Thunderstone 7000 - Troubleshoot Manual

Thunder 7000 Troubleshooting Guide – 4/1/20
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Thunder 7000 Tarp System Troubleshooting Guide
Below you will find troubleshooting steps for common tarp system issues.
 Remote function not working.
1. Reset system by removing trailer power connection for 15 seconds then reconnect.
2. Turn on the tarp system by pressing the (Open) & (Close) buttons simultaneously on the keypad for 3-5
seconds until the LED and buttons illuminate.
3. Test remote function.
4. If no function, reset system power and reprogram remote per the remote programming instructions.
5. If remote function now works, this can be an indication that the trailer power connection is loose and
needs reworked and tightened.
6. If still no remote function, check battery level indicated by a continuously flashing status LED on the
remote when the flip lid is opened indicating less than 25% charge, replace if needed.
7. Replacement of keypad or remote may be necessary if above steps fail to work.
 Tarp system will not power on.
1. Make sure that the 2-pole power cord is plugged into the trailer and has the proper polarity and voltage
to the tarp system. Vertical plugs are + positive on top, horizontal plugs are + positive to roadside.
2. Check that the tarp system circuit breaker, near the tractor battery, is allowing power through by using a
voltmeter or test light. Replace if necessary.
3. Turn on tarp system by pressing the (Open) & (Close) buttons simultaneously on the keypad controller
for 3-5 seconds until the LED and buttons illuminate.
4. Test the remote functions of the tarp system by pressing the (Open) & (Close) buttons simultaneously
on the remote 3-5 seconds to verify keypad button failure.
5. Check for grease, dirt, and corroded connections at the battery terminals, circuit breaker and also at
the trailer power receptacle plug and outlet.
6. Check for proper voltage (12v-14v) on the back side of the 2-pole trailer receptacle. Also check for corrosion
and looseness.
7. Check for proper connection of the communication cable between the inner control box and the keypad
controller.
8. Unplug the trailer power from the 2-pole receptacle, wait 15 seconds, re-plug power and verify operation.
9. If the status LED illuminates green briefly on the keypad controller after plugging in power but does not turn
on when pressing the (Open) & (Close) buttons simultaneously, then this indicates the keypad controller has
failed and needs to be replaced.

Summary

Troubleshoot Remote Function

Reset System Power

Reset the tarp system by removing and reconnecting trailer power for 15 seconds.

Activate System and Test Remote

Turn on the tarp system via keypad and test remote functionality after initial reset.

Reprogram Remote and Check Battery

Reprogram the remote if needed and check battery level for low charge.

Consider Keypad or Remote Replacement

Replace keypad or remote if troubleshooting steps fail to restore remote function.

Troubleshoot System Power Issues

Verify Power Cord and Circuit Breaker

Ensure proper polarity/voltage of the 2-pole power cord and check circuit breaker.

Activate System via Keypad

Turn on the tarp system by pressing Open & Close buttons simultaneously on the keypad.

Check Connections and Receptacle

Inspect battery terminals, circuit breaker, and receptacle for dirt, corrosion, or looseness.

Perform Power Cycle and Verify Operation

Unplug trailer power, wait 15 seconds, re-plug, and verify system operation.

Diagnose Keypad Controller Failure

If LED illuminates green briefly but system doesn't power on, keypad controller may have failed.

Troubleshoot Power On No Function

Check Voltage and Connections

Verify low voltage and loose connections, and check motor terminal wiring.

Test Remote and Cycle Power

Test remote functions and perform a power cycle to verify operation.

Diagnose Motor Brush Wear

Continuous green LED flash after verifying motor connections may indicate worn motor brushes.

Troubleshoot Error Codes and Red Flashing Light

Two Flashes: Overcurrent Protection

Indicates overcurrent fault, check for obstructions or increased drag causing excess amperage.

Three Flashes: Overheat Protection

Occurs with rapid start/stop or increased drag; re-check system after cool down.

Four Flashes: Over Voltage Protection

Check tractor batteries and alternator voltage; ensure it does not exceed 15.5 volts.

Five Flashes: Under Voltage Protection

Check for low voltage, loose connections, and corrosion; connect alternate power source.

Seven Flashes: Driver Error Fault

Indicates insufficient amperage/voltage or motor/wire short; verify power source and connections.

Eight Flashes: COM Failure

Indicates communication failure between control box and keypad; check cable for damage.

Troubleshoot Intermittent Start;Stop

Check Power Source Amperage;Voltage

Diminished amperage/voltage from the power source can cause intermittent operation.

Verify Battery and Charging System

Ensure the battery is fully charged and the charging system is functioning properly.

Check Motor Connections and RF Interference

Inspect motor connections for looseness/corrosion and be aware of RF interference.

Overview

1. Function Description
2. Important Technical Specifications
3. Usage Features
4. Maintenance Features

The Thunder 7000 Tarp System is a robust and reliable solution designed for efficient and automated tarp deployment and retrieval on trailers. This system is engineered to provide seamless operation, enhancing productivity and safety for various hauling applications.

Function Description:

The primary function of the Thunder 7000 Tarp System is to automatically cover and uncover the load on a trailer using a motorized tarp. It is controlled via a keypad controller and a remote control, offering flexibility in operation. The system aims to minimize manual effort, reduce the risk of injury, and ensure loads are securely covered during transit, protecting them from environmental elements and preventing spillage. The system incorporates various protective features such as overcurrent, overheat, overvoltage, and undervoltage protection to ensure safe and reliable operation.

Important Technical Specifications:

While specific numerical technical specifications like motor power or voltage ratings are not explicitly detailed in the provided document, several operational and electrical characteristics can be inferred:

• Power Source: The system operates on a 12V-14V DC power supply, typically from a tractor battery. It requires a lead-acid type high amperage battery source for optimal performance. Multiple 12V batteries wired in parallel are recommended for proper operation, suggesting a need for significant current delivery.
• Connectivity: It utilizes a 2-pole power cord for connection to the trailer's power receptacle. Vertical plugs are positive on top, and horizontal plugs are positive to the roadside, indicating a specific wiring standard. A communication cable connects the inner control box to the keypad controller.
• Control Interface: The system features a keypad controller with LED indicators and "Open" and "Close" buttons. A remote control provides wireless operation, enhancing user convenience.
• Protective Features:
  • Overcurrent Protection: Prevents damage from excessive current draw, which can occur due to obstructions (e.g., snow, ice) or increased drag in the tarp motor.
  • Overheat Protection: Safeguards the motor from overheating, typically triggered by rapid start/stop cycles or increased drag.
  • Over Voltage Protection: Protects the system from damage due to input voltage exceeding 15.5 volts.
  • Under Voltage Protection: Ensures the system operates within a safe voltage range, preventing damage from low voltage conditions.
• Error Indication: The keypad controller features a red flashing LED to indicate specific error codes, allowing for quick diagnosis of issues. These codes flash, pause, and repeat until the problem is resolved.

Usage Features:

• Remote Control Operation: The system can be operated wirelessly using a remote control, providing convenience and flexibility, especially when the operator is not directly at the keypad. The remote has a flip lid and a status LED to indicate battery level.
• Keypad Control: A physical keypad controller on the trailer provides direct control with "Open" and "Close" buttons. It also features LED indicators for system status and error codes.
• System Reset: A simple reset procedure involves disconnecting and reconnecting the trailer power for 15 seconds, which can resolve minor operational glitches.
• Error Code Diagnostics: The red flashing light on the keypad controller provides clear error codes (two to eight flashes) that correspond to specific issues, guiding the user through troubleshooting.
• Driver Error Fault: A "Driver Error" fault (seven flashes) indicates insufficient amperage or voltage from the power source or a short in the drive motor/wires, prompting the user to check power supply and wiring.
• Intermittent Operation: The system may start/stop intermittently due to diminished amperage/voltage, RF interference, or loose connections, requiring specific troubleshooting steps.

Maintenance Features:

• Battery Level Check: The remote control's status LED continuously flashes when the flip lid is opened if the battery charge is below 25%, indicating a need for replacement.
• Connection Inspection: Regular inspection of all connection points is crucial. This includes battery terminals, circuit breaker, trailer power receptacle plug and outlet, motor terminals, and the communication cable for grease, dirt, corrosion, and looseness.
• Circuit Breaker Check: The tarp system circuit breaker, located near the tractor battery, should be checked with a voltmeter or test light to ensure it's allowing power through. Replacement may be necessary if it's faulty.
• Motor Brush Inspection: Continuous green flashing of the LED status, even after verifying motor connections, may indicate worn motor brushes, necessitating motor replacement.
• Wiring Integrity: Motor wires should be regularly checked for cuts, abrasions, or bare spots that could cause shorts to ground.
• Obstruction Removal: In cases of overcurrent faults, users are advised to check for and remove obstructions such as snow or ice buildup that might impede tarp operation.
• Power Source Verification: Regularly verify the proper voltage (12V-14V) at the back of the 2-pole trailer receptacle and ensure the truck's charging system or power supply is running and working properly.
• Software Updates: For issues like intermittent starting/stopping due to RF interference, a software patch may be available through a Thunderstone dealer, indicating a potential for firmware updates.
• Component Replacement: The guide outlines scenarios where components like the keypad controller, remote, circuit breaker, or motor may need replacement if troubleshooting steps fail.

Thunderstone 7000 Specifications

General

Brand	Thunderstone
Model	7000
Category	Industrial Equipment
Language	English