R1 Para 7 to 11 and 20 to 22. The procedure for the trolley bus can be activated with wash program 15 or with a light barrier (SOF Para 5 special input = 017). Switch 3: Wash data vehicle length capturing for bus program, from 1.33r1 000 = Standard, no special length capturing active; + 004 = special vehicle length capturing for wash data active. For analyzing wash data with the program Profit. Three different vehicle lengths for busses and special busses are captured and counted in different programs depending on the length: up to 9.5 m as program stationary drive-through wash from 9.5 to 16 m as program short wash bay over 16 m as program reverse wash. Switch 4: Wash data wash time capturing for all programs, from 1.34L 000 = Standard, no data capturing active; + 008 = Wash data capturing active, For analyzing wash data with the program Profit. Only active together with 042 CKL Para 5 = 002; instead of vehicle length the wash time is stored for all programs.



048 R 1 Reserve

Parameters for Soko Verkehrsbetriebe Endingen: Only possible with 047 SOF Para 4 = 008, from 1.27e Para 1 00000 pulses Regio-Shuttle, start roof brush off front

Para 2 00000 pulses Regio-Shuttle, start roof brush off rear

Para 3 00000 pulses Railcar NE81, start roof brush off

Para 4 000 pulses Regio-Shuttle, length roof brush off front

Para 5 000 pulses Regio-Shuttle, length roof brush off rear

Para 6 000 2 x Imp. Railcar NE81, length roof brush off

At this NE81 the switch-off range has possibly to be longer then pulses, therefore here the doubled value is used for switch-off. (Example: 180 = 2 x 2.2 cm/Imp = 7.9 m)

General Parameters Para 12 000 value 1 x roof brush front wash offset in direction front, from 1.32p5

With auxiliary 1 x roof brush front wash the roof brush moves in reverse wash at a portal counter (vehicle front + 140 - R1 Parameter 12) in initial position

Para 13 000 value 1 x roof brush front wash offset in direction rear, from 1.32h With auxiliary 1 x roof brush front wash the roof brush moves in reverse wash at a portal counter (vehicle front + 140 - R1 Parameter 13) in initial position

Para 14 000 value Show additional information in the event protocol, from 1.28p 001 = who starts the program, (0 = nobody; 1 = CKL; 2 = operating unit; 3 = start key) 002 = Auxiliaries of the program, hexadecimal, like BED Para 2 003 = washed program, number, 001 = truck, etc. Also afterwards appears in the event list at the end of the line the corresponding number, depending on the selection.



048 R 1 continued

Parameter for trolley bus France: Only possible with 047 SOF Para 14 = + 002 The sequence is activated with program 15 or the special input SOF Para 5 = 17, from 1.33r1 Para 7 000 pulses Trolley bus, maximum wash height at rear

Up to this height in DB pulses the roof brush lowers behind the collector in forward wash. The wash is continued below the collector up to the rear.

Para 8 000 pulses Trolley bus portal distance behind rear for end of collector The portal moves up to portal position vehicle rear + para 8 so that the roof brush may lower without risk behind the collector to DB height according to t R1 Para 7.

Para 9 000 pulses Trolley bus portal distance behind pickup position for portal stop In short wash bay sequence the portal moves up to portal position (value + vehicle front + DB-Para 3). The roof brush is lifted to the height of R1 Para 10; Thant he traffic light switches to green so that the vehicle can move forward until the brushes are behind the rear.

Para 10 000 pulses Trolley bus roof brush locking height after pickup position The roof brush is lifted up to this height after the portal has reached the position (vehicle front + DB-Para 3, pickup locking).

Para 11 000 pulses Trolley bus portal distance for cycle change after vehicle rear The portal moves up to this position is after the roof brush has finished the rear wash in wash position and to finish afterwards the cycle behind the collector. All devices move in initial position and the wash is finished.

Para 20 000 value Trolley bus lowering speed in Hz for roof brush rear wash Determines the lowering speed of the roof brush for the rear wash. (Min. value = 10)

Para 21 000 pulses Trolley bus portal distance reverse at rear for side brush rear wash 000 = no reverse wash. value > 000, portal moves in wash forward cycle (when the side brushes are behind the rear) backwards again until the side brushes pick up load. From here the side brushes wash the distance according to para 21 in portal pulses backwards so that the side brushes are again on the side. From here the normal rear wash starts. Reason: Improved wash quality in this area.

Para 22 000 0.1 sec. Trolley bus roof brush washes for time at rear in position according to R1 Para 7 If value > 0 the roof brush washes on the spot for time according to Para 7. Reason: Improved wash quality in this area.

049 RPD Real Power Device, power measurement Up to 1.29o: module name: „R 2 Reserve“, without function.

Para 14 000 value Torque or power measurement, from 1.29o 000 = Measurement with torque boards; 001 = one RPD fitted, Solo machine 002 = two RPD fitted, Tandem machine.



050 LS Light barrier board Only used for MaxiWash Combi with contour capturing for high-pressure roof nozzle; up to 1.30h: module name: „R 3 Reserve“, without function.

Para 4 002 value Contour light barrier 1. from top (B20), from 1.30h 000 = not active 001 = Low1, Power level 1 002 = Low2, Power level 2 003 = High1, Power level 3 004 = High2; Power level 4

Para 5 002 value Contour light barrier 2. from top (B21), from 1.30h like Para 4



Para 8 003 value Contour light barrier 5. from top (B8), from 1.30h and vehicle light barrier traffic light backwards like Para 4

P 15-17 000 value Module fitted; 000 = not fitted 001 = must be set if light barrier board is fitted (Maxi Combi)

051 to 057 R4 to R11 Reserve no parameters

Created: Bernd Zeller on: 14.10.1996 Approved: Bernd Zeller

Changed: Klaus Grössler on: 13.11.2007

File: NU-TH-GB_N201-01-01-E-Anlagen-Parameter_c_13-11-07.docx

Technical Manual Model series, CPU K201 N201-01-02-E-HW Electronics: Displays, Code switches 22. April 2004 Page 1 of 4


The CPUs have to be reset after a change of the coding or hex- switches (Power (fuse F50) off-on).

CPU, K201 CPU K201: SN 189 602; CPU K201 repaired: SN 790 189 602 4 x serial interface: SN 194 951 2 x serial + 2 x FC: SN 200 681 Software EPROM SN 192 003 EEPROM SN 179 384

LED‘s and fuses of the CPU K201: LD6 yellow 24 V supply for control unit, at X13

LD5 yellow 24 V supply for limit switch at X10, must be lit at all times

LD4 yellow CAN supply, must be lit at all times

LD3 yellow Power OK, power line adequate, must be lit at all times

LD2 green Watchdog, Software running must be lit at all times

LD1 red no fixed function (tests for engineering)

F1 Fuse 3,15 A T, lead

F2 Fuse 2 A T, 24 V limit switch, at X10

F3 Fuse 0,5 A M, 24 V operating unit, at X13 (not used for the Nufa)

K201-BTL.BMP

DIL switches of the CPU K201 machine: The coding (DIL) switches determine the machine type:

- = Off Switch: ................................ 1 2 3 4 5 6 7 8 Solo machine: .................... - - - - - - - - Tandem M 1: ....................... - On - - - - - - Tandem M 2: ..................... On On - - - - - - Elite France ..................... - - - - - - - On

some French machines are equipped with a terminal at the serial interface RS 485 plug X13 instead of a CAN terminal.

Battery jumper: Remove jumper for approx. 2 minutes before installing a CPU. For spare parts: do not remove the jumper after disassembly! Or when removed: plug on shortly before installation. Otherwise the battery is discharged during storage.

Technical Manual N201-01-02-E-HW Model series, CPU K201 22. April 2004 Electronics: Displays, Code switches Page 2 of 4


IO boards 48/60, 24/20 , 8 FCs , Light barrier board IO board 48/60: SN 179 102; repaired: SN 146 068 IO board 24/20: SN 179 107; repaired: SN 180 885 IO board 8FC: SN 192 066; repaired: SN 790 192 066 Light barrier board 8 channel SN 206 640;

0 = IO board 48/60 no. A2 Machine, general 1 = IO board 24/20 no. A3 for HP-Nufa 2 = IO board 24/20 no. A4 for parallel operating unit 4 = Light barrier board no. A6 for MaxiWash Combi D = IO board 8 FCs no. A16 for Omron FC (for test or if more than 2 serials are required) E = IO board 24/20 no. A17 for special function „Bork“

Hex-switch setting:

Compare connection diagram

E2-BUP8.BMP

RPD Real Power Device RPD: SN 206 654;

WDG = Watchdog, off, no function CAN = CAN control, flashes, turns than off; flashing 1 Hz = initial connection missing flashing 5 Hz = connection interrupted Run = ready for operation, must be lit at all times

LEDs:

Address 1 = bridge from X6/1 to X6/6

Address:

The CAN connection is used to program the RPD and to deliver motor data (retrievable with P3 Monitor Module 50 R2)

CAN connection:

CAN wiring: from the K201-CPU to RPD X4.

Technical Manual Model series, CPU K201 N201-01-02-E-HW Electronics: Displays, Code switches 22. April 2004 Page 3 of 4


CAN terminal or MCR terminal 6-0193 Assembly Terminal: SN 190 270; repaired: SN 790 190 270; Terminal CPU stand-alone: SN 190 268; repaired: SN 790 190 268; Insert foils: Auxiliary keys (right keypad): SN 190274 Operation keys (left keypad): SN 190273 Inscription WashTec: SN 126232

Software: Eprom1 all boards: SN 181 365, Eprom 1 only single boards: SN 181 368 Eprom 2 TXT 28 pol (old): SN 181 374 Eprom 2 TXT 32 pol (new): SN 190 964

MK-BLD1.BMP

Contrast potentiometer for display D10 D11 top bottom

8

Prom 1 Prom 2 D8 D9

1

LED displays: D21 yellow CAN supply, indicates CAN 12 V voltage supply to X11

These are at the bottom left and must be lit at all times.

D11 yellow 24 V supply for the card reader; These are at the top in a group of 4 LED's and must be lit at all times.

D10 yellow 5 V supply for the CPU; These are at the top in a group of 4 LED's and must be lit at all times.

D9 green Flashing (approx. 1 Hz) indicates that the software is running; These are at the top in a group of 4 LED's and must be lit at all times.

D8 red CAN status; flashing (approx. 2 Hz) indicates that the CAN connection to the K201 has been broken any time in the past. These are at the top in a group of 4 LED's and normally always flash since the machine is switched off at night, but the MCR has a permanent voltage supply and therefore the CAN connection fails. By resetting the MCR (disconnecting and then reconnecting voltage supply X8), the connection can be rechecked. If the result of this check is OK, the LED is switched off.

Technical Manual N201-01-02-E-HW Model series, CPU K201 22. April 2004 Electronics: Displays, Code switches Page 4 of 4


DIL switches on the Terminal/MCR CPU 6-0193: Switch: ............................ 1 2 3 4 5 6 7 8 Terminal 1: ...................... - On - - - On - - Terminal 2 ...................... - On - - - On - On

There are two terminals at the HP Nufa, for some Solo and Tandem machines or in combination with the CAN- MCR.

Meaning of the various switches: - = Off S1 = On = Reset active, must always be Off S2 = On = Temperature reset active, must always be On S3 = On = Load original data, not used S4, S5 = Reserve S6 = On = Nufa/WS-MCR, keyboard with LED’s.

Off = without keyboard LED’s (for EC2000) S7, S8 = MCR no. for connection of several MCR’s;

Off/Off = no.1, Standard; Off/On = no.2, HP Nufa; On/Off; On/On = no.3 - 4, reserve.

Contrast potentiometer: For adjusting the brightness at the LED text display.

For spare parts the potentiometers are normally not adjusted. At wrong adjustment the display is very bright (like without text) or the individual character fields are dark rectangles.

Created: Bernd Zeller on: 26. 6.1997 Approved: Bernd Zeller

Changed: Klaus Grössler on: 22. 4. 2004

File: NU-TH-GB_N201-01-02-E-Elektronik_b_22-04-04.docx Changes since 13.10.1998 are written coloured and marked by „|” at the outer margin.

Technical Manual Model series Nufa, CPU K201 N201-01-05-E Special bus program 14. November 2007 Mirror bypass Page 1 of 4


The mirror bypass is used to bypass non-removable rear-view mirrors at busses. The roof and side brushes wash only parts of the bus front; from Software 1.29.

Pay attention to the conditions:The new generation of side brush frames (from approx. April 2001) is installed

Outer side brush limit switch: the rotating brushes do not touch the splash guard. Inner side brush limit switch: the rotating brushes have a distance of approx. 15 cm.

A. Teach parameters for the wash position of the brushes Move machine in initial position (roof brush is up and side brushes are outside).

P2 Module 001 DB Para 1 = 000 Modules 002 SBL and 003 SBR Para 27 = 000

P3 Monitor Test Program, activate roof brush: 001 DB Byte 2 = 007 Let roof brush move once from the top into the bottom roof brush switch (wash position). Parameter 1 is now automatically recorded. Roof brush Byte 2 = 002 roof brush moves back into initial position

Activate test program side brushes: 002 SBL and 003 SBR Byte 2 = 007 Let side brushes move once into the inner side brush switches (wash position). Parameter 27 is now automatically recorded. SBL and SBR Byte 2 = 002; the side brushes move back into initial position.

Check recorded parameters: Wash height cm: 330 360 390 420 450 495 DB Para 1 Winding drive: new belt 188 197 206 219 231 250 Winding drive: 192 202 212 226 239 259 Tooth belt: 205 225 245 265 285 315 Wash width in cm: 260 290 SBL and SBR Para 27 Counter inside (approx. value) 120 125

If the values deviate for more than 5 check the setting of the limit switches. Repeat the teaching.

B. Factory setting of the parameters for special bus At factory setting no mirror bypass is done. The brushes do not wash the front. The wash is started after the vehicle front.

Roof brush:

001 DB Para 2 = 00200 = wash start on the roof DB Para 20, 21 + 22 = 000 = no mirror bypass

Side brushes:

002 SBL, 003 SBR Para 2 = 00160 = wash start at side of the vehicle SBs Para 20, 21 + 22 = 000 = no mirror bypass

new: old:

Technical Manual N201-01-05-E Model series Nufa, CPU K201 14. November 2007 Special buy program Page 2 of 4 mirror bypass


C. Parameters for mirror bypass. Experienced values for wash width 2600 mm:

Para 2 Para 20 Para 21 Para 22 DB 00060 025 080 180 SBL and SBR 00060 025 001 100

Roof brush, from Software 1.27g:

First the roof brush lowers, than the portal searches for the vehicle.

001 DB Para 22 = distance 3, Up to this value of the lift counter the roof brush washes at the front upwards below the mirrors.

DB Para 20 = distance 4, The portal moves backwards from the front by this value.

DB Para 21 = distance 5, Up to this value the roof brush moves upwards in front of the mirrors.

DB Para 2 = distance 6, The portal moves this distance forwards, the roof brush is above the mirrors. At the end the roof brush is controlled normally [from portal counter = (vehicle front - Para 20) + Para 2)]. Para 2 has to be at least 15 larger than Para 20!

Side brushes, from Software 1.27g:

First the side brushes move inwards, than the portal searches for the vehicle.

Depending on the setting (047 SOF Para 13) a center overlapping is done (the distance of the center overlapping is limited by Para 22).

002 SBL, 003 SBR Para 22 = distance 3, the side brushes wash up to this value of the infeed counter at the front from the center outwards.

SBL/R Para 20 = distance 4, the portal moves backwards from the front by this value.

SBL/R Para 21 = distance 5, SBL/R move up to this value of the infeed counter outwards (in front of the mirrors), if Para 21 = 001 the side brush moves outwards up to the limit switch and the rotation is stopped, if Para 21 > 001 the rotation remains switched on.

SBL/R Para 2 = distance 6, the portal moves this distance backwards, the side brushes are outside of the mirrors, At the end of the distance the side brushes are controlled normally [from portal counter = (vehicle front - Para 20) + Para 2)]. Para 2 has to be at least 15 larger than Para 20!

Tandem, from Software 1.28n3:

030 M2 Para 7 = 140 = Offset mirror bypass; In Tandem operation the mirror bypass is done by M2. First M2 starts with reverse wash, however it doesn’t know where the front of the bus is. Therefore a safety distance (offset) has to be entered so that the reverse wash is finished in time.

P2 6 P21 7 1 5 P20 P22 4 3 2 View from the left side

onto the roof brush

P2 6 P21 7 1 5 P20 P22 4 3 2

View from the top to the right side brush, mirror image for the left side brush

Technical Manual Model series Nufa, CPU K201 N201-01-05-E Special bus program 14. November 2007 Mirror bypass Page 3 of 4


D. Manual determination of the parameters for mirror bypass The P3 Monitor Program can be used to read off the according counters of brushes and portal. First move machine into initial position and position a special bus. Roof brush:

Move the roof brush manually downwards to the limit switch; Move the portal forwards until the roof bush is shortly in front of the bus (the rotating brush would have now an immersion depth of 10 cm); Read off P3 Monitor 000 POR Word 1 = POR counter 1 and note. Lift the roof brush until it is just below the mirrors; (the rotating brush would not yet have contact to the mirrors); Read off P3 Monitor 001 DB Word 1 = DB counter 1 and note. Now move the portal backwards until the roof brush is in front of the mirrors; (the rotating brush would not yet have contact to the mirrors); Read off P3 Monitor 000 POR Word 1 = POR counter 2 and note. Lift the roof brush further until it is above the mirrors; (the rotating brushes have no contact to the mirrors while lifting); Read off P3 Monitor 001 DB Word 1 = DB counter 2 and note. Now move the portal forwards until the roof brush is behind the mirrors (on the roof); Read off 000 POR Word 1 = POR counter and note.

Examples: POR counter 1 = 00195 POR counter 2 = 00170 POR counter 3 = 00230 DB counter 1 = 00180 DB counter 2 = 00080

Now enter the parameters for the roof brush: Example: 001 DB Para 2 = POR counter 3 – POR counter 2 = 230 - 170 = 00060 001 DB Para 20 = POR counter 1 – POR counter 2 = 195 - 170 = 025 001 DB Para 21 = DB counter 2 = 080 001 DB Para 22 = DB counter 1 = 180 Side brushes:

The sequence is like for the roof brush DB; first move the machine into initial position. Move the side brushes manually inwards up to the limit switch; move the portal forwards until the side brushes are shortly in front of the bus (the rotating brushes would have now an immersion depth of 10 cm); Read off P3 Monitor 000 POR Word 1 = POR counter 1 and note. Move the side brushes manually outwards until shortly below the mirrors; (the rotating brushes would not yet have contact to the mirrors); Read off P3 Monitor 002 SBL, 003 SBR Word 1 = SB counter 1 and note. Move the portal backwards until the side brushes are shortly in front of the mirrors; (the rotating brushes would not yet have contact to the mirrors); Read off P3 Monitor 000 POR Word 1 = POR counter 2 and note. Move the side brushes further outwards until to the limit switch (or until they are outside of the mirrors); (the rotating brushes have no contact to the mirrors while moving outwards); Read off P3 Monitor 002 SBL, 003 SBR Word 1 = SB counter 2 and note. If the rotation should be off during the next forward movement of the portal then SB Para 21 must be 001; with rotation Para 21 must be > 001.

Now move the portal forwards until the side brushes are behind the mirrors (at the side windows); Read off P3 Monitor 000 POR Word 1 = POR counter 3 and note.

Example: POR counter 1 = 00120 POR counter 2 = 00095 POR counter = 00155 SB counter 1 = 00100 SB counter 2 = 00000 (or 00003)

Now enter the parameters for the side brushes: Example: 002 SBL, 003 SBR Para 2 = POR counter 3 - POR counter 2 = 155 - 095 = 00060 002 SBL, 003 SBR Para 20 = POR counter 1 - POR counter 2 = 120 - 095 = 025 002 SBL, 003 SBR Para 21 = SB counter 2 = 001 (or 003) 002 SBL, 003 SBR Para 22 = SB counter 1 = 100

Technical Manual N201-01-05-E Model series Nufa, CPU K201 14. November 2007 Special buy program Page 4 of 4 mirror bypass


E. Test wash: Wash a bus without overwidth mirrors to check the mirror bypass.

Busses with the most extreme mirrors have to be considered for the setting.

Adapt the parameters if necessary.

F. Activate center overlapping at mirror bypass: Attention: Eventually the side brush frame may damage the mirror during center overlapping.

Module 047 SOF Para 13 = + 001 = release center overlapping during mirror bypass

Wash a bus without prominent mirrors to check whether there is sufficient space between mirror and side brush frame. The distance of the center overlapping is also limited by Para 22.

G. Information for bus operators or public utilities: For security reasons: Select the special bus program as standard program if mainly busses with overwidth mirrors are washed. (Therewith you don’t forget to select the special bus program).

Module 036 LT1 Para 01 = 011 = wash program at Power on = special bus

Module 044 BED Para 07 = 001 = change wash program at end of wash: the basic program is activated like during Power on = special bus

H. Mirror bypass for further wash programs by selection switch: Only possible for Solo machine (first time for Korea), from Software 1.28h Activate mirror bypass for truck, truck + trailer, semitrailer, bus, short wash bay and/or Pick-Up.

A selection switch has to be connected to input E 211 (relay board A2, plug X14, Pin 4). If input E 211 = 1, the mirror bypass is automatically activated at the front of the vehicle.

I. Optical signal for the special bus program: A special output can be switched as an optical signal (light) for the special bus program.

With 047 SOF Para 8, 9 or 10 = 011 = on while a special bus is selected; SOF Para 10 is preferred because output A159 potential free.

As soon as the special bus program or the mirror bypass is selected the output is switched on and the light is illuminated.

If the parameter is increased by +100 (= 111, inverse function) the output is switched on as a warning which indicates that the mirror bypass is not yet active.

Created: Klaus Grössler on: 14.05.2004 Approved: Bernd Zeller

Changed: Bernd Zeller on: 14.11.2007

File: NU-TH-GB_N201-01-05-E-Sonderbus_a_14-11-07.docx

Changes since 14.05.2004 are written coloured and marked by „|” at the outer margin.

Technical Manual Model series Nufa, CPU K201 N201-02-01-D Errors, error numbers, failure classes 13. April 2006 Page 1 of 4

© Copyright reserved Wash Tec 2001

Valid up to software K201: to 1.35

Error Class Text Cause / Explanation

000 0 Switched on for Modcon service program 001 0 Switched off for Modcon service program 002 2 Ready for use No error exists 003 5 Program aborted Machine has been working in one position for more than

120 seconds, portal speed < 3 Hz; waiting for units (initial or turning position

004 5 Default Data loaded (up to 1.24g: ROM data loaded)

The data saved in the EEPROM and in the RAM were incorrect. The original data have been loaded from the EPROM. Station numbers, program assignment, prices and changed parameters have been lost, Turn the main switch off and on again.

005 2 Faulty data repaired (up to 1.24g: EEPROM data loaded)

The RAM data were incorrect. The data have been loaded from the EEPROM. Check battery.

006 2 Data memory OK (up to 1.24g: RAM checksum OK

When the system was switched on the working data check was OK.

007 5 Counters destroyed The counters in the RAM and EEPROM were faulty, they have been deleted

008 1 Data exchange with PC Data is exchanged with the PC. Old: Communication error Communication error, the data exchange to the frequency

converter or terminal is faulty. 009 1 No Communication Communication error, the data exchange to the frequency

converter is interrupted. 010 8 Emergency Stop An Emergency Stop has been pressed or a motor

protection switch has been tripped. 011 9 24 V missing The 24 V supply is faulty, all inputs are "0". 012 5 Data backup faulty

(up to 1.24g: EEPROM faulty) The backup in the EEPROM is faulty not identical to the data in the RAM. Call P0, change any parameter, „“ save parameters, change parameter back to original value. The normal procedure is not started if the EEPROM does not exist (or empty), the machine is not ready for operation. By pressing the key „“all data is copied into an EEPROM, after successful copy the machine is ready for operation again.

013 5 Not in initial position The unit is no longer in the initial position. During the wash the module attempts to clear for approx. 3 seconds.

014 5 Water flow not enough (old: Flow switch)

Option: The water flow is not adequate for washing.

015 5 Antifreeze active Option: The machine has shut down because of frost, the lines are being drained

016 5 2 limit switches Both limit switches (outside/inside or top/bottom) have been actuated at the same time.

Technical Manual N201-02-01-D Model series Nufa, CPU K201 13. April 2006 Errors, error numbers, failure classes Page 2 of 4



017 5 Error initial position (up to 1.23: Initial position not reached

The system has not reached the initial position in time (120 sec.) or The counter is still too high when reaching initial position (SB, DB > 30), from 1.23L (from 1.27v the counter remains until acknowledgement) or the limit switch initial position top/outwards/wash bay start is not released, from 1.24e

018 5 Wash position not reached The washing position was not reached in time. 019 5 Rotation: No current

measured Old: underload

The torque measurement found values which are too low (less than 15). Interruption in motor supply line (L2) or The measured torque values dropped below the reference value by 12, from 1.23L

020 5 Rotation motor overload Old: Overload

The torque measurement found values which are too high (more than 240).

021 5 Idling measuring faulty Old: Torque measuring fault

The torque idling adjustment could not be completed (<50 or >150). or from 1.25k (<15 or >180) No torque idling adjustment could be performed within 25 seconds (unbalance too high), from 1.23L.

022 5 Pulse count faulty A pulse counter for the portal, roof or side brushes is not counting correctly SB: 1.5 sec. no pulse (before 1.24: 4 sec.) DB: 4 sec., if v > 10 Hz POR: 3 sec., if v > 20 Hz

023 0 Anti collision switch Tandem: The anti collision switch (collision guard) has been tripped, the two machines are too close together, from 1.

024 5 Frequency converter error FCP or FCH report an internal error, trip. 025 8 K201 - IO boards

configuration The IO boards are not set correctly or the connection is not working (Hex switches, Bus cables, voltage supply to the boards).

026 5 Initialisation is running The frequency converters are not initialized after mains on or Emergency Stop

027 8 230 V voltage missing (F55) The voltage P4 230 V after Emergency Stop is missing, from 1.

028 0 Parameter update After a software change sometimes parameters are automatically changed. The message appears with the first booting of the software instead „RAM OK“, from 1.10 from 1.27y the automatic update is only done back to program 1.18k. At updates of older versions the ROM data is automatically loaded

029 5 Motor protection pumps A motor protection switch from the pump cabinet has triggered.

030 5 Catenary wire active For trams: the electric contact wire is switched on, the machine movements are locked; from 1.23

Technical Manual Model series Nufa, CPU K201 N201-02-01-D Errors, error numbers, failure classes 13. April 2006 Page 3 of 4



031 2 Card memory full The card memory cannot store further cards, 1000 chip cards washes are stored. The data has to be transferred to the PC by using the AWA-Manager

032 2 Remaining amount not enough

Residual value of a wash card is too low.

033 2 Card invalid Data of the wash card is invalid. Wrong station number, card expired, card not readable Up to 1.24e the station number must not have the final digit 4, 8 or 0!

034 2 Roof nozzle touched A toggle switch of the roof nozzle of the HP Nufa is actuated.

035 2 Start up lock HP pump active The restart interlock of the 55/75KW HP pump is active. Starts 10 minutes after the last switch-off.

036 5 Belt tension faulty Flat belt of roof brush or HP roof nozzle is loose or torn, from 1.23; Between 1.27n and 1.27v not active; Up to 1.27x the inputs of roof brush and HP have been interchanged. To activate the roof brush belt protection the inputs have to be rewired: E074 E208 and E075 E209. Attention: at OK the input is = 0

i.e. no error message if nothing is connected or wrongly connected.

From 1.29j modified function possible OK = 1 if 032 CHK Para 10 = 1

037 5 Pulse counter fault initial pos. From 1.29 o The values of the pulse counter are too large when reaching initial position because of miscount. Normal = 0. (in case of error POR > 60, DB > 30 , SBL/R > 40)

038 5 Light barrier board voltage missing

From 1.30h Light barrier board is defect or power missing If the light barrier board is not found or missing the 050 LS Para 15 has to be set to 0, otherwise error 038. (factory setting 050 LS Para 15 = 1)

039 5 Shortcut transmitter From 1.30h; light barrier transmitter has shortcut 040 5 Shortcut receiver From 1.30h; light barrier receiver has shortcut 041 5 Cable break transmitter From 1.30h cable of light barrier transmitter his broken 042 5 Cable break receiver From 1.30h cable of light barrier receiver his broken

043 2 Power limit reached From 1.30h light barrier amplifier has reached power limit 044 5 Backup deviates From 1.30k;

data in RAM and in EEPROM is not identical 045 5 Belt error in wash position From 1.32pe

flat belt of the roof brush or HP roof nozzle is wrongly wound-up.

046 5 Air pressure too low From 1.33k no compressed air, input 062 = 000

Technical Manual N201-02-01-D Model series Nufa, CPU K201 13. April 2006 Errors, error numbers, failure classes Page 4 of 4


Error classes: The error class determines how the controller reacts to different errors.

Error class 0 no reaction, the error is not displayed on the terminal, the error is recorded in a list

1 like class 0

2 no reaction, the error is displayed and recorded in a list.

3 not used for the Nufa For this error an auto correction is done for 5 seconds. If the error is not remedied after this time the machine is completely shut-off. The error is displayed and recorded.

4 not used for the Nufa For this error an auto correction is done for 5 seconds. If the error is not remedied after this time the machine is completely shut-off. The error is displayed and recorded.

5 The machine is immediately switched off. The error is displayed and recorded.

6 and further have the same meaning as class 5, but with higher priority.

For some software versions (around 1.24 to 1.24g OK) the error classes 8 and 9 don’t work (is overwritten during change by 0 or 1. At problems (Emergency Stop does not appear in the display) please use error class 6 and 7.



File: NU-TH-GB_N201-02-01-D-Fehler_c_05-11-07.docx Changes since 20.04.2004 are written coloured and marked by „|” at the outer margin.

Technical Manual Model series Nufa, CPU K201 N201-02-02-D Line Numbers 05. November 2005 for P4 Hardware Test Page 1 of 7


CPU board K201 +SM1.A1 8 Analogue inputs E000 SB left torque x2 1 E001 SB right torque x2 2 E002 DB torque x2 3 E003 Joystick Portal x3 1 E004 Joystick DD lift x3 2 E005 Joystick reference x3 3 E006 Voltage L1 x4 1 E007 free x4 2

Signals for Omron FCs (from1.19 e) Add. Board on CPU 2FC, 2SER +SM1.A0 Frequency Converter Portal (FCP) E008 Trip FCP x16 5/6 A009 Speed FCP x16 2 A010 Start backwards FCP x16 3 A011 Start forwards FCP x16 4 Frequency Converter Lift (FCH) E012 Trip FCH x17 5/6 A013 Speed FCH x17 2 A014 Start downwards FCH x17 3 A015 Start upwards FCH x17 4

Machine Installation IO board 1 (48/60) +SM1.A2, Hex switch = 0 24 V DC inputs E016 DB limit switch top x15 1 E017 DB limit switch bottom x15 2 E018 DB counter x15 3

E019 SB left limit switch outside x15 4 E020 SB left limit switch inside x15 5 E021 SB left counter x15 6 E022 SB right limit switch outside x15 7 E023 SB right limit switch inside x15 8 E024 SB right counter x15 9

E025 Portal initial position x15 10 E026 Portal turning position x15 11 E027 Portal counter x15 12 E028 LS KFZ length x15 13 (CPW, drive through, lights backward) (for MaxiWash Combi E216) E029 Drive through LS x15 14

Continued machine, 24 V DC inputs E030 Start LS x15 15 (and traffic light stop) E031 UBW LS x15 16

E032 Pump 1 Fr. wa. flow monitor x15 17 (fr. 1.13) PMP Para 6 E033 Pump 2 Proc. wa. flow monitor x15 18 (fr. 1.13) PMP Para 7 E034 Pump 3 HP wa. flow monitor x15 19 (fr. 1.13) PMP Para 8 E035 free x15 20 E036 Motor protection pumps (from 1.13) x15 21 Pump / Flow monitor (up to 1.12) PMP Para 5 E037 Start interlock BED para 8 x15 22 E038 Temperature monitor x15 23 E039 Emergency stop signal x15 24

E208 DB-rope switch left, from 1.23 x14 1 OK = 1, Error = 0; up to 09/2003 OK = 0, compare 032 CHK Para 10 (for HD-Nufa 6-0297 E074) E209 DB- rope switch right, from 1.23 x14 2 (for HD-Nufa 6-0297 E075)

E210 Tandem, switch short wash bay prog., x14 3 from 1.28a E211 Tandem select switch x14 4 special bus program, from 1.28d Solo: mirror bypass, for all vehicles, from 1.28h

E040 Tandem initial position 2. Start position, SOF Para 5 = 8 x14 10 E041 Tandem collision x14 9

E042 Door control on/off x14 11 E043 Winter door controller on/off x14 12 E044 Door open button x14 13 E045 Door1 close limit switch x14 14 E046 Door2 close limit switch x14 15

E047 Start key BED Para 9 x14 16 E048 Stop key x14 17

E049 Special input SOF Para 5 x14 18 (up to 1.16k ANL Para 11) E050 Special input SOF Para 6 x14 19 (up to 1.16k ANL Para 11) E051 Special input SOF Para 7 x14 20 (up to 1.16k BED Para 7)

Technical Manual N201-02-02-D Model series Nufa, CPU K201 05. November 2005 Line Numbers Page 2 von 7 for P4 Hardware Test


IO board 1 (48/60) +SM1.A2, Hex switch = 0, continued 230 V AC inputs E052 U P4 (after Emergency Stop)) x2 1 E053 free x2 3 42 V AC inputs E054 free x2 5 E055 free x2 7

High-pressure Nufa 6-0297 IO board 2 (24/20) +SM1.A3, Hex switch = 1 24 V DC inputs E056 DD Default position x9 1 E057 DD Wash position x9 2 E058 DD counter x9 3 E059 DD Stop left x9 4 E060 DD Lift Stop x9 5 E061 DD Stop right x9 6 E062 Pressure monitor air x9 7 E063 HP roof on x9 8 E064 HP side bottom on x9 9 E065 HP side top on x9 10 E066 HP chemicals on x9 11 E067 HP on x9 12 E068 ND on x9 13 E069 DD Rotation forwards x9 14 E070 DD Rotation backwards x9 15 E071 HP pump on x9 16 E072 HP pump off x9 17 E073 Wiper on x9 18 E074 DB-rope switch left, from 1.23 x9 19 OK = 1, Error = 0; up to 09/2003 OK = 0, compare. 032 CHK Para 10 (for normal Nufa E208) E075 DB-rope switch right, from 1.23 x9 20 (for normal Nufa E209)

Note: The new Maxi-Wash Combi uses a

large IO boards instead of the 2 small IO boards 20/24.

MaxiWash Combi 6-0302, from 1.31 IO board 2 (48/60) +SM1.A3, Hex switch = 1 24 V DC inputs E056 DD initial position x14 1 E057 DD wash position x14 2 E058 DD counter x14 3 E059 DD Stop left x14 4 E060 DD Lift Stop x14 5 E061 DD Stop right x14 6 E062 Pressure monitor air x14 7 E063 DD Position 1 x14 8 E064 DD Position 2 x14 9 E065 DD Position 3 x14 10 E066 DD Position 4 x14 11 E067 DD-rope switch left x14 12 E068 DD-rope switch right x14 13 E069 DD Rotation forwards x14 14 E070 DD Rotation backwards x14 15 E071 DD Lift on x14 16 E072 DD Lowering on x14 17 E073 DD Locking on x14 18 E074 CPW Roof on x14 19 E075 HP Roof on x14 20



Inputs parallel operating unit not for MaxiWash Combi 6-0302 IO board 3 (24/20) +SM1.A4, Hex switch = 2 E076 Prog 1 x9 1 E077 Prog 2 x9 2 E078 Prog 3 x9 3 E079 Prog 4 x9 4 E080 Prog 5 x9 5 E081 Prog 6 x9 6 E082 Prog 7 x9 7 E083 Prog 8 x9 8 E084 Prog 9 x9 9 E085 Prog 10 x9 10 E086 Prog 11 x9 11 E087 Prog 12 x9 12 E088 Prog 13 x9 13 E089 Prog 14 x9 14 E090 Prog 15 x9 15 move in initial position 1, from 1.15 E091 Prog 16 x9 16 move in initial position 2, from 1.15

E092 Portal forwards x9 17 E093 Portal backwards x9 18 E094 DB lifting x9 19 E095 DB lowering x9 20 E096 DB locking x9 21 E097 SB out x9 22 E098 SB in x9 23 E099 SB locking x9 24

Inputs parallel operating unit MaxiWash Combi 6-0302, from 1.31 IO board 2 (48/60) +SM1.A3, Hex switch = 1 E076 Prog 1 x15 1 E077 Prog 2 x15 2 E078 Prog 3 x15 3 E079 Prog 4 x15 4 E080 Prog 5 x15 5 E081 Prog 6 x15 6 E082 Prog 7 x15 7 E083 Prog 8 x15 8 E084 Prog 9 x15 9 E085 Prog 10 x15 10 E086 Prog 11 x15 11 E087 Prog 12 x15 12 E088 Prog 13 x15 13 E089 Prog 14 x15 14 E090 Prog 15 x15 15 move in initial position 1, from 1.15 E091 Prog 16 x15 16 move in initial position 2, from 1.15

E092 Portal forwards x15 17 E093 Portal backwards x15 18 E094 DB lifting x15 19 E095 DB lowering x15 20 E096 DB locking x15 21 E097 SB out x15 22 E098 SB in x15 23 E099 SB locking x15 24



Outputs machine IO board 1 (48/60) +SM1.A2, Hex switch = 0 X3: Potential P1 (230 V AC before Emergency Stop, primary) A100 Position light red (stop) x3 1 A101 Position light forwards x3 2 A102 Position light backwards x3 3 A103 Entry light red x3 4 A104 Entry light green x3 5 A105 Exit light red x3 6 A106 Exit light green x3 7 X4: Potential P3 (230 V AC before Emergency Stop, secondary) A107 Door 1 Entrance off x4 1 A108 Door 1 Entrance close x4 2 A109 Door 2 Exit off x4 3 A110 Door 2 Exit close x4 4 A111 Portal forwards, from 1.29k x4 5 (if no FCP exists) A111 Portal-Converter net, from 1.32p5 x4 5 (only FCP exists and no FCH) A112 Portal backwards, from 1.29k x4 6 (if no FCP exists) A113 Special Output P3 SOF Para 8 x4 7 (from 1.16 to 1.16k ANL Para 12) X5: Potential P4 (230 V AC after Emergency Stop, secondary) A114 Pump 1 fresh water x5 1 A115 Pump 2 recycled water x5 2 A116 Pump 3 1 High pressure net x5 3 A117 Pump 3 2 HP star x5 4 A118 Pump 3 3 HP delta x5 5 A119 Overflow valve x5 6 A120 Pump Res x5 7 X6: Potential P4 (230 V AC after Emergency Stop, secondary) A121 DoP Shampoo M20 x6 1 A122 DoP CDA M21 x6 2 A123 DoP CPW M22 x6 3 A124 DoP Reserve M23 (not active) x6 5 A125 Y16 Reserve x6 4 A126 Y17 Reserve x6 6 A127 Y18 Reserve x6 7

Continued outputs machine X7: Potential P4 (230 V AC after Emergency Stop, secondary) A128 Y1 FreWa V-N-Arch x7 1 A129 Y2 FreWa post spray arch x7 2 A130 Y3 ProcWa brush watering x7 3 A131 Y4 ProcWa V-N-Arch x7 4 A132 Y6 CDA V-N- Arch x7 5 A133 Y7 CDA add. post spray arch x7 6 A134 Y40 HP side (wheel washer) x7 7 X10: Potential P4 (230 V AC after Emergency Stop, secondary) A135 Y8 CPW x10 1 A136 Y41 UBW x10 2 A137 Y42 Blow out Nufa x10 3 A138 Y43 Blow out HD x10 4 A139 Y44 Drain UBW x10 5 A140 Y45 Drain water lines x10 6 A141 Y46 HP additional arch x10 7 X11: Potential P4 (230 V AC after Emergency Stop, secondary) A142 SB left rotation forwards x11 1 A143 SB left rotation backwards x11 2 A144 SB right rotation forwards x11 3 A145 SB right rotation backwards x11 4 A146 SB left inwards x11 5 A147 SB left outwards x11 6 A148 SB right inwards x11 7 X12: Potential P4 (230 V AC after Emergency Stop, secondary) A149 SB right outwards x12 1 A150 DB rotation forwards x12 2 A151 DB rotation backwards x12 3 A152 Converter net or DB up (for DB w/o FC), from 1.29k x12 4 A153 Lift brake x12 5 A154 DB down (if w/o FC) , from 1.29k x12 6 A155 Special Output P4 SOF Para 9 x12 7 (from 1.16 to 1.16k ANL Para 13) X13: Floating contacts A156 FCP controller release x13 1,2 A157 FCH controller release x13 3,4 A158 Emergency Stop release x13 5,6 A159 Special output, SOF Para 10 x13 7,8 (up to 1.16k ANL Para 5



Outputs HP-Nufa 6-0297 IO board 2 (24/20) +SM1.A3, Hex switch = 1

Floating contacts A160 Y13 HP roof x2 1,2 A161 Y15 HP side top x2 3,4 A162 Y14 HP side bottom x2 5,6 A163 free x2 7,8

A164 Y12, Y12.1 HP CPW roof x3 1,2 A165 Y11, Y11.1 HP CPW side top x3 3,4 A166 Y10, Y10.1 HP CPW side bottom x3 5,6 A167 M23 DOP HP -Chemistry x3 7,8

A168 Wiper x4 1,2 A169 free x4 3,4 A170 free x4 5,6 A171 free x4 7,8

Floating contacts A172 DD Lift at FC x7 1,2 A173 DB Lift at FC x7 3,4 A174 DD Rotation forwards x7 5,6 A175 DD Rotation backwards x7 7,8

A176 Display HP pump on x8 1,2 A177 free x8 3,4 A178 free x8 5,6 A179 free x8 7,8

Outputs MaxiWash Combi 6-0302, from 1.31 IO board 2 (48/60) +SM1.A3, Hex switch = 1 X3: Potential P1 (230 V AC before Emergency Stop, primary) A160 Y13 HP roof x3 1 A161 Y14 HP side bottom x3 2 A162 Y15 HP side top x3 3 A163 free x3 4 A164 Y12, Y12.1 HP CPW roof x3 5 A165 Y11, Y11.1 HP CPW side top x3 6 A166 Y10, Y10.1 HP CPW side bottom x3 7 X4: Potential P3 (230 V AC before Emergency Stop, secondary) A167 M23 DOP HP chemistry x4 1

A168 Rotation side nozzle x4 2 A169 free x4 3 A170 free x4 4

A171 free x2 1 X5: Potential P4 (230 V AC before Emergency Stop, secondary) A172 DD Lift at FC x5 1 A173 DB Lift at FC x5 2 A174 DD Rotation forwards x5 3 A175 DD Rotation backwards x5 4

A176 Y19, Y19.1 SD swivelling x4 5

A177 free x5 6 A178 free x5 7

A179 free x2 3



Outputs parallel operating unit not for Maxiwash Combi 6-0302 IO board 3 (24/20) +SM1.A4, Hex switch = 2 Floating contacts A180 MKL-A-Signal x2 1,2 A181 MKL-B-Signal x2 3,4 A182 Program selection - release x2 5,6 A183 free x2 7,8

A184 free x3 1,2 A185 free x3 3,4 A186 free x3 5,6 A187 free x3 7,8 A188 free x4 1,2 A189 free x4 3,4 A190 free x4 5,6 A191 free x4 7,8 A192 free x7 1,2 A193 free x7 3,4 A194 free x7 5,6 A195 free x7 7,8

A196 Portal initial position 1 reached x8 1,2 A197 Portal initial position 2 reached x8 3,4 A198 Special function: Lock Kienzle x8 5,6 only Schierle, Aalen A199 free x8 7,8

Outputs parallel operating unit MaxiWash Combi 6-0302, from 1.31 IO board 2 (48/60) +SM1.A3, Hex switch = 1 X13: Floating contacts A180 MKL-A-Signal x13 1,2 A181 MKL-B-Signal x13 3,4 A182 Program selection - release x13 5,6 A183 free x13 7,8

A184 free x2 5,6 A185 free x2 7,8 X6: Potential P4 (230 V AC after Emergency Stop, secondary) A186 free x6 1 A187 free x6 2 A188 free x6 3 A189 free x6 4 A190 free x6 5 A191 free x6 6 A192 free x6 7 X7: Potential P4 (230 V AC after Emergency Stop, secondary) A193 free x7 1 A194 free x7 2 A195 free x7 3 A196 Portal GS1-erreicht x7 4 A197 Portal GS2 erreicht x7 5 A198 Special function: Lock Kienzle x8 5,6 only Schierle, Aalen A199 free x7 7



Signals for Omron FC, from 1.19 e IO board 8Fus +SM1.A6, Hex switch = D Only when board is not available on CPU. Frequency converter portal (FCP) E200 Trip FCP x04 5/6 A201 Speed FCP x04 2 A202 Start backwards FCP x04 3 A203 Start forwards FCP x04 4 Frequency converter lift (FCH) E204 Trip FCH x05 5/6 A205 Speed FCH x05 2 A206 Start downwards FCH x05 3 A207 Start upwards FCH x05 4

Further inputs: MaxiWash Combi 6-0302, from 1.31 Light barrier board +SM1.A6, Hex switch = 4 Light barrier board channel 1-8 X8: 8 Analogue inputs E212 LS 1, B20 contour 1. LS from top x8 1 E213 LS 2, B21 contour 2. LS from top x8 3 E214 LS 3, B22 contour 3. LS from top x8 5 E215 LS 4, B23 contour 4. LS from top x8 7

E216 LS 5, B8 LS vehicle length x8 9 (CPW, drive-through, light backwards) (or E028 for normal Nufa) E217 LS 6, x8 11 E218 LS 7, x8 13 E219 free x8 15

Special function machine Bork: IO board 4 +SM1.A.17 (24/20), Hex switch = E 24 V DC inputs E412 Wash bay light barrier backwards x9 13 E413 Wash bay light barrier forwards x9 14 E414 LS rim cleaning x9 15

E422 Feedback 2. Emergency Stop x9 23 E423 S21 Stat. HP arch top x9 24 Potential free outputs A500 Y10 HP bottom (wash bay) x2 1,2 A501 Y11 HP top (wash bay) x2 3,4 A502 Rim cleaner (wash bay) x2 5,6 A503 CPW (wash bay) x2 7,8

A504 Y22 DOP CPW x3 1,2 A505 Y20 UBW x3 3,4

A508 Pre-wash unit x4 1,2

Created: Bernd Zeller at: 27.06.1997 Approved: Bernd Zeller

Changed: Klaus Grössler at: 05.11.2005

Datei: NU-TH-GB_N201-02-02-D-Leitungen-Tabelle_c_05-11-05.docx


Technical Manual Model series Nufa, CPU K201 N201-02-03-D P3 MONITOR Bytes 13. November 2007 Page 1 of 29


Valid until Software K201: up to 1.35

Content:

Structure of module interface ________________ 2 Byte 1 - Status, generally _________________ 2 Byte 2 - Activity, generally _________________ 3 Byte 9 - Overview error numbers ___________ 3 Modul - Bytes / Words, detailliert ______________ 4

000 POR Portal _________________________ 4 000 POR, continued, from Byte 9 _______________ 5

001 DB Roof brush _______________________ 5 001 DB, continued, from Byte 5 ________________ 6 001 DB, continued, from Byte B ________________ 7

002 SBL Side brush left; 003 SBR Side brush right __________________ 7

002 SBL, 003 SBR, continued, from Byte 5 _______ 8 002 SBL, 003 SBR, continued, ab Byte 9 _________ 9

004 DD (High-pressure) roof nozzle_________ 10 005 UBW (also segment controlled) _________ 11 006 HD side (Y40 for wheels) _____________

007 Y1 FreWa VN arch 008 Y2 FreWa add. N arch 009 Y3 ProWa brushes 010 Y4 ProWa VN arch 011 Y6 CTH VN arch 012 Y7 CTH add. N arch 013 Y8 CVW 014 Y46 split arch top 015 Y10 HP chemic. side bottom 016 Y11 HP chemicals side top 017 Y12 HP chemicals roof 018 Y13 HP roof 019 Y14 HP side bottom 020 Y15 HP side top 021-023 Y16-Y18 Reserve 024 Y19 swivelling HP side 025 Y20 Reserve _____________________ 12

026 DOP Dosing pumps __________________ 13

027 PMP Water pumps __________________ 13 028 ANL System, sequence control _________ 14

028 ANL, continued, from Byte 8 ______________ 15 028 ANL, continued, from Byte C ______________ 16

029 M1 Machine 1; 030 M2 Machine 2; _____ 16 031 M3 Machine 3 ______________________ 17 032 CHK Check ________________________ 17 033 FUH Frequenz-Umrichter Hub; 034 FUP FU-Portal ______________________ 18 035 FUR Frequency converter, reserve ______ 19 036 LT1 Auxiliaries table 1 ________________ 19 037 LT2 Auxiliaries table 2 ________________ 19 038 PRG Programs _____________________ 20 039 EFT Entry door; 040 AFT, Exit door ______________________ 20 041 MKL Magnetic card reader, CAN unit ____ 21 042 CKL Chip card reader ________________ 21

042 CKL, continued, from Byte 7 ______________ 22 043 SER Serial interface _________________ 23

043 SER, continued, from Word 2 _____________ 24 044 BED Operating unit __________________ 24 045 KFZ Vehicle position _________________ 25 046 TST Test __________________________ 25 047 SOF Special functions ________________ 26 048 R 1 Reserve 1 ______________________ 27 049 RPD Real Power Device ______________ 27 050 LS Light barrier monitoring module _____ 27 051 R4 Reserve _______________________ 28 052 R 5 Reserve DB Lift + Portal controller __ 28 053 R 6 Reserve SBL Adjusting + Portal

controller 054 R 7 Reserve SBR Adjusting + Portal

controller ____________________________ 29 055- 057 R 8 - R11 Reserve _____________ 29

Technical Manual N201-02-03-D Model series Nufa, CPU K201 13. November 2007 P3 MONITOR Bytes Page 2 of 29


Structure of module interface

Byte 1 Status

Byte 2 Activity

Byte 3 Actual value

Byte 4 Target value

Byte 5 Step

Byte 6 Reference

Byte 7 Byte 8 Speed

Byte 9 Error

Byte A Byte B Byte C Word 1 Counter

Word 2 Word 3 Word 4

The data interface consists of 16 numerical values. The first 12 are bytes (3-digits from 0 to 255), the last 4 are words (5-digits from 0 to 65535).

The meaning of the values depends on the module. In general applies:

Byte 1 = Status, status of the module; Byte 2 = Activity, Command which is initiated from the sequence control to the module; Byte 9 = Error byte, here a module indicates an error (000 = no error).

Important meanings of other Bytes/Words:

Byte 3 = Actual torque of the brushes; Byte 4 = Target torque of the brushes; Byte 5 = Step number in the brush sequence Byte 6 = Reference value of the brushes, the measured idle torque without contact to the vehicle; Byte 8 = Maximum speed of the portal as predefined by the according module Word 1 = Pulse counter of the brushes an of the portal.

Byte 1 - Status, generally

Status = Meaning

001 = Off, position not defined 002 = Initial position reached (outside, top, wash bay start) 003 = Module active, position not defined 004 = Module active, contact with vehicle 005 = Wash position reached 006 = Side brushes: center overlapping POR: wash bay end, turn position, (S15) 007 = Tandem position 008 = Start position, advanced initial position 009 = Stop position, end of wash 010 = locked, not active in initial position/wash position 017 = waiting for door



Byte 2 - Activity, generally

Activity = Meaning

001 = Switch off everything 002 = Move in initial position (outwards, upwards, wash bay start) 003 = Module active, position not defined 004 = Control, wash vehicle 007 = Test program, continuous test = moving between the limit switches or function on with pumps

Byte 9 - Overview error numbers

000 Switched on 001 Switched off 002 Ready 003 Program abort 004 Standard data loaded from ROM

old: ROM Data loaded 005 Defect data in RAM renewed

old: EEPROM data loaded 006 Ram without failure

old: RAM checksum OK 007 Counters destroyed 008 Data exchange with PC,

old: Communication error 009 Communication interrupted 010 Emergency Stop pressed 011 No 24 V supply (P7) 012 Backup failure

old: Read/Write error EEPROM 013 Initial position left 014 Water pressure too low

old: Flow monitor: water deficiency 015 Frost protection activated 016 Both limit switches actuated 017 Error initial position

old: Initial position not reached 018 Wash position not reached 019 Rotation: No current measured/underload 020 Rotation motor overload 021 Idling adjustment

022 Pulse count faulty old: pulse counter

023 Anti Collision switch 024 Frequency converter error 025 K201 - IO boards configuration 026 Initialisation running 027 230 V voltage missing 028 Parameter update

partly config update to (1.18) 029 Pump cabinet motor protection 030 Contact wire switched off 031 Card memory full 032 Residual value too low 033 Card invalid 034 Roof nozzle touched 035 Restart interlock active 036 Belts not tensioned 037 Pulse counter in initial position too large 038 Light barrier board voltage missing 039 Shortcut transmitter 040 Shortcut receiver 041 Cable break transmitter 042 Cable break receiver 043 Power limit reached 044 Backup deviates 045 Belt error in wash position 046 Air pressure too low



Module - Bytes / Words, detailed

000 POR Portal Byte 1 Status 001 = Off, position not defined

002 = Initial position reached, wash bay start 003 = Module active, position not defined 004 = Module active 006 = Wash bay end, turn position reached 007 = Tandem initial position reached 008 = Start position, 2. Initial position 009 = Stop position, end of wash 017 = wait for door

Byte 2 Activity 000 = no activity 001 = off 002 = move into initial position 003 = forward until limit switch, speed according to byte 8 speed of the modules 004 = backwards until limit switch, speed according to byte 8 speed of the modules 005 = Portal forwards, 70 Hz 006 = Portal backwards, 70 Hz 007 = Continuous test forward/backward, 25 Hz with Byte 8 " speed ": speed changeable, max. 100 Hz 008 = move into 2. initial position (advanced) 009 = Test portal forwards and backwards, 1 second each 010 = Brake with ramp (8 Hz slower for each 0,2 sec.) if POR remains in Act.10 during the wash the start condition for the next cycle is missing (e.g. DB in initial position)

Byte 3 Actual speed current speed, in Hz; feedback from FU Byte 4 Target speed current speed, in Hz; target to FU Byte 5 Direction Travel direction; 3 = forward; 4 = backward; 0 = stop; Byte 6 max. speed Solo: like Byte 8 speed, of the modules

multiple portals: max. speed defined by another portal Byte 7 Distance Distance analysis for TANDEM operation

The distance of both portal counters is evaluated. Thereby the relative portal speed is adjusted. if moving together: 001 = Actual distance < Min. distance, 002 = Actual distance < Min. distance + 40, 003 = Actual distance >= Min. distance + 40, 004 = Cycle M1 > Cycle M2 if moving apart: 010 = Actual distance >= Min. distance + 30, 011 = Actual distance < Min. distance + 30, Note: Min. distance at (brush cycle = 130, CTH cycle = 120) actual distance = WORD 4

Byte 8 Speed maximum speed of the cycle, in Hz



000 POR, continued, from Byte 9 Byte 9 Error Errors detected by the module

013 = Initial position left 017 = Error initial position 022 = Pulse count faulty 023 = Anti-collision switch 037 = Pulse counter in initial position too large

Byte A Brake Number of the module which is currently braking Byte B Last Stop Number of the module which the portal last stopped Byte C Tandem area Area of portal position for Tandem systems

003 = Portal position is smaller than Tandem initial position 004 = Portal position is larger than Tandem initial position

Word 1 Portal counter Counter for the portal pulses Word 2 Counter like Word 1; Word 3 Initial Position Initial position (50) Word 4 Distance Distance between M1 and M2 in a Tandem system

001 DB Roof brush Byte 1 Status 001 = Off, position not defined

002 = Initial position reached, top 003 = Module active, position not defined 004 = Module active, contact to vehicle 005 = Wash position reached, bottom 009 = Stop position, end of wash 010 = locked

Byte 2 Activity 000 = no activity 001 = Off 002 = Everything off and move to initial position 003 = fast start up to target value, lower to wash position (partly without rotation) 004 = control 005 = Rotation on forward cycle 006 = Rotation on reverse cycle 007 = Test function: Continuous test, up/down, 50 Hz Speed can be changed with byte 4 "Desired value", max. 80 Hz from 1.24e: the lift height of the roof brush is learnt during test function. first change 001 DB Para 1 = 000 in P2 Modcon, then start test; The roof brush moves slowly to the lower limit switch and records the counter into Para 1 automatically. 008 = idle adjustment, for test of zero balancing 013 = stationary drive-through wash 014 = Rotation off

Byte 3 Actual value Current torque value, filtered; Average of several values to compensate unbalance.

Byte 4 Target value Predefined toque value (contact pressure); is created from reference value and para contact pressure



001 DB, continued, from Byte 5 Byte 5 Step Step number for the different steps

000 = Wait for stabilization, after rotation on, start phase 001 = Wash start 001 = search min-max limit at start of brushes 002 = fill min-max limit buffer at start of brushes 003 = create min-max limit reference value at start of brushes 004 = for stationary drive-through wash, if Activity = 13

200 = lift roof brush during side brush center overlapping 250 = Roof brush idle balancing 255 = move roof brush into start position

055 = Auto search: no load bearing, roof brush in wash position 056 = Auto search: vehicle found, roof brush in wash position 005 = Auto search: no load bearing, roof brush not in wash position 006 = Auto search: vehicle found, roof brush not in wash position

060 = Front wash 008 = Side wash, rear not yet possible 009 = Side wash, rear possible 010 = Rear wash

011 = Cycle change at end of wash 012 = Cycle change, during start-up and rotation = off 013 = Cycle change, during start-up and switching rotation off 014 = Cycle change, during old cycle

155 = further vehicle and no load bearing 156 = further vehicle and load bearing

100 = Manual function Stop 101 = Manual function lower roof brush 102 = Manual function lift roof brush 103 = Manual function Start 104 = Manual function portal forwards 105 = Manual function portal backwards

Byte 6 Reference Measured idle moment; is built at start of wash after rotation is switched on.

Byte 7 AD value Torque, unfiltered directly read analog input.

Byte 8 Speed Maximum permissible portal speed Byte 9 Error Errors detected by the module

013 = Initial position left 016 = Both limit switches actuated 017 = Error initial position 018 = Wash position not reached 019 = Rotation: No current measured/underload 020 = Rotation motor overload 021 = Idling adjustment 022 = Pulse count faulty 036 = Belts not tensioned 037 = Pulse counter in initial position too large

Byte A Vehicle number Number of the currently washed vehicle 000 = truck, 001 = trailer or chain wash next vehicle etc.



001 DB, continued, from Byte B Byte B Rotation Rotation sequence;

Standard: The rotation direction is always opposed. During reverse wash the rotation is changed because of the wipers at trucks and buses. Thereby the wipers are always brushed from bottom to top. Position = Para 10 before front. No rotation change for cars or trailers. 000 = no rotation change necessary (standard rotation direction) 001 = rotation change done when vehicle center is reached (opposed to standard) 002 = rotation change finished (after center)

Byte C Steep vehicle Detection if a steep front is washed; 000 = normal vehicle contour, 001 = steep front, more than 30 lift pulses for 10 portal pulses, the side brushes are lifted from the vehicle.

Word 1 Lift counter Counter for lift pulses Word 3 Trailer front Counter of portal, in pulses at trailer rear

002 SBL Side brush left; 003 SBR Side brush right Byte 1 Status 001 = Off, position not defined

002 = Initial position reached, outside 003 = Module active, position not defined 004 = Module active, contact to vehicle 005 = Wash position reached, inside 006 = Center overlapping 009 = Stop position, end of wash 010 = locked, not active in initial position/wash position

Byte 2 Activity 000 = no activity 001 = Off 002 = Everything off and move to initial position 003 = start fast to wash position, without rotation 004 = control, without center overlapping 005 = control, with 1 x center overlapping (at front) 006 = control, with 2 x center overlapping, Standard (at front and rear) 007 = Continuous test inwards/outwards from 1.24e: the infeed of the side brushes is learnt during test function. first change 002/003 SBL/R Para 27 = 000 in P2 Modcon, then start test; The side brush moves slowly to the inner limit switch and records the counter into Para 27 automatically. For wide machines Para 9 towbar width and Para 10 loading platform are automatically adapted (increased by 20) 008 = idling adjustment, for test of zero balancing 009 = Rotation on forward cycle 010 = Rotation on backward cycle 013 = stationary drive-through wash

Byte 3 Actual value Current torque value, filtered; Average of several values to compensate unbalance.

Byte 4 Target value Predefined toque value (contact pressure); is created from reference value and para contact pressure



002 SBL, 003 SBR, continued, from Byte 5 Byte 5 Step Step number for the different steps

001 = Wash start 002 = Idle adjustment at wash start 003 = Idle error during wash phase idle adjustment at wash start 004 = Wait for end of idle adjustment 040 = move side brush in start position (in forward cycle) 041 = move side brush in start position (in backward cycle)

005 = Auto search: no load bearing, side brush not in wash position 006 = Auto search: during load bearing:, side brush not in wash position 007 = Auto search: vehicle detected 008 = Front wash, side = false 009 = Side wash , side = true , around the corner = true 010 = Auto search: no load bearing, side brush not in wash position 011 = Search for next vehicle, vehicle detected 014 = Cycle change, during old cycle

020 = Side brush center overlapping, at rotation change 021 = Side brush center overlapping 022 = Side brush center overlapping, move side brush again in wash position 024 = Side brush center overlapping, at the end move side brush out at front 025 = Side brush center overlapping, switch off side brush infeed at the end 026 = Side brush center overlapping, end

055 = Auto search: no load bearing, side brush in wash position 056 = Auto search: during load bearing, side brush in wash position 060 = Front wash , side = false , around the corner = false

080 = Rear wash start 081 = Rear wash, side brush in wash position, xistw-3 > xsollw 082 = Rear wash, side brush in wash position, xistw-3 =< xsollw 083 = Rear wash, side brush not in wash position, xistw-3 > xsollw 084 = Rear wash, side brush not in wash position, xistw-3 =< xsollw 085 = Rear wash, vehicle detected, infeed off 090 = Search for next vehicle, vehicle not yet detected (for chain washes)

100 = search min-max limit at start of brushes 112 = Stabilization of brushes and search min-max limit 113 = min-max limit ready and ok 116 = Sequence stationary drive-through wash (activity = 013)

155 = Search for next vehicle, no load bearing 156 = Search for next vehicle, load bearing

198 = Wash pause start 199 = Wash pause wait for end

200 = Manual function Stop 201 = Manual function side brushes inwards 202 = Manual function side brushes outwards 203 = Manual function Start 204 = Manual function portal forwards 205 = Manual function portal backwards

Byte 6 Reference Measured idle moment; is built at start of wash after rotation is switched on.

Byte 7 AD value Torque, unfiltered directly read analog input.

Byte 8 Speed Maximum permissible portal speed



002 SBL, 003 SBR, continued, ab Byte 9 Byte 9 Error Errors detected by the module

013 = Initial position left 016 = Both limit switches actuated 017 = Error initial position 018 = Wash position not reached 019 = Rotation: No current measured / underload 020 = Rotation motor overload 021 = Idling adjustment 022 = Pulse count faulty 037 = Pulse counter in initial position too large

Byte A Vehicle number. Number of the currently washed vehicle 000 = truck, 001 = trailer or chain wash next vehicle etc.

Byte B Mirror Bypass of the mirror for special bus (only when Para 20 – 22 active) 000 = no bypass 001 = from outside 002 = from inside 003 = from front 004 = from rear

Byte C Wash phase Separation of the individual sequences (the separation is not as detailed as the steps) 000 = Wash start 001 = Idling adjustment 002 = Move into start position 003 = Search vehicle 004 = Center overlapping front 005 = Front wash (value like side wash!) 005 = Side wash 006 = Rear wash 007 = Center overlapping rear 008 = Cycle change 009 = End of wash 010 = not used 011 = Wash pause 012 = further vehicle

Word 1 Counter Infeed counter, 5-digits Word 3 Moves free Edge detection at rear:

255 = the portal has moved a defined distance without load bearing of the side brush

Word 4 Set free Edge detection at rear: 255 = a defined infeed distance has been covered without load bearing of the side brush If the condition of Word 3 + 4 is met (both = 255): switchover from side wash to rear wash.



004 DD (High-pressure) roof nozzle Byte 1 Status 001 = Off, position not defined

002 = Initial position reached, top 003 = Module active 005 = Wash position reached, bottom 009 = Stop position 010 = locked, not active in initial position/wash position

Byte 2 Activity 000 = no activity 001 = Off 002 = Everything off and move to initial position 003 = Move with Joystick ( Lift and portal ) 004 = control, with contour cycle, for MaxiWash Combi 005 = move roof nozzle in wash position 007 = Continous lift test up - down Speed can be changed with byte 4 "Desired value", max. 80 Hz 008 = Continous lift test down - up, at 5 seconds lifting and 2 seconds pause.

Byte 3 Joystick Only for HP-Nufa 6-0297: 000 = Joystick in initial position 255 = Joystick actuated

Byte 3 Rot. Status Only for MaxiWash Combi: Adjusted direction of the HP nozzle orientation; 000 to 012, like the hour hand of a clock (viewed from the right)

Byte 4 Target speed actual lift speed, in Hz; predefined to FU for continuous test Byte 5 Lifting direction 003 = upwards; 004 = downwards Byte 6 Travel direction 003 = forwards; 004 = backwards Byte 7 Reference Reference value for Joystick (only for HP-Nufa) Byte 7 Rot. direction only for MaxiWash Combi: Predefined rotation orientation of the roof nozzle;

The entered values correlates with the hour hand of a clock; e.g. 006 = 6 o‘clock = vertical downwards; here you may enter values for testing.

Byte 8 Speed Maximum permissible portal speed Byte 9 Error Errors detected by the module

013 = Initial position left 016 = Both limit switches actuated 017 = Error initial position 018 = Wash position not reached 022 = Pulse count faulty 034 = Roof nozzle touched

Byte A Step Step number in sequence of the roof nozzle; not further defined

Byte B Portal joystick Analog value from Joystick at portal movement Byte C Lift joystick Analog value from Joystick at lifting movement Word 1 Lift counter Counter for lift pulses Word 2 Contour Roof nozzle contour in pulses Word 3 Light bar. status only for MaxiWash Combi: Status of the contour light barriers

000 = all dark, 001 = B20 free 002 = B20 + B21 free 003 = B20, B21 + B22 free 004 = B20 to B23 free 005 = all free (B20 to B24)

Word 4 Rotation path Rotation path in number of quarter turns *1000 + 100 at rotation forwards, + 200 at rotation backwards.



005 UBW (also segment controlled) Byte 1 Status 000 = off

004 = on 009 = Stop position, UBW wash finished

Byte 2 Activity 000 = no activity 001 / 002 = everything off (with relevant water pump) 003 = on, immediately (with relevant water pump) 006 = on UBW via UBW light barrier 010 = UBW on via UBW light barrier 011 = on UBW segment controlling via program matrix

Byte 3 V pump associated water pump 000 = no water pump 003 = High-pressure pump 004 = High-pressure pump with star-delta-start

Byte 5 S status Status display during segment controlling of the UBW 000 = off, no segment controlling active. 001 = High-pressure pump on for UBW 002 = UBW segment 1 on 003 = UBW segment 2 on, UBW segment 1 off 004 = UBW segment 3 on, UBW segment 2 off 005 = UBW segment 4 on, UBW segment 3 off 006 = UBW segment 4 off, High-pressure pump off

Byte 6 Timer1 UBW Time counter for spray period for each segment (according to Para 12) Byte 7 Release shows if the valve is fitted in this machine and if it is active

000 = off or not fitted 001 = active

Byte B Fitted shows if this valve in this machine exists in the configuration parameters (Para 15)

Byte C Timer2 UBW Time counter for delayed shut off of pump (according to Para 29) Word 1 Start UBW on; Start portal counter (according to Para 1) Word 2 Stop UBW off; Stop portal counter (according to Para 2)



006 HP side (Y40 for wheels) 007 Y1 FreWa VN arch 008 Y2 FreWa add. N arch 009 Y3 ProWa brushes 010 Y4 ProWa VN arch 011 Y6 CTH VN arch 012 Y7 CTH add. N arch 013 Y8 CVW 014 Y46 split arch top 015 Y10 HP chemic. side bottom 016 Y11 HP chemicals side top 017 Y12 HP chemicals roof 018 Y13 HP roof 019 Y14 HP side bottom 020 Y15 HP side top 021-023 Y16-Y18 Reserve 024 Y19 swivelling HP side 025 Y20 Reserve

Byte 1 Status 002 = off 004 = on 009 = Stop position, wash finished

Byte 2 Activity 000 = no activity 001 / 002 = Everything off (with related water and dosing pump) 003 = on, immediately (with related water and dosing pump) 004 = control, switch on depending on portal position (with related water and dosing pump) 005 = SoKo Bork: On Y20 + auxiliary additional arch and light barrier 006 = SoKo Bork: Y11 on with manual switch 007 = on, adjust spray pattern, switches also dosing and water pump 008 = only valve (without pumps, drain at frost) on 009 = SoKo Bork: valve Y08 on by wash by position light barrier 010 = Valve on by UBW - light barrier 014 = like 004 without dosing, only valve and water pump on

Byte 3 V pump related water pump 000 = no water pump 001 = Fresh water pump 002 = Process water pump 003 = High-pressure pump 004 = High-pressure pump with star-delta-start

Byte 4 V dosing related dosing pump 000 = no dosing pump 001 = Shampoo dosing pump 002 = CTH dosing pump 003 = CVW dosing pump 004 = High-pressure chemical dosing pump

Byte 7 Release shows if the valve is fitted in this machine and if it is active 000 = off or not fitted 001 = active

Byte 8 Speed Maximum permissible portal speed Byte B fitted shows if this valve in this machine exists in the configuration parameters (Para

15 ff) Word 1 Start Valve on; Start portal counter Word 2 Stop Valve off; Stop portal counter Word 3 Wash pause 000 = if key Stop has been actuated

001 = if key Start has been actuated 002 = if key portal forwards has been actuated 003 = if key portal backwards has been actuated

Word 4 Portal basic speed



026 DOP Dosing pumps Byte 1 Shampoo 002 = off; 004 = on; Byte 2 CTH 002 = off; 004 = on; Byte 3 CVW 002 = off; 004 = on; Byte 4 HD 002 = off; 004 = on; Byte A Request from dosing pump, binary (from P0 bleed dosing pumps)

000 = no pump active Bit 1 = Shampoo Bit 2 = CTH Bit 3 = CVW Bit 4 = High-pressure chemistry

027 PMP Water pumps Byte 1 Fresh water 002 = off; 004 = on; Byte 2 Process water 002 = off; 004 = on; Byte 3 High-pressure 002 = off; 004 = on; Byte 9 Error Errors detected by the module

014 = Water pressure too low 035 = Restart interlock active

Byte A Request from water pump, binary (from P0 adjust spray pattern) 000 = no pump active Bit 1 = Fresh water Bit 2 = Process water Bit 3 = High-pressure

Byte B Star-Delta Status for star-delta start 000 = no pump active 001 = Pump 1 – 4 off 002 = Initial position / pump off 003 = On, power and star, continue 004 004 = start-up time approx. 4 sec., continue 005 005 = Star off and wait 100mS, continue 006 006 = Delta mode on

Byte C Start-up time Counter for start-up time from star-delta start



028 ANL System, sequence control Byte 1 Status Sequence status

001 = Off 003 = Active 009 = Enter 010 = Swipe card 011 = Start key 012 = Auto wash 013 = Driven too far 014 = Not ready 015 = Ready 016 = Shampoo prewash 017 = CPW prewash 018 = HP prewash 019 = Brush wash 020 = HP chemicals 024 = Drying aid, run 027 = Exit 026 = UB wash 028 = Solo M1 ready 030 = Error 031 = Wait for M2 032 = Frost 033 = Wait for door 034 = Wait for program synchronisation

Byte 2 Activity Process activities 000 = Off 001 = Initialisation 002 = Initial position 003 = Active 004 = Wait for M2 005 = Wait for M3 006 = FU ready 007 = Check initial position 008 = Vehicle position, winter door 009 = Vehicle position 010 = Vehicle stationary 011 = Wait for units 012 = Wait for doors 013 = Wait for end of run 014 = Drive into position

Byte 3 Error no. Last reported error number Byte 4 Module no. Module number of the last error Byte 5 Error status Program pause at error, 255 = Error Byte 6 Portal number (0, 1, 2) Byte 7 Last readed key (key code);

after releasing a key 128 is added to the code number. Key ............... pressed. ........ free Key................ pressed. ........ free Key ................ pressed. ....... free

Start ....................... 90 ........ 218 Truck ..................... 71 ........ 199 Spoiler .................... 79 ........ 207 Safety- ................... 64 ........ 192 Truck+trailer. ........ 72 ........ 200 Ski basket .............. 81 ........ 209 Portal forwards ...... 04 ........ 132 Semitrailer………….73 ........ 201 DB on ..................... 82 ........ 210 Portal backwards ... 05 ........ 133 Bus + other. ........... 74 ........ 202 SB on ..................... 83 ........ 211

Stop ....................... 06 ........ 134 2x wash. ................ 75 ........ 203 UBW....................... 84 ........ 212 DB lift ..................... 01 ........ 129 Cent. overlap on .... 76 ........ 204 CVW....................... 85 ........ 213 DB lower ................ 02 ........ 130 2x DB front ............. 77 ........ 205 HP .......................... 86 ........ 214 DB lock .................. 03 ........ 131 Sonderfunkt. .......... 78 ........ 206 Additional arch ....... 87 ........ 215

SBs outwards ........ 88 ........ 216 SBs inwards ......... 127 ........ 255 SBs lock. ............... 89 ........ 217

Shift - D ................. 68 ........ 196 Shift - P .................. 80 ........ 208 Shift - +/- ................ 45 ........ 173 Shift - E .................. 69 ........ 197 Shift - 7 .................. 55 ........ 183 Shift - 1 .................. 49 ........ 177 Shift - F .................. 70 ........ 198 Shift - 8 .................. 56 ........ 184 Shift - 2 .................. 50 ........ 178 Shift - A .................. 65 ........ 193 Shift - 9 .................. 57 ........ 185 Shift - 3 .................. 51 ........ 179

Shift - B .................. 66 ........ 194 Shift - * ................... 42 ........ 170 Shift - CR ............... 13 ........ 141 Shift - C ................. 67 ........ 195 Shift - 4 .................. 52 ........ 180 Shift - < .................. 60 ........ 188 .................................... .............. Shift - 5 .................. 53 ........ 181 Shift - 0 .................. 48 ........ 176 .................................... .............. Shift - 6 .................. 54 ........ 182 Shift - > .................. 62 ........ 190

CKL no card ......... 000 .............. CKL cancel ............. 90 ........ 218 CKL time/date ......... 60 CKL Plus1 ............ 122 .............. CKL Data read ........ 07 CKL Enter ............... 13 .............. CKL-Para-updat ..... 61



028 ANL, continued, from Byte 8 Byte 8 MKL text Text number of last process message

000 = Drive in vehicle 001 = Swipe card 002 = Program ?? running 003 = Program stop 004 = Move to initial position 005 = Portal forwards 006 = Portal backwards 007 = Raise roof brush 008 = Side brush in 009 = Lower roof brush 010 = Side brush out 011 = Please wait ... 012 = Drive out vehicle 013 = Start key 014 = System not ready 015 = CONTINUOUS TEST 016 = *** NOT OFF *** 017 = Partner not ready 018 = Man. change of direction 019 = Solo mode 020 = Tandem mode 021 = Vehicle not ready 022 = ??? in position 023 = Frost guard active 024 = Select program 033 = Error rectify active 026 = Railcar program 027 = RegioShuttle program 028 = not assigned 029 = not assigned 030 = Insert coin 031 = Lift roof nozzle 032 = Lower roof nozzle 034 = Rectify error 035 = Quit error 036 = UBW manual mode 037 = HP manual mode 036 = CPW manual mode 039 = CDA manual mode 040 = Shampoo on 041 = Truck program 042 = Truck and trailer 043 = Semi-trailer program 044 = BUS program 045 = Car program 046 = Trailer program 047 = Stat. DF wash 048 = Short wash bay program 049 = Pickup program 050 = Pickup L+H 051 = Reverse wash 052 = Special bus 053 = HP wash 054 = Pickup semitrailer 055 = Van + trailer 056 = Trolley bus 057 = Machine setup

Byte 9 Error Errors detected by the module 002 = Ready 003 = Program abort 004 = Standard Data loaded from ROM 005 = Defect data in RAM renewed 006 = Ram without failure 007 = Counters destroyed 008 = Data exchange with PC 009 = Communication interrupted 012 = Backup failure 028 = Parameter update 030 = Contact wire switched off 044 = Backup deviates

Byte A Sequence Wash sequence functions machine 000 = No sequence 001 = Switch off machine 002 = Machine initial position 003 = Machine washes 004 = Station. Drive-through wash 005 = DB lift 006 = DB lowering 007 = SB outwards 008 = SB inwards 009 = Portal forwards 010 = Portal backwards 011 = UBW on 012 = HP on 013 = CVW on 014 = Switch-over Tandem/Solo 015 = Cycle change 016 = CTH on 017 = Roof nozzle lifting

Byte B stat. sequence Wash sequence functions stationary devices 000 = stat. devices wait for start 001 = switch off all stat. devices. 002 = all stat. devices in initial position 003 = stat. devices wash (Matrix 0) 004 = not assigned 005 = wait until machine is ready 006 = Drive-out monitoring 007 = wait for start of machine



028 ANL, continued, from Byte C Byte C Cycle Flag, if another cycle follows

000 = last cycle runs 001 = another cycle follows Word 1 Time Out Current status of abort timer, in seconds, countdown Word 2 Bork Sequence activity for SoKo Bork;

Description like Byte 2 Word 4 index Memory blocks in EEPROM each in 64 steps

029 M1 Machine 1; 030 M2 Machine 2; Byte 1 Status Sequence status, like module 028 ANL Byte 2 Matrix Current wash program matrix Byte 3 Machine type Machine type as per DIL switch settings on CPU K201

000 = Solo machine 001 = Tandem M1 002 = Tandem M2

Byte 4 Cycle Current cycle number of the wash program Run 1 to 10, 254 = Error cycle (aborted with error), 255 = No cycle

Byte 5 Door Data exchange between machines Byte 6 Pumps Data exchange between machines Byte 7 Function Data exchange between machines Byte 8 Speed Current portal speed in Hz Byte 9 Error Errors detected by the module

023 = Anti Collision switch Byte A Prog. Selected wash program

000 = Truck 001 = Truck + trailer 002 = Semitrailer 003 = Bus 004 = Car 005 = Trailer 006 = Stationary drive-through wash 007 = Short wash bay 008 = Pickup 009 = Pickup + trailer 010 = Reverse wash 011 = Special bus 012 = High-pressure wash 013 = Pickup semitrailer wash 014 = Van + trailer 015 = Trolley bus

Byte B Terminal User of the terminal at Tandem machines 001 = M1 has the terminal

Byte C Cycle type: BW, CTH 000 = undefined, wash start 002 = brush wash

Word 1 Position Current portal counter status, in pulses Tandem: only with P3 Monitor from M1: Word 2 Rear Module M1, Tandem: measured rear position by M1, in pulses Word 2 Front Module M2, Tandem: measured front position by M2, in pulses Tandem: only with P3 Monitor from M2: Word 2 Front Module M1, Tandem: measured front position by M2, in pulses Word 2 Rear Module M2, Tandem: measured rear position by M1, in pulses Tandem: with P3 Monitor from both machines: Word 3 Auxiliary activated auxiliaries

(description see parameter list module LT1 Para 2)



031 M3 Machine 3 No bytes or words defined

032 CHK Check Byte 1 No function Byte 2 Emergency Stop monitor

001 = Do not close Emergency Stop circuit; 004 = Release Emergency Stop circuit, pulse to switch unit.

Byte 3 Status COM 1; 000 = o.k. (FU) Byte 4 Status COM 2; 000 = o.k. (FU) Byte 5 Status COM 3; 000 = o.k. (Printer, CKL, PC ...) Byte 6 Status COM 4; 000 = o.k. (Printer, CKL, PC ...) Byte 8 Control voltage; 255 = OK 000 = no voltage; Byte 9 Error Errors detected by the module

010 = Emergency Stop pressed 011 = No 24 V supply (P7) 027 = 230 V voltage missing

Byte A Anti-freeze 000 = Anti-freeze not active 255 = Anti-freeze active

Byte C Voltage Display of the supply voltage as digital value of input E006; from 1.33o2 for monitoring the torque board and for voltage compensation

Word 1 Cycle time Max. cycle time for one software cycle, in msec.



033 FUH Frequency converter lift; 034 FUP Frequency convert. portal Byte 1 Status Status message from frequency converter, binary

The displayed decimal value must be converted into binary form. Bit 0 = 1 = Error shut down Bit 1 = 1 = Standstill Bit 2/3 = 00 = Stop = 01 = Clockwise = 10 = Anti-clockwise = 11 = Holding moment Bit 4 = 1 = Final frequency reached Bit 5 = 1 = Frequency is greater than fixed frequency 5 Bit 6 = 1 = Current limit value exceeded Bit 7 = 1 = Incorrect generator operation

Byte 2 Activity 000 = Ready 001 = Roof brush working ( = module No.) 004 = Sensing nozzle working ( = Module No.) 33,34 = (= Module No.) Switch on initialisation or error processing No data connection to frequency converter

Byte 3 Actual value Actual speed, feedback Byte 4 Target value Target speed, definition Byte 5 Direction Actual direction

003 = Forwards/up 004 = Backwards/down

Byte 6 Target direction Target direction Byte 7 Status Error message from frequency converter to controller,

000 = o.k. 001 = 1 Power on 002 = Watchdog 032 = Received parameter unknown 064 = Change not permissible 128 = Invalid value

Byte 8 Start Controller release 000 = off 003 = on

Byte A Data to FU Number of repeats for a data telegram Byte B FU status 001 = Operating status of the FU is queried;

000 = Status query finished Byte C FU errors Errors detected by the module

009 = Communication interrupted 024 = Frequency converter error 026 = Initialisation running

Word 1 Options status Type interface board on K201; 000 = board with 4x interface, (Lust FU is controlled serially on K201; possibly. 8 FU board for Omron) 001 = board with 2x serial and 2x FU fitted; for Omron FU

Word 1 Error counter Continous error counter of controller locking Word 2 Error counter Continous error counter for number of not-acknowledged messages Word 3 Error counter Continous error counter for number of checksum errors Word 4 Wait Remaining runtime for waiting FU to power, after power off



035 FUR Frequency converter, reserve No bytes or words defined

036 LT1 Auxiliaries table 1 Each byte corresponds to a program or Auxiliary

000 = Auxiliary is not active; 255 = Auxiliary is active

Byte 1 Truck program Byte 2 Truck with trailer program Byte 3 Semi-trailer program Byte 4 Program selection, Bus, car, trailer, stat. passage ect. Byte 5 Wash twice auxiliary Byte 6 Central overlap auxiliary Byte 7 DB front wash twice auxiliary Byte 8 Special function auxiliary Byte 9 Spoiler auxiliary Byte 10 Ski basket / loading ramp auxiliary Byte 11 Roof brush on auxiliary Word 1 Wash program Currently selected wash program

000 = Truck 001 = Truck and trailer 002 = Semi-trailer 003 = Bus 004 = Car 005 = Trailer 006 = Stationary passage wash 007 = Short hall 008 = Pickup 009 = Pickup with trailer 010 = Reverse wash 011 = Special bus with mirrors 012 = High-pressure wash 013 = Pickup semitrailer wash 014 = Van + trailer 015 = Trolley bus

Word 2 LEDs left Terminal LEDs, left panel, display status, binary Word 3 LEDs right Terminal LEDs, right panel, display status, binary

037 LT2 Auxiliaries table 2 Each byte corresponds to a program or auxiliary

000 = Auxiliary is not active; 255 = Auxiliary is active

Byte 1 Side brushes on auxiliary Byte 2 Underbody wash auxiliary Byte 3 CVW auxiliary Byte 4 HP auxiliary Byte 5 Additional arch auxiliary Byte 6 Lock DB auxiliary Byte 7 Lock SBs auxiliary Byte 8 Shampoo auxiliary (always active) Byte 9 CDA auxiliary (always active)



038 PRG Programs No bytes or words defined

039 EFT Entry door; 040 AFT, Exit door Byte 1 Status 002 = Initial position, top, open

005 = Wash position, bottom, closed Byte 2 Activity 001 = Open after Emergency Stop

002 = Open 003 = Open/Close door depending on selector switch and machine status 004 = Door activation during programs 005 = Open door 006 = Close door 007 = Continuous test open/closed (without pause)

Byte 3 Door timer Time counter for door movement (see para 5) Byte 4 Pulse timer Time counter for door pulse (see para 4) Byte 5 Winter door 255 = Winter door on

000 = off Byte 7 Step Step number;

000 = Wash not started yet 001 = Program started (program key pressed); 002 = Wash started, close door 008 = Wash not yet in last cycle 009 = Last cycle wash forward cycle, Portal still before door open position 010 = Last cycle wash backward cycle, Portal still before door open position 011 = Wait until door is open, delay 012 = Wait until end of wash 013 = Wash is finished, wait until system is in initial position; 014 = Wash is finished, vehicle should drive out 015 = Winter door: Timer initialization 016 = Winter door: wait until drive-through light barrier is dark an until start light barrier is light (vehicle leaves wash bay); 017 = Winter door: wait until drive-through light barrier is light + delay door closed; 019 = Winter door: Close door after vehicle has left the wash bay and closing delay

Byte A Pulses Number of door pulses since machine on (Open + Close) Byte B Winter door: Exit door to query

000 = Conditions for closing not satisfied; 255 = Washing/Drying completed, vehicle must exit wash bay, then close AFT.

Byte C Machine status Winter door: Machine status for exit vehicle 000 = Machine is still active; 001 = Washing completed, timer initialisation; 002 = Wait until exit door light barrier is dark (vehicle exits wash bay); 003 = Wait until light barrier is light again and door close delay; 004 = Wash bay empty, close door.



041 MKL Magnetic card reader, CAN unit Byte 1 Status MKL-1 Status of MKL 1

000 = Machine error 001 = Program not accepted, MKL disabled 002 = MKL released 003 = Program accepted 010 = Parameter update 255 = MKL basic status after power on

Byte 2 Activity MKL-1 Status feedback from MKL, binary, for construction 000 = card operation Bit 1: 0 = card operation, 1 = manual operation, Bit 0, Bit 2 to 7 = data from MKL

Byte 6 Status- Ack 1 Feedback from MKL-1 to K201 like Byte 1

Byte 7 Status MKL -2 Status of MKL 2, like byte 1 Status is always = 255 = default after power on

Byte 8 Activity MKL-2 Status feedback from MKL 2, like Byte 2 Byte C Status-Ack 2 Feedback from MKL 2 to K201, like Byte 6 Word 1 Login: 1st MKL / Terminal

001 = 1st MKL/Terminal exists at address 1 Word 2 Login: 2nd MKL/Terminal

001 = 2nd MKL /Terminal exists when MKL Para 4 = 001 (2 terminal operation) Word 3 Counter when transmitting parameters Word 4 Counter during parameter update (if byte 1 = 010)

042 CKL Chip card reader bis 1.14 IOM IO module, distributer cabinet, CAN device, however not used Byte 1 Status Status of CKL 1

000 = Machine error 001 = Program not accepted, CKL disabled 002 = CKL released 003 = Program accepted 004 = Wash finished 005 = Program running 006 = Anti-freeze

Byte 2 Activity 000 = Off 001 = Off 002 = CKL lock when system is not ready 003 = CKL lock while program runs 004 = CKL start program with card 005 = CKL lock, wait for card 008 = CKL read cards

Byte 3 Acceptance Program from card accepted 000 = Not yet accepted 255 = Program accepted

Byte 4 Card type Card type, 000 = Single card, 001 = Multiple card, 002 = Cash card, 003 = Authorization card, 004 = Discount card, 005 = Voucher card 006 = Wash card 007 = Single/auxiliary card 008 = Multiple/auxiliary card 009 = Cash card Euro

Byte 5 Timeout Timeout counter for receiving key code



042 CKL, continued, from Byte 7 Byte 7 Step 001 = CKL not fitted

002 = Draw in card 003 = Return card 004 = Lock card 005 = Query card status 006 = Request password 007 = Query CKL Power ON 008 = Query CKLPower OFF 009 = Read card 010 = Write card 011 = Generate password 020 = CKL wait for card 101 = Send CKL text 098 = Receiving telegram telegram-crc <> buffer data 099 = Receiving telegram telegram-crc = buffer data 100 = Receiving telegram telegram O.K.

Byte 8 Card valid Step number when verifying the card validity 000 = Card invalid 001 = Card not locked 002 = Query station code 004 = Query if card date up to ’96 (2096) 005 = Query if current date up to ‘96 055 = Card valid if card date and current date up to ‘96 006 = Query if card date beyond 1996 to 1999 007 = Query if current date beyond 1996 to 1999 008 = Card valid if card date and current date beyond 1996 to 1999 009 = Password of CKL = wrong 010 = Password of = O.K.

Byte 9 Error Errors detected by the module 031 = Card memory full 032 = Residual value too low 033 = Card invalid

Byte A CKL key Key code from CKL 000 = No key 007 = Card recognized, data read 090 = Start / Cancel 013 = Acknowledge/Enter

Byte B Function Function Transponder 001 = Serial chip card reader with PC 002 = Serial chip card reader without PC 003 = Serial chip card reader with PC and time capturing 005 = CAN chip card reader with PC 006 = CAN chip card reader without PC 014 = CAN transponder reader Datamat TKL

Byte C Mode of paym. Mode of payment for card operation, from Rev. 1.30F 000 = Single card 001 = Multiple card 002 = Cash card 003 = Authorization card 004 = Discount card 005 = Voucher card 006 = Wash card (type par. reader) 007 = Single auxiliary card 008 = Multiple auxiliary card 009 = Cash card Euro

Word 1 Nufa program Wash program or vehicle type (Truck, T+T, Semitrailer, Bus.......) Word 2 Nufa option Program auxiliaries of the wash program Word 3 Data amount Number of the currently stored CKL washes, maximum 1000



043 SER Serial interface bis 1.14 LED LED displays, CAN device, however not used Byte 3 Receive Receiving data Byte 4 Transit Transmitting data Byte 6 Active Flag 000 = not active

255 = active Byte 7 Transmission 004 = Event ready for reporting

003 = Machine reports 000 = Hung up 002 = Transmits SMS (with M20) 001 = Accepted (without M20-Modem)

Byte 8 PC release 000 = No connection to PC 255 = PC connection active, valid password

Byte A Modem status binary display of transmission status Bit 0 = DCD - data carrier detected Bit 1 = Ring Bit 2 = DTR - data terminal ready Bit 3 = RTS - request to send Bit 4 = CTS - clear to send Bit 5 = DSR - data set ready

Word 1 Connection Connection status and connection function Here 2 values are shown at the same time. The thousand place shows the connection status, the unit place shows the connection function Thousand: Unit: connection status: connection function: 10 = direct 010 = direct 20 = modem answer 020 = modem answer 30 = modem originate 030 = modem originate 40 = modem init 040 = modem init 41 = modem lift 041 = modem lift 42 = modem hang up 042 = modem hang up 43 = modem call 043 = modem call



043 SER, continued, from Word 2 Word 2 Diagnosis Modem and diagnosis status

Here 2 values are shown at the same time. The thousand place shows the diagnosis status, the unit place shows the modem status Thousand: Unit: Diagnosis status Modem status 50 = DS OK 000 = MS OK 51 = Execution error 001 = connect 52 = No authorization 002 = ring 53 = Parameter error 003 = no carrier 54 = Function unknown 004 = error 55 = Device address wrong 005 = connect 1200 56 = CRC error 006 = no-dial-tone 57 = Time out 007 = busy 58 = Connection interrupted 008 = no answer 59 = SMS transmitted 010 = connect 2400 011 = connect 4800 012 = connect 9600 013 = connect 7200 014 = connect 12000 015 = connect 14400 016 = ready 253 = timeout 254 = falsch

044 BED Operating unit Byte 1 Status Status message at parallel program input

000 = Not ready 255 = Ready



045 KFZ Vehicle position The values of the vehicle measurement are deleted at program start. Byte 1 Trailer flag 000 = Trailer front not yet recognised;

001 = Trailer front recognised (position = DB word 3) Byte 2 Drawbar flag 000 = Drawbar not yet recognised;

001 = Drawbar recognised (position = KFZ word 3) Byte 3 Vehicle LS Light barrier status vehicle length

000 = LS free 255 = LS dark

Byte 4 Position sensor Portal number, Where the positioning light barrier is fitted Byte 5 Vehicle length Vehicle length in dm Byte 6 Vehicle number Number of the currently washed vehicle;

000 = first vehicle; 002= second vehicle, etc. at truck+trailer, tractor = 000, trailer =001.

Byte 7 HP time Duration of high pressure wash in seconds Byte 8 Vehicle sensor 001 = Light barrier (with traffic light)

002 = Wheel trough (without traffic light) Byte A Front flag 000 = Front of vehicle not yet reached

255 = The front has been recognised and entered (word 1) Byte B Middle flag 000 = Middle of the vehicle is not yet reached

255 = The middle has been recognised and entered (word 2) Byte C Rear flag 000 = Rear of the vehicle not yet reached

255 = The rear has been recognised and entered (word 4) Word 1 Front Portal counter status for vehicle front Word 2 Middle Portal counter status for vehicle middle Word 3 Drawbar Portal counter status, start of drawbar Word 4 Rear Rear Portal counter status for rear

046 TST Test Byte 9 Error Error number only during POWER ON Word 3 Gap Size of the gap in which no brush can be lowered (Kombi-Nufa); from 1.32p5

in portal pulses, depending on DD Para 6. Word 4 Mode of paym. Mode of payment for card operation, only up to Rev. 1.30e, see CKL Byte 12

000 = Single card 001 = Multiple card 002 = Cash card 003 = Authorization card 004 = Discount card 005 = Voucher card 006 = Wash card (type parallel reader) 007 = Single auxiliary card 008 = Multiple auxiliary card 009 = Cash card Euro



047 SOF Special functions With support of byte 2, Activity experienced values may be loaded for the according parameters of the different special functions. Thereby many parameters can be set in a very short time. Byte 2 ParaKonfig 000 = No function;

003 = Load parameters mirror bypass. DB, SBL and SBR Para 2, 20,21, und 22. valid for most special buses. (see adjustment instruction mirror bypass N201-01-05) 004 = Load parameters for French machines with short wash bay sequence (Maxiwash Chrono) Here the short wash bay sequence and the language are set. 005 = Load parameters for Swiss machines with short wash bay sequence and early leaving of the wash bay. 006 = Load parameters MaxiWash Kombi. Here the wash sequence matrixes 15, 30 and 31 are adapted and the modules DD and LS are activated by setting parameter 15. 007 = Deleting the parameters for the wash position of DB, SBL/R and DD. DB Para 1, SBL/R Para 27 and DD Para 13 are set to 000. Afterwards the test program can be called by the according byte = 007 to learn the respective wash position again. 008 = Load parameters Pickup programs. For the programs Pickup, Pickup+trailer, Semitrailer-Pickup are special settings required. This function is used to set the parameters with according experienced values. DB Para 3, POR Para 6 and 11. Also Matrix 30 is assigned to this programs. In cycle 4 the Activity of the DB = 002 and Y01 = 004 are then set. 009 = Load parameters conversion fresh water in backward cycle. Here different parameters and matrix changes are adapted. (see conversion instruction N201-12-04) 010 = Config of the program allocation of 6 wash programs France. Here 6 wash programs and auxiliaries for parallel input are allocated and set. Also the language is set and the terminal is switched to 8 programs. 011 = Adapt abbreviations of module names and program names to the set language. E.g english DB RB For modules only the first 7 modules (POR to HD) 012 = Load parameters MaxiWash Kombi. DD Para 18 = 50, 19 = 035, 29 = 001, 30 = 001 are set. 013 = Load parameters UBW with 4 segment pairs (Kemi Finland). 014 = Parameter default for Tandem systems. 015 = Load parameters trolley bus with collector 016 = Load parameters wash data capturing length depending bus 101 = Dosing pumps and water pumps in module Y10 to Y15 Para 4 and 8 delete. (set to 000) For testing the DD contour cycle without water and chemistry. 102 = Activate pumps and dosing pumps in module Y10 to Y15 Para 4 and 8 again. Para after test will be set accordingly.



048 R 1 Reserve 1 No bytes or words defined

049 RPD Real Power Device No bytes or words defined

050 LS Light barrier monitoring module Only for MaxiWash Combi with integrated light barrier board. from Rev. 1.31 Up to Software 1.29 the module 050 R 3 has not been used. Byte 1 Status binary O. K. for values from 000 to 007, error if larger

Bit 0: Mode 0 = stop, 1 = run Bit 1: Busy, Bit 2: Live, Bit 3: Alarm 1 Power limit reached Bit 4: Alarm 2 Transmitter or receiver defect

Byte 2 Activity 002 = Read the set power Display on Byte 3 to 6 and A to C 007 = Evaluation optical axle, current power /transmission quality Display on Byte 3 to 6 and A to C

Byte 3 LS 7 Reserve, display depending on value set in Byte 2. Byte 4 LS 1 HP 1. LS from top, display depending on value set in Byte 2. Byte 5 LS 2 HP 2. LS from top, display depending on value set in Byte 2. Byte 6 LS 3 HP 3. LS from top, display depending on value set in Byte 2. Byte 7 LS step Step number of the light barrier monitoring

001 = Function LIVE, if status = busy 002 = Function LIVE, if status <> live and status = busy 003 = Function RUN, if status = busy 004 = Function RUN, if mode <>stop and status = busy 005 = Function STOP, if status = busy 006 = Function STOP, if mode <> stop and status = busy 007 = Function RESET, if status = busy 008 = Function RESET, if mode <> stop and status = busy 009 = Light barriers read power 010 = Light barriers read transmission quality 012 = Light barriers initialize channel 1-16 013 = Light barriers evaluation, if status = busy 014 = Light barriers, read error registry

Byte 8 LS valid 000 = O. K. 255 = Evaluate light barrier alarm and determine cause of failure, Power limit or a defect in the light barrier system has been reported.

Byte 9 LS error Error number light barriers 038 = Light barrier board voltage missing 039 = Shortcut transmitter 040 = Shortcut receiver 041 = Cable break transmitter 042 = Cable break receiver 043 = Power limit reached

Byte A LS 4 HP 4. LS from top, display depending on value set in Byte 2. Byte B LS 5 Vehicle length, display depending on value set in Byte 2. Byte C LS 6 Reserve, display depending on value set in Byte 2. Word1 LS inactive 000 = No channel active, > 000 = Binary mask for active channels Word2 LS line Line number of the defect light barrier (currently 212 to 216)



051 R4 Reserve No bytes or words defined

052 R 5 Reserve DB Lift + Portal controller Up to software 1.29 module 049 R2 has been used. Bytes / Words of the reserve module are for the construction department. Byte 1 Basic speed Basic speed Byte 2 Speed Speed Byte 3 Lift speed Lift speed Byte 4 Sharp edge 255 = Sharp edge Byte 5 Front area 255 = Front area Byte 6 Rear area 255 = Rear area Byte 7 Wash phase Wash phases in wash sequence; from 1.32p3

000 = Wash start 001 = Idling adjustment 002 = Move in start position 003 = Search vehicle 004 = Center overlapping front 005 = Front wash 006 = Side wash 007 = Rear wash 008 = Center overlapping rear 009 = Cycle change 010 = End of wash 011 = Wash pause 012 = Search next vehicle

Word 1 DB-H-Diff. Lift controller: difference actual value – target value Word 2 DB-H-Set. Lift controller: manipulated variable Word 3 DB-P-Diff. Portal controller: difference actual value – target value Word 4 DB-P-Set. Portal controller: manipulated variable



053 R 6 Reserve SBL Setting + Portal controller 054 R 7 Reserve SBR Setting + Portal controller

Up to software 1.29 modules 050 R3 and 051 R4 have been used. Byte 1 Basic speed Basic speed Byte 2 Speed Speed Byte 3 Inward-Outward Value for moving inwards and outwards, manipulated variable or 40 (switch-on

time from infeed contactor) Byte 4 Speed Portal manipulated variable, (< 0 too close, > 0 too far away) Byte 5 Diff Difference target value – actual value Byte 6 Target value Adjusting controller target value Byte 7 Actual value Adjusting controller actual value Byte 8 Counter Adjusting controller calls; counts when active Word 1 SBH_Diff Adjusting controller: difference actual value – target value Word 2 P part Adjusting controller: P part Word 3 I part Adjusting controller: I part Word 4 SBH_Set Adjusting controller: manipulated variable

055- 057 R 8 - R11 Reserve No bytes or words defined



File: NU-TH-GB_N201-02-03-D-Monitor-Bytes_c_13-11-07.docx Changes since 25.05.2004 are written coloured and marked by „|” at the outer margin.

Technical Manual Model series Nufa K201 6-0395 N201-D-2-5 Torque Converter Board, SN 109 204 04 January 2001 Test Manual Page 1 of 3


Location of the test points

Test points

Table for Evaluation Test Point

Designat. Ua Tolerance Formular Example Remarks

TP1 +15V +15 V ± 0,6 V desired = + 15V

TP2 GND 0 V 0V (Ground)

TP3 -15V -15 V ± 0,6 V desired = -15V

TP4 SBL 10 V at 3A ± 0,6 V Ua At 1,8 A = 6 V = I x 3,33 TP5 SBR 10 V at 3A ± 0,6 V Ua at 1,8 A = 6 V = I x 3,33 TP6 DB 10 V at 4,3A ± 0,6 V Ua at 2,3 A = 5,4 V = I x 2,33 only valid for DB Nufa

TP7 L1 10 V at 250 V ± 0,6 V Ua at 230V = 6,7 V = (U -190) : 6 TP8 L2 10 V at 250 V ± 0,6 V Ua at 230V = 6,7 V = (U -190) : 6 TP9 L3 10 V at 250 V ± 0,6 V Ua at 230V = 6,7 V = (U -190) : 6

Declarations: Ua

I = Motor current DB, SBL, SBR connected to plug X2 of the torque converter board. = DC voltages at the test points TP1 bis TP9.

U = Mains voltage AC L1, L2, L3 connected to plug X3 of the torque converter board. The examples show the expected idling values of the rotation motors.

C25 C22

Tp3Tp2

Tp1

Tp9 Tp8 Tp7 Tp6 Tp5 Tp4

X2X31 1

1

Technical Manual N201-D-2-5 Model series Nufa K201 6-0395 04 Januar 2001 Torque Converter Board, SN 190 204 Page 2 of 3 Test Manual


Mains Voltages L1, L2, L3

Rotation Currents DB, SBL, SBR

190 195 200 205 210 215 220 225 230 235 240 245 250

0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 A Current Motor

10.09.59.08.58.07.57.06.56.05.55.04.54.03.53.02.52.01.51.00.50.0

5 V

5.8 V

6.7 V

7.5 V

8.3 V

4.2 V

5 V

6.7 V

5.8 V

7.5 V

4.2 V

3.3 V

4.7 V

5.2 V

5.8 V

4.1 V

3.5 V

3.3V

10.09.59.08.58.07.57.06.56.05.55.04.54.03.53.02.52.01.51.00.50.0

Test

Poi

nts:

L

1, L

2, L

3

Test

Poi

nts:

D

B, S

BL,

SB

R

only for DB

not for DB of NUFA

190 195 200 205 210 215 220 225 230 235 240 245 250 VAC Mains Voltage

0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0

2.33V

2.9 V

Technical Manual Model series Nufa K201 6-0395 N201-D-2-5 Torque Converter Board, SN 109 204 04 January 2001 Test Manual Page 3 of 3


Volt meter AC-Range >250V , Volt meter DC-Range >15V , Ampere meter AC-Range >5A Required instruments:

Meassuring of all voltages Ua

of the test points TP4 to TP9 against Ground = test point TP2 (GND)

Test point TP1 +15V and TP2 -15V to test point TP2 (GND).

Order of meassuements:

AC voltage phase L1 at X3.1 and DC voltage (Ua

AC voltage phase L2 at X3.3 and DC voltage (U

) at testpoint TP7 (L1) or at X1.4.

a

AC voltage phase L3 at X3.5 and DC voltage (U


a

First meassure the mains voltages phase L1, L2 and L3 at plug X3.


From this AC voltage the desired value of the DC voltage at the test points TP7 to TP9 ( L1, L2, L3 ) can be calculated by a formular (see table) or taken from the graphic.

The DC voltage has to be within the tolerance of ± 0.6 V.

Activate the rotation motor of DB, SBL, SBR with the P3 Monitor program or P4 Hardware Test.

AC motor current SBL at X2.1 and DC voltage (Ua

AC motor current SBR at X2.3 and DC voltage (U

) at test point TP4 (SBL) or at X1.1.

a

AC motor current DB at X2.5 and DC voltage (U

) at test point TP5 (SBR) or at X1.2.

a

) at test point TP6 (DB) or at X1.3.

First meassure the current of the motor at the plug X2.

From this AC current the desired value of the DC voltage at the test points TP4 to TP6 can be calculated by a formular (see table) or taken from the graphic.

The DC voltage has to be within the tolerance of ± 0.6 V.

If all voltages are within the tolerance the board is ok.

Results:

With higher deviations the board is out of order and has to be changed.

Produced by: Bernd Zeller on: 04.01.2001 Approved by: Bernd Zeller

Amended: on: Signature

File: NU-TH-GB_N201-02-05-D-Dremo.docx

Technical Manual Model series Nufa K201 6-0395 N201-02-10-D Drives with frequency converter 17. July 2005 Diagnosis: Omron-, Fuji-, Lust-FC Page 1 of 7


Frequency converter

Filter installed below, here without brake resistor

Cover of motor terminals can be pulled of upwards

Jumper: must be plugged on source

Content: Frquency converter (FC) FRN 0,75 C1S-7E, from Fuji __ 1

Part numbers ______________________________________ 1 Connection information: ______________________________ 2 Front view frequency converter ________________________ 2 Terminal assignment: _______________________________ 3 Programming the Fuji frequency converter: ______________ 3

Frequency converter OMRON 3G3EV ______________ 4 Part numbers ______________________________________ 4 LED displays oft he frequency converter: ________________ 4 Control signals: ____________________________________ 4 Converter type: ____________________________________ 4 Parameter setting: __________________________________ 4

Frequency converter LUST VF 1204 _______________ 6 Part numbers ______________________________________ 6 LED displays of the frequency converter: ________________ 6 Checking the contacts "Controller Release - RFR": _________ 6 Check the data transmisision between K201 and FC: _______ 6

General _____________________________________ 7 Checking the mechanic of the drive: ____________________ 7 Checking the supply voltage: __________________________ 7 Test cycles for DB, DD and POR with different speeds: _____ 7 For portal stops during the wash: _______________________ 7 For HP Nufa: Are all contactors fort he switchover DD/DB

switched correctly? ________________________ 7

Frequency converter (FC) FRN 0,75 C1S-7E, from Fuji A new frequency converter from Fuji was introduced. The old Omron-FC SN 761 152 950 is not produced anymore. The new frequency converter is fully compatible to the Omron FC.

Part numbers SN 211 323 frequency converter Fuji FRN 0,75 C1S SN 211 324 Filter (3 leads) for portal SN 211 945 Filter with brake resistor (5 leads), for lifting roof brush and roof nozzle, winding drive The frequency converter is specially programmed for WashTec by Fuji. The FC cannot be used with the Fuji factory setting (Danger: The roof brush may fall down during Emergency Stop). Changing of parameters is disabled.

Also a manual control of the drive from the operating device of the FC is disabled (danger of accident).

Warning:

A remaining voltage may occur for up to 5 minutes after switching off! The heat sink below the FC may become very hot!

Technical Manual N201-02-10-D Model series Nufa K201 6-0395 17. July 2005 Drives with frequency converter Page 2 of 7 Diagnosis: Omron-, Fuji-, Lust-FC


Connection information: Line filter

Front view frequency converter

Most important characteristics: Motor rating 0.75 kW Rated current 5.0 A Overload capacity 150 % for 1 min. 200% for 0,5 sec. Input voltage 200 - 240 V, 50/60 Hz

Operating keys and Poti, w/o function

Removed cover with drawing of the terminal assignment

Control terminals Power terminals; The bridge between P1 and P+ must not been removed!

Power supply

Filter with brake resistor wire br, bl, gnye = power, 2 x bk = brake

Filter without brake resistor wire br, bl, gnye power to FC



Terminal assignment: Fuji Omron Note Ground, 0 V CM + 11 + 30C FC + SC + MC Speed target value 12 FR 0 - 10 V DC Start backwards / lifting REV SR Start forwards / lowering FWD SF (Reset) (X3) (S1) Not used Error 30B MB Feedback from FC + 24 V / 50 mA (for error) PLC FS Brake P1 B1 Only for lifting

DB B2 Only for lifting Lead L1 L1

N N PE PE

Motor line U U V V W W PE PE

In the current wiring diagram the terminals for both frequency converters are drawn.

Programming the Fuji frequency converter: For the first Fuji-FCs the programming was not fully correct. It could happen that the drive continued moving very slowly in one direction. This was caused by the wrong setting of parameter F09 (torque increase in %):

Check if parameter F09 = 20.0 if yes, change setting to 17.5;

Procedure:

Activity/Key Display and subsequent activities

Connect FC to power Display 0.00 PRG/RESET Display 1F__ FUNC/DATA Display F00 FUNC/DATA Display 0; if display 1, then STOP + until display 0 FUNC/DATA Display SAVE, if parameter F00 changed Display F01 Multiple times until display F09 FUNC/DATA Display 20.0 Multiple times until display 17.5 FUNC/DATA Display SAVE Display F10 Multiple times until display F00 FUNC/DATA Display 0 STOP + until display 1 FUNC/DATA Display SAVE Display F01 PRG/RESET Display 1F__ PRG/RESET Display 0.00



Frequency converter OMRON 3G3EV Part numbers FC Omron ______________________ 761 152 950 Repaired:_____________________ 790 152 950 Filter __________________________ 761 152 681 Operating unit (not installed for Nufa) _ 761 152 948 Blind cover: ___________________ 761 152 949 Control cable lift ____________________ 201 422 Control cable portal _________________ 201 421

LED displays of the frequency converter: green: run, red: Alarm Normal: flashes on Power on, FC ready; on off Frequency converter is started, motor running; Warning: flashes flashes simultaneous forwards and backwards order on flashes overvoltage or undervoltage, overtemperature Error off on Overcurrent, overvoltage or undervoltage, shut-off: Control voltage error, overtemperature, Motor or internal overload, external error Error in: internal RAM, Parameter, AD converter, Options off off Control voltage missing

Control signals: Target value definition: Voltage between 0 and 10 V DC

Test with hardware test: Default from 255 (10 V), 128 (5 V), 064 (2,5 V), 032 (1,25 V), 016 (0,625 V) and 008 (0,3 V); Measure each voltage defined at the terminal, between FR (Signal) and FC (0 V).

Start signals: 24 V DC for start at SR (start revers) or SF (start forward) against FC (0 V).

Converter type: Usually the standard frequency converter from Omron is installed. For delivery shortage Omron has also delivered a compatible multifunctional type. The type can be identified by the Omron identification on the type label: Standard: 3G3EV-AB007 -GE Multifunction: 3G3EV-AB007 M -GE

Parameter setting: The Omron frequency converter has a special WashTec programming which deviates from the Omron factory setting. The programming is identical for all systems (Nufa, WS, CK45 ...). The multifunctional FC has some additional parameters which have no meaning for the standard FC.

Para- no. Description

Factory setting WashTec Standard

Factory setting WashTec

Multifunctional Factory setting

OMRON Specified display

n01 Selection parameter write protection /

parameter initialization 1 1 1

n02 Selection of the operating mode 3 3 0 MODE n03 Selection of the stop operating mode 0 0 0 n04 Selection of the rotation direction (forwards / backwards) For For For F/R n05 Acitvate/deactivate reverse rotation direction lock - 0 0 n06 Selection of the multifunctional input 1 (S1) 1 1 1 n07 Selection of the multifunctional input 2 (S2) - 2 2 n08 Selection of the multifunctional input 3 (S3) - 4 4 n09 Selection of the multifunctional output 1 (MA und MB) 0 0 1 n10 Selection of the multifunctional output2 (PA) - 0 0 n11 Frequency target value 1 6,0 (Hz) 6,0 (Hz) 6,0 (Hz) FREF n12 Frequency target value 2 0,0 (Hz) 0,0 (Hz) 0,0 (Hz) FREF n13 Frequency target value 3

- 0,0 (Hz) 0,0 (Hz) FREF

n14 Frequency target value 4 - 0,0 (Hz) 0,0 (Hz) FREF n15 Frequency target value 5 - 0,0 (Hz) 0,0 (Hz) FREF



Para- no. Description

Factory setting WashTec Standard

Factory setting WashTec

Multifunctional Factory setting

OMRON Specified display

n16 Frequency target value 6 - 0,0 (Hz) 0,0 (Hz) FREF n17 Frequency target value 7 - 0,0 (Hz) 0,0 (Hz) FREF n18 Frequency target value 8 - 0,0 (Hz) 0,0 (Hz) FREF n19 Tipp frequency order - 6,0 (Hz) 6,0 (Hz) n20 Acceleration time 1 0,4 (sec.) 0,4 (sec.) 10,0 (sec.) ACC n21 Brake time 1 0,1 (sec.) 0,1 (sec.) 10,0 (sec.) DEC n22 Acceleration time 2 - 10,0 (sec.) 10,0 (sec.) ACC n23 Brake time 2 - 10,0 (sec.) 10,0 (sec.) DEC n24 Maximum frequency 100,0 (Hz) 100,0 (Hz) 60,0 (Hz) FMAX n25 Maximum voltage 230 (V) 230 (V) 200 / 400 (V) VMAX n26 Cut-off frequency 50,0 (Hz) 50,0 (Hz) 60,0 (Hz) FBAS n27 Average output frequency - 1,5 (Hz) 1,5 (Hz) n28 Output voltage at average output frequency - 12 (V) 12 (V) /24 (V) n29 Minimum output frequency - 1,5 (Hz) n30 Output voltage at minimum output frequency - 12 (V) /24 (V) n31 Nominal current of the motor 3,5 3,5 s. info. 1 THR n32 Thermo-electronic protection behaviour - 0 0 n33 Anti-lock during braking 0 0 0 n34 Anti-lock level during acceleration - 170 (%) 170 (%) n35 Anti-lock level during operation - 160 (%) 160 (%) n36 Behaviour after voltage drop 2 0 0 n37 Carrier frequency (2,5 to 15 kHz) 3 (10 kHz) 4 (10 kHz) 4 (10 kHz) n38 Automatic torque amplification - 1,0 1,0 n39 Frequency target value amplification (analogue input) 1,00 (once) 1,00 (once) 1,00 (once) n40 Frequency target value offset (analogue input) 0 (%) 0 (%) 0 (%) n41 Upper frequency target value limit - 100 (%) 100 (%) n42 Lower frequency target value limit - 0 (%) 0 (%) n43 Function of the input FR - 0 0 n44 Multifunctional analogue output - 0 0 n45 Multifunctional analogue output amplification - 0,30 0,30 n46 DC braking 25 (%) 25 (%) 50 (%) n47 DC braking time at stop 5,0 (sec.) 5,0 (sec.) 0,5 (sec.) n48 DC braking time at start - 0,0 (sec.) 0,0 (sec.) n49 S-shaped acceleration and braking characteristic - 0 0 n50 Overload torque detection - 0 0 n51 Over-torque level - 160 (%) 160 (%) n52 Over-torque detection time - 0,1 (sec.) 0,1 (sec.) n53 Frequency detection level - 0,0 (Hz) 0,0 (Hz) n54 Slip compensation amplification - 0,0 (%) 0,0 (%) n55 Motor no-load current - 40 (%) 40 (%) n56 Mask out frequency 1 - 0,0 (Hz) 0,0 (Hz) n57 Mask out frequency 2 - 0,0 (Hz) 0,0 (Hz) n58 Mask out frequency 3 - 0,0 (Hz) 0,0 (Hz) n59 Mask out frequency width - 1,0 (Hz) 1,0 (Hz) n60 Number of restart tries - 0 (number) 0 (number) n61 Activation of the stop key at the programming console 0 0 0 n62 Slip compensation delay time - 2,0 s 0,1 s n64 Activation of the ENTER key at the programming console for

frequency target value acceptance (only for 400V class) 0 Not accessible 0

n68 Error history (only display) (only display) (only display) n69 PROM number (Note from manufacturer) - (only display) (only display)

Information: - The adjusting range and the factory setting for n31 (nominal current of the motor) depend on the frequency converter type. In general the motor current is set with parameter n31. - Parameter n02 and all further parameters can only be adjusted if para n01 is set to value 01.



Frequency converter LUST VF 1204 Part numbers FC with Filter: ______________________ 180 909 Repaired: __________________________ 146 070 Heat conducting foil: _________________ 181 349

LED displays of the frequency converter: - "red" on = Power on, FC ready; - "green" on = Frequency converter started, motor running; - "red" + "green" on = Overload protection is active; In case of error the red LED flashes: - "red" flashes 1x = Error in computer, -> Press Emergency Stop; - "red" flashes 2x = Overvoltage, appears during switch-off; - "red" flashes 3x = Overcurrent switch-off (above 180%), -> Check cable and motor; - "red" flashes 4x = Overvoltage or motor generator, -> Check supply voltage and drive - "red" flashes 5x = Overcurrent for a longer period (up to 150%) motor overloaded, -> check drive; - "red" flashes 6x = Overcurrent for a longer period (up to 150%) FC overloaded, -> check drive; - "red" flashes 7x = Overtemperature Motor, is not used; - "red" flashes 8x = Overtemperature FC, must not appear; - "red" flashes 9x = EEPROM error, must not appear, -> Press Emergency Stop. Error 1, 7, 8 and 9 must not appear more often, must be remedied after reset (Emergency Stop). Caused by FC. At over temperature check the supporting surface of the FC towards the mounting plate for bumps. Errors 3, 4, 5 and 6 are caused by the drive (motor, gear, cable, guidance).

Checking the contacts "Controller Release - RFR": Only after the contact "Controller Release" has been closed the motor is driven by the converter. The FC acts with an open contact like the contact would have been closed, i.e. no error message, but the motor does not start. Here a voltage of approx. 10 V is switched. Line no. 156 = RFR Portal, Line no. 157 = RFR DB lift. Possible error: Roof brush remains in initial position at wash start, the machine switches off after timeout. The controller release may be bridged shortly for testing purposes (terminal 1 and 4 at FC).

Check the data transmission between K201 and FC: Observe Byte 2, Byte 8 and Byte A from module FC? Byte 2 must not remain on 033 or 034. This is the initialization of the FC after switch-on or after an error. The initialization is not finished at missing feedback from FC. Byte A shows the number of data transfers to the FC. The data telegram is repeated if there is no feedback from the FC. At more than 1 repetition (Byte A larger than „1“) the control release is switched off (Byte 8 = 0).



General Checking the mechanic of the drive: - Let the drive run in continous test (Monitor, Byte 2 = 007); - Are the distances from the mechanical stopper sufficient? - Has the guidance sufficient clearance? - Are there any noises?

Checking the supply voltage: At strong fluctuations up to below 220 V: - Search for a more stable power phase and rewire supply of the frequency converter; - Set FUH, FUP Para 5 = 50, max. frequency = 50 Hz (otherwise 60 - 68 Hz).

Test cycles for DB, DD and POR with different speeds: Attention: don’t let run the slow speeds too long because increased current values are switched to the motor which causes a strong heating. - Monitor POR Byte 2 Activity = 7, Portal moves with 25 Hz; Byte 2 = 005, forwards with 70 Hz; Byte 2 = 006, backwards with 70 Hz; - Monitor DB Byte 2 Activity = 7, Byte 4 target value = 50 Hz, load brush during lifting with approx. 70 kg Byte 4 = 5 - 10 Hz Byte 4 = 60 - 70 Hz; - only HP Nufa: Monitor DD Byte 2 Activity = 7, Byte 4 target value = 50 Hz, Byte 4 = 15 - 20 Hz; Byte 4 = 50 - 70 Hz; If the above tests are ok the frequency converter is ok.

For portal stops during the wash: Check what has caused the stop: - Monitor: POR Byte A = brake: Module number of the cause which currently brakes most; - Monitor: POR Byte B = Last stop: Module number of the cause which has stopped the portal lately; - Look for Byte 8 "Chain" of the active modules (DB, SBL, SBR, (DD)), at the cause of the stop is Byte 8 = 0 (this is the maximum portal speed).

For HP Nufa: Are all contactors fort he switchover DD/DB switched correctly? K4 switches the motor of DB and K16 the HP DD at the FC.



File: NU-TH-GB_N201-02-10-D-Frequenzumrichter_c_17-07-05.docx

Technical Manual Model series Nufa K201 6-0395 N201-05-05-I Option Anti-freeze 2. July 2004

Page 1 of 1


Installation and Implementing: 1. Install the temperature sensor low positioned in the chemical cabinet. 2. All non-existing valves set Para 15 = 0. 3. Pilot run: Reduce the blow out time CHK Para 5= 005, reduce waiting time CHK Para 4= 001;

Rev-up the thermostat, the blow out cycle begins; check if all valves are opened. After the first pass the run can be interrupted by a reset.

4. Adjust the thermostat from +3 ° to +4°C, readjust CHK Para 4 = 100 and Para 5 = 150. 5. Inform the customer that the draining of water does not work during Emergency Stop!

Function: With the option antifreeze the water conduit will be blown out and drained after a delay.

The function is activated automatically after the input 038 (temperature monitor) = 1. Portal position: Arbitrary, the machine has not to be in initial position. Lights: The lights become red, the MKL and the start key will be locked. Manuel machine movements are possible. Emergency Stop: The antifreeze does not work during an Emergency Stop!!!

The control voltage for the valves is missing. With error: The antifreeze is independent of other errors. Also during other errors the draining is started,

possibly the display „Frost“ doesn’t appear. Valves: Every existing water valve (if Para 15 = 1) will be activated together with the valve Y42 „machine

blow out“ one after the other. (Y1, Y2, Y3, Y4, Y6, Y7, Y8, Y10, Y11, Y12).

HP: Every existing HP valve (Y40, Y46, Y13, Y14, Y15) will be activated together with the valve Y43 „HP arch blow-out“ one after the other.

UBW: The valve Y41 UBW will be activated with Y44 „UBW drain“. Drain water hoses: And the valve Y45 „draining valve water conduit“ will be activated alone (draining the

water hoses in the drag cable). Centrifuging: At the end of the blow-out the brushes will be centrifuged for the time CHK Para 5. The complete blow-out cycle is repeated one time. Blow out time: For the time 032 CHK Para 5 (in sec., standard = 150 = 2,5 min.) the valves will be blown

out respective drained one after the other. Complete cycle time: For all non-existing valves change the parameter 15 = 0

(for Tandem also the parameters 16 and 17). Therefore these valves are not blown out, the complete cycle time is reduced (otherwise it is 85 min.).

Thermostat: Adjust from + 3 ° to + 4 ° C.; installed low positioned in the chemical cabinet; Is connected to the input 038. As long the input is „0“ (or nothing is connected) is no frost indicated.

Waiting time draining: After frost is recognized the time of CHK Para 4; (in 0,1 min.) is waited after the last wash before draining, standard= 100 = 10 minutes.



File: NU-TH-GB_N201-05-05-I-Frost_b_02-07-04.docx Changes since 15.02.2000 are written coloured and marked by „|” at the outer margin:

Technical Manual Model series Nufa K201 6-0395 N201-05-10-I Tandem system 2. July 2004 Commissioning Page 1 of 2


Installation and commissioning 1. Tandem setting K201:

M1: coding switch 2 = ON, Reset; M2 coding switch 1 = On, 2 = On, Reset. Check is data connection between terminal and both machines is ok. (e.g. DB1 down – up, DB2 down – up).

2. Only if point 1 was not successful: Test machines individually as Solo: M1: all coding switches to Off, Reset, M2: unplug CAN plug; Check is data connection between terminal and M1 is ok. (e.g. DB1 down – up). M2: all coding switches to Off, Reset, insert CAN plug, M1: unplug CAN plug; Check is data connection between terminal and M2 is ok. Reinsert CAN plug M1.

3. Portal limit switch: M1: E025 Solo initial position S14/1: inside track 1 (X2/10) E040 Tandem initial position S18/1: inside track 2 (X3/1) E026 end of wash bay S15/1: inside track 1 (X2/11) M2: E025 Solo initial position S14/2: outside track 1 (X2/10) E040 Tandem initial position S18/2: outside track 2 (X3/1) E026 end of wash S15/2: outside track 1 (X2/11)

4. Connections only at machine 1: E049 switch Tandem-/Solo operation (X3/10.) M1 Parameter 047 SOF Para 5 = 1; E041 anti-collision switch S20 (X3/2).

5. Set start and stop positions for M1 and M2: Assure that both Para 2 of the modules M1 and M2 in both machines are set to 0. Activate Tandem operation and move both machines manually in Tandem initial position. Start the bus program. Both machines move now first in Solo initial position and then back to Tandem initial position. Thereby the portal counters are determined and automatically recorded into Para 2 of the modules M1 and M2. Afterwards the wash is started. up to Software 1.23k: Tandem operation: Move both machines manually to initial position (wash bay start, exit). Move M1 manually to Tandem initial position: Read off portal counter M1 with P3 Monitor M1: 000 POR Word 1; Enter the value in both machines P2 Modcon 029 M1 Para 2. Move M2 manually to Tandem initial position: Read off portal counter M2 with P3 Monitor M2: 000 POR Word 1; Enter the value in both machines P2 Modcon 030 M2 Para 2.

6. Wash program at power on: The wash program for Tandem operation is automatically the bus program; Enter 036 LT1 Para 1 = 3 Bus (or the desired program for Solo operation) in both machines.

7. If necessary: Auxiliary pre-selection at Power on for M1 and M2: 036 LT1 Para 2 = Machine 1, 037 LT2 Para 2 = Machine 2; Enter the same values in both machines.

8. If necessary: Traffic light in Solo operation: 028 ANL Para 12 = 000 = Standard, Para 12 = 001 = traffic light off for car (is installed too high for cars) Para 12 = 002 = traffic light off for all vehicles (wash bay light barrier is covered by M1)

9. If necessary: Mirror bypass normal setting of the parameters for mirror bypass (DB, SBL/R Para 2, 20, 21, 22) additionally 030 M2 Para 7 = 140 = Finish backwards wash in time.

Technical Manual N201-05-10-I Model series Nufa K201 6-0395 2. Juli 2004 Tandem system Page 2 of 2 Commissioning


10. If necessary: 4-brush Tandem (without roof brushes): The configuration parameters for 001 DB und 033 FUH Para 16 and Para 17 = 000.

General functions: Tandem/Solo switch: Connected to machine 1. Special input E049 (X3/10.)

M1 047 SOF Para 5 = 1; Solo operation: Only machine 1 can wash in Solo operation.

All wash programs, vehicle types are available. Tandem operation: Both machines wash together one bus.

M1 washes approx. 2.6 m backwards (adjustable with M1 Para 4), then forwards up to the rear and back again to Tandem initial position. M2 washes backwards to the front, then forwards to Tandem initial position.

Utility programs: In Tandem operation the key “Special function“ switches between M1 (LED off) and M2 (LED on). In Solo operation only M1 can be activated.

Moving to initial position: Solo operation: Both machines move to wash bay entry. Tandem operation: Both machines move first to wash bay entry, then to Tandem initial position.

Ant-collision switch: The distance between the machines is monitored. If the minimal distance is reached (029 M1 Para 3) the machines will not move anymore.

Manual interference: Anytime the wash sequence can be interfered with the control keys on the operating unit. The key “Special function” is used to select whether M1 or M2 should be moved.

Selection M1 or M2 with the key „Special function“: Only possible in Tandem operation: The key “Special function” is used to select whether M1 or M2 should be moved and is displayed in line 3. At the same time applies: LED off = M1, LED on = M2. The switchover is also valid for the utility programs P0, P1, P2 etc.

Configuration parameters: Para 15, 16 and 17 are configuration parameters, Para 15 = Solo machine, Para 16 = Tandem M1, Para 17 = Tandem M2. You define which module exists in the individual machine. Para = 1 = exists, Para = 0 = not existing.

Up to 1.24b Tandem operation was only possible with automatic start and traffic light.

Therefore the following setting is necessary: KFZ Para 8 = 001 (1 LS for position), SOF Para 4 = 001



File: NU-TH-GB_N201-05-10-I-Tandem_c_02-07-04.docx Changes since 09.05.2001 are written coloured and marked by „|” at the outer margin.

Technical Manual Model series Nufa 6-0395 N201-05-15-I (Radio) Modem Port 7. Juli 2004 Commissioning Page 1 of 2


1. Parameter Settings, Serial Interface With P2 Modcon-Service - Plant Parameters the data transfer has to be released in module 043 SER serial interface. 043 SER Para 2 = 10 releases the plug X2 for the connection to the modem or PC.

(with para 5 the plug X5 can be chosen alternatively). Para 8 = 1 selects SMS transfer in case of error Para 9 = 0 selects the regular telephone network modem = 1 selects a radio modem.

2. Modem at the machine, Setting of telephone numbers With P2 Modcon-Service - Station Parameters - Modem-No.: you can edit 4 telephone numbers the machine is calling.

Number 1: Receiver of the SMS or SMS head office of phone company.

Number 2: free or Receiver of the SMS, if the SMS is procured by the head office.

Number 3: own number of the modem, is transferred with the SMS automatically.

Number 4: reserve There can be connected a regular telephone network modem or a radio modem. Depending on the modem different parameters or phone numbers has to be set.. The report of the machine can be transmitted to a to a central SMS server (of WashTec) or to a D1- or D2 mobile phone. At the mobile phone the report appears like a text message. Overview of the adjustable numbers: Receiver: WashTec SMS Server D1 - cell phone D2 – cell phone Analog Modem No. 1 +49 171 / 07 60 256 +49 171 / 25 21 002

SMS head office D1 +49 172 / 22 78 020

SMS head office D2 No. 2 free cell phone no.: D1 cell phone no.: D2 No. 3 station phone number

Radio Modem (SIM card D1)

No. 1 +49 171 / 07 60 256 +49 171 / 07 60 000 SMS- head office radio net

No. 2 free cell phone no.: D1 with country codes 0049 171.

cell phone no.: D2 with country codes 0049

No. 3 station phone number with country codes 0049 Depending on the available radio network „00“ instead of „+“ has to be entered for the country identification. Without country identification only „0171 …“ can be entered. The SIM card for the radio modem is normally delivered by the WashTec Service. This card is only released for SMS transmission.

3. Edit a phone number From 1.25m the first digit is automatically reserved for „+“ (because in foreign countries not always the prefix 00 is used). An existing phone number must therefore be shifted by one place. From 1.26a: Some special inputs are possible with the character numbers of the left keypad: D = delete, deletes a character C = code, input of the code character „+“, only possible on first place.

Technical Manual N201-05-15-I Model series Nufa 6-0395 7. Juli 2004 (Radio) Modem Port Page 2 of 2 Commissioning


4. Parameter Settings, „Machine reports“ With P1 Erpros - Error Classes the array for all errors (or only the ones that should be reported) has to be changed „SMS (N)“ from N = No to J = yes. (elder software releases display “Mld” instead of “SMS”)

5. Reset Codes With P2 Modcon - Station parameters - Reset codes the codes has to be reset after installation. The access to the machine is protected by a code. By the reset the code is set to the standard value.

6. Mains off / on For the initialisation of the modem everything is to be switched off and on. Order: Control and modem off, control on, modem on.

7. Common At a serial interface a modem can be connected for a data transfer between a stationary computer and the machine. At the PC the software „AWA-Manager“ or „Service-Manager“ could be installed, the connection could also be direct, without a modem. AWA-Manager: It is a PC software for the owner of the plant running under MS-Windows. It is possible to query the counters, to create a clearing of payments, change the prices and times, change texts of LED displays, change program names and title lines of a ticket printer, create chip cards and query the memorised event list of the machine. Service-Manager: It is a PC software for service support of the technician. It is possible to edit parameters (start stop, options, prices, texts), to query counters or the event list and to make online diagnostics (display line numbers of I/Os and Monitor bytes). Machine reports: From the software 1.18r possible. After special machine states it will call a telephone number and reports the errors by a SMS (Short Message Service). The SMS could also be send to a mobile phone instead to a PC.


Changed: Bernd Zeller Date: 07.07.2004

File: NU-TH-GB_N201-05-15-I-Modem-b-07-07-04.docx Changes since 27.06.2001 are written coloured and marked by „|” at the outer margin.

Technical Manual Model series Nufa, CPU K201 N201-07-01-F Utility program P2 Modcon - Service 3 June 2004 Flow diagram


The utility program Modcon - Service (Module Control) is for setting of different parameters of the service level.

Modcon V 2.1

P

2 Anlagen Parameter

P 2 Module No.: 000

2 POR Para 1 00150P0

2 Prog.: 00 Modul: 00P

P

2 P00 POR Run 01 075P

2 Change Programs

2 Prog.assignment

0

2 par. control unitsP0

0

0

0

2 E076 ->LKW ProgP0

2 assign Matrix

2 Prog LKW = Matrix 15 (wash once)P

P

0

0

2 PlantParameter

Change individual plant-parameters Move the parameters

from Para 1 to 30 + / - Select change mode

move the cursor (underlined) 0 - 9 change the values

+ / - save the change

Change individual run parameters (not possible when wash program is running): Move the parameters

from Run 1 to 10 + / - Select change mode

move the cursor (underlined) 0 - 9 change the values 0 - 9 change the values

+ / - save the change next previous module

next previous module

next previous line

next previous program

continued on next page

continue to "par. control units"

Enter program matrix and module No

Enter module No

E076 is the first wash program input for the parallel control units

+ / - Select change mode Shift off enter program / service

i.e. bus, 2xwash, DB, SB ect. Shift on + / - save the change

Program matrix 15 is for all vehicles for wash once, matrix 31 for wash twice matrix 32 for stat. passage wash. matrix 33 for contra wash, 1. bus (forward wash) matrix 34 for contra wash 2. bus (backward wash) Matrix 35 for HP program.

Followed by programs: L+H, SAZ, Bus, PKW, Hae, SDF, KHa, PUP, PUH, GEW, SBU, HP, PUS, 15, 16; and then the same with wash twice

Information: Up to Software 1.28n a change of the matrix is only possible when the selection in the basic level (1x or 2x washing) corresponds with the matrix which should be changed!

Technical Manual N201-07-01-F Model series Nufa, CPU K201 3 June 2004 Utility program P2 Modcon Service Page 2 of 4 Flow diagram



continued from previous page



next previous key (to key 16)

The last 3 figures in the order number + / - select change mode



Enter using the character table + / - select change mode



The operator codes are reset to their original values, P0 = 00000, P8 = 88888

Enter call No.:

move the cursor (underlined) 0 - 9 change the values C = „+“ country prefix D = Delete = delete character + / - save the change

The call numbers for a SMS transfer to a PC or mobile phone can be entered No. 1 = SMS receiver = SMS server or radio net SMS head office No. 2 = free or No. Of mobile phone, if via SMS head office No. 3 = own call No. of the machine No. 4 = reserve

When used in foreign countries the module shortcut can be adapted

+ / - select change mode Shift the cursor (underlined) 0 - 9 change the values

+ / - save the change continue to "Station-No. 000"

2 Station No.= 000P

P 2 Station parameters

0

0

2 change prog. names

2 Button 01 LKWP

0

2 Reset codes

2 Codes resetedP0

0

2 Modem No.:

2 Call No. 1 : . . . . . . . . . . . . . . . . . . . .P

00

2 Change module name

2 Module name: 01 POR changeP

00

Technical Manual Model series Nufa, CPU K201 N201-07-01-F Utility program P2 Modcon - Service 3 June 2004 Flow diagram


Character table: To edit a character 2 numbers has to be entered. After the input of the 2nd

Capital letter:

number the cursor moves to the next sign automatically.

Small letter: Numbers: Special characters:

00 = A 10 = K 20 = U 26 = a 36 = k 46 = u 52 = 0 62 = (leer) 01 = B 11 = L 21 = V 27 = b 37 = l 47 = v 53 = 1 63 = ! 02 = C 12 = M 22 = W 28 = c 38 = m 48 = w 54 = 2 64 = ? 03 = D 13 = N 23 = X 29 = d 39 = n 49 = x 55 = 3 65 = * 04 = E 14 = O 24 = Y 30 = e 40 = o 50 = y 56 = 4 66 = + 05 = F 15 = P 25 = Z 31 = f 41 = p 51 = z 57 = 5 67 = - 06 = G 16 = Q 32 = g 42 = q 58 = 6 68 = _ 07 = H 17 = R 33 = h 43 = r 59 = 7 69 = / 08 = I 18 = S 34 = i 44 = s 60 = 8 09 = J 19 = T 35 = j 45 = t 61 = 9


When the CPU is changed the data for system can be reproduced from the EEPROM


All parameters are set to their original values. All changings are deleted, counters are set to "0", the Erpros list is deleted.

The washing program parameters are set to their original values.

The plant parameters are set to their original values. continue to "Load from EEPROM"

P 2 Load data

0

P

2 EEPROM loadedP0

2 Load from ROM

2 ROM data loadedP

2 Load from EEPROM

0

2 Load programs

2 Programs loadedP0

2 Load parameters

2 Parameters loadedP0

Technical Manual N201-07-01-F Model series Nufa, CPU K201 3 June 2004 Utility program P2 Modcon Service Page 4 of 4 Flow diagram


Drawn: Bernd Zeller Date: 28.11.1997 Approved: Bernd Zeller

Updated: Bernd Zeller Date: 03.06.2004

File: NU-TH-GB_N201-07-01-F-Prog-P2_b_03-06-04.docx Amendments made after 07.05.2001 are coloured and marked by "|" in the outer margin.


The station parameters are printed.

continue to "Plant parameters"

next previous change

Change of wiring: The first line No is now connected to the terminal of the second line No. 10 modifications may be entered, [0] to [9].

+ / - select change mode move the cursors (underlined) 0 - 9 change the values


Select a program: e.g. Bus, 1 x wash The run parameters (matrix) of the selected program are printed.

The plant parameters are printed.

The counters are printed. Page 1: „washes started“ + / - Page 2: „Tenant counter“ (daily counter) + / - Page 3: „ washes finished “

Display the counter values: ABS = absolute counter (from "load ROM", cannot be deleted) ABB = Aborted washes (cannot be deleted) REL = relative counter = can be changed (enter old counter value if CPU is changed)

Change the relative counter: + / - select change mode

move the cursors (underlined) 0 - 9 change the values


P

2 Print programs

0

2 Print parameters

0

2 Print counters

0

2 Display counters

2 ABS= 0008176 ABB=0000012 REL=0008176P0

?

0

2 Print Stat-Para.

2 Nr 999 -> 999 [0]P

2 I/O List

0

0

Technical Manual Model series Nufa, CPU K201 N201-07-02-F Utility program P0 Operator Program 14 April 2006 Flow diagram Page 1 of 4


When the operator program is called up without a password the menu points "Delete counter", ”Auxill. Selection on/off“, ”MKL on/off“ and "Change password" do not appear.

Operator program

P

Counter program ?

P Totel counter

P B= 0005981 A=0000093

Auxiliaries counters

P CVW G 0002124 T 0000045

Program counters

P LKW G 0002124 T 0000045

Manual mode

P Prog LKW B= 0000738 E= 0000741

Delete counters

P Delete counters ??

Counters deleted !

P

? ? ? ??

0

Save parameters


The two keys and have the same meaning and either can be used. In the following only the (Enter) key is used.

Pressing the key quits the utility program

During the save process a new checksum is formed and the parameters are copied into the EEPROM.

Switch keypad so that the LED is lit

Enter number of required utility program

5-figure password or without password

If an incorrect password is entered the level without password is activated (some functions don’t appear)

Counter - total of all programs B = Washes started A = Aborted washes

G = Total counter T = Day counter (may be deleted)

next counter

next counter

continue to "Total counters"

G = Total counter T = Day counter (may be deleted)

B = washes started (Begin) E = washes completed (End)

The day counters, manual mode and card counters are deleted.

or multiple card or single card

or

LKW = truck L+H = truck with trailer SAZ = semi truck BUS = Bus PKW = car Hae = trailer SDW = solo passager wash for bus KHa = short hall PUP = pickup PUH = pickup with trailer GEW = conter wash SBU = special bus with mirrors HD = high pressure PUS = Pickup semi truck T+H = van with trailer

CVW = chemical pre wash HD = high pressure 1xW = wash once 2xW = wash twice UBW = under body wash Kfz = not yet defined HDZ = high pressure time WAZ = wash time SHA = shampoo WAX = Wachs CTH = chemical dry agent BW = brush wash TD = scanning nozzle (HP)

Technical Manual N201-07-02-F Model series Nufa, CPU K201 14 April 2006 Utility program P0 Operator Program Page 2 of 4 Flow diagram


Continued next page Continue next page “2nd init. position“

Continued from previous page

Defines whether the various auxiliaries (f. ex. wash once or twice) can be selected or not in the washing mode.

Manual: Start wash by pressing „Start“ + „“ keys Automatic: Start wash after positioning with light barrier.

Off: Start wash by pressing "Start" + ““ keys On: Start by inserting card

This menu will not appear when there is no MCR.

This menu will not appear when “2nd init position“ is selected.

"Initial position = bottom" for dead end hall, thus saving time.

With +/- 3 different speeds can be selected: Speed 3 = Standard speed Speed 2 = 15 Hz slower Speed 1 = 25 Hz slower

This menu will not appear when the function is not released.

DB = roof brush or SBL = side brush left or SBR = side brush right

Using the digit keys you can change the contact pressure.

The entry is made in percent (%). Higher values produce greater contact pressure, smaller values produce lower pressure. The

This menu will not appear when there are no traffic lights.

Turn the positioning lights on and off.

Auxill. selection = onP

P System settings ?

Auxill. selection = off

Manual start

Automatic start

MKL = off

MKL = on

DB init. pos = top

DB init. pos = bottom

POR Speed 3

Cont. press DB = 100

Cont. press DB = 100

Lights = off

Lights = on

Technical Manual Model series Nufa, CPU K201 N201-07-02-F Utility program P0 Operator Program 14 April 2006 Flow diagram Page 3 of 4


Switch the 2nd initial position on- and off.

Shampoo offP

P

Bleed dosing pu.

Shampoo on

Shampoo offP

Spray switch on ?

Shampoo on

Roof brush = on

Roof brush = off

Shampoo = on

Shampoo = off

CTH = on

CTH = off

P 2nd init. pos = off

2nd init. pos = on

Continued from previous side

Continued next page Next previous spray pattern (CTH, CVW)

Continue to "Auxill. selection"

Continue previous side “Lights“

After the end of the program the machine moves to an advanced initial position to make it easier to start around a curve.

The roof brush can be disabled with all its functions. Errors by limit switches, frequency converter or motors are ignored. The wash can be continued in 2 brush mode.

Caution: The roof brush is not cleared!!! Move DB up and secure before turning off. If this isn’t possible dismantle the brush.

The dosing pump can be switched of for longer time. e.g. when there is to many shampoo in the reclaim water.

The dosing pump can be switched of for longer time. e.g. while rainy weather.

The "Shampoo" dosing pump will run and can be bled.

The "Shampoo" spray arch is activated (with water and dosing pump).

next previous dosing pump (CTH, CVW, HP chemicals)

Technical Manual N201-07-02-F Model series Nufa, CPU K201 14 April 2006 Utility program P0 Operator Program Page 4 of 4 Flow diagram


Drawn: Bernd Zeller Date: 04.03.1997 Approved: Bernd Zeller


File: NU-TH-GB_N201-07-02-F-Prog-P0_c_14-04-06.docx Amendments made after 03.06.2004 are coloured and marked by "|" in the outer margin.

Continued from previous page

2 = Tuesday, the 25th of March 1997 1 = Mo, 2 = Tu, 3 = We, 4 = Th, 5 = Fr, 6 = Sa, 7 = So

continue to "Counter program"

+ / - Start change mode move the cursors (underlined) 0 - 9 change the values


+ / - Start change mode move the cursors (underlined) 0 - 9 change the values


The authorisation codes for calling up the customer utility programs can be changed here.

Utility program P8 to establish cards

Utility program P0 to see the operator data

Only for CAN Datamat TKL transponder card reader Create cards and read off card data. Further operator guidance takes place in the transponder card reader.

P

P

Set clock ?

Card Code P8 88888 P

Change auth. codes ?

Opeat. code P0 00000

Time: 10:55:40

Date: 2 25.03.97

Card program OFFP

Create cards?

Card program ON

Technical Manual Model Series Nufa K201 6-0395 N201-07-03-F Utility programs P1 ERPROS 3. June 2004 Flow diagram Page 1 of 2


P1 Erpros - Event Protocolling System

Continue to „Display list“

On 17. 02. at 11:32 the module CHK - Check saved the event 010 "Emergency stop" (some texts are incomplete) Maximally 128 events are saved.

Select module No. The events on the selected module are no longer saved. + / - start the change mode move the cursor (underlined) 0 - 9 enter numbers + / - save the change

Select event No. these events are no longer saved.

next previous event

The saved event list is printed by a connected printer.

This prevents saving events in the list (this leaves space for more important events).

99 = no module or event disabled

Select an error No. Move the cursors (underlined) 0 - 9 enter numbers + / - save the change

next previous event

1 Erpros V 1.3

P

1 Display list

P 17.02/11:32 CHK E010 Emergency Stop

0

P

1 Print list

1 Disable entry

1 Modul 99 99 99 99

0

P

1 E-Nr. 99 99 99 99

0

0

1 Error class

1 Error-No.: 000

0

P

2 000 Clas: (0) EPS: (J) Disp: (N) SMS (N) P

0

Technical Manual N201-07-03-F Model Series Nufa K201 6-0395 3. June 2004 Utility programs P1 ERPROS Page 2 of 2 Flow diagram


Menu error class: With this menu different settings according the events are possible.

1. Clas: error class The error class defines how the machine reacts to the error: 0 = No reaction, the error is not displayed at the terminal but memorised in the list. 1 = like class 0 2 = No reaction, the error is displayed and memorised in the list. 3 = Not in use for the Nufa.

The machine tries itself to rectify the error for 5 seconds. If the error remains, the machine is switched off with the error message and an entry is made in the events log.

4 = Not in use for the Nufa. The machine tries itself to rectify the error for 30 seconds. If the error remains, the machine is switched off with the error message and an entry is made in the events log.

5 = The machine will be switched off immediately. The error is displayed and memorised;

6 and more have the same meaning like 4 but higher priority.

2. EPS: Event Protocol Defines whether the event is memorized or not. J = Yes, it will be memorized. N = No, it is not memorized.

3. Disp: Display at the terminal Defines whether the event is displayed at the terminal, must be set to “J” for all errors. J = Yes, it will be memorized. N = No, it is not memorized

4. SMS (former Mld): Report (Meldung) Defines whether the machine sends a report. In case of an error a short message is send to a PC or via a radio modem. J = Yes, the machine reports; N = No, the machine doesn’t report.



File: NU-TH-GB_N201-07-03-F-Prog-P1_b_03-06-04.docx Updates made after 05.06.2001 are colored and marked by „|” at the left margin.

Technical Manual Model series Nufa K201 6-0395 N201-07-04-F Utility program P3 Monitor 4 June 2004 Flow diagram Page 1 of 1


The Monitor service program is for testing functions and observing the individual modules during the wash. The data interface between the software sequential controller and the individual modules can be observed and changed. Access is through the module numbers.

Commands (Activities) can only be entered when the system is at a standstill

General meaning of the individual bytes / words:

Bytes:

1 = Status

2 = Activity

3 = Actual value

4 = Desired value

5 = Various

6 = Reference value

7 = AD value

8 = Conveyor

9 = Error

A = Various

B = Various

C = Various

Words:

1 = Counter

2 = Stop

3 = Various

4 = Various

"Various" means that this point has various meanings, depending on the module.



File: NU-TH-D_N201-07-04-F-Prog-P3_b_04-06-04.docx Updates made after 18.04.2001 are colored and marked by „|” at the left margin.

3 Monitor V 1.0

P

3 Modul Nr.: 000

P 3 POR 1=002 2=001 3=000 4=000

3 POR 1=002 2=001 ...

3 POR 00050 00050 00000 00000

0

Meaning of the individual values, see description of Monitor bytes.

move the cursor (under lined) 0 - 9 enter numbers

Enter module No

next module

previous module

Display the Monitor bytes /words move the bytes / words from byte 1 to C, word 1 to 4

Save the change and execute the command (activity).

Representation of the 4 Words

start change mode.

Technical Manual Model series Nufa K201 6-0395 N201-F-7-5 Service programs P4 Hardware test 8 December 1997 Flow diagram Page 1 of 1


The service program P4 Hardware test is designed for testing individual inputs and outputs, with access through the line number.

Several outputs can also be switched in series.

During the wash there must be no outputs switched in the hardware test since this may cause conflicts in the sequential controller.

The hardware test is to be completed for all external cables during the commissioning process.

4 Hardware-Test V 1.0

P

4 E: 000

P 4 E000 = 000Enter line No. see list of cable No. mainly: 000 - 099 = Inputs 100 - 179 = Outputs

Display the analogue inputs: 000 to 255 = means 0 - 10 V DC

4 A150 = - - - - - - 0 -

1

0

invert the output

switch off output

next line No. previous line No.

switch on output

Status of outputs: 0 = off; 1 = on

4 E020 = - - - 1 - - - - Display the digital inputs: 0 = 0 V DC; 1 = 24 V DC


Amended by: Bernd Zeller on: Signature

File: NU-TH-GB_N201-07-05-F-Prog-P4.docx

Technical Manual Model series Nufa K201 6-0395 N201-F-7-6 To call up and quit service programmes 8 December 1997 Flow diagram Page 1 of 1


Service program with version No.

P

1st menu point

P

? ? ? ??5-figure password

If an incorrect password is entered the old display reappears

?

Switch key to lit the LED

Pressing the "*" key quits the serviceprogram.

Save ParametersDuring the save process a new checksum is formed and the parameters are copied into the EEPROM.

Enter number of required serviceprogram

P0 = Operator (operator password) P1 = Erpros (service password) P2 = Modcon (service password) P3 = Monitor (service password) P4 = Hardware test (service password)

Only appears if parameters are changed in P0, P1 or P2.


Amended by: Bernd Zeller on: Signature

File: NU-TH-GB_N201-07-06-F-Prog-Aufruf.docx

Technical Manual Model series Nufa K201 6-0395 N201-F-7-7-BA Operating manual 21 May 2001 Brief version Page 1 of 2


This brief operating manual is affixed to the control terminal in the form of a sticker (SN 197 711).

1. Preparation for the vehicle wash

1.1 Switch the main switch to "On": Electronics ready for operation Emergency-stop button released.

1.2 System in home position: The roof brush is raised (or in a hall with a door only at one end it may be lowered), the side brushes are moved out. If the system is not in its home position, it can be moved into the home position by pressing the Start and Enable buttons simultaneously (see point 2.2b).

1.3 Driving in the vehicle: Drive in the vehicle in the center of and parallel to the tracks, and up to the Nufa (the vehicle must be at least 0.5 m away from the foot of the system).

Apply the brakes, fold back the mirrors, close the windows, retract the aerial, remove any loose parts. Ensure that there are no iron parts lying on the floor in the area of the proximity switches, otherwise the system may not operate correctly.

2. Choosing the right vehicle wash 2.1 Selecting a suitable vehicle program: Keys for vehicle selection (the present wash program is displayed in the 1st line of the LCD) or or or

Truck Truck Articulated Buses with trailer truck and if this key is pressed several times, further programs are displayed: Cars, Solo trailer, Stationary drive through, Short hall, Pick-up program, Reverse wash.

Select an additional program if there is a roof spoiler on the roof of the cab and/or a loading ramp at the rear of the vehicle. and/or

Spoiler Loading ramp Ski box

2.2 Starting the system a)

The system starts with the set program when the "Start" key and the „Enable" key are pressed simultaneously.

The system is in the home position

b)

The system can be moved into the home position by pressing the "Start" key and the "Enable" key simultaneously.

The system is not in the home position

Technical Manual N201-F-7-7-BA Model series Nufa K201 6-0395 21 May 2001 Operating manual Page 2 of 2 Brief version


2.3 Meaning of the service keys Pressing a service key activates the service allocated to the key. This service remains active for subsequent washes until it is switched off again. The LED lights up. A service can be switched off again by pressing an activated service key again. The LED goes out.

Wash x 2 Off : Only during forward movement (no function during return) On : During forward and return movement Center overlapping off : Without center overlapping on : With center overlapping of side brushes at the front and rear Front wash with roof brush 2x off : Front wash during forward movement only on : Front wash during forward and return movement Spoiler (optional) off : Without spoiler on : The roof brush is stopped in the spoiler area Loading ramp, ski box (optional) off : Without loading ramp or ski box on : Roof brush and side brushes are only moved as far as the set

position at the rear. Roof brush off : Without roof brush wash on : With roof brush wash Side brush off : Without side brush wash on : With side brush wash Underchassis wash (optional) off : Without underchassis wash on : With under chassis wash Chemical prewash (optional) off : Without chemical prewashing agent on : With chemical prewashing agent High pressure side wash (optional) off : Without high-pressure side wash on : With high-pressure side wash

2.4 Manual override during the wash program Complicated vehicle contours can be washed manually by pressing the override keys. The automatic wash program is deactivated for as long as the override key is pressed. The system only carries out the selected movement.

Forward Backward Raise Lower Move side Move side movement movement Roof brush roof brush brushes out brushes in Once the manual override is complete, the automatic wash can be continued by pressing the "Start" key and the "Enable" key simultaneously.

3. End of the wash - The system moves into its home position and switches off automatically. - If use of the system is not planned for a longer period, switch off the electricity and water supplies.


Amended by: Bernd Zeller on: 21.05.2001 Signature

File: NU-TH-GB_N201-07-07-F-Kurz-BA.docx

Technical Manual Model series Nufa K201 6-0395 N201-07-08-F-Wa Water valve control and wash programs 12. July 2004 Page 1 of 3


Valve Designations: Y1 = Fresh water valve (FreWa) for VN arch (pre or after rinse) Y3 = Recycled water valve (RecWa) for brushes (Option) Y4 = Recycled water valve for VN arch Y8 = Valve for chemical prewash (option) Y40 = Valve for HP side (option), wheel area in case of divided arch Y46 = Valve for HP side (option), canvas cover area for divided arch Option: The valves Y2, Y6 and Y7 are only installed together with the additional after rinse arch (N arch) Y2 = Fresh water valve for additional N arch Y6 = Valve CDA for VN arch Y7 = Valve CDA for add. N arch

CTH = Option, Standard = without dosing pump

The additional post-rinse arch is only installed with the options „single wash“, „stationary drive-through wash“ or „Reverse wash“.

Program 2 x Wash (program matrix 31) Cycle Active components Remarks

1 ---------> 75 Hz, Y8 CPW (with FreWa) Chemical pre-wash 2 <--------- 20 Hz Slow run for reaction 3 ---------> 70 Hz, Y4 RecWa for VN arch,

DB, SBs, Y3 RecWa for brushes (with shampoo), Y40 HP side, Y46 add. HP side

Pre spraying Brush wash „Wheel wash“

4 <--------- 70 Hz, DB, SBs, Y3 brushes (without shampoo), Y1 FreWa and Y6 CDA for VN arch

Brush wash Post-rinse

Technical Manual N201-07-08-F-Wa Model series Nufa K201 6-0395 12. July 2004 Water valve control and wash programs Page 2 of 3


Program 1 x Wash (program matrix 15) Cycle Active components Remarks

1 ---------> 75 Hz, Y8 CPW (with FreWa) Chemical pre-wash 2 <--------- 75 Hz 3 ---------> 70 Hz, Y4 RecWa for VN arch,

DB, SBs, Y3 RecWa for brushes (with shampoo), Y40 HP side, Y46 add. HP side

Pre-spraying Brush wash „Wheel wash“

4 <--------- 75 Hz, Y3 RecWa for brushes (with shampoo) Y1 FreWa and Y6 CDA for VN arch

Post-spraying rinsing

Cycle 1 and 2 are skipped when option CVW is not selected. The programs 1x or. 2x wash apply for all vehicle types (bus, truck, trailer, car, etc.).

Program Stationary drive through Wash (program matrix 32) Busses drive through the stationary machine. The portal position is arbitrary

Cycle Active components Remarks

Without Y4 RecWa for VN arch Y40 HP side, Y46 add. HP side SBs, Y3 brushes (with shampoo), Y2 FreWa and Y7 CDA for add. N arch

Pre-spraying „Wheel wash“ Brush wash Post-spraying

Program Reverse Wash (program matrix 33/34) 2 times single wash for busses.

Cycle Active components Remarks

1 ---------> (matrix 33) 1st

60 Hz, Y4 RecWa for VN arch Y40 HP side, Y46 add. HP side SBs, Y3 brushes (with shampoo), Y2 FreWa and Y7 CDA for add. N arch

Bus


Positioning of the next bus 2 <--------- (matrix 34) 2nd

60 Hz, Y2 FreWa for add. N arch Y40 HP side, Y46 add. HP side SBs, Y3 brushes (with shampoo), Y1 FreWa and Y6 CDA for VN arch

Bus


Program HP wash (program matrix 35) Cycle Active components Remarks

1 ---------> 50 Hz, Y8 CVW (with FreWa) Chemical pre-wash 2 <---------- 50 Hz, Y40 HP side, Y46 add HP side High-pressure

Technical Manual Model series Nufa K201 6-0395 N201-07-08-F-Wa Water valve control and wash programs 12. July 2004 Page 3 of 3


Example: Programm matrix 31, 2 x wash Wash program matrixes can be changed in P2 Modcon - „change programs“. Shown are 8 cycles, however the Nufa uses not more than 4 cycles. Module Cycle: 1 2 3 4 5 6 7 8

00, Por 075 020 070 070 000 000 000 000 01, DB __ __ 004 004 __ __ __ __ 02, SBL __ __ 006 006 __ __ __ __ 03, SBR __ __ 006 006 __ __ __ __ 04, DD __ __ __ __ __ __ __ __ for HP Nufa 05, UFLU __ __ __ __ __ __ __ __ 06, HP side (Y40) __ __ 004 __ __ __ __ __ 07, Y 1 FreWa VN arch __ __ __ 004 __ __ __ __ 08, Y 2 FreWa add. N arch __ __ __ __ __ __ __ __ 09, Y 3 ProWa brushes __ __ 004 014 __ __ __ __ 10, Y 4 ProWa VN arch __ __ 004 __ __ __ __ __ 11, Y 6 CTH VN arch __ __ __ 004 __ __ __ __ 12, Y 7 CTH add. N arch __ __ __ __ __ __ __ __ 13, Y 8 CVW 004 __ __ __ __ __ __ __ 14, Y 46 HP side split arch top __ __ 004 __ __ __ __ __ 15, Y 10 HP CVW lower side __ __ __ __ __ __ __ __ for HP Nufa 16, Y 11 HP CVW upper side __ __ __ __ __ __ __ __ for HP Nufa 17, Y 12 HP CVW roof __ __ __ __ __ __ __ __ for HP Nufa 18, Y 13 HP roof __ __ __ __ __ __ __ __ for HP Nufa 19, Y 14 HP lower side __ __ __ __ __ __ __ __ for HP Nufa 20, Y 15 HP upper side __ __ __ __ __ __ __ __ for HP Nufa 21- 25, Y 16 - Y20 Reserve __ __ __ __ __ __ __ __

To improve the readability only "__" is shown instead of "002 – initial position, not active". The display shows "002".

Meaning of the cycle parameters for the respective module Generally the cycle parameters are activities, which can be read with P3 Monitor on Byte 2; exception POR Portal.

POR Portal maximum portal speed in Hz for this cycle For all further modules 002 = off or remains in initial position DB Roof brush 004 = Control at vehicle SBL, SBR Side brushes 004 = Control at vehicle

005 = Control with 1 x center overlapping at front (or rear) 006 = Control with 1 x center overlapping at front and rear 013 = Stationary drive-through wash

DD Roof nozzle No relevance because manual operation UBW, Underbody wash No relevance because only stationary HP + Y?, Valves; (with dosing pumps)

003 = on, without observance of the on/off parameters 004 = control, on after parameter and rear 014 = like 004, without dosing


Changed: Bernd Zeller on: 12.07.2004 File: NU-TH-GB_N201-07-08-F-Ventile_b_12-07-04.docx


Technical Manual Model series Nufa K201 6-0395 N201-SW-8-1 Software Upgrade 10 January 2001 Hints for Alternation Page 1 of 1


With the upgrade of a software version adaptions could be nessecary because of new parameters or functions.

Upgrade to 1.12 and following Common: The parameter centre overlapping was implement to change the distance.

Unfortunately the parameter wasn’t automatically updated. Without the update no centre overlapping will be done

1. Set parameter„SB No. of pulses for centre overlapping“ SBL / SBR Para 14 = 30.

Upgrade to 1.13 and following Common: With the software 1.13 a new pump cabinet was implemented. By this new inputs for a

motor protection circuit and flow monitor for now 3 pumps come into existance.

The inputs for the flow monitorings were brought together, thereby the wire numbers have changed.

The parameters of the module PMP, pumps for pressure built up time and relief time (Para 4 und 5) and these for the flow monitoring (Para 6 bis 8) were brought together, thereby were displacements for the para 5 and 7.

1. If there is a flow monitor: Change wiring from old: X2/21, E021 to new: X2/18, E033; Set parameter „Pump 2 RecWa flow monitor release“ PMP Para 7 = 1 (was Para 5 before).

2. Wire bridge from P7 (24V) to X2/21 (E021). 0 V at the input produces the error „Pump cabinet motor protection“.

3. Set parameter „Pressure relief time“ PMP Para 5 = 10 (was Para 6 before)


Amended by: on: Signature

File: NU-TH-GB_N201-08-01-SW-ab-1-13.docx

Technical Manual Model series Nufa K201 6-0395 N201-SW-8-2 Software Upgrade 10 January 2001 Hints for Alternation Page 1 of 1


With the upgrade of a software version adaptions could be nessecary because of new parameters or functions.

For necessary parameter changings the software will update these values automatically after the first power up from the version 1.14 (and for the followings too). It appears the display „parameter update“ for a short time. This will be done also for parameters of elder software versions.

The software recognizes if there was an elder version installed.

Upgrade to 1.14 and following Automatically the following changes will be done:

New program names are added: PUH - Pick-Up with trailer, GEW - conter wash, SBU - Special bus with mirrors.

POR Para 9 = 200, wash start for special bus, pulses.

SBL, SBR Para 14 = 30 (if it was 0 before).

PMP Para 5 = value of Para 6, pressure relief time; Para 7 = 1, if old Para 5 = 1 release flow monitoring recycling water; Para 10 = 40 star delta run up time.

The modules IOM and LED get new names 042 CKL - chip card reader and 043 SER - serial interface.


Amended by: on: Signature

File: NU-TH-GB_N201-08-02-SW-ab-1-14.docx

Technical Manual Model series Nufa, CPU K201 N201-09-01-HW CPU Exchange 14. November 2007 Page 1 of 1


CPU K201: new SN 189 602, repaired SN 790 189 602 Option board 4 x serial: SN 194 951 Option board 2 x serial and 2 x FC: SN 200 681 Software EPROM: SN 192003

Procedure of exchanging the K201 CPU: Using the old CPU before removal first call up P2 - Service and quit with „“

(if possible). A parameter backup is done and the current data will be saved into the EEPROM.

Remove the jumper from the battery from the new CPU before installation - - wait for 5 minutes (or install the CPU meanwhile) Thereby the RAM memory is deleted from the CPU - reconnect the jumper.

Relocate the software EPROM and the parameter EEPROM from the old to the new CPU. Install CPU and switch “power ON”. The control system indicates „Faulty data repaired“ (old: EEPROM data loaded).

(This message appears only for approx. 2 seconds at the terminal, afterwards the message is overwritten by the nromal sequence messages)

In P0 operator: set date and time. One more reset for a new initialization, power off/on.

The machine is now fully functional again. Alternatively the data may also be fetched manally with the P2 Service menue point:

„Load Data +/- Load EEPROM Data +/- EEPROM data loaded “. Attention: Before the display „EEPROM data loaded“ the -key must not be pressed in no circumstances. Otherwise the parameter save will copy the data from the RAM into the EEPROM and our wanted data will be overwritten.

As additional backup, a backup can be made to the EEPROM of the new CPU. - after backup on the old EEPROM



File: NU-TH-GB_N201-09-01-HW-CPU-Tausch_b_14-11-07.docx


Technical Manual Model series Nufa, CPU K201 N201-11-01-A Amendments from 6-1677 23. April 2004 Page 1 of 2


Amendments to the new Nufa 6-0395 compared to the previous edition 6-1677

Control terminal, control cabinet, controller There is now a new control terminals with an LCD text display and buttons for manual machine

movements and for function selection purposes. Comparable with the Euro terminal on the car wash line and EC2000.

Using this terminal the machine can be moved and washing functions selected. The functions are indicated by LED's. The service programs Erpros, Modcon, Monitor and Hardware Test can be used by the service technician for making adjustments and diagnostic purposes (such as with EWS, EC2000 and Toss). In addition there is a user program for the customer which allows him to make basic settings. New functions, such as manual CVW spraying have been added. This function can be started from the terminal with the key „CVW“ + „Safety key“, the „Start“ key switches off again.

The control cabinet is mounted on the machine. As an option it is also possible to mount the control cabinet and chemicals cabinet externally, in a utility room.

It has a new controller, the K201. The controller is similar to the K188 on the EC2000 and CK45. The K201 is connected to the control terminal via the CAN interface.

It is possible to actuate the doors.

The CAN-MKL 6-0193 can be used. This differs from the EC2000 model only in terms of its different keypad with LED's in the various buttons. The magnetic cards contain the data for the composition of the programs/services, there are single and multiple cards, but no charge cards (charging by vehicle length is not possible).

Old control units (WKL, button boxes) can only be connected together with a CAN terminal.

Motors The motors for side brushes and portal movement have been increased in power

(both new 0.37 kW).

The drive unit for the roof brush lift and the portal has two frequency converters. The same frequency converters as on the EC2000 and CK45 are used.

Technical Manual N201-11-01-A Model series Nufa, CPU K201 23. April 2004 Amendments from 6-1677 Page 2 of 2


Roof brush completely new with: Lifting motor with brake ( the same as on the WS drier 6-0690)

Lifting shaft with lifting motor on top of the frame (shaft in roof brush pipe no longer necessary)

Pedestal bearing for the lifting shaft (as on the car wash line system)

Circulating toothed belts

Pulse generator New for measuring length for the roof brush lift, side brushes and portal movement.

This means that a variety of limit switches, such as roof brush rotary direction changer, spoiler, semi-trailer, stationary passage position and drawbar position.

The limit switches, inside/outside, top/bottom and wash bay start/end are left to act as synchronisation points.

Frame The bearings in the chassis and on the side brushes are now all dual hole flange bearings as in

the CK45.

All limit switches are openers M18 x1, as in the CK45, (SN 191 649 with 20 m cable).

The tilt protection has been revised.

Splash guard

Spray device The chemicals cabinet with the dosing pumps is mounted on the machine. There is space in it for

three dosing pumps with containers for shampoo, CTH and the chemical pre-wash option (the first three customers also receive one with 2 dosing pumps).

The additional post-spray spray arch is not fitted on the standard Nufa. This arch is only fitted for the simple wash option.

The chemicals arch is a single-part component and is mounted on the swivel frame of the side brushes.



File: NU-TH-GB_N201-11-01-A-Änderung-6-1677_b_23-04-04.docx


Technical Manual Model series Nufa, CPU K201 N201-11-02-A HP Nufa 6-0297 12. July 2004 Amendments from normal Nufa Page 1 of 3


The HP Nufa 6-0297 is an extended Nufa of the model series 6-0395. It was produced in 2003. Since 2004 the new HP Nufa MaxiWash Combi 6-0302 is produced.

The machine will not be turned like the 6-0588. The entrance is still at the side brushes. The HP attachments and the cabin are at the exit side.

Spray system The flow volume of the HP centrifugal pump is limited by assembly and size of the nozzles.

The larger the water volume the larger the consumed current and the pump is overheated! Therefore the number and the size of the nozzles must not be changed. The pump has an integrated thermic overload protection. The pump would be strongly overloaded when using the old nozzle equipment from the 6-0588.

HP pump: 55 kW, IN = 98 A, pressure approx. 30 bars (roof only approx. 45 bars), volume 30 m3/h. Optionally a 75 kW pump is also available; IN = 128 A, P=50 bar, V=30 m3/h. The current has to be measured for commissioning, maximum 10 % above IN

In the meantime the pump keeps running through the bypass.

are permitted. Such large pumps may only be switched on 6 times within one hour (start-up). Thereby the pump is only switched on for UBW or HP side during the brush wash. The pump is switched off manually by the operator with the key „off“ when there is no further demand.

HP hoses are permitted up to 100 bars; HP piping is checked up to 100 bars (yellow point). Construction for HP chemicals in ¾“ stainless steel and HP water in 1 1/4“ galvanized

(no plastic like in 6-0588). There are 3 spray circuits: roof, lower and upper side. The water assembly is from GSR, comparable with the one from the Euro Combi. Air controlled HP valves and water supply are located at the right frame. Flow control valves are installed for switching the HP valves on and off. The air pressure should be set to 6 bars. The air is monitored by the input pressure.

In case of error a message appears. Option: Two types of chemicals will be available for the HP side chemistry, acid and alkaline with

2 dosing pumps and 2 valve sets. Each side arch can be switched individually, i.e. acid chemicals can be used above and alkaline chemicals below or vice versa. The roof chemistry cannot be changed. The switch “HP chemicals” switches both pumps.

Mechanical system An additional frame with the HP spray pipes is installed at the rear of the machine. At the left rear side a cabin for travelling and controlling of the HP pre-wash is installed.

Therefore the left travel base is extended. The control cabinet for the machine is located below the cabin. The roof is sprayed with an adjustable roof nozzle (up-down and rotating).

Technical Manual N201-11-02-A Model series Nufa CPU K201 12. July 2004 HP Nufa 6-0297 Page 2 of 3 Amendments from normal Nufa


Electrical system The roof nozzle is controlled by the same frequency converter as the roof brush.

Switchover is done by two contactors. The brake in the roof nozzle lift motor is continuously opened by the contactor during HP operation.

There are proximity switches on the left and right side of the roof nozzle for portal-drive-stop (tilt), at the lift drive is a switch for lifting-stop (winding by a lever). If the limit switches are actuated the last used travel direction(s) is locked. (Lift and/or portal), the nozzle may be moved freely in the opposite direction.

Lifting is monitored by the limit switches “top“ and “bottom“. A pulse generator (punched disc) will be available.

Operating units and operation The normal Nufa terminal for the different wash programs is installed inside the wash bay

(Coding switch 7 and 8 = OFF). A second terminal is inside the cabin (CS 7 = Off, 8 = ON; both are completely equal).

This terminal may also not contain a CAN terminal resistor because only two terminal resistors may be installed in the complete system. Additionally a manual HP control panel is available for manual HP wash.

The HP control panel has different switches and buttons: 2 buttons for HP pump (55 or 75 kW) “On“ and “Off“ with a pilot light. 3 switches for the spray circuits roof, lower side and upper side “On/Off“. A toggle for the pumps “LP - Off - HP“, low-pressure (for the chemistry) or high-pressure. A switch HP chemistry “On/Off“ for the dosing pumps. A rotary switch for the roof nozzle rotation “right - off - left. A switch wiper “On/Off“. and a joystick for controlling the portal backwards/forwards(to the right/left) or roof nozzle up/down (upwards/downwards).

To activate HP operation mode the joystick (e.g. lower roof nozzle) has to be pressed. Afterwards the safety key has to be pressed (pay attention to the sequence). Afterwards all HP functions can be activated directly with the keys and buttons. Additionally the text ”HP“ appears in line 2. To switch back use “Start“ and safety key , the text “HP“ disappears.

If the terminal key “CVW“ is actuated before program start (before the brush wash) an automatic spray cycle with the arch „HP-Chemical-side-bottom“ is executed, the key “add. arch“ activates “HP-Chemical-side-top“.

The dosing pump depends on the switch HP chemistry. During the brush wash the terminal key HP“ activates the arch „HP-side-bottom“ and the HP

pump (55kW), the key „add. arch“ activates „HP-side-top“. The HP pump is not switched off automatically afterwards. .

Technical Manual Model series Nufa, CPU K201 N201-11-02-A HP Nufa 6-0297 12. July 2004 Amendments from normal Nufa Page 3 of 3


Software and new functions The functionality of the HP Nufa requires program version 1.23 or larger. The recognition that the system is an HP Nufa is done automatically by the IO board 20/24 with

hex switch = 1(additionally installed in the computer). A brush wash program can be interrupted anytime by HP operation.

For example HP operation can be activated by actuating the joystick together with the safety key ▲ after the cabin has been washed; first the brushes move away from the vehicle and then a special attachment can be washed with HP; afterwards the brush wash is continued from the current portal position in the same cycle by pressing „Start“ and safety key ▲ .

When pressing „Start“ and safety key ▲ without previous brush wash the machine moves in initial position.

For the valve modules of the stationary spray arches (UBW, HP, CVW) new parameter have been introduced: Para 14 = 001 = stationary version active via light barrier for only one wash 002 = stationary version active via light barrier 000 = Valve at machine, controlled by program sequence (Matrix) Para 10 = Switch-on delay for stat. version (in sec.) after light barrier dark, E = 0 Para 11 = Switch-off delay for stat. version (in sec.) after light barrier light, input = 1

If the UBW should be operated with the usual 15 kW pump now pump 6 (= add. HP pump = A120 Pu-Res.) can be entered in Para 4. A necessary star-delta start-up is realized with a time relay in the pump cabinet. If the UBW is operated with pump 3 = 55 kW HP pump, the pump is not switched off anymore (has to be done manually).

For 2nd initial position: after the wash, while the portal moves to 2nd initial position, fresh water with CTH is sprayed to improve the cleaning of the vehicle front.

The old modules IOM and LED have no meaning: 042 CKL = Chip card reader 043 SER = serial interfaces

The new module SER has new parameters for free assignment of the serial interfaces on the attached module, on the CPU (like for the new wash tunnel). Para 2 = Plug X2, Para 3 = X3, Para 4 = X4, Para 5 = X5; 000 = not active, 002 = Bon printer, 003 = Chip card reader, 006 = Protocol printer, 010 = AWA Manager.



File: NU-TH-GB_N201-11-02-A-HD_b_12-07-04.docx Changes since 18.08.1998 are written coloured and marked by „|” at the outer margin.

Technical Manual Model series Nufa, CPU K201 N201-12-01-UM Conversion instructions: Frequency converter (FU) 14. April 2005 Lust to Omron / Fuji Page 1 of 3


To improve the performance of the frequency converter drives the old Lust converters may be replaced by the more powerful Omron or Fuji converters.

1. Before start of work: move the roof brush half way up and the portal to the center of the wash bay. At wrong rotation direction after the conversion the devices may move against the mechanical stopper and wedge there.

Work to be carried out:

2. Switch off main switch, remove cover from K201 controller.

3. Disassemble both Lust frequency converters and remove the cables to the serial interface (to K201 X12 + X14).

4. Install the adapter plates SN 201 206 with 4 screws M5 x 10 on the old drilling holes of the Lust converters (use the screws of the old converters).

5. Install the line filter with 4 screws M5 x 6 on the adapter plates. Power connection upwards.

6. Connect power connection to line filters (the upper right terminals with the designation Mains or Line; L1 and N, (see wiring diagram page 3)

7. Install Omron or Fuji converters on the filters by using the screws supplied with the line filter. Power connection upwards.

8. Remove label U2 (for portal FU) and U3 (for Lift FU) from the old converters and stick them on the respective converter (Portal FU is on top, Lift FU below).

9. Wire power connection from filter to FU: from Filter (left terminals with designation Inverter or Line) to terminal L1 and N/L2 at FU, (see wiring diagram page 3.) cable colour for L1 = black or brown, N = blue, PE = green-yellow.

10. Connect motor cable to lift drive. Cable 1 = terminal U; 3 = V; 2 = W (see wiring diagram page 3).

11. Connect motor cable to portal drive. Cable 1 + 4 = terminal U, 3 + 6 = V, 2 + 5 = W (wiring diagram page 3).

12. Connect grounding cable green-yellow to the housing of each converter.

13. Plug serial interface board (2x serial, 2x FU) SN 200 681 on the CPU K201.

14. Establish connection from interface board plug X14 to the terminals of P7 and P9. X 14: Pin 1 = P9, X 14 Pin 2 = P7. Cable colour: blue.

15. Run and connect control cable for portal converter U2 from interface board plug X 16 to portal converter (see wiring diagram page 3).

16. Run and connect control cable for lift converter U3 from interface board plug X 17 to lift converter (see wiring diagram page 3).

17. Ground the shielding of the motor cable and the control cable besides the converters with clamps to the grounding plate.

Technical Manual N201-12-01-UM Model series Nufa, CPU K201 14. April 2005 Conversion instructions: Frequency converter (FU) Page 2 of 3 Lust to Omron / Fuji


18. Install new software (min. rev. 1.23 or larger), if not already done; set required parameters if necessary, mostly not necessary. Compare parameter list for software from rev. 1.23.

19. Install cover of controller.

20. Switch on main switch. Release Emergency Stop.

21. Set parameters of controller K201 in MODCON P2 Parameter: Set in module 033 FUH and 034 FUP the Para 15 = 002 = Omron FU (also valid for Fuji).

22. Actuate RESET of controller or switch off main switch for approx. 10 seconds to assure that the changes are safely accepted.

23. Lower roof brush shortly, readjust the rotation direction at the lift converter is lifting direction is wrong. (terminal V – W)

24. Move portal forward shortly, readjust the rotation direction at the portal converter is travel direction is wrong (terminal V – W).

25. Actuate „initial position“ to move the system in initial position or start position.

26. Call portal test or lift test via P3 MONITOR (000 POR, 001 DB: Byte 2 = 007). Only for Omron FU: If necessary the target speed can be adapted to the actual speed. Target = POR Byte 8, DB Byte 4, read off actual speed at the operating console of the frequency converter. Use the Omron parameter FBAS (= Para n24 = maximum frequency) for correction. Default: FBAS = 100 Hz (value from experience for correct target: FBAS = 96,4)

27. Now you can start the test washes.

For conversion to Omron frequency converter: 2 SN 761 152 950 Frequency converter Omron 3G3EV 2 SN 761 152 681 Filter for Omron frequency converter 1 SN 761 152 948 Operating console for Omron frequency converter (if not existing).

Parts list fort he conversion of a machine:

or to Fuji frequency converter: 2 SN 211 323 Frequency converter Fuji FRN 0.75 C1S-7E 1 SN 211 945 Filter with brake resistor for Fuji frequency converter (for DB/DD lifting) 1 SN 211 324 Filter for Fuji frequency converter (for portal) 8 SN 000 603 Flat-head screw M5 x 8 Required parts for both frequency converters: 1 SN 200 681 Interface board 2x serial-2x FU 2 SN 201 206 Adapter plate for ground plate from Lust to Omron or Fuji 4 SN 750 001 670 Screws M5 x 10 Cheese-head 4 SN 190 070 Screws M5 x 8 hexagonal 1 SN 201 421 Cable complete for controlling portal converter with plug X16 1 SN 201 422 Cable complete for controlling lift converter with plug X17 2 SN 199 804 Clamp 1 SN 179 383 Plug 2 pol Combicom for plug X14, terminals screwable 2 m Jumper wire 1.5 mm2 blue flexible 0.2 m Jumper wire 1.5 mm2black flexible 10 Wire-end ferrules 1.5 mm1 SN 192 003 Software Nufa, at least 1.23 (only if no current version is installed)

2

Technical Manual Model series Nufa, CPU K201 N201-12-01-UM Conversion instructions: Frequency converter (FU) 14. April 2005 Lust to Omron / Fuji Page 3 of 3


Connections between frequency converter and K201 controller:

30B 30C Fwd Rev X3 11 PLC 12 CM Terminal strips P+ P1 DB O O O O O O O O O Fuji-FU O O O MA MB MC SF SR S1 SC FS FR FC B1 B2 O O O O O O O O O O Omron-FU O O U2 / U3 X16 / X17 bl ye gn bk br wt Brake resistor bk bk 6 O lifting only 5 O 4 O FU filter O O 3 O Inverter Mains 2 O Load Line 1 O N L1 L1 N Fuji only O O O O bk bl to power X14 connection bl bk bl Converter 2 O P7, +24 V O O U2 = Portal 1 O P9, 0 V PE L1 N/L2 U3 = Lift bl Motor connection at FU Terminals at K201 Lift Portal interface board SN 200 681 U V W U V W O O O O O O 1 3 2 1,4 3,6 2,5

to terminal strip



File: NU-TH-GB_N201-12-01-UM-Lust-Omron-Fuji_b_14-04-05.doc


Technical Manual Model series Nufa, CPU K201 N201-12-02-UM Conversion: power measurement with RPD 19. May 2004 Page 1 of 6


Since the roll-over wash system SoftCare a new power measurement device RPD (Real Power Device), SN 206 654 is used for the torque control of the brushes.

It measures three-phase the effective power of 3 drives. Also the phase shifting (cos φ) is considered.

The performance is transferred to the CPU with an analogue signal (0 to 10 V).

In contrary the current torque converter board SN 190 204 measures only the current of the rotation drive.

Large supply voltage fluctuations may cause control inaccuracies

A conversion to the RPD is possible on demand.

. These fluctuations have no impact when using a RPD.

1 SN 206 654 RPD power measurement device 1 SN 206 659 shielded cable complete with plug X7 (SN 206 203) 4 pol. (analogue signals) 1 SN 206 655 CAN connection cable with plug X4 4 pol.

Parts list fort he conversion of the power measurement with RPD

3 SN 206 625 Receptacle 8 pol. for X1, X2 X3 (Motor cables) 1 SN 206 206 Receptacle 8 pol. for X6 (power supply an coding) 2 SN 180 903 Receptacle

22 m SN 062 794

4 pol. for X5 (CAN reserve) and X2 (analogue connection CPU)

Plastic covered conductors black 1.5 mm2 3 m SN 180 920 Plastic covered conductors dark-blue 1.5 mm2 1.5 m SN 062 796 Plastic covered conductors yellow/green 1.5 mm

SN 210 218 Wiring diagram, page 13, 16 and 33, for exchange of existing diagrams.

2

1 SN 192 003 Software Nufa 1.30 or larger (only on demand)

Working time: maximum 1.5 hour

Technical Manual N201-12-02-UM Model series Nufa, CPU K201 19. May 2004 Conversion: power measurement with RPD Page 2 of 6


Remove the following connections: from to remark

Roof brush: Q1 (F1) / 2 K1V / 1 Motor protection to contactor wiring diagram Q1 (F1) / 4 +SM1.U4_X2 / 5 Motor protection to torque SN 209 843 Q1 (F1) / 6 K1V / 5 Motor protection to contactor page 13 +SM1.U4_X2 / 6 K1V / 3 Torque to contactor +SM1.U4_X1 / 3 +SM1.A1_X2 / 3 Torque to CPU

wd 209 843 p.13



Remove further connections: from to remarks

Side brush left Q2 (F2) / 2 K2V / 1 Motor protection to contactor wiring diagram Q2 (F2) / 4 +SM1.U4_X2 / 1 Motor protection to torque SN 209 843 Q2 (F2) / 6 K2V / 5 Motor protection to contactor page 16 +SM1.U4_X2 / 2 K2V / 3 Torque to contactor from from remarks

Side brush right Q3 (F3) / 2 K3V / 1 Motor protection to contactor wiring diagram Q3 (F3) / 4 +SM1.U4_X2 / 3 Motor protection to torque SN 209 843 Q3 (F3) / 6 K3V / 5 Motor protection to contactor page 16 +SM1.U4_X2 / 4 K3V / 4 Torque to contactor

+SM1.U4_X3 / 1 K3R / 1 Torque to contactor +SM1.U4_X3 / 3 K3R / 3 Torque to contactor +SM1.U4_X3 / 5 K3R / 5 Torque to contactor +SM1.U4_X3 / 7 1X100 / N Torque to terminal strip from to remark

further +SM1.U4_X1 / 1 +SM1.A1_X2 / 1 Torque to CPU wiring diagram +SM1.U4_X1 / 2 +SM1.A1_X2 / 2 Torque to CPU SN 209 843 +SM1.U4_X1 / 4 +SM1.A1_X4 / 1 Torque to CPU page 16 +SM1.U4_X1 / 8 +SM1.A1_X2 / 4 Torque to CPU

wd 209 843 S.16



Further tasks: Disassemble the old torque conversion board SN 190 204 with the support sheet and send back to the spare parts storage.

Install the new RPD into the free space on the vertical c-rail, to the right of the controller.

Establish new connections: From to remark

Roof brush +SM1.U4_X3 / 8 Q1 (F1) / 2 RPD to motor protection wiring diagram +SM1.U4_X3 / 7 K1V / 1 (K1R / 1) RPD to contactor SN 210 218 +SM1.U4_X3 / 5 Q1 (F1) / 4 RPD to motor protection page 13 +SM1.U4_X3 / 4 K1V / 3 (K1R / 3) RPD to contactor +SM1.U4_X3 / 2 Q1 (F1) / 6 RPD to motor protection +SM1.U4_X3 / 1 K1V / 5 (K1R / 3) RPD to contactor +SM1.U4_X7 / 3 +SM1.A1_X2 / 3 RPD to CPU

wd 210 218 S.13



Establish further connections: from to remark

Side brush left +SM1.U4_X1 / 8 Q2 (F2) / 2 RPD to motor protection wiring diagram +SM1.U4_X1 / 7 K2V / 1 (K2R / 1) RPD to contactor SN 210 218 +SM1.U4_X1 / 5 Q2 (F2) / 4 RPD to motor protection page 16 +SM1.U4_X1 / 4 K2V / 3 (K2R / 3) RPD to contactor +SM1.U4_X1 / 2 Q2 (F2) / 6 RPD to motor protection +SM1.U4_X1 / 1 K2V / 5 (K2R / 5) RPD to contactor +SM1.U4_X7 / 1 +SM1.A1_X2 / 1 RPD to CPU from to remark

Side brush right +SM1.U4_X2 / 8 Q3 (F3) / 2 RPD to motor protection wiring diagram +SM1.U4_X2 / 7 K3V / 1 (K3R / 1) RPD to contactor SN 210 218 +SM1.U4_X2 / 5 Q3 (F3) / 4 RPD to motor protection page 16 +SM1.U4_X2 / 4 K3V / 3 (K3R / 3) RPD to contactor +SM1.U4_X2 / 2 Q3 (F3) / 6 RPD to motor protection +SM1.U4_X2 / 1 K3V / 5 (K3R / 5) RPD to contactor +SM1.U4_X7 / 2 +SM1.A1_X2 / 2 RPD to CPU +SM1.U4_X7 / 5 +SM1.A1_X2 / 4 RPD to CPU

wd 210 218 S.16



Establish further connections: from to remark

CAN of the RPD +SM1.U4_X4 / 1 Terminal strip 1X8 / 1 wiring diagram +SM1.U4_X4 / 2 Terminal strip 1X8 / 2 SN 210 218 +SM1.U4_X4 / 3 Terminal strip 1X8 / P14 page 33 +SM1.U4_X4 / 4 Shielding from cable shielding from cable 1X8 / PS from to remark

Power supply for RPD U4_X6 / 1 U4_X6 / 6 Bridge for RPD Address wiring diagram U4_X6 / 5 Terminal strip 1X9 / P9 0 V from + 24 V SN 210 218 U4_X6 / 7 Terminal strip 1X9 / P8 + 24 V page 33 U4_X6 / 8 Terminal strip 1X6 / PE

Exchange the pages 13, 16 and 33 (from wiring diagram SN 210 218) in the electric documentation of the machine. Insert EPROM SN 192 003 with Rev. 1.30 or larger.

Power on P2 Modcon module 049 R2 (new RPD) Para 14 = 001 = number of the installed RPDs

Exit P2 with and wait until parameter backup is finished.

Power off / on. After switching on the red CAN-LED of the RPD starts flashing, it is switched off after a couple of seconds if everything is ok. The RPD is now ready for operation.

Start test wash. If necessary adapt DB, SBL/R parameters 4 to 6 and 12 to 13.


File: NU-TH-GB_N201-12-02-UM-RPD_a_19-05-04.doc

wd 210 218 S.33

Technical Manual Model series Nufa, CPU K201 N201-12-03-UM Conversion instruction: brush profiles for silo trucks 19. May 2004 Page 1 of 1



File: NU-TH-GB_N201-12-03-UM-BürstenProfilSilozug_a_19-05-04.doc

SN 196981

SN 196981

SN 196981

SN 196980

SN 196980

SN 204463

SN 204463

SN 204463

SN 196982

SN 196979

SN 196979

SN 196979

SN 196979

SN 202809

Side brush profile NUFA 6-3395

Co. Reichle GmbH 92224 Amberg

Order no.: 65-59-5190 14.12.2000

Technical Manual Model series Nufa, CPU K201 N201-12-04-UM Conversion instructions: Fresh water in backward cycle19. May 2004 Page 1 of 1


For an improved rinsing with fresh water during backward wash some customers ask for a modified sequence.

Sequence description for backward wash (cycle 4): Bus program: fresh water during the complete backward wash

Truck, truck + trailer, semitrailer programs: Driver cabin with fresh water: Process water, as long as the portal counter is larger as module Y06 Para 1 (250), Fresh water, as long as the portal counter is lower as module Y02 Para 2 (250).

Necessary parts: SN 203 006 conversion kit water assembly (additional water valve Y02 connection to X6/2)

On demand SN 192 003 EPROM Rev. 1.29 or larger

Wiring changes: Install bridge from X6/2 to X6/4 (Y02 Y04) Install bridge from X6/3 to X6/6 (Y03 Y06)

Changes in P2 MODCON - system parameter: Module 008 Y02 (FreWa add. N-arch) Para 1 = 052, 2 = 250, 4 = 001, 7 = 050 Module 009 Y03 ProWa brushes Para 1 = 052, 2 = 2000, 4 = 002, 7 = 050 Module 010 Y04 ProWa VN arch Para 1 = 055, 2 = 2000, 4 = 001, 7 = 050 Module 011 Y06 CTH VN arch: Para 1 = 250, 2 = 2000, 4 = 002, 7 = 050

Changes in P2 MODCON - change programs: Program 30 (Bus) Program 31 (truck, truck + trailer …)

Module 008 Y02 Cycle 3 = 002 Module 008 Y02 Cycle 3 = 002 Module 008 Y02 Cycle 4 = 002 Module 008 Y02 Cycle 4 = 014




Changes in P2 MODCON - Program allocation - assign matrix: For BUS program assign matrix 30


File: NU-TH-GB_N201-12-04-UM-SonderFrischwasser_a_19-05-04.doc

Technical Manual Model series Nufa, CPU K201 N201-Glossar Key word index 15. July 2004 with short explanations Page 1 of 18


Controller: 2nd

initial position

Additional rinsing:

After end of wash the machine moves to this portal counter, 000 POR Para 4, 14

At start of wash first moving to wash bay entry When the 2nd

With 007 Y1 Para 9 = 1 an additional rinsing during forward cycle to 2

initial position is active the lower initial position of the roof brush is automatically locked (from 1.18). The menu does not appear anymore in P0.

nd initial position can be initiated after the end of the wash.

Automatic start After positioning the vehicle the machine starts the wash program after a short delay.

028 ANL Para 8 = 1 or switching to P0 or switching with special input

Only possible with traffic light, is automatically switched on (from 1.19m)

Automatic start Delay 045 KFZ Para 7 = time delay (0.1 sec.) Wash starts after the traffic light shows Stop

Auxiliaries Roof brush on/off Switching to 2-brush operation Roof brush tries nevertheless a zero balance.

If this is ok the brush can added anytime during the wash.

Auxiliaries Front wash 2x/ 1x 2 x: The roof brush washes back down to the lower limit switch during backward wash.

1 x: The roof brush is switched off at the rotation change position during backward wash (moves to initial position).

Auxiliaries Center overlapping Center overlapping of the side brushes at front and rear Auxiliaries Ski basket/

Loading platform Loading platform: For truck, truck + trailer, semitrailer or

trailer Side brushes wash only up to ski basket position at the rear - SBs Para 10, Roof brush washes to drawbar Para 9

Ski basket: Side brushes wash only up to ski basket position at the rear (for busses), Roof brush washes to drawbar Para 9

Exception: with 001 DB Para 28 = 1 the roof brush washes completely downwards (Ski basket), from 1.21e.

Bus See wash program Car See wash program Chain wash Several vehicles one after the other, from 1.18

Is activated with 028 ANL Para 5 = 060; The value defines for how many pulses behind the rear the next vehicle is searched.

Without chain wash: the para should be set to 000 to 002. From 1.23o: 000 to 015 = no chain wash.

Rotation change for each vehicle. Counted is only 1 wash each.

Technical Manual N201-Glossar Model series Nufa, CPU K201 15. July 2004 Key word index Page 2 of 18 with short explanations


Chip card reader (CKL)

General Card type

Create cards

Card invalid:

Card ID

Without AWA-Manager

Only single or multiple cards possible. Prices cannot be managed because most times the vehicle length is used for invoicing. Cash, authorization or discount cards are not possible.

„MKL on“ switches the terminal off, at „MKL off“ program start with CKL or Terminal.

With PC and AWA-Manager and special card generation device (connected to PC).

Card validity: Station number, date of validity, price zone (1), Blacklist: individual cards may be locked (after locking cards the data has to be sent to the machine). (Up to 1.24e station numbers with the final digit 0, 4 or 8 have been identified as invalid.)

The card ID (identification) is assigned automatically during creation;

For CKL version without AWA-Manager cards cannot be created by oneself.

Chip card reader serial Activation with 042 CKL Para 4 = 1 with AWA-Manager Para 4 = 2 = without AWA-Manager additionally 043 SER Para 2 = 3

Chip card reader CAN 6-0799 Activation with 042 CKL Para 4 = 5 with AWA-Manager Para 4 = 6 = without AWA-Manager

Contact wire switched-off

See also tram SOF Para 5 = 009, Para 10 = 009, from 1.22 The contact wire is switched off before each machine

movement (A159 = 1 = switch off contact wire). If contact wire is off (E049 = 1 = contact wire is switched

off) the wash/movement starts. If there is no feedback within 2 sec. the error message

„030 contact wire switched off“ appears. Controller Torque converter Measuring points for:

Supply voltage (+ 15 V DC, - 15 V DC); Current values of the rotation drives DB, SBL and SBR (0 – 10 V DC); Supply voltages L1, L2 und L3 (0 – 10 V DC)

Counter Service See: utility program P2 Modcon - Counter Counter Chain wash Several vehicles may be washed one after the other Cycle change Portal Change from forward cycle to backward cycle, is done

automatically at rear of the vehicle, at latest at the wash bay end.

The manual backward wash can be initiated by pressing the key „Safety key“ + portal backwards for 2 - 3 seconds.

Direction change Portal See cycle change portal Doors Exit door Is monitored with the drive-through light barrier E029

If no light barrier exists, bridge to + 24 V.



Doors Winter door Both doors are closed; Door open key (E044) Entrance door opens; Vehicle is positioned (Start light barrier E030 = dark) Program start: Entrance door closes, vehicle will be

washed Program finished: Exit door opens Vehicle leaves the system (Start light barrier = light) Drive-through light barrier (E029) gets dark Wait actuation time 040 AFT Para 11; Wait closing delay 040 AFT Para 12.

Doors Activate winter door E043 = 1 = Winter door operation Monitor 040 AFT Byte 5 = 255

Doors Winter door drive-through light barrier

Light barrier actuation time: 040 AFT Para 11 When the vehicle leaves the wash bay the drive-through light barrier has to be dark

The door is closed only after the light barrier is free. Doors Winter door

exit door closing delay

040 AFT Para 12 After the drive-through light barrier is free the door closes only after this time.

Drive manually Portal forwards, backwards

Additionally for bypassing obstacles during the wash. See also: Cycle change.

Drive-through light barrier

Input 029 Detection if the vehicle has already left the wash bay. Avoids closing of the exit door.

For non-existing light barrier bridge to +24 V. Otherwise the exit door does not close.

Frequency convert. DB/DD-Lift Stepless speed control. Depending on the torque of the brush; Depending on the position of the joystick.

Frequency convert. Switch-on delay After power on or Emergency stop the system will wait for the time set in FU Para 4 before the FU power contactor is switched.

Frequency convert. Initialisation Only for Lust FU The parameters of the FU are transferred from the K201 to

the FU. Initialisation is done after each power on (also after Emergency Stop).

Frequency convert. Controller release Only for Lust FU The motor is switched on only at closed controller release.

A contact of the controller closes the connection. Is switched off when the limit switch is actuated. Is switched off when a data telegram has to be transferred

to the FU more than once. Frequency convert. Monitor Initialisation: Byte 2 Activity is set to the module number

(033 or 034). Frequency convert. Monitor Controller release Frequency convert. Parameter Para 15 = FU type: 1 = Lust, 2 = Omron Frequency convert. Trip Safety shut-down of the FU (e.g. over current).

roof brush lifting is at the upper limit



Frequency convert. Type Lust Controlling via RS 485 from CPU, Data telegram with feedback

Initialisation after power on Release with contact controller release

Frequency convert. Type Omron From 1.18b possible Controlling additional board serial interface with 2 FUs Signals: speed (0 - 10 V DC), start forwards, start

backwards, feedback trip Frost Functions

Portal position Traffic light

Emergency Stop

At error Valves HP

UBW Drain Spin drying

Water lines are drained when freezing. Is activated automatically if input 038 = 1.

When the temperature rises during blowing out the cycle is aborted after the next valve. At some older software versions the cycle is completed. The cycle can only be interrupted by switching the main switch off-on.

The machine must not be positioned in initial position. The traffic light turns red, the MKL and the start button are

locked. Machine movement is possible. Does not work during Emergency Stop!!!

The control voltage for the valves is missing! The function is independent of other errors.

The draining is started also with an error, possibly the message „Frost“ may not appear.

Each existing water valve (if Para 15 = 1) (von Y1, Y2, Y3, Y4, Y6, Y7, Y8, Y10, Y11, Y12) is activated individually together with the valve Y42 „Nufa blowing out“.

Each existing HP valve (Y40, Y46, Y13, Y14, Y15) is activated individually together with Y43 „HP blowing out“.

The valve Y41 UBW is activated withY43 „UBW draining“. And the valve Y45 „Water system draining“ is activated

alone (draining the water hoses in cable carrier). After blowing out the brushes are spun for the time set in

CHK Para 5. The complete cycle is repeated once.

Frost Blow-out time For the time set in 032 CHK Para 5 (in sec. Standard = 150 = 2.5 min.) the individual valves are subsequently blown out or drained.

Frost Total cycle time Change for all non-existing valves parameter 15 = 0. Thereby they are not blown-out and the total cycle time is reduced.

Frost Thermostat Setting to 3 – 4 ° C. Install temperature sensor in chemical cabinet (below). Will be connected to input 038. As long as the input is „0“ (or nothing is connected) no frost

is reported. Frost Wait time draining After frost has been detected the system will wait for the

time set in CHK Para 4 after the last wash (in 0,1 min.)



Fuse F55, 230 V P3, P4 Control voltage: Supply for control contactors, water valves,

brake for lift drive DB Height of machine See wash height Language 028 ANL Para 10 = 000 = German

= 001 = English = 002 = French = 003 = Danish, from 1.09d = 004 = Netherlands, from 1.16 = 005 = Spanish = 008 = Norwegian, from 1.09d

Operating unit Foreign / parallel

Program/Auxiliary assignment

Counter: Magnetic card reader

On

Old wash card reader or magnetic card reader or foreign device. 16 parallel inputs for the wash programs

See: Utility program - P2 Modcon – program allocation - parallel operating units

Counted is to „manual washes“ and „performance counter" For operation the magnetic card reader has always be

switched on (P0); thereby the operating unit is locked Operating unit CTE5

Reset with special

output:

Like foreign / parallel The parallel program inputs start the sequence

For operation the magnetic card reader has to be on! The CTE5 requires additionally a low reset pulse

A159 = 0, when wash is finished: (from 1.19: SOF P10 = 101);

Operating unit Kienzle

Active with release:

Active with start locking:

Like foreign / parallel The parallel program inputs start the sequence

For operation the magnetic card reader has to be on! Additionally the Kienzle reader requires a release

A159 = 1 if program is running (ANL P5 = 000, from 1.19: SOF P10 = 000); or A159 = 1 if machine is ready (ANL P5 = 007, from 1.19: SOF P10 = 007 )

Or: Kienzle grants only release for program input at terminal with E037 Start interlock (BED P8 = 0) (if E037 = 1 Input locked) Feedback to Kienzle with A159 = 1 program is running

Operating unit Magnetic card reader Like Terminal, keyboard and display are identical. With „MKL on“ the program/auxiliary keas are locked

Operating unit Terminal Coding switch

CAN connection between K201 and Terminal 2 and 6 to On

Operating unit Number of terminals: For HP Nufa 2 terminals exist (both must have identical software!!)

Release 2nd

For 2 terminal: 041 MKL Para 4 = 2

nd terminal (in cabin!) additionally coding switch 8 has to be ON

Pick-Up See wash program Pick-Up + Trailer See wash program Portal Monitor Module brake, load stop Portal Monitor Test activities



Pulse counter Error Possible causes: Defect limit switch Defect input Side brush: damaged wire in Airflex hose top Broken star bridge in clipboard motor Counter too high when reaching the limit switch.

Receipt printer Connection At serial interface (043 SER Para 2 = 002) Up to 1.18t additionally 046 TST Para 4 has to be set to 2

Receipt printer Function At the end of the wash a receipt is printed with program, auxiliaries and vehicle length

The receipt is also printed when the wash is aborted. Same for stop key.

Reverse wash See wash program Rinse Process water pipes SoKo Kups: if input 038 (normal Frost) = 1 all existing

valves are switched on (Para 15=1). The customer supplied water supply switches the pump on.

This function is not possible simultaneously with frost monitor!

Roof brush Drawbar height Height locking of the roof brush between truck and trailer DB Para 9; Wash height 330 360 390 420 450 495 Toothed belt 190 100 120 140 160 180 210 Winding drive 170 110 130 150 170 190 220 Winding, new belt 130 150 170 190 210 240

Roof brush Change of rotation During backward wash, this way the front is always brushed from bottom to top (because of wipers)

Adjustable with DB Para 10, pulse before front. At front wash 1 x the roof brush is lifted from this position Also possible for car: Activation with DB Para 30

Roof brush Contact pressure Adjustable with: DB Para 4 truck forward cycle, Para 5 truck backward cycle, Para 12 car forward cycle, Para 13 car backward cycle

Default: truck, bus etc. = 80, car = 60 Roof brush Speed search car SoKo: roof brush with 800 mm ∅. The search speed has to

be reduced because of the short reaction times, 001 DB Para 14.

Roof brush Initial position top / bottom

Switchable in P0 Operator or P2 028 ANL Para 6 Changes simultaneously the function dead-end or drive-

through wash bay (traffic light forward or reverse after end of wash)

from 1.21.a: exception: ANL Para 11 = 1; despite roof brush above, traffic light reverse at end of wash

Roof brush Monitor Lift counter: Word 1 Roof brush Monitor Actual / target / reference value Roof brush Monitor Max. portal speed Byte 8 Roof brush Monitor Test activities: Byte 2 = 7 = continuous lift test



Roof brush Control behaviour Lift DB Para 6, default: 60 - 80; Affects how strong the roof brush lifts and lowers. Too

large value let the roof brush jump. Roof brush Control behaviour

Portal DB Para 7, default: 60 - 80; Affects how strong the portal moves towards and away

from the vehicle during front and rear wash. Too large values cause too long portal distances.

Roof brush Exists 001 DB Para 15 = 1 If Para 15 = 0, the brush does not exist

(2 brush system; no brush, no limit switches) Additionally set 033 FUH Para 15 = 0.

For Tandem: Para 16, 17 Roof brush Wash height

Teaching

001 DB Para 1 = 225 (wash height 420, standard) Wash height 330 360 390 420 450 495

From 1.24 the monitor test program can be used to learn the wash height. 1. Set DB Para 1 = 0 2. P3 Monitor DB Byte 2 = 007 start test program The test program determines the height and records the parameter.

Toothed belt 190 188 197 206 219 231 250 Winding drive 170 192 202 212 226 239 259 Winding, new belt 205 225 245 265 285 315

Rotation direction Generally opposite direction See also: DB, change of rotation direction

SB, change of rotation direction Wiper

RPD Real Power Device Power measurement device for capturing the brush contact pressure.

Independent of voltage fluctuationsReplaces the torque conversion board.

.

Semitrailer See wash program Short wash bay See wash program Side brush Drawbar width Adjustable with SBs Para 9; default 30

Must be increased for wide machines (approx. 50 - 60) otherwise wrong rear detection possible!

By reaching the position the rear is detected depending on the vehicle.

Side brush Rotation direction change

Option: During backward wash, this way the front is always brushed from inside to outside (because of wipers)

Adjustable with SB Para 1, pulses before front (adjust like DB Para 10), Para 1= 0 = no rotation change.

Option: When washing the rear once Release with SB Para 3 = 001

From 1.27 k also possible for cars: Activation with DB Para 30 = 2



Side brush Contact pressure Adjustable with: SBs: Para 4 truck forward cycle, Para 5 truck backward cycle, Para 12 car forward cycle, Para 13 car backward cycle

Default: truck, bus etc. = 130, car = 90 Side brush Monitor Actual / target / reference value Side brush Monitor Max. portal speed Side brush Monitor Pulse counter = Word 1 Side brush Monitor Test activities Side brush Control behaviour

infeed SBs Para 6, default: 160 (to 220); Determines how strong the side brushes move inwards.

Large values required so that the brushes move around the corners

Special bus See wash program Special inputs Inputs 049, 050 and 051

Free programmable 047 SOF Para 5, 6, 7 000 = no function 001 = Solo (0), Tandem (1) 002 = Auxiliary selection on (0), off (1) 003 = Automatic start off (0), on (1) 004 = MKL on (0), off (1) 005 = Key close entry door (1) 006 = Traffic light reverse light barrier at wash bay wall (instead off CVW light barrier) 007 = 1st Initial position, normal (0), 2nd Initial position (1) 008 = 1st Start position, normal (0), 2nd

Up to SW 1.17 programmable with ANL Para 4, Para 11 and BED Para 7

Start position (1)

Special outputs Outputs 113, 155 und 159 Free programmable with 047 SOF Para 8, 9, 10

Output on if: 000 = Program is running 001 = Wash finished, until vehicle is driven out 002 = MKL release 003 = MKL locked 004 = Anti-freeze active 007 = Ready for operation 008 = SoKo RVA Obersdorf: door must not open, because portal is too close, from 1.16f 009 = Request switch off contact wire, from 1.22 value + 100 = inverse function, from 1.19e

Up to SW 1.17 programmable with ANL Para 4, Para 11 and BED Para 7

Start interlock The input 037 can avoid a start. Parameter 044 Bed Para 8 selects the different

possibilities: Para 8 = 0: if E037=1 no wash start possible P8=1: if E037=1 no machine movement possible P8=2: if E037=0 no wash start possible P8=3: if E037=0 no machine movement possible

Start position Normal The wash starts from portal position wash bay entry



Start position 2nd See 2 initial position nd initial position Start position 2nd

Limit switch:

start position

Release: Switch-over:

Drive in 2nd

Portal counter with 2

start position:

nd

Advanced start position.

start position:

A limit switch for one portal position is connected to input E040 (Tandem initial position), e.g. 5 meters in front of wash bay entry. The switch rail is installed on an outer track.

The parameter POR Para 10 = 002 releases the function. The key „special function“ switches now from normal to

advanced start position. LED off = normal, LED on = 2nd

Or a special input (049, 050 or 051) is used for switchover to advanced start position. The input must be programmed therefore: 047 SOF Para 5 = 008 (for E049).

start position

After switch-over to 2nd

When the 2

start position the machine moves automatically to the new start position. After switching back the machine moves to normal initial position. .

nd

At 2

start position is reached for the first time the portal counter is set to default (50). Therewith all portal related functions are possible (Spoiler, semitrailer, special bus ...)

nd start position the backward moving is limited by the limit switch. The limit switch act like the limit switch at the wash bay entry.

Station number See utility program P2 Modcon Stationary drive-

through wash See wash program

Stationary spray arch

for 005 UBW and 013 Y8 CVW Is activated with Para 14 = 001 or 002;

001 = active only up to end of the next wash , 002 = always active,

Valve and pump are switched on, if input 031 - UBW-light barrier reports dark.

Switch-on delay with Para 10 = 002 (=0.2 sec.) Para 10 must not be 000 or 001!

Switch-off delay with Para 11 = 002 (=0.2 sec.) Para 11 must not be 000 or 001!!

From 1.27a also for 006 HP and 014 Y46 add. HP possible Tandem Anti-collision switch Only for M1: S20, input 41:

Avoids that the portals move together Tandem Utility programs For M2: can only be activated in Tandem operation.

Switch-over with key „special function.“ LED on = M1, LED off = M2

Only one utility program can be called from one machine.



Tandem Initial position Limit switch M1 track inside, M2 track outside S18/1 = Tandem initial position M1, inside track 2

approx. bus last third S18/2 = Tandem initial position M2, outside track 2

approx. bus center S14/1 = Solo initial position M1, inside track 1 S14/2 = Solo initial position M2, outside track 2

simultaneously park position for Solo operation M1 Tandem Was bay exit or turn

position S15/1 = wash bay exit M1, inside track 1

simultaneously park position for Solo operation M2 S15/2 = wash bay exit M2, outside track 2

Tandem Manual activities, manual movement

Switch-over with key „Special function“ LED off = M1, LED on = M2

Display „M1“ or „M2“ in line 2 between „vehicle length“ and „date“ (for older software display S1 or. S2)

Tandem Coding switch on CPU

Detection whether M1 or M2: M1: CS 2 = On M2: CS 1 and CS 2 = On

Tandem Machine1, 2 Machine 1 is at entrance Machine 2 at exit

Tandem Remscheid special functions

Activated with 047 SOF Para 4 = 1: (Standard Tandem Para 4 = 0);

An extra switch switches over from: 0 = Solo operation, manual operation, MKL on at night, different vehicles with MKL 1 = Tandem operation, automatic start, MKL off daily, only busses, with auto start, without MKL The switch switches simultaneously the inputs 049 (Solo/Tandem), 050 (manual/autom.) and 051 (MKL on/off).

Tandem Tandem operation, Solo operation

Switch-over with external switch at M1: special input E049, SOF Para 5 = 1 E049 = 0 = Solo; E049 = 1 = Tandem operation

Solo operation only possible M1. Display „M1“, „M2“ or „S1“ in line 2 between

„vehicle length“ and „date“ Than key „Initial position“ and the machines move to initial

position Tandem Tandem operation M2 must be set to automatic operation;

Light barriers (traffic light) are not evaluated by M2.



Traffic light Positioning With 1 light barrier: only red or green 045 KFZ Para 8 = 1 E30, Start light barrier switches the traffic light; Chemical pre-wash light barrier is not used, must not have a bridge to +24V!!!

With 2 light barriers: Forward - Stop – Reverse E28 Chemical pre-wash light barrier switches from Stop to Reverse E30 Start light barrier switches from Forward to Stop

With 2 light barriers and 2nd initial position E28 Chemical pre-wash light barrier cannot be used; E30 Start light barrier switches from Forward to Stop E50 is second wash bay light barrier for Reverse therefore from 1.17: 047 SOF Para 6 = 6; (up to 1.16k: 028 ANL Para 11 = 002)

Trailer See wash program Tram SoKo: Stadtwerke

Bielefeld From 1.22; with traffic light. Buses and trams are washed,

Tram = truck + trailer program. The tram actuates a contact = input 076 when driving in;

parallel program 1 = truck + trailer; Tram is positioned with traffic light, after additional

preparations the wash is started with the start key. The contact wire is switched off before wash start

(special output 159 SOF Para 10 = 009; 1 = switch-off contact wire)

If contact wire is off (special input 049 SOF Para 5 = 009; 1 = contact wire is switched off) the wash starts.

If there is no feedback within 2 seconds the error message „030 contact wire is switched on“ appears.

The contact wire is switched on (A159 = 0) after end of wash (portal in initial position).

The tram actuates an exit light barrier = input 077 when driving out; parallel program 2 = bus.

Travel direction change

Portal See cycle change portal

Truck See wash program Truck + Trailer See wash program



Utility program P2 MODCON - IO list

Change wiring Display: 2 No 999 999 [0] The first number (line number) will be rewired to the

second line number. The first line number uses the terminal of the second.

Example: input E016 DB top is defect, the input is rewired to input 035 (free): 2 No 016 035 [0] Now rewire from terminal X2/1 auf X2/20

Maximum 10 re-wirings are possible. Please observe: For outputs always the same voltages

have to be switched (each plug has its own potential supply).

Utility program P2 MODCON - Program allocation

Parallel operating units: Each line number must have a program with related auxiliaries allocated. e.g. SAZ, 2xWa, MÜ, DB, SB, CVW. At default setting no auxiliary is active, i.e roof brush and side brushes do not wash.

No changes possible when „MKL on“, „Auxiliary selection off“ or program is running.

Utility program P2 MODCON - Program allocation

Allocate wash program matrix: Here a wash program matrix is allocated to the functions 1x wash or 2x washes.

No meaning for the Nufa. Utility program P2 MODCON –

change programs: The wash program matrix can be changed.

e.g. the maximum travel speed of the portal can be changed for the individual wash cycles.

Speed changes work only when the module is active in this cycle. e.g.: cycle 2 = 20 Hz can only be changed if Y16 (Reserve) is set to 004. Without active module the portal moves with the default speed (68 Hz)

Utility program P2 MODCON – Station parameter:

Station number for MKL or CKL 3-digit code no. which has to be identical on magnetic card and in controller.

Program names: The short descriptions (LKW, SAZ ...) can be adapted in foreign countries.

Reset codes: The operator codes of P0 and P8 are set to default 00000 or 88888.

Modem no.: Phone number for „machine answers“ can be entered.

Change module name: from 1.27f The short descriptions of the modules (POR, DB ...) can be adapted in foreign countries



Utility program P2 MODCON -Counter:

Will be deleted when ROM data is loaded. ABS = Total counter wash start ABB = Aborted washes REL = Relative counter, changeable = total counter of the customer (P0)

Valves Switch point front Changeable with Para 1 Valves Switch point at rear

Changeable with

Para 6 before rear (larger values shift the switch point towards the exit) or Para 7 after rear (larger values shift the switch point towards the entrance)

Wash height Heights:

Settings:

Standard: 420 cm, Option: 330, 360, 390, 450 or 495 cm

Parameter changes required for DB Para 1 wash position, DB Para 9 drawbar height

Wash program Bus Roof brush starts from bottom, washes at the rear down to bottom;

Side brushes from inside, at rear to inside; center overlapping at front and rear possible;

Rotation change in backward wash. Wash program Reverse wash Fast program for Bus.

Roof brush starts from bottom, washes at the rear down to bottom;

Side brushes from inside, at rear to inside; center overlapping at front and rear possible;

The 1st

The bus leaves the wash bay.

bus single wash forwards, machine stops approx. 2 m behind rear.

The next bus drives through the portal to normal position. The 2nd

Additional post-spray arch required. bus will now simply be washed backwards.

Wash program Trailer

2nd

The trailer can be positioned forwards or backwards (drawbar at front or at rear).

version:

Roof brush starts at drawbar height, washes at the rear down to drawbar height.

Side brushes start at drawbar width, at rear up to drawbar width. No center overlapping possible;

Rotation change in backward wash. If the trailer is always positioned with the drawbar to the

front the rear wash fort he side brushes may be released with Para 28 = 001. Side brushes wash up to inner position at rear. Center overlapping at rear is possible.

Wash program HP wash Special program for ESA Switzerland Program matrix 35

1st cycle CVW, Y08 2nd

With SOF Para 4 = 10 = automatic stop after 1 cycle HP, Y40 + Y46

st cycle, 2nd cycle is started after start key is pressed.



Wash program Short wash bay

Wash sequence:

2 x wash:

Bus program for 14 m bus and 12 m rails (example). Only with traffic light, only 1 x wash. Roof brush starts from bottom,

washes at the rear down to bottom; Side brushes from inside, at rear to inner position;

center overlapping at front and rear possible; The bus will be positioned, traffic light red, wash start;

normal front wash, then side wash up to portal approx. 2 m before wash bay exit (POR Para 3) Traffic light green Bus drives slowly forwards until the side brushes rotate freely at the rear, then the traffic light turns red, the bus stops, the rear of the bus is washed normally, The machine switches off and moves back to initial position.

Possible in theory, but not very useful in practice because only the rear part of the bus is washed twice: The machine washes backwards again until initial position. In backward cycle rotation change, wash end at wash bay entry. The bus does not drive backwards.

Wash program Short wash bay for semitrailer

From 1.25n: The key „Spoiler“ activates the semitrailer locking for the

side brushes (POR Para 2 and 7) The roof brush is locked das usual with the spoiler

parameters (POR Para 1 and 8) Wash program Truck Roof brush starts at bottom,

washes at the rear down to drawbar height. Side brushes start from inside, at rear up to inner position.

Center overlapping at front and rear is possible; Rotation change in backward cycle.

Wash program Truck + Trailer Between truck and trailer the roof brush and the side brushes move only up to drawbar height and drawbar width.

Roof brush starts at bottom, washes at the rear down to drawbar height;

Side brushes start from inside, up to inner position; Center overlapping at truck front and trailer rear is possible;

Rotation change in backward cycle. Wash program Pick-up

Attention Parameter exchange:

Like truck program. Roof brush clears after drivers cabin

(DB Para 3 (2) after the front) from 1.27g Para 2 and 3 have been exchanged for the roof

brush so that side and roof brush use the same parameters for special bus.

Wash program Pickup + Trailer Roof brush clears after drivers cabin (DB Para 3 (2) after the front)



Wash program Car

Rotation change

Roof brush starts from bottom, washes at the rear down to bottom;

Side brushes from inside, to inner position; center overlapping possible;

The torque thresholds for detection of a vehicle are smaller as for normal trucks, bus …

In backward cycle is a rotation change only optionally possible by roof brush with DB Para 30 = 1. From 1.27k also for side brush with DB Para 30 = 2.

Wash program Semitrailer The brushes are locked in the area between tractor and trailer (POR Para 1 and 7 and 11);

Roof brush starts at bottom, washes at the rear down to drawbar height;

Side brushes start from inside, up to inner position; Center overlapping at front and rear is possible;

Rotation change in backward cycle. From 1.24: POR Para 11 extended area for semitrailer

With Para 11 = 1 the locking area is extended by 256 pulses (5.6 m)

Wash program Special bus

Attention Parameter exchange:

1st

version, without front wash

The bus has large mirrors which cannot be removed. The bus has to be positioned as exactly as possible. A traffic light is highly recommended!

from 1.27g Para 2 and 3 have been exchanged for the roof brush so that side and roof brush use the same parameters for special bus.

The bus is only washed behind the front. The roof brush starts washing when portal counter = DB Para 2 (3) (approx. 200). The side brushes when portal counter = SB Para 2 (approx. 160). Up to this portal counters the brushes are locked in initial position (with rotation).



Wash program Special bus 2nd

version, Mirror bypass

Sequence up to 1.27f

Sequence from 1.27g:

Center overlapping

Roof brush front wash

Backward wash

Roof and side brushes bypass the area where the mirrors are fastened. Adjustable with DB Para 2 (former 3), 20, 21 and 22 or SB Para 2, 20, 21 und 22.

If Para 20, 21 and 22 = 0 no mirror bypass is performed (version 1).

(Side brushes accordingly) 1 = Roof brush lowers to lower limit switch 2 = Search vehicle 3 = Wash upwards to Para 22 (Y1 + Y2) below mirror 4 = Portal backwards to Para 20 (X1) in front of mirror 5 = Lift roof brush to Para 21 (Y1) above mirror 6 = Portal forwards to Para 2 (3) (X2 = Wash start) behind mirror 7 = Lower roof brush to vehicle and wash roof

With front detection 1 = Roof brush lowers to lower limit switch 2 = Search vehicle front 3 = Wash upwards to Para22 (Y2) below mirror 4 = Portal backwards to Para 20 pulses (X1) until in front of mirror 5 = Lift roof brush to Para 21 (Y1) above mirror 6 = Portal forward to Para 2 (3) pulses (X2 = Wash start) until behind the mirror 7 = Lower roof brush to vehicle and wash roof

For side brushes only possible with modified side brush frame, from April 2001.

If a side brush reaches the outer limit switch during bypass (if Para 21 = 001) the rotation is switched off as long as it is in initial position.

Up to 1.27f: No center overlapping of the side brushes at the front.

From 1.27g: Center overlapping for the side brushes can be activated with SOF Para 13 = 1. The distance is limited by Para 22.

The roof brush washes the front only once. No mirror bypass during backward wash because there is a risk of miscounting.

The roof brush is locked after the rotation change. The side brushes are cleared and switched off after

reaching Para 2. Wash program Special bus

3. version, Bus positioned in machine; from 1.27g

The bus is positioned in a way that the side brushes reach already the side of the bus while moving inwards. (SB Para 2 = 000)

If the inner limit switch is reached while moving inwards (the bus is not positioned far enough to the front) the wash is aborted.



Wash program Stationary drive-through wash

Any portal position; Roof brush remains in the upper initial position and is

switched off; Side brushes wash to position „stat. drive-through width“

(Para 11) Required valves and pumps are switched on. One bus after the other drives through the stationary portal

by own engine power. Emergency Stop quits the program. Additional post-spray arch required.

Wash width Widths:

Settings:

Note:

Standard: 260 cm, option: 290 cm (rail track width 3.42 m or 3.72 m or roof brush has 9 or 10 brush shells)

Parameter changes required for SBs Para 9 drawbar width, SBs Para 10 ski basket/loading platform width SBs Para 11 stat. drive-through width

The side brushes must not reach the drawbar or loading platform width during side wash because otherwise the rear will not be detected.

Water Consumption 95 l/min (2 bar) to 116 l/min (3 bar) Wide machine See wash width Winter door See doors Wiper The rotation direction of the roof brush at the wiper has to

be always from bottom to top. Otherwise there is a risk that the wiper is torn off.

Wiring Change See: Utility program Modcon – IO list



Mechanical system: Bearing Plastic Problem with grease nipples which break off during

greasing. In the beginning the grease nipples have been shorter.

New replacement: SN 009 209 with longer thread. HP Nufa Pressure relief valve Bypass, so that the pump keeps running as long as there

is no consumption from the machine. Is switched on with pump on (power - star). Is switched off as soon as a HP valve is switched on,

without time delay, or with pump off.

Is switched on as soon as all HP valves are off, without time delay.

Roof brush Lift 1st

2

generation

nd

New flat belt:

generation

For revolving toothed belts, danger of skipping when ice is in the teeth.

Winding drive with flat belts, the roof brush is suspended freely to the flat belt.

New flat belt with winding noses; the winding noses (transverse notches) have to be inside of the winding roller (towards the shaft).

New additional limit switches for monitoring the belt (breakage or brush on roof).

Side brush Frame: 1st

2

generation

nd

Problem during mirror bypass:

generation

The side brush frame could damage the mirror during center overlapping

From approx. 04/01: increased distance between brush and frame by inclined attachment of the upper and lower cross-beams



File: NU-TH-GB_N201-Glossar_b_20-04-04.doc


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