CLASS™ INSTALLATION and SETUP USER MANUAL
Contents
1. Diagnostic 6 1 1 Floor a At an absolute minimum there must be a value for the distance to the floor from each sensor Using a metric tape measure or equivalent measure the distance from the transmitting face white circle of each sensor to the floor in centimeters Connect the laptop to the CLASS Controller Turn on the CLASS Controller Run CLASS Diagnostic Insert the measured floor values in the appropriate boxes Program the floor values into the CLASS Controller by selecting Save to EEPROM g Reset the CLASS Controller and see what other fixed targets appear in the boxes gt OoOaQa0d0d0 6 1 2 Other Targets Using an appropriate oscilloscope and adapter cable connected to the CLASS Controller visually check for targets or possible targets Check each sensor for targets through the door s full range of motion This is made easier by dumping the air and operating the door by hand being careful to not introduce extra targets such as one s head hand etc Check both the single sensor operating by itself and also with the other two active Any target seen with the oscilloscope should be evaluated for inclusion in the fixed target table Evaluation includes verifying the source and location of any target and a decision regarding the target s echo amplitude Any target whose amplitude is greater than 25 of the Vref Normal should be included in the table unless it can be physically elim2. MRN 03002 8 TB08 03 192 High 11 29V when INT ENAJ 7 door IS enabled Std f Use IN4 unlocked i i Use IN4 when enable signal Connect to Green Light non Low GND or OPEN is low going IN4 ENA grounded side Std 8 when door is NOT enabled Pigi LT eo when Connect to Ground for SINK Goon Openiequest For non PLC bus connect to Optional requires SOURCE Connect to 24V source at rear door aioe KiC 19 Low GND when door for SOURCE pol dnaminal ts selver rit 29V ONLY when the door is open request requires bledand safe to exit SINK enabled and safe to exi Disconnect wire from N O Contact of Fully Closed Switch or Prox to Bus Same as IN3 DNC EEC COM Contact of Fully Closed Not Used Typically not used Switch connected to 24V K2C 15 used to interrupt fully for AOSC doors due to closed signal to bus SONNEGEA C TO CUESNG OL WITE mechanical lock leading to N O Contact of Fully Closed Switch or to output of Fully Closed PNP Prox OUTPUTS TO BUS From CLASS High OPEN when O1 status light is OFF Connect to negative non 24V side STA 9 Low GND when of Status lamp See AS STANDARD Bus status light is ON High OPEN when sensors do NOT detect a target When 02 10 activated by IN2 Optional connect to PLC per Bus Not Used DAO Low GND when a Builder instruction sensor detects a target When activated by IN2 Low GROUND when door re open request 03 14 is ACTIVE Op
3. Contact Vapor for further information MRN 03002 8 TB08 03 192 Page 28 of 34 5 2 2 Sensors Connections After Sensors are mounted and their cables are routed terminate the cables with the pins Crimper AMP 90758 1 connectors and hoods provided in Vapor Kit 50110187 Insert the pins into the connectors as follows see pin insertion view below for pin location details Panel Sensors P4 amp P6 Pin Wire Colors Signal Beige cable 1 Red POWER 2 Green or Orange SEND 3 Black GROUND 4 White or Brown ECHO 5 Shield SHIELD Center Sensor P5 Pin Wire Colors Signal Beige cable 6 Red POWER 5 Green or Orange SEND 4 Black GROUND 3 White or Brown ECHO 2 Shield SHIELD Sensor cable may be Red Black Orange Brown Shield or Red Black Green White Shield T Insert P4 P5 and P6 into J4 J5 and J6 respectively on the CLASS Control box making sure that the connectors latch in place NEVER connect or disconnect sensors while power is applied to the CLASS controller MRN 03002 8 TB08 03 192 Page 29 of 34 6 Setup 6 1 Initial Measurements Once the mechanical installation and electrical interface are complete the next step is to determine and verify fixed targets Refer to TBO8 05 097 for software instructions as necessary to use CLASS
4. assembly and the Switch connection needs a 6 ring tongue terminal On the door side of the bus locate spare wires 12 and 13 that are routed in the wire harness from over the front door to the back door area Hook up the Light negative lead terminal to the 13 spare using 16 AWG wire The negative terminal end of the Light will needs a 14 Fast On female to mate with the 14 Fast On male of the Light lead and the spare wire connection needs a 16AWG butt splice The Switch needs to be hooked up to the 12 spare using 16 AWG wire The Switch connection terminal end needs a 6 ring tongue terminal and the spare wire end needs to be butt spliced to the spare wire For convenience the Vapor part numbers for the 16 AWG terminals are as follows P N Description 98010749 Terminal 14 Fast On Male Insulated 98010749 01 Terminal 1 4 Fast On Female 98320180 20 Terminal 6 Ring Tongue 98320180 23 Terminal 10 Ring Tongue Handle Installation Attach the handle to the existing upper 5 16 18 RIVNUT on the trailing edge of the door and mark the location of the lower hole with the handle vertical Drill a 413 423 hole use a letter Z 4130 or a 27 64 4219 drill bit for the RIVNUT Install the 5 16 RIVNUT from the kit using a B F Goodrich wrench type header tool number C 722 3118 Finishing Patch the small rivet and screw holes in the door from the touch strip mounting and put in a flush plug in the wire hole after sizing the
5. found at P1 18 verify that the On Off switch is ON verify the connection to the On Off Switch and verify the bus RUN switch is ON Unlock the exit door The Green Light should be ON Verify that the SEND lights for LPS and RPS are ON If the SEND light is not ON a Verify that the CLASS controller is receiving power System Voltage at P1 7 ENA or GND at P1 8 ENA i If power is not found at P1 8 ENA check that Green Light is ON and verify the connection to the appropriate limit switch ii Verify that there is System Voltage at P1 5 DNC or GND at P1 6 DNC from the Fully Closed Switch If the SEND light is on place an object in the beam area of the LEFT panel sensor as follows a Make sure that the object is oriented so as to reflect sound back to the sensor b Make sure the object is at least 10 from the face of the sensor c Make sure the object is no more than 40 from the face of the sensor d If necessary move the object slowly up or down to make sure it is not ina dead zone Verify that the LPS orange light is ON when the object is in the sensor s beam area Page 31 of 34 8 If the LPS orange light is not ON a Verify that the sensor is transmitting ultrasound pulses by lightly placing a finger on the white circle at the face of the sensor A slight vibration should be felt when the sensor is transmitting This vibration is not at the frequency of the ultrasound pulse it is the repet
6. hole for the plug Sand and repaint the repaired area with a semi gloss black Attach supplied labels if appropriate to the doors MRN 03002 8 TB08 03 192 Page 21 of 34 5 2 Electrical 5 2 1 Wiring Harness Connections Although the CLASS 1 O requirements are well defined differences in bus wiring types of controllers polarities etc all contribute to the fact that each type of bus must be carefully assessed to ensure that the requirements of the I O are correctly fulfilled The following section describes the input output and power interface for the CLASS controller and provides a description of requirements and alternatives 1 DEFINITIONS 1 1 Active the active state of a signal is the state when the event of interest occurs It is usually described by the name of the signal As an example for the Fully Open signal the active state occurs when the door is fully open When the door is not fully open the signal is not active 1 2 High going a signal is high going when it is connected to a positive voltage usually 24V when it is active When it is not active it may be connected to GND or it may be open A signal which is high going when active is also called an active high signal 1 3 Low going a signal is low going when it is connected to GND when it is active When it is not active it may be connected to a high voltage or it may be open A signal which is low going when active is also called an acti
7. it is not a situation where an echo will be received in the beam but not outside it instead the echo amplitude will be more and more reduced as the distance from the center axis increases until it reaches a point where it is below threshold The effective beam width depends on the strength of the transducer and the threshold value set in the CLASS parameters CLASS Beam Width vs Distance Panel 6 92 Middle 1 22 Panel Sensor 6 deg Middle Sensor Panel Sensor 9 deg Distance inches MRN 03002 8 TB08 03 192 Page 6 of 34 2 2 Door Movement Figure 1 shows the basic movement pattern of the doors and indicates the sensors zones Figures 2 3 and 4 show three dimensional graphical depictions of the sensing zones in both door closed and door open positions Sensing zone Panel Sensor Panel Sensor mounted on top edge of panel Doors Fully Open vo Doors XK Door panel Closed Left i Right fo Middle Sensor ceiling mounted Sensing zone Middle Sensor Top View Vehicle Interior Figure 1 Sensors and Sensing Zones Page 7 of 34 MRN 03002 8 TB08 03 192 Figure 2 Doors Closed and Enabled Shading indicates active s
8. open function e While the doors are closing CLASS can enhance the sensitive edge function 2 1 CLASS system components include the following e CLASS CONTROLLER e Left Panel Sensor LPS e Middle Sensor Unit MSU e Right Panel Sensor RPS The panel sensors LPS RPS are directly mounted on each door panel These sensors have a relatively narrow beam angle approximately 6 9 degrees and operate at a frequency of 150 170 KHz Their functions are 1 to initiate door opening and 2 enhance the sensitive edge while closing The center sensor MSU is typically located on the door header approximately at the center of the doors Its function is to monitor the door pathway while the doors are open to prevent premature closing It has a wider beam angle approximately 12 degrees and operates at a frequency of 120 KHz When the sensors sense the presence of a passenger in the defined zones and the door is authorized to open the CLASS CONTROLLER sends a Door Open Request DOR signal to the Door Operator Unit DOU Once the passenger or passengers exit the doorway and the exit area is clear the DOR signal is removed and the door is allowed to close MRN 03002 8 TB08 03 192 Page 5 of 34 The chart below shows the typical Beam Width or cone diameter vs distance for CLASS transducers Note that the Beam Width is approximate that is it is defined as point at which the sensitivity is one half the on axis value So
9. to paragraph 4 1 for connection details 4 2 Fully Closed Override Normally when the bus PLC receives the fully closed signal it releases interlocks and allows the bus to move CLASS needs to have enough time after the door is fully closed but prior to allowing the bus to move to make sure that nothing is caught in the door Such as a purse strap belt etc Relay K2 is used to delay the fully closed switch information from reaching the bus PLC for that short time just long enough for CLASS to ensure nothing is entrapped Connecting K2 means that the original connection from the fully closed switch to the PLC is broken and re routed through K2 in the CLASS controller Note that while this technique works well on a door with a differential engine for an Air Open Spring Close door the lock pawl will fall into the mechanically locked position once the door is fully closed and CLASS is not able to re open the door so K2 is not used 4 2 1 K2C connected to the output of the fully closed switch 4 2 2 K2NC connected to where the output of the fully closed switch used to be connected typically to bus PLC 5 POWER 5 1 PWR this is normally connected to the N O terminal of the On Off switch whose Common terminal is connected to a local source of bus system voltage 12V or 24V 5 2 SWPW this switched power is connected to a local near the rear door source of bus system voltage 12V or 24V This signal is use
10. 2 used 12V vehicle of On Off Switch connected to Bus 12V Connect to N O Contact of Optional 23 a is Not Used On Off Switch COM Contact On24 used 24V vehicle of On Off Switch connected to Bus 24V INPUTS TO CLASS From Bus Use IN1 IN1 DFO 1 Connect to N O Contact of Std High 11 29V when Use IN1 Fully Open Switch COM IN1 DFO 2 Door IS Fully Open Low GND or OPEN when Door is NOT Connect to N O Contact of Fully Open Switch COM Contact of Fully Open Switch connected to 24V or Contact of Fully Open Switch connected to GND or to Non Sid Fully Open to output of Fully Open PNP Prox i ot FUN Qpen NEN High 11 29V to ACTIVATE Middle Sar 3 Sensor when door is NOT enantad Optional connect to PLC per Bus IN2 DAl Low GND or OPEN Builder instruction Eee ue Non Std 4 to DEACTIVATE Middle Sensor when door is NOT enabled Use IN3 IN3 DNC 5 aa ee Connect to N O Contact of Fully Connect to N O Contact of Std R Closed Switch COM Contact of Fully Closd Switch COM IN3 DNC 6 Non Std than 5 Low GND or OPEN when door is open GREATER than 5 MRN 03002 8 TB08 03 192 Fully Closed Switch connected to 24V or to output of Fully Closed PNP Prox Contact of Fully Closed Switch connected to GND or to output of Fully Closed NPN Prox Page 26 of 34 SIGNAL DESCRIPTION STD Bus STANDARD NON STANDARD
11. N Vapor Bus International Released May 15 2003 Revised August 9 2006 CLASS INSTALLATION and SETUP USER MANUAL P 1 of 34 MRN 03002 8 TB08 03 192 age NOTICE All equipment systems and or devices supplied and described in this manual remain the property of Vapor Bus International Buffalo Grove IL and may be totally or in part a patented combination Illustrations specifications and engineering data submitted herein remain the property of Vapor Bus International and shall not be divulged to others or reproduced or altered or used in whole or in part as the basis for manufacture without express consent of Vapor Bus International No part of this manual may be reprinted reproduced or utilized in any form by electronic mechanical or other means now known or hereafter invented including photocopying nor used in any information storage and retrieval system without written permission of Vapor Bus International This manual is furnished for the express purpose of servicing systems and components supplied by Vapor Bus International U S and foreign Patents are applicable and or pending to products described and illustrated herein Vapor Bus International reserves the right to discontinue products or change product specifications at any time without notification MRN 03002 8 TB08 03 192 Page 2 of 34 TABLE OF CONTENTS Definitions System Overview Description of Operation Electronic Control Unit Installation Se
12. SS is requesting the PLC to open the door similar to a touchtape See O5 for the active high version of this signal 3 5 O5 OPN this signal will be high when CLASS is requesting the PLC to open the door similar to a touchtape If the bus PLC logic responds to to a touchtape input while the door is closing it is also used when CLASS is requesting the PLC to re open the door similar to a sensitive edge If not O6 must also be used See O4 for the active low version of this signal 3 6 O6 RCY this signal will be high when CLASS is requesting the PLC to re open the door similar to a sensitive edge This output is used MRN 03002 8 TB08 03 192 Page 23 of 34 when the bus PLC logic does not respond to a touchtape input while the door is closing See O3 for the active low version of this signal 3 7 TGT this signal is at GROUND when any sensor detects a target It may be used to control an indicator light but is not capable of driving a high current load 4 RELAY 4 1 Door Open Request K1 this relay is optionally available for non typical requirements The output terminal is by default configured as Normally Closed although it may be reconfigured as Normally Open if necessary K1 is active whenever OUT4 is active 4 1 1 K1C Connect to system high voltage 12V or 24V for an active high request Connect to GND for an active low request 4 1 2 K1 O This is the Door Open request output Refer
13. Table 1 defines the color and function of the LED s o _ _ _ _ _ w SYSTEM Orange Slow Flashing System is running Calibration is complete Orange Fast Flashing Problem detected BIT failure Green LPS is Sending MSU RPS Table 1 CLASS CONTROLLER LEDS 4 2 CLASS CONTROLLER Connectors Figure 6 shows the location of connectors J1 and J2 VEHICLE INTERFACE Figure 6 Interface MRN 03002 8 TB08 03 192 Page 13 of 34 Tables 2 and 3 detail the CLASS CONTROLLER connector functions and pin definitions Table 2 J1 Vehicle I O Interface Pin Signal Function Description WireName 1 IN1 DFO Door Fully Open From Fully Bus System Voltage when door Open switch or sensor is fully open open otherwise 2 IN1 DFO Door Fully Open From Fully GROUND when door is fully Open switch or sensor open open otherwise 3 IN2 DAI Drunk Alarm May be used Bus System Voltage when to activate the selected drunk alarm function is sensor s only when the door desired open otherwise is NOT enabled to allow detection of passengers in immediate vicinity of doorway Drunk Alarm function 4 IN2 DAI Drunk Alarm May be used GROUND when drunk alarm to activate the selected function is desired open sensor s only when the door otherwise is NOT enabled to allow detection of passengers in immediate vicinity of doorway Drun
14. Table 5 J5 MSU Pin Signal Description No Connection Shield Grounded at CLASS CONTROLLER ECHO Returned to CLASS CONTROLLER GND Provided by CLASS CONTROLLER SEND Controlled by CLASS CONTROLLER Power Provided by CLASS CONTROLLER O Po O O1 Table 6 J3 Test Pin Signal Description 1 SEND Use as scope trigger identical to 4 amp 5 2 LPS Echo Use to measure LPS echo 3 MSU Echo Use to measure MSU echo 4 SEND Use as scope trigger 5 SEND Use as scope trigger 6 RPS Echo Use to measure RPS echo 7 Gnd Scope probe ground 8 Gnd Scope probe ground MRN 03002 8 TB08 03 192 Page 17 of 34 5 0 Installation 5 1 Mechanical 5 1 1 Sensor Alignment Panel Sensors The panel sensors have two functions open the door and protect the door s edge So their positions should be as close as possible to the door edge without intruding into the non metal zone The sensor has about 12 inches of dead zone from its surface and the beam fan is a 3D cone aligning the cone axis straight down as shown below allows sensing both the edge and the touch to open zone Figure 8 Panel Sensor Alignment MRN 03002 8 TB08 03 192 pagade gros 5 1 2 Sensor Alignment Middle Sensor Figure 9 shows the recommended alignment of the Middle Sensor on the bus floor with the door closed The top of the drawing is the outside of the bus It is su
15. d instead of Pwr 5 1 when the optional internal power relay K3 is used MRN 03002 8 TB08 03 192 Page 24 of 34 5 2 GND this is permanently connected to bus ground 5 3 On12 When the optional internal power relay is used on a 12 Volt vehicle it is controlled by this signal coming from the N O terminal of the On Off switch If On12 is used PWR 5 1 is not used SWPW 5 2 is used instead The On Off switch Common terminal is connected to bus system voltage 12V via a wire from the same source as used for paragraph 5 2 5 4 On24 this is used similarly as On12 but for a 24V vehicle The following table lists standard connections and alternatives for non standard connections MRN 03002 8 TB08 03 192 Page 25 of 34 CLASS Harness Connections for Standard and Non Standard Bus STANDARD NON STANDARD SIGNAL DESCRIPTION STD Bus 11 to 29 VDC when CLASS is to be ON POWER Connect to N O Contact of On Off Switch COM Contact of On Off Use Local 12 24 and On Off PANE 18 0 VDC when Bus is Switch connected to bus system 12 or On Off 24 OFF voltage GND 24 Vehicle Ground Connect to Bus Ground at rear door e Bus roundi Local rear door Optional p4 Source of power when Not Used eae a ye 0 SWPW optional power relay is oboe Sto used VDC when Bus is OFF Connect to N O Contact of Optional 22 pie inoue ee is Not Used On Off Switch COM Contact On1
16. e observing the LEDs on the CLASS controller housing 1 2 1 Verify that the LEFT CENTER and RIGHT lights flash Green SEND at least once and Orange DETECT at least once 1 2 2 After 1 2 1 is complete verify the SYSTEM light is flashing Orange slowly at approximately 1 Hz and all the other lights are OFF Move the driver s door control handle to the Rear Door Open position and ensure that the Green Light above the rear door is ON 1 3 1 Verify that the at least the LPS and RPS lights on the CLASS controller housing are on Green Place a hand in the area indicated to be used to open the door using the LPS 1 4 1 Verify that the door opens Once the door opens fully stand so as to be detected by the center sensor 1 5 1 Verify that the MSU light turns Green when the door fully opens and turns Orange while standing so as to be detected by the center sensor 1 5 2 Verify that the door either remains open or if it starts to close reopens after closing partially Note that door behavior depends on PLC or Controller Move back to allow the door to close almost fully Just before fully closing place a hand so as to be detected by the left panel sensor Verify that the door reopens Repeat for the right panel sensor Repeat step 1 4 but for RPS Repeat step 1 6 allowing the door to fully close before placing a hand under the sensor and make sure to place the hand under the sensor more than 1 second after the door pa
17. ensing regions MPN 03002 8 TB08 03 192 Page 8 of 34 Figure 3 Doors Fully Open Shading indicates active sensing regions MPN 03002 8 TB08 03 192 Page 9 of 34 Figure 4 Doors Fully Open Shading indicates active sensing regions MPN 03002 8 TB08 03 192 Page 10 of 34 3 Description of Operation 3 1 System Block Diagram The CLASS CONTROLLER contains the system s signal processing and control electronics It is connected to the bus as indicated in the block diagram in Figure 5 VEHICLE DOOR CONTROLS OPERATOR gt gt z a 4 T o Gr Sa rE ay F Od ca Q eia oz QO aa Ow a Q o Ox a 9 a Status DRIVER PANEL CLASS ECU LEFT RIGHT PANEL hei PANEL SENSOR EN SENSOR Figure 5 Interface Block Diagram Signals and Descriptions e DFO The Door Fully Open signal from the operator is active when the door panels 85 Degree are Fully Open e DNC The Door Nearly Closed signal from the operator is active when the door 5 Degree panels are almost Fully Closed e OPEN The Door Open Request becomes active when the CLASS CONTROLLER detects a target on an enabled door panel and is routed to the bus PLC e ECHO An analog signal representing the echo received by the sensor e ENABLE The PLC indicates to the CLASS CONTROLLER that the door is enabled to respond to an Open Request e On Off A switch that controls the CLASS CONTROLLER power e SEND A signal that turns on the sensor s ultras
18. etected by CLASS s sensing system Fixed Target a Target that is part of CLASS s fixed environment i e always present Fixed Targets may be permanently programmed by the installer or may be automatically determined by CLASS at turn on Acquired Target a Target that is not fixed typically a passenger MRN 03002 8 TB08 03 192 Page 4 of 34 2 System Overview Vapor s Contact Less Acoustic Sensing System CLASS is designed to operate in public transportation environments principally buses It combines acoustic technology with signal processing techniques to enable passengers to initiate door opening and exit a vehicle without physical contact with the doors The CLASS system consists of three ultrasonic sensors and a signal processing and control unit CLASS CONTROLLER When activated the sensors emit bursts of ultrasonic pulses to survey specific spaces within the doorway The echoes received by the sensors are analyzed by the CLASS CONTROLLER to determine whether or not an object typically a person is present When an object is detected the CLASS CONTROLLER signals the door controls which initiate the appropriate response CLASS can provide different functionality during each phase of door operation e When a door is enabled but still closed CLASS can emulate a touch bar or touch tape for passenger actuation e While a stream of passengers is exiting CLASS can provide a hold
19. ggested to point the beam slightly outside so it will protect exiting passengers but will not see farther objects trees poles etc Figure 9 Middle Sensor Alignment 5 1 3 Typical Installation The following instructions are for a typical installation Specific details may be different for different buses they depend on the type of bus type of door etc Preparation Remove the Grab Handles and Touch Tape from the rear doors Flange locking bolts 5 16 18 attach the handles and require a 9 16 box or socket wrench for removal The Touch Tape is secured by 4 small cross recessed screws 2 at the top and 2 at the bottom that are removed with a Phillips screw driver The tape is also held by an aluminum track that the tape can be slid out of Once the tape has been removed from the track the attaching pop rivets can be removed by drilling through with a 1 8 inch diameter drill Cut the wire of the touch tape tape the live ends and remove to the connection point above the doors Because of the routing of the wire along the path of the sensitive edge tubing it may be best to cut the wire in the roller area accessed by removing the cover plate Sensor Mounting Door Sensors The door sensors should be attached to the upper leading inboard edge of the doors There should be approximately 1 4 inch from the top of the door to the top of the sensor bracket The MRN 03002 8 TB08 03 192 Page 19 of 34 bottom of both sensor
20. ght and Switch Mounting The master Switch and Indication Light are mounted to the switch panel above the bus driver s seat located behind the cover Mount the bracket behind the right side of the existing switch mounting bracket Align the holes with the other switches if possible After drilling through both brackets attach with 2 ea 6 or 8 sheet metal screws or pop rivets The Light and Switch mounting holes should be aligned horizontally on the right with the attachment screws on the left side of the bracket Due to the geometry available the mounting flange is not used and will be sticking towards the front of the bus Mount the Switch in the left hole and the Light in the right hole The Light has insulated Fast On spade terminals The negative Light terminal is the insulated male 14 Fast On and may need the MRN 03002 8 TB08 03 192 Page 20 of 34 corners shaved by scraping with a knife blade to be able to fit through the 50 diameter mounting hole Once the negative wire is routed through the hole the positive lead can be threaded through and the Light can be snapped into the bracket Locate 24 V DC positive on terminal 2 of the terminal strip located behind the switches and connect to the Light positive lead and the common terminal of the Switch using 16 AWG wire The terminal strip needs 10 ring tongue terminals the Light needs an insulated 14 Fast On male to fit into a 4 fast on female for the positive lead of the Light
21. inated Example if Vref Normal is 2 0 enter any target greater than 0 5 When entering the target measure the actual distance to the target in centimeters and enter that value 6 1 3 Other Settings Once the targets are determined review all the other settings and make any necessary changes 6 1 4 Update a Once all settings are appropriate upload the settings to the CLASS Controller Save to EEPROM and reset it 6 1 5 Test Test the door for all phases of operation See section 8 for acceptance testing or section 7 if necessary for troubleshooting MRN 03002 8 TB08 03 192 Page 30 of 34 7 Basic Operation and Troubleshooting Notes 1 2 3 All references to P1 x refer to the Vehicle Interface Harness connector to the CLASS controller mating connector J1 where x is the pin location designator See Figure 6 or Table 2 System Voltage refers to the operating voltage of the bus typically 24V Measurements are with respect to P1 24 CLASS Ground Process 1 MRN 03002 8 TB08 03 192 Make sure that the exit doors are CLOSED and the doorway is CLEAR of any people or objects Turn on CLASS usually by turning on the bus RUN switch and CLASS On Off switch Verify that the SYSTEM LED turns Red initially and then begins flashing Orange If the SYSTEM LED does not turn on Verify that the CLASS controller is receiving power System Voltage at P1 18 Pwr If power is not
22. ional used only when Bus System Voltage when bus SWPW optional power relay K3 is used is ON optional Connect to power source near components controller required 22 On Off 12 Optional used only when 12V when CLASS is to be ON12 optional power relay K3 is used ON Open otherwise optional From On Off switch connected components to 12V nominal power required 23 On Off 24 Optional used only when 24V when CLASS is to be ON24 optional power relay K3 is used ON Open otherwise optional From On Off switch connected components to 24V nominal power required 24 GND GND Return for Power GROUND Table 3 J2 Diagnostic and Programming Pin Signal Description 2 RCV Data from CLASS to Diagnostic Computer 3 XMIT Data from Diagnostic Computer to CLASS 5 GND Ground 4 PSEN Used to set controller firmware program mode See CLASS Diagnostic TB08 05 097 Figure 7 shows the location of the J3 J4 J5 and J6 connectors SENSORS MIDDLE LEFT RIGHT a EB WV T J6 Figure 7 Connectors J3 J6 MRN 03002 8 TB08 03 192 Page 16 of 34 Table 4 J6 LPS J4 RPS Pin Signal Description Power Provided by CLASS CONTROLLER SEND Controlled by CLASS CONTROLLER GND Provided by CLASS CONTROLLER ECHO Returned to CLASS CONTROLLER Shield Grounded at CLASS CONTROLLER No Connection 0l amp OO PO
23. itive trigger pulse which occurs every 20 25 milliseconds when the sensor is transmitting b If no vibration can be felt verify that the sensor is correctly plugged into the controller and in the correct location See Figure 2 9 If the LPS orange light goes ON the door should have opened If not a Verify the door is physically unlocked and capable of opening b Verify that P1 13 OPEN is connected to the bus PLC at the appropriate input usually the touchbar input and is at System Voltage referenced to Bus PLC Ground when the LPS orange light is ON 10 Repeat steps 6 9 for the RIGHT sensor and RIGHT orange light 11 Once the door is fully open repeat steps 7 9 for the MSU and MSU orange light The door must remain fully open while verifying the MSU If necessary block the door open and ensure that the fully open switch remains activated Verify System Voltage is at P1 1 DFO or GND is at P1 2 DFO 12 If the MSU orange light is not ON a In addition to the actions to step 8a and 8b verify that the Fully Open switch is activated and the Fully Closed switch is deactivated MRN 03002 8 TB08 03 192 Page 32 of 34 8 CLASS Acceptance Test 1 1 1 2 1 3 1 4 1 5 1 6 1 7 1 8 1 9 MRN 03002 8 TB08 03 192 Verify the bus is ON the CLASS Power switch is OFF and the driver s door control handle is in the Rear Door Closed position Turn on the CLASS Power switch whil
24. k Alarm function 5 IN3 DNC Door Nearly Closed From 5 Bus System Voltage when door switch or sensor connection is nearly closed open removed from bus PLC if K2 is otherwise used 6 IN3 DNC Door Nearly Closed From 5 GROUND when door is nearly switch or sensor connection closed open otherwise removed from bus PLC if K2 is used 7 IN4 ENA Enable From bus PLC when Bus System Voltage when door door is enabled authorized is enabled open otherwise 8 IN4 ENA Enable From bus PLC when GROUND when door is door is enabled authorized enabled open otherwise 9 O1 STA Status Active low signal to GROUND when active open turn on the Status LED if otherwise CLASS detects an internal malfunction 10 O2 DAO Drunk Alarm Active low GROUND when active open signal when a sensor detects a otherwise target Use in conjunction with DAI or DAI MRN 03002 8 TB08 03 192 Page 14 of 34 03 RCY Recycle Request Obstruction Recycle Request Output to bus PLC usually in parallel with sensitive edge GROUND when active open otherwise 12 O4 OPN Open Door Open Request GROUND when active open Output to bus PLC usually in otherwise parallel with touchtape touchbar 13 O5 OPN Open Door Open Request Bus System Voltage when Output to bus PLC active open otherwise 14 O6 RCY Recycle Request Obstruction Bus Sys
25. le to the sensitive edge tubing taking care to not pinch the plastic tubing Middle Sensor The middle sensor is mounted to a bracket installed using Rivnuts into the bottom of the door operator base plate Attach the sensor to the bracket using a 4 20 x 50 pan head screw washer and lock washer from the hardware kit Position the sensor centered in the opening with the attaching screw to the outboard of the bus Mark the holes of the bracket for drilling the base plate Drill the holes for installing the 14 20 Rivnuts after assuring that the door operator base plate is clear Use the installation tool to attach the 2 Rivnuts Use the 2 ea 14 20 x 75 pan head screws with lock washers and flat washers to attach the assembled sensor bracket to the base plate Use the existing wire hole or drill a 5 16 diameter hole to route the cable up to the controller mounting area Apply 2 layers of heat shrink tubing and route the cable up to the controller Control Box Mounting The Control Box is mounted to the bus structure above the door operator inside the Air Conditioning Duct via a mounting plate Locate a section on the bus structure to drill 11 64 1719 diameter holes located from the mounting holes in the mounting plate Select an area of the structure that picks up at least 3 of the 4 holes Use the 10 32 self tapping screws to mount the plate to the structure sheet metal Secure the Control Box to the plate with 10 32 nuts and washers Li
26. onic pulse burst e STATUS This signal turns on a light if the CLASS CONTROLLER malfunctions Since the PLC is often programmed to ignore the touch bars once closing doors past the 5 degree position the 5 degree signal from the door operator to the PLC may be rerouted through the CLASS CONTROLLER allowing the controller to delay the 5 degree indication to the PLC long enough to ensure that if a target is detected a re open request can be acted upon MRN 03002 8 TB08 03 192 Page 11 of 34 3 2 Theory Of Operation The CLASS state machine diagram is shown below For a complete description of CLASS operation refer to CLASS Theory of Operation TB08 05 096 _ Drunk Al CLASS States eee aie i te PLC Mode Idle is ACTIVE Panel OFF Drunk Alarm Timer2 Elapsed mo amp ENABLE is OFF OFF ENABLE is ON T Touch To Open Timer2 Active Timer2 Elapsed Panel ON i Panel Reduced Middle Reduced amp ENABLE is Middle OFF K1 OFF ON K1 OFF K2 ON K2 OFF Panel amp Middle Panel or Middle Panel is Sensed are Not ES d ot is Sense N a JP OFF oor Is Closin Panel ON Middle Reduced K1 OFF K2 ON Door Is Opening Panel ON Middle OFF K1 ON K2 OFF Panel or Middle is Sensed A 85 is Panel or 85 is OFF Middle ON is Sensed Wait for Close Panel or Panel ON Middle t _ _ gt Door Full
27. s open otherwise If a proximity sensor is used make sure that it is a PNP sensor If an NPN sensor is used or the switch connects to GND when the door is fully open use IN3 DNC instead Note that not all buses have a 5 switch or sensor For these buses a 5 switch is a required installation item 2 1 4 IN4 ENA this input must be high when the door is unlocked and or enabled to be opened When this input goes high CLASS turns on its panel sensors and begins looking for targets It is usually supplied from the positive side of the Green Light If a low going signal is all that is available use IN4 ENA instead 3 OUTPUTS CLASS has both low going and high going outputs depending on function Both output types are open when not active 3 1 O1 STA this must be connected to the status light If a spare wire is available it may be used if not wires are added The other side of the status light is connected to bus voltage 12V or 24V 3 2 O2 DAO this signal will be low when any sensor detects a valid target in Drunk Alarm mode It is for use by the bus PLC with IN2 3 3 O3 RCY this signal will be low when CLASS is requesting the PLC to re open the door similar to a sensitive edge This output is used when the bus PLC logic does not respond to a touchtape input while the door is closing See O6 for the active high version of this signal 3 4 O4 OPN this signal will be low when CLA
28. s should be the same distance from the floor for the installation of the sensors to several busses The sensor is held to the bracket by a 20 x 50 flathead screw Lead the sensor cable out correct side of the sensor case toward the bracket mounting holes A 5 16 hole must be drilled through the roller bracket to route the sensor cables along with the sensitive edge tubing to where the controller will be mounted above the door operator The sensor mounting brackets are attached to the door by 14 20 RIVNUTS installed in the aluminum door extrusion The brackets have counter bored slots for side to side adjustment and to clear the flange of the RIVNUTS Mark the location centered in the slot width for drilling the two holes in the extrusion when the bracket is held in the correct vertical position The 14 20 RIVNUTS are included in the sensor hardware kit with the brackets Drill a 332 338 diameter hole use an 8 5mm 3346 or a Q 3320 letter drill for installation Use a B F Goodrich wrench type header tool number C 845 2520 to set the RIVNUT available from Liberty Engineering in Chatsworth California phone 818 786 8111 Attach the assembled sensor and bracket to each door using 2 ea 14 20 x 750 pan head screws washers and lock washers Apply 2 layers of heat shrink tubing 2 38 long tight to the sensor Route the cable through the hole into the roller bracket and up to the controller area Loosely tie nylon wire tie the cab
29. sses the 5 point Verify that the door reopens Note that the Green light above the rear door must still be ON Note This step is optional and not used if K2 functionality is not installed typically K2 functionality is not used with A O S C doors Repeat step 1 7 but with the driver s door control handle in the Rear Door Closed position and making sure to place the hand under the sensor within less than 1 second of the door passing the 5 point Verify that the door reopens Page 33 of 34 1 10 Repeat step 1 9 but make sure to place the hand under the sensor more than 1 second after the door passes the 5 point Verify that the door does NOT reopen and the SEND light on the CLASS controller housing is OFF Note steps 1 8 1 10 assume that Timer 2 is set to 1 second adjust accordingly otherwise 9 Specifications 9 1 Voltage and Current Summary of Requirements and Specifications A Power Vehicle supplied 12V or 24V Nominal requirements applied as follows 1 Minimum Operating Voltage 9VDC 2 Nominal Operating Voltage 12VDC or 24VDC 3 Maximum Operating Voltage 30VDC 4 Total System Power Consumption 15W max B K1 and K2 Dry contacts capable of driving up to 1 Amp load C O1 O4 Solid state low side output drivers capable of sinking 500 mA to a load connected to vehicle power D O5 O6 Solid state high side output drivers capable of sourcing 500 mA to a load connected to the
30. tem Voltage when Recycle Request Output to active open otherwise bus PLC usually in parallel with sensitive edge 15 K2 C K2C 5 degree Override In 5 Same as active contact of 5 signal from source originally degree switch sensor connected to bus PLC 16 K2 N C 5 Override Out 5 signal to Connected to K2 C when door K2NC PLC rerouted through is allowed to be de authorized CLASS open otherwise 17 TARGET Target Provides an active low GROUND when active open TGT signal sufficient to drive a low otherwise current indicator light Active while any target is detected 18 POWER Power Connect to power Bus System Voltage when bus PWR source near controller via is ON On Off switch when optional power relay K3 is not used 19 K1 C K1C Open Used when a normally Bus System Voltage or closed Open Request signal is GROUND as required required Usually connected to local power but can be connected to Ground if required by bus PLC 20 K1 OUT Open Used when a normally If N C Open when door open K1 O closed Open Request signal is request is active connected to required Output to bus PLC Polarity determined by K1 C internally configurable as N C default or as N O K1 C otherwise If N O Connected to K1 C when door open request is active Open otherwise MRN 03002 8 TB08 03 192 Page 15 of 34 21 Local 12 24 Opt
31. tional connect to PLC per Bus Not Used RCY High OPEN when Builder instruction door re open request is INACTIVE Low GND when door open request is ACTIVE Active low door open request ON te High OPEN when Nor Uged connect appropriately door open request is INACTIVE Page 27 of 34 SIGNAL DESCRIPTION STD Bus STANDARD NON STANDARD High Bus system voltage when door open request is eee O5 OPN 13 ACTIVE Relive tread bean Not Used Low OPEN when connect at Bus touchtape input door open request is INACTIVE High Bus system cae Hier Connect to sensitive edge O6 14 CNE q N input when bus logic does not ot Used RCY Low OPEN when respond to touchtape while door re open request doo is eloeing is INACTIVE ee atte For non PLC Bus custom Optional AVE Connect to Touchtape input to Bus connection must be KG 20 OPEN when do r LC determined for each ober rediestis application Discuss with ACHE Vapor Engineering TM ier ee Disconnect wire from N O Contact of INACTIVE 2e Closed GWEN or ProT DUS Not Used Typically not used K2NC 16 CLOSED to K2 C for AOSC doors due to when CLASS Fully conned Be e WIG mechanical lock Closed is ACTIVE Pe PES ee Connect to low current 15 TGT 17 High OPEN when no Not Used ma Typ indicator connected tar t is detected to Bus system voltage Note Signals labeled as Optional require the use of optional components
32. tup Basic Operation and Troubleshooting Acceptance O ON OV B NMS Specifications Referenced Documents CLASS Theory Of Operation TB08 05 096 CLASS Diagnostic Software TB08 05 097 CLASS Specifications and I O TB08 04 019 MRN 03002 8 TB08 03 192 Page 3 of 34 1 Definitions AUTHORIZE Authorizing the door is done by the Controlling PLC activating the Enable input on CLASS BIT Built in Tests Self Tests that CLASS runs on power up CLASS Contact Less Acoustic Sensing System DEAD ZONE Any region in which an object is not detectable and therefore cannot become a Target There are typically four regions in which dead zones occur i Within a short distance from the face of the sensor typically 10 12 inches ii Within a tolerance band around any existing Target iii Outside the sensing range of the sensor iv Regions ignored under program control example see MSU Limit DE AUTHORIZE De authorizing the door is done by the Controlling PLC releasing the CLASS Enable input DFO Door Fully Open normally an 85 switch or proximity sensor DOU Door Operator Unit the device that opens the door DNC Door Nearly Closed normally a 5 switch or proximity sensor DOR Door Open Request CLASS output to bus PLC LPS RPS MSU Left Panel Sensor Right Panel Sensor Middle Sensor Unit Center Sensor PLC The onboard bus computer that issues commands to CLASS TARGET An object d
33. ve low signal Notes All signal names below are as used on the CLASS interface harness and are in bold Non standard connections are in brackets 2 INPUTS 2 1 Input Signals For the standard CLASS installation inputs may be high going or low going when active The appropriate input must be used for each case 2 1 1 IN1 DFO this input must be high when the door is fully open and low or open otherwise This signal is usually provided by a switch or proximity sensor on the baseplate If a switch is used make sure it closes to system high voltage when the door is fully open and is open otherwise If a proximity sensor is used make sure that it is a PNP sensor If an NPN sensor is used or the switch connects to GND when the door is fully open use IN1 DFO instead 2 1 2 IN2 DAI If IN2 becomes high when the door is not in operation the sensor s will be turned on for use as a drunk alarm This input is used together with OUT2 which will provide target detection status for the MRN 03002 8 TB08 03 192 Page 22 of 34 drunk alarm and is intended for use by the bus PLC If a low going command is preferred use IN2 DAI instead 2 1 3 IN3 DNC this input must be high when the door is fully closed and low or open otherwise This signal is usually provided by a switch or proximity sensor on the baseplate If a switch is used make sure it closes to a system high voltage when the door is fully closed and i
34. vehicle power return E Tgt Solid state low side output driver capable of sinking 15 mA to a load connected to vehicle power 9 2 Full Specifications For complete specifications see CLASS Specifications amp IO TBO8 04 019 MRN 03002 8 TB08 03 192 Page 34 of 34
35. y Open Middle ON KIZOFF is Sensed PEN R nels K2 ON Panel or wee Middle ON Middle K1 ON is Sensed BesOFF Timer1 Elapsed Timer1 Active A Panel ON Panel amp Middle Middle ON are Not K1 ON lt ____ Sensed K2 OFF MRN 03002 8 TB08 03 192 Middle OFF input K1 OFF a K2 OFF is INACTIVE Drunk Alarm Panel OFF Middle ON K1 OFF K2 OFF ENABLE is ON 5 is ON amp Time gt 2 Sec Remarks 1 The K1 Door Open Request Relay is energized as long as an object is detected K1 will de energize after no object is detected for Timer 4 seconds or when Timer1 elapses Note when K1 is active Outputs 4 and 5 are active If the door is RE opening Outputs 3 and 6 are also active 2 The K2 5 Relay is energized when Timer1 elapses and is released only after Timer2 elapses 3 In Touch To Open state the panel sensors scan only up to 110cm from the sensor 4 In Door Is Closing state the middle sensor scans only up to a programmable distance from the sensor 5 The activation of sensors may be different if the Snow Mode is in use 6 Each sensor has a 12 approx dead zone at its surface Page 12 of 34 3 3 Diagnostic Software For a complete description of CLASS diagnostic software refer to CLASS Diagnostic TB08 05 097 4 CLASS CONTROLLER 4 1 CLASS CONTROLLER LEDs The CLASS CONTROLLER LEDs are located on the top of the controller housing
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