Crescent SC500 Service Manual

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Service Manual

SC500

www.crescentindustrial.co.uk

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Contents

03 - General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Machine General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Service Manual Purpose and Field of Application . . . . . . . . . . . . . . . . . . . . . 6

Other Reference Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Name Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Lifting The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Transporting The Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Technical Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Know Your Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Service and Diagnostic Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20

Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Contents iiService Manual – SC500

Visible Symbols on the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Symbols. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Control panel Disc deck (Prod. Nr.: 9087352020, 9087354020, 9087350020, 9087351020)

Control panel REV deck (Prod. Nr.: 9087353020, 9087355020) . . . . . . . . . . . .16

Control panel Disc deck (Prod. Nr.: 9087403020, 9087404020, 9087400020,9087401020)

Control panel REV deck (Prod. Nr.: 9087405020, 9087402020) . . . . . . . . . . . .17

SC500 Disc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

SC500 REV. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22

04 - Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Product Nr.: 9087352020, 9087354020, 9087350020, 9087351020, 9087353020, 9087355020 23

Functional Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .23

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .25

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .26

Main machine controller (EB1) Alarm Codes. . . . . . . . . . . . . . . . . . . . . .26

Black-box: Recording of Alarms, Parameters (see pages 34-35), Partial Operating Time

Counter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Display, Main Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Display, Alarms Log Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .32

Display, Machine Settings Screen . . . . . . . . . . . . . . . . . . . . . . . . . . .33

Display, Operating Time Counter Screen. . . . . . . . . . . . . . . . . . . . . . . .35

System for Flow Rate Regulation as Function of Speed . . . . . . . . . . . . . . . . 36

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Main machine controller (EB1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Display Controller (EB2) and User interface controller (EB3) . . . . . . . . . . . . 39

Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

Main machine controller (EB1) Connectors . . . . . . . . . . . . . . . . . . . . . .41

Connectors of the Display Controller (EB2) . . . . . . . . . . . . . . . . . . . . . . 47

Shop Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .49

Shop Measurements - Main machine controller (EB1) . . . . . . . . . . . . . . . . 49

Shop Measurements - Display Controller (EB2) . . . . . . . . . . . . . . . . . . . .56

Page 3

05 - Control System, Magnetic Smart Key . . . . . . . . . . . . . . . . . . . . . . . . 60

Product Nr.: 9087403020, 9087404020, 9087400020,9087401020, 9087405020, 9087402020 60

Functional Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .63

Main machine controller (EB1) Alarm Codes. . . . . . . . . . . . . . . . . . . . . .63

Black-box: Recording of Alarms, Parameters (see pages 71-72), Partial Operating Time

Counter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .68

Display, Main Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Display, Alarms Log Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .69

Display, Machine Settings Screen . . . . . . . . . . . . . . . . . . . . . . . . . . .70

Display, Operating Time Counter Screen. . . . . . . . . . . . . . . . . . . . . . . .73

Display, Magnetic Smart Keys Management Screen. . . . . . . . . . . . . . . . . .74

System for Flow Rate Regulation as Function of Speed . . . . . . . . . . . . . . . . 75

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .76

Main machine controller (EB1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Display Controller (EB2), User interface controller (EB3) and Smart Key Reader (IB) 78

Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .80

Main machine controller (EB1) Connectors . . . . . . . . . . . . . . . . . . . . . .80

Connectors of the Display Controller (EB2) . . . . . . . . . . . . . . . . . . . . . . 86

Shop Measurements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .89

Shop Measurements - Main machine controller (EB1) . . . . . . . . . . . . . . . . 89

Shop Measurements - Display Controller (EB2) . . . . . . . . . . . . . . . . . . . .96

Contents iiiService Manual – SC500

10 - Chassis System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Chassis (main parts) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

20 - Wheel System, Traction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .101

Functional Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Drive System Gear Motor Current Draw Test . . . . . . . . . . . . . . . . . . . . 106

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Speed Potentiometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

24 - Electrical System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109

Functional Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Battery Charger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Battery Charge State Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112

Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Setting the Installed Battery Type . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Battery installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Battery Charging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Checking/Replacing Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

General Wiring Diagram (Product Nr.: 9087352020, 9087354020, 9087350020, 9087351020,

9087353020, 9087355020) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

General Wiring Diagram (Product Nr.: 9087403020, 9087404020, 9087400020,9087401020,

9087405020, 9087402020) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Page 4

30 - Solution System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Functional Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Water Level Sensor Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127

Cleaning the Detergent Solution Tank and Filter . . . . . . . . . . . . . . . . . . 127

Cleaning the EcoFlex Detergent Tank . . . . . . . . . . . . . . . . . . . . . . . . 128

Draining the EcoFlex System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Solenoid Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

Detergent Pump (Piston Pump) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Detergent Pump (Peristaltic Pump) . . . . . . . . . . . . . . . . . . . . . . . . . 134

Checking the Water Level Sensor Operation . . . . . . . . . . . . . . . . . . . . . 135

Water Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

34 - Scrub System, Disc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .138

Functional Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

Brush Release System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

Brush Deck Actuator System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

Brush Installation/Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .143

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

Brush Motor Current Draw Test . . . . . . . . . . . . . . . . . . . . . . . . . . . 145

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

Brush Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146

Checking/Replacing Brush Motor Carbon Brushes . . . . . . . . . . . . . . . . . 149

Brush Motor Disassembly/Assembly . . . . . . . . . . . . . . . . . . . . . . . . . 150

Brush Deck Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Contents ivService Manual – SC500

34 - Scrub System, REV . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

Functional Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Brush Deck Actuator System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

Brush Installation/Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .157

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

REV Motor Current Draw Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

REV Deck . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

Checking/Replacing REV Motor Carbon Brushes . . . . . . . . . . . . . . . . . . 162

Brush Deck Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165

Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166

Page 5

38 - Squeegee System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .167

Functional Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

Squeegee cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

Checking/Replacing the Squeegee Blades . . . . . . . . . . . . . . . . . . . . . . 170

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

Gas Spring on the Squeegee Support . . . . . . . . . . . . . . . . . . . . . . . . . 172

Spring on the Squeegee Support . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

40 - Recovery System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .175

Functional Description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

Maintenance and Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

Recovery Tank Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179

Vacuum Motor Current Draw Test . . . . . . . . . . . . . . . . . . . . . . . . . . 180

Removal and Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

Vacuum Motor Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

Container and Vacuum Motor Disassembly/Assembly. . . . . . . . . . . . . . . . 182

Specications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

Contents vService Manual – SC500

90 - Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

Page 6

03 - General Information

Machine General Description

The SC500 is a “walk-behind” industrial machine designed to wash and dry oors in one pass. The machine

is powered by on-board batteries, models can be equipped with EcoFlex system. The machine features

variable oor pressure disc brush or REV system, controlled detergent solution dosing and a rear squeegee with rubber blades that vacuums and dries the oor.

Service Manual Purpose and Field of Application

The Service Manual is a technical resource intended to help service technicians when carrying out maintenance and repairs on the SC500, to guarantee the best cleaning performance and a long working life for the machine.

Please read this manual carefully before performing any maintenance and repair procedure on the machine.

6Service Manual – SC500

Other Reference Manuals

Model Product Nr. Instructions for use Spare Parts List

Advance SC500 X20 B 9087352020

Advance SC500 X20R B 9087353020

Advance SC500 20D B 9087354020

Advance SC500 X20 B V 9087403020

Advance SC500 X20R B V 9087405020

Advance SC500 20D B V 9087404020

Nilsk SC500 53 B FULL PKG 9087350020

Nilsk SC500 53 B 9087351020

Nilsk SC500 53R B 9087355020

Nilsk SC500 53 B FULL PKG V 9087400020

Nilsk SC500 53 B V 9087401020

Nilsk SC500 53R B V 9087402020

Assembly Instructions Instruction Code Machines concerned

EcoFlex Kit 9100000923 SC500 Nilsk

Battery charger kit 9100000924 SC500 Nilsk

Vacuum system motor kit 9100000753 All SC500

TrackClean 9100000057 All SC500

9099980000 9099981000

9099974000 9099975000

These manuals are available at:

• Local Advance or Nilsk retailer

• Advance website: www.advance-us.com

• Nilsk website: www.nilsk.com

• EZ-Data application

Page 7

Conventions

Forward, backward, front, rear, left or right are intended with reference to the operator’s position, that is to say in driving position.

Name Plate

Reference to Figure 1

The machine serial number and model name are marked on the plate (see the example to the side).

Product code and year of production (Date code: A17, as January 2017) are marked on the same plate.

7Service Manual – SC500 03 - General Information

Model: Scrubber-Dryer SC500 20 B

Prod. Nr: 9087352020

GVW: 207 kg/456 lb 21 A Charg.100-240Vac 50-60 Hz

Type E Scrubber Dryer

UL 583

CSA C22.2 N.68-92

Figure 1:

IPX4

A Nilfisk-Advance Brand

3084826

Serial No: ..................

Date code: .......

LpA = 63 dB(A)

Battery 24 Vdc

“Made in Hungary” Nilfisk-Advance, Inc. Plymouth, MN, USA www.advance-us.com

Page 8

Safety

max.2%

The following symbols indicate potentially dangerous situations. Always read this information carefully and take all necessary precautions to safeguard people and property.

Visible Symbols on the Machine

WARNING: Carefully read all the instructions before performing any operation on the

machine.

WARNING: Do not wash the machine with direct or pressurized water jets.

WARNING: Do not use the machine on slopes with a gradient exceeding the

specications.

8Service Manual – SC500 03 - General Information

Symbols

The following symbols are used to help you recognize the information concerning the safety and the prevention of problems.

DANGER: Indicates a potentially hazardous situation which, if not avoided, will result in death or

serious injury.

WARNING: Indicates a potentially hazardous situation which, if not avoided, could result in death

or serious injury.

CAUTION: Indicates a potentially hazardous situation which, if not avoided, could result in minor

or moderate injury.

Note: Indicates an important informational message.

Page 9

General Safety Instructions

Specic warnings and cautions to inform about potential damages to people and machine are shown below.

DANGER: Before performing any maintenance, repair, cleaning or replacement procedure,

remove the ignition key and disconnect the battery connector).

− This machine must be used by properly trained operators only.

− Do not wear jewels when working near electrical components.

− Do not work under the lifted machine without supporting it with safety stands.

− Do not operate the machine near toxic, dangerous, ammable and/or explosive

powders, liquids or vapors: This machine is not suitable for collecting dangerous powders.

− When using lead (WET) batteries, keep sparks, ames and smoking materials away

from the batteries. During the normal operation explosive gases are released.

− When using lead (WET) batteries, battery charging produces highly explosive

hydrogen gas. During battery charging, lift the recovery tank and perform this

procedure in well-ventilated areas and away from naked ames.

9Service Manual – SC500 03 - General Information

CAUTION: Carefully read all the instructions before performing any maintenance/repair procedure.

− The machine ignition key has a built-in magnet. Do not place objects having magnetic

bands (such as credit cards, electronic keys, phone cards) near the key. The built-in magnet can damage or erase the data stored on the magnetic bands.

− Before using the battery charger, ensure that frequency and voltage values, indicated

on the machine serial number plate, match the electrical mains voltage.

− Do not pull or carry the machine by the battery charger cable and never use the battery

charger cable as a handle. Do not close a door on the battery charger cable, or pull the battery charger cable around sharp edges or corners. Do not run the machine on the battery charger cable.

− Keep the battery charger cable away from heated surfaces.

− Do not charge the batteries if the battery charger cable or the plug are damaged.

− To reduce the risk of re, electric shock, or injury, do not leave the machine

unattended when it is plugged in. Before performing any maintenance procedure, disconnect the battery charger cable from the electrical mains.

− Do not smoke while charging the batteries.

− To avoid any unauthorized use of the machine, remove the ignition key.

− Do not leave the machine unattended without being sure that it cannot move

independently.

− Always protect the machine against the sun, rain and bad weather, both under

operation and inactivity condition. Store the machine indoors, in a dry place: This machine must be used in dry conditions, it must not be used or kept outdoors in wet conditions.

− Before using the machine, close all doors and/or covers as shown in the User Manual.

Page 10

− This machine is not intended for use by persons (including children) with reduced

physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision or instruction concerning use of the machine by a person responsible for they safety.

− Children should be supervised to ensure that they do not play with the machine.

− Close attention is necessary when used near children. Use only as shown in this

Manual. Use only Nilsk or Advance recommended accessories.

− Check the machine carefully before each use, always check that all the components

have been properly assembled before use. If the machine is not perfectly assembled it can cause damages to people and properties.

− Take all necessary precautions to prevent hair, jewels and loose clothes from being

caught by the machine moving parts.

− Do not use the machine on incline.

− Do not tilt the machine more than the angle indicated on the machine itself, in order to

prevent instability.

− Do not use the machine in particularly dusty areas.

10Service Manual – SC500 03 - General Information

− Use the machine only where a proper lighting is provided.

− While using this machine, take care not to cause damage to people or objects.

− Do not bump into shelves or scaffoldings, especially where there is a risk of falling

objects.

− Do not lean liquid containers on the machine, use the relevant can holder.

− The machine operating temperature must be between 32°F and 104°F (0°C and +40°C).

− The machine storage temperature must be between 32°F and 104°F (0°C and +40°C).

− The humidity must be between 30% and 95%.

− When using oor cleaning detergents, follow the instructions on the labels of the

detergent bottles.

− To handle oor cleaning detergents, wear suitable gloves and protections.

− Do not use the machine as a means of transport.

− Do not allow the brush/pad to operate while the machine is stationary to avoid

damaging the oor.

− In case of re, use a powder re extinguisher, not a water one.

− Do not tamper with the machine safety guards and follow the ordinary maintenance

instructions scrupulously.

− Do not allow any object to enter into the openings. Do not use the machine if the

openings are clogged. Always keep the openings free from dust, hairs and any other

foreign material which could reduce the air ow.

− Do not remove or modify the plates afxed to the machine.

− When the machine is to be pushed for service reasons (missing or discharged

batteries, etc.), the speed must not exceed 2.5 mi/h (4 km/h).

Page 11

− This machine cannot be used on roads or public streets.

− Pay attention during machine transportation when temperature is below freezing point.

The water in the recovery tank or in the hoses could freeze and seriously damage the machine.

− Use brushes and pads supplied with the machine or those specied in the User

Manual. Using other brushes or pads could reduce safety.

− In case of machine malfunctions, ensure that these are not due to lack of maintenance.

If necessary, request assistance from the authorised personnel or from an authorised Service Center.

− If parts must be replaced, require ORIGINAL spare parts from an Authorised Dealer or

Retailer.

− To ensure machine proper and safe operation, the scheduled maintenance shown in

the relevant chapter of this Manual, must be performed by the authorised personnel or by an authorised Service Center.

− Do not wash the machine with direct or pressurised water jets, or with corrosive

substances.

11Service Manual – SC500 03 - General Information

− The machine must be disposed of properly, because of the presence of toxic-harmful

materials (batteries, etc.), which are subject to standards that require disposal in special centres.

Page 12

Lifting The Machine

WARNING: Do not work under the lifted machine without supporting it with safety stands.

Transporting The Machine

WARNING: Before transporting the machine, make sure that:

− All covers are closed.

− The recovery tank and the detergent tank are empty.

− The batteries are disconnected.

− The ignition key is removed.

− The machine is securely fastened to the means of transport.

12Service Manual – SC500 03 - General Information

Page 13

Technical Specications

13Service Manual – SC500 03 - General Information

Description / Model

SC500

DISC REV

Solution tank capacity 12 US gal (45 liters)

Recovery tank capacity 12 US gal (45 liters)

Machine length 50.3 in (1277 mm) 51.2 in (1302 mm)

Machine width with squeegee 28.3 in (720 mm)

Machine width without squeegee 21 in (532 mm) 21.2 in (538 mm)

Machine height 41.8 in (1063 mm)

Cleaning width 20 in (530 mm)

Driving wheel diameter 7.8 in (200 mm)

Driving wheel specic pressure on the oor (*) 101 psi (0.7 N/mm

)

Rear wheel diameter 3.1 in (80 mm)

Rear wheel specic pressure on the oor (*) 304 psi (2.1 N/mm

)

Brush/pad diameter 20 in (530/508 mm)

Brush pressure with extra-pressure function turned off 33 lb (15 kg) 49 lb (22 kg)

Brush pressure with extra-pressure function turned on 66 lb (30 kg) 66 lb (30 kg)

0.75 cl/m / 1.5 cl/m

0.38 cl/m / 0.75 cl/m

Solution ow values

3.0 cl/m / 2.8 l/min

1.5 cl/m / 2.8 l/min

EcoFlex system detergent percentage Ratio 1:400 ÷ 1:33 (0.25% ÷ 3%)

Sound pressure level at workstation (ISO 11201, ISO 4871, EN 60335-2-72) (LpA)

63 ± 3 dB(A) 65 ± 3 dB(A)

Sound pressure level at workstation in silent mode (LpA) 60 ± 3 dB(A) 61 ± 3 dB(A)

Machine sound power level (ISO 3744, ISO 4871, EN 60335-2-72) (LwA)

Vibration level at the operator’s arms (ISO 5349-1, EN 60335-2-72)

81 dB(A) 83 dB(A)

< 98.4 in/s

(< 2.5 m/s2)

Maximum gradient when working 2%

Drive system motor power 0.27 hp (200 W)

Drive speed (variable) 0 - 3.1 mi/h (0 - 5 km/h)

Vacuum system motor power 0.37 hp (280 W)

Vacuum system circuit capacity 29.9 in H

O (760 mm H2O)

Brush motor power 0.6 hp (450 W) 0.9 HP (670 W)

Brush rotation speed 155 rpm -

Total power draw (EN 60335-2-72) 0.7 hp (500 W)

IP protection class X4

Protection class (electric) III (I for the battery charger)

Page 14

14Service Manual – SC500 03 - General Information

Description / Model

SC500

DISC REV

Battery compartment size 13.7x13.7x10.2 in (350x350x260 mm)

System voltage 24V

Standard batteries (2) 12V 105 AhC5

Battery charger 24V 13A

Operating time (standard batteries) (EN 60335-2-72) 3.5 hour

Weight without batteries and with empty tanks 187 lb (85 kg) 194 lb (88 kg)

Gross vehicle weight (GVW) 456 lb (207 kg) 463 lb (210 kg)

Shipping weight 256 lb (116 kg) 262 lb (119 kg)

(*) Machines have been tested under the following conditions:

◦ Battery maximum size

◦ Maximum brush and squeegee size

◦ Full detergent tank

◦ Optional equipment installed

◦ Wheel weight checked

◦ Print on the oor checked on cement for each single wheel

◦ Result expressed as maximum value for both front and rear wheels

Page 15

Maintenance Schedule

15Service Manual – SC500 03 - General Information

Procedure

Battery charging

Squeegee cleaning

Brush/pad cleaning

Recovery tank and debris tray cleaning, and cover gasket check

EcoFlex system cleaning and draining

Squeegee blade check

Solution Filter Cleaning

Battery (WET) uid level check

Squeegee blade replacement

Brush motor carbon brush check or replacement

Drive system motor carbon brush check or replacement

Brush deck vibration-damper replacement (only for REV version)

Daily, after use

Weekly/

Monthly

Every 6 Months

Annually

Page 16

Know Your Machine

Control panel Disc deck (Prod. Nr.: 9087352020, 9087354020, 9087350020, 9087351020)

Display

16Service Manual – SC500 03 - General Information

EcoFlex system push-

button

Vacuum system

adjustment/deactivation

push-button

Detergent ow adjustment

push-button

Detergent percentage

adjustment push-button

Machine start/stop push-

button

max.2%

Figure 2:

Control panel REV deck (Prod. Nr.: 9087353020, 9087355020)

One-Touch Scrub ON/OFF

push-button

Brush release push-button

Machine speed adjustment

push-buttons

Machine ignition key

Operator key (grey)

Super user key (yellow)

EcoFlex system push-

button

Vacuum system

adjustment/deactivation

push-button

Detergent ow adjustment

push-button

Detergent percentage

adjustment push-button

Machine start/stop push-

button

Figure 3:

Display

max.2%

One-Touch Scrub ON/OFF

push-button

REV function push-button

Machine speed adjustment

push-buttons

Machine ignition key

Operator key (grey)

Super user key (yellow)

Page 17

Control panel Disc deck (Prod. Nr.: 9087403020, 9087404020, 9087400020,9087401020)

max.2%

Display

17Service Manual – SC500 03 - General Information

EcoFlex system push-

button

Vacuum system

adjustment/deactivation

push-button

Detergent ow adjustment

push-button

Detergent percentage

adjustment push-button

Machine start/stop push-

button

Figure 4:

Control panel REV deck (Prod. Nr.: 9087405020, 9087402020)

One-Touch Scrub ON/OFF

push-button

Brush release push-button

Machine speed adjustment

push-buttons

Smart key reader

Magnetic smart key

Blue = User

Yellow = Supevisor

EcoFlex system push-

button

Vacuum system

adjustment/deactivation

push-button

Detergent ow adjustment

push-button

Detergent percentage

adjustment push-button

Machine start/stop push-

button

Figure 5:

Display

One-Touch Scrub ON/OFF

push-button

REV function push-button

Machine speed adjustment

push-buttons

Smart key reader

Magnetic smart key

Blue = User

Yellow = Supevisor

Page 18

18Service Manual – SC500 03 - General Information

Can holder

Recovery tank

cover

Battery charger

Tank lifting

handle

Solution drain

and level check

hose

Serial number

plate/technical

data/conformity

certication

Solution lter

Solution tap

Drive handlebar

Forward/reverse

gear and activation

paddle

Control panel

Battery charger

cable

Battery charger

cable housing and

document holder

Recovery water

drain hose

Battery connector

(red)

Squeegee vacuum

hose

Squeegee lifting/

lowering pedal

Rear pivoting wheels

Figure 6:

Squeegee adjusting

knob

Squeegee mounting

handwheels

Page 19

19Service Manual – SC500 03 - General Information

Debris

collection tank

Detergent

solution tank

side ller cap

Vacuum grid

with automatic

shut-off oat

Solution tank

Recovery tank

Batteries

Recovery tank

cover

Vacuum system

motor

Detergent

solution tank

front ller

Water

removable ller

hose

EcoFlex

detergent tank

Squeegee

Front driving

wheels

Figure 7:

Machine

straight forward

movement

adjusting knob

Disc brush deck

Brush

REV deck

REV brush

Page 20

Service and Diagnostic Equipment

Besides a complete set of standard meters, the following instruments are necessary to perform fast checks

and repairs on Nilsk machines:

• Laptop computer charged with the current version of EzParts, Adobe Reader and (if possible) Internet connection

• Digital Volt Meter (DVM)

• Amp clamp with possibility of making DC measurements

• Hydrometer

• Battery charge tester to check 12V batteries

• Static control wrist strap

• Dynamometric wrench set

• A copy of the Instructions for Use Manual and Spare Parts List of the machine to be serviced (provided

with the machine or available at www.advance-us.com or other Nilsk websites).

The following equipment is also available at Nilsk or Advance Centers:

20Service Manual – SC500 03 - General Information

• Vacuum water lift gauge, P/N 56205281

Figure 8:

Page 21

Dimensions

SC500 Disc

21Service Manual – SC500 03 - General Information

41.8 in (1063 mm)

28.3 in (720 mm)

50.3 in (1277 mm)

21 in (532 mm)

Figure 9:

Page 22

SC500 REV

41.8 in (1063 mm)

22Service Manual – SC500 03 - General Information

Figure 10:

28.3 in (720 mm)

51.2 in (1302 mm)

21.2 in (538 mm)

Page 23

04 - Control System

Product Nr.: 9087352020, 9087354020, 9087350020, 9087351020, 9087353020, 9087355020

Functional Description

23Service Manual – SC500

The architecture of the electronic control system for the machine’s electrical components is composed of a Main machine controller (EB1) and a Display controller (EB2), in turn connected to a User interface controller (EB3) which represents the main user interface.

The Main machine controller (EB1) manages all components and drives the following components directly:

• Drive system motor (M3)

• Vacuum system motor (M2)

• Deck actuator (M5)

• Brush motor (M6)

• Solution ow solenoid valve (EV1)

• Detergent pump (M4)

The Display controller (EB2) serves mainly as an aggregator for all input signals (buttons) and outputs (LEDs) from the User interface controller (EB3),

which it is connected to via 2 at cables.

Mounted on the Display controller (EB2) is also the LCD display and the 2 sensors which detect the presence and type of magnetic key inserted in the Main machine controller.

The Display controller (EB2) sends all the input and output signals of these components to the Main machine controller (EB1) using 2-wire 2-way serial communications protocol.

The system is completed by the on-board battery charger which also uses a proprietary serial protocol to communicate with the Main machine controller (EB1), in order to display its operating status (charging phase) to the operator on the LCD display.

Main machine

controller (EB1)

User interface controller

(EB3)

Flat calbes from

(EB2) to (EB3)

Display controller (EB2)

Page 24

Wiring Diagram

DISPLAY CONTROLLER (EB2)

BATT +

Power supply +

B+

24Service Manual – SC500 04 - Control System

USER INTERFACE CONTROLLER (EB3)

Figure 1:

User interface controller power supply +

User interface controller serial +

Microprocessor

FCI DUFLEX (2.54 pitch) 8-way, male pins

FCI DUFLEX (2.54 pitch) 9-way, male pins

User interface controller serial -

User interface controller power supply -

Return from key

J1.1

J1.2

J1.3

J1.4

J1.5

BATT -

J3.1

User interface contr. power supply +

J3.2

User interface contr. serial +

J3.3

User interface contr. serial -

J3.4

User interface contr. power supply -

J3.5

Return from key

MAIN MACHINE CONTROLLER (EB1)

SIGNAL CIRCUITS FUSE (F2)

Power supply -

B-

Microprocessor

Page 25

Component Locations

25Service Manual – SC500 04 - Control System

Main machine

controller (EB1)

Figure 2:

Display controller (EB2)

Flat calbes from

(EB2) to (EB3)

User interface

controller (EB3)

Figure 3:

Page 26

Troubleshooting

Main machine controller (EB1) Alarm Codes

The Main machine controller indicates a series of alarms in case of malfunction of one or more systems, and in case of abnormal conditions detected in the input signals.

The alarms are shown on the display in the following format: ALARM <XX> <DESCRIPTION> (Figure 4).

26Service Manual – SC500 04 - Control System

Figure 4:

In case the display is malfunctioning, the alarms are also repeated by the yellow and red diagnostic LEDs (Figure 5) on the Main machine controller (EB1), as indicated in the following tables.

Figure 5:

General alarms

Alarm on Main machine controller - FLASHING YELLOW + RED LEDS

Alarm code

--------------------------

Description

-----------------------

EEPROM ERROR

No.

Flashes

Meaning Condition Effect

2 EEPROM error EEPROM error Function block

+ Default setting reset

Service Suggestions

If the machine continues to function after G2 has been displayed, this may have been caused by a significant external electromagnetic disturbance.

1. Check that the settings and parameters (see pages 34 - 35) are correct (they may have returned to their defaults). If the error persists, the Main machine controller must be replaced.

Page 27

General alarms

Alarm on Main machine controller - FLASHING YELLOW + RED LEDS

Alarm code

--------------------------

Description

-----------------------

MAIN FUSE FAILURE

No.

Flashes

Meaning Condition Effect

3 Blown F1 fuse. Blown F1 fuse. Function block.

Broken battery.

27Service Manual – SC500 04 - Control System

Service Suggestions

F1 is a safety fuse primarily included to prevent a short circuit or serious damage to the Main machine controller causing currents such as to melt cables and/or cause smoke or fire. If F1 has blown, this is usually indicative of serious damage to the Main machine controller.

1. Removing the cover should allow you to understand the extent of the damage, but the solution in any case should be to replace the Main machine controller.

2. Try replacing fuse F1 only if there is no clear damage to the Main machine controller and wiring.

3. Ensure you tighten the fuse contacts correctly.

It could happen also if a battery is broken:

-----------------------

BATTERY LOW VOLTAGE

-----------------------

BATTERY OVERVOLTAGE

-----------------------

HARDWARE FAILURE

-----------------------

HARDWARE FAILURE

4 Undervoltage. The battery voltage

5 Excessive battery

voltage.

6 Serial

communication error with the User interface controller.

7 General relay

fault.

remains below 18.4V for over 10 seconds (for WET CELL batteries, 19.6V for GEL-AGM batteries).

Battery voltage over 32V. Function block.

No signal or error in communications decoding between the Main machine controller (EB1) and the Display controller (EB2).

Relay closes or closed at start-up.

Function block.

No block.

Function block.

Check the battery voltage under load.

1. Check the battery voltage under no-load conditions and under load. Replace the faulty battery/batteries if necessary.

2. Recharge the batteries by performing a complete charging cycle.

Check the voltage of the installed batteries and that the terminals are correctly tightened.

1. Check the 5 cables from the 6-way User interface controller connector to connector J3 pins 1, 2, 3, 4.

2. If there is continuity, the User interface controller must be replaced.

Replace the Main machine controller.

Page 28

Main machine controller alarms

Alarm on Main machine controller - FLASHING RED LED

Alarm code

--------------------------

Description

-----------------------

BRUSH MOTOR OVERLOAD

-----------------------

VACUUM MOTOR OVERLOAD

-----------------------

DECK ACTUATOR FAILURE

-----------------------

HARDWARE FAILURE

-----------------------

PRESSURE GAUGE FAILURE

-----------------------

OVERHEATING

-----------------------

No.

flashes

Meaning Condition Effect

2 BRUSH motor

amperometric protection.

3 VACUUM

SYSTEM

amperometric protection.

4 DECK

ACTUATOR overcurrent.

5 Short circuit on

the vacuum or brush motor drive MOSFET.

6 PRESSURE

GAUGE FAILURE

(Not used)

7 Motor drive

section thermal cut-out.

8 Brush motor

output short circuit.

The motor current is greater than the value of the parameter (see page

35) VS1

The current draw of the vacuum motor is greater than 30A for over 10 seconds.

Current greater than 4A detected for more than 1 second.

MOSFET short circuit. Function block.

- -

The heatsink on the Main machine controller has reached a temperature of 194°F (90°C).

I > 150A for 20µsec. Function block.

Brush motor output stop.

Vacuum system block.

Brush function block.

Function block.

28Service Manual – SC500 04 - Control System

Service Suggestions

Check the current draw of the brush motor. It should remain below the value set in the parameter “VS1” during operation.

1. Check for any debris in the vacuum motor.

2. Check that the motor rotor turns freely.

3. Replace the vacuum motor if necessary.

1. Check that there is no friction on

the brush deck linkage; lubricate if necessary.

2. Check that the actuator and deck travel is not blocked by mechanical obstructions.

3. If the problem persists, replace the actuator.

1. Check that there are no short circuits in the motor wiring.

2. Replace the Main machine controller.

Check the vacuum and brush motor power draw and that the openings of the electrical compartment are not blocked.

Check for short circuits in the wiring or motor.

BRUSH MOTOR FAILURE

-----------------------

VACUUM MOTOR FAILURE

9 Vacuum

motor output overcurrent.

I > 150A for 20µsec. Function block.

Check for short circuits in the wiring or motor.

Page 29

Drive system alarms

Alarm on Main machine controller - FLASHING YELLOW LED

Alarm code

--------------------------

Description

-----------------------

DRIVE MOTOR OVERLOAD

-----------------------

RELEASE THE PADDLE !

-----------------------

PADDLE INPUT FAILURE

-----------------------

HARDWARE FAILURE

-----------------------

DRIVE MOTOR FAILURE

-----------------------

OVERHEATING

No.

flashes

Meaning Condition

2 Amperometric

protection intervention.

3 Paddle not in rest

position when the machine is turned

on.

4 Incorrect voltage

measured at the paddle potentiometer input.

5 Drive system

power section damage

6 Overcurrent

(motor D.C.)

7 Drive motor drive

section thermal cut-out.

Drive motor current draw greater than the parameter (see page 35) “INOM” for more than the parameter (see page 35) “TMAX”.

Voltage on J1.2 of the Display controller (EB2) out of range 1.29V - 1.49V with respect to - BAT.

Voltage on J1.2 of the Display controller (EB2)

above 3V.

MOSFET short circuit.

Drive motor current draw greater than 1.5 times the value of the parameter (see page 35) “IMAX”.

The heatsink on the Main machine controller has reached a temperature of 194°F (90°C).

Effect

Drive blocked. Check the current draw of the drive motor

Drive blocked. Check that the paddle moves correctly,

Drive blocked. 1. Check the connection of the

Drive blocked. 1. Check that the cables of the gear motor

Drive blocked. 1. Check that the gear motor cables are

Drive blocked. 1. Check the drive motor power draw

29Service Manual – SC500 04 - Control System

Service Suggestions

(this should be around 6-8amps without load and remain below 10-12amps during operation).

lubricating if necessary; check the linkage and potentiometer.

potentiometer to the Display controller.

2. Replace the potentiometer.

3. Replace the Display controller (EB2).

are not short circuited (try disconnecting the connectors from contacts M1 and M2) and try starting the machine and pressing the pedal again

2. If the alarm persists, replace the Main machine controller

not short circuited

2. Check that the motor of the gear motor unit is not short circuited (the impedance of the motor should be around 0.6 – 0.8 Ohm)

3. If necessary, replace the gear motor unit motor

and that the openings of the electrical compartment are not blocked.

2. If everything is within normal parameters, this may simply have been caused by extreme working conditions such as: Ambient temperature over 86°F (>30°C), sloping working sections. Simply leave the system to cool and turn the machine back on.

All alarms of the drive system operate by cutting the power supply to the gear motor unit motor until the KEY input is reset (with the exception of alarm T3 which is reset as soon as the input voltage of the paddle potentiometer returns within the values corresponding to “machine stopped”). In case of simultaneous

errors, the one with greater priority is shown rst (priority order is opposite to the number of ashes).

Page 30

On-board Battery Charger Alarms

Alarm code

30Service Manual – SC500 04 - Control System

--------------------------

Description

-----------------------

CHARGER COMMUNICAT.

-----------------------

BATTERY OVERVOLTAGE

-----------------------

CHARGING TIME I EXPIRED

-----------------------

CHARGING TIME II EXPIRED

-----------------------

Meaning Condition

Communication problem between the battery charger and the Main machine controller.

Battery overvoltage.

Charging phase I expired.

Charging phase II expired.

Battery charger internal short circuit.

No signal from battery charger via gate J4.4 for over 3 seconds.

Battery voltage over 32V.

Battery excessively discharged or at end of life cycle.

Battery charger internal short circuit.

Effect

The battery charger is performing the standard recharging cycle for generic GEL/ AGM batteries.

Battery charger block. 1. Check the connections of the batteries and

Battery charger block. If the problem persists, replace the batteries.

Battery charger block. Replace the battery charger.

Service Suggestions

Check the wiring between the battery charger and the Main machine controller.

the voltage of the installed batteries.

2. Disconnect and reconnect the battery charger.

CHARGER FAULT

Page 31

Black-box: Recording of Alarms, Parameters (see pages 34-35), Partial Operating Time Counter

The alarms activated during normal machine operation are stored and can be read in the corresponding log (Alarm Log Screen).

Display, Main Screen

1. Insert the Super User (yellow) key in place of the operator (grey) key (Figure 6) to access the main screen (Figure 7) of the display.

31Service Manual – SC500 04 - Control System

Figure 6:

2. Press One-Touch push-button to change the machine settings (see Machine Settings Screen section).

3. Press the brush release button Alarms Log Screen section).

4. Press the “hare” button Screen section).

5. Press the “tortoise” button

to check the machine’s hours of operation (see Operating Time Counter

or REV button to check for any stored machine alarms (see

to exit service mode and return to operator mode.

Figure 7:

Page 32

Display, Alarms Log Screen

The alarms log screen (Figure 8) function allows you to check any alarms stored on the machine.

32Service Manual – SC500 04 - Control System

To return to the main screen (Figure 6), press the One-Touch button

repeatedly.

Figure 8:

Each alarm (See table of alarms in the Main machine controller Alarm Codes section) is stored along with the working hour (machine operating time counter) at which it occurred and all alarms are recorded in the order in which they occurred, from the most recent to the oldest.

The memory holds up to 20 alarm records, after which the oldest are overwritten when new alarms occur.

Improper uses of the batteries or battery charger are also recorded, as in the following table:

On-board Battery Charger Alarms

Alarm code

--------------------------

Description

GB-N

-----------------------

CONTINUOUS LOW BATTERY VOLTAGE

-----------------------

CHARGER DISCONN BEFORE END CYCLE

GD-N

-----------------------

CHARGING TIME LESS THAN 4 HOURS

Meaning Condition

Time of continuous use with discharged batteries

Charging cycle interrupted before completion

Charging phase duration

“N” is the number of hours from key on to off when the battery level is below 20.4V for WET CELL (21.6 for AGM) batteries. This event is not recorded if the usage time is below 10 minutes.

Disconnection of battery charger before stage IV = battery symbol with 3 segments lit steadily.

N = Number of hours from battery charger connection to completion of PHASE II (red LED on) if < 4

Effect

Incorrect use by customer. Risk of reduced battery life.

Page 33

Display, Machine Settings Screen

The machine settings screen (Figure 9) functions allow you to customise some parameters described in the

following table of modiable parameters.

33Service Manual – SC500 04 - Control System

1. Press the “hare” button value of the current parameter.

to increase the

3. Press the One-Touch button the next parameter.

to move to

4. To return to the main screen (Figure 6), press

2. Press the “tortoise” button value of the current parameter.

Figure 9:

to decrease the

the brush release button

Modifiable Parameters

Code Description Min. Value Factory Setting Max. Value

CHM1 Detergent concentration level 1

CHM2 Detergent concentration level 2 1:400 (0.25 %) 1:125 (0.80 %) 1:33 (3 %)

Level 1 solution flow rate in relation to level 3

P1/P3

P2/P3

P3 Level 3 solution flow rate

P4 Level 4 solution flow enabling (2.8 l/min regardless of speed) OFF OFF ON

SPT EcoFlex function timer 0 (disabled) 60 sec. 300 sec.

XPRES Brush deck extra pressure enable OFF ON ON

FVMIN Minimum forward speed 0 % 25 % 100 %

FVMAX Maximum forward speed 10 % 100 % 100 %

RVMAX Maximum reverse speed 10 % 30 % 50 %

BAT Installed battery type 0 1 5

TOFF Automatic shut-off time 0 (disabled) 300 sec. 600 sec.

BRGH Display contrast 5 20 50

VRID Vacuum power in silent mode 1 1 5

RPM (*) Reduced brush rpm activation threshold 5 9 20

RESET (**) Restore factory settings for all parameters OFF OFF ON

(see section “System for Flow Rate Regulation as Function of Speed”)

Level 2 solution flow rate in relation to level 3

(see section “System for Flow Rate Regulation as Function of Speed”)

DISC 1.0 cl/m 3.0 cl/m 5.0 cl/m

REV 1.0 cl/m 1.5 cl/m 5.0 cl/m

1:400 (0.25 %) 1:400 (0.25 %) 1:33 (3 %)

0 % 25 % 100 %

0 % 50 % 100 %

(*) Increase the value of this parameter to reduce the brush motor speed in a wider range of applications and vice versa (**) The RESET function acts only on “MODIFIABLE PARAMETERS” and not on “HIDDEN PARAMETERS”.

Page 34

The following parameters are displayed only when, on reaching the last parameter RESET, the One-Touch

34Service Manual – SC500 04 - Control System

button

If the One-Touch button

is pressed together with the EcoFlex and vacuum buttons.

is not pressed, the system will return to the rst parameter CHM1.

Hidden Parameters

Code Description

TSERV Service advisory timer

AR Maximum acceleration ramp (sec.) 0.5 sec. 1.5 sec. 5 sec.

DISC 0.5 sec. 1.5 sec. 8 sec.

VS1 Brush 1 motor protection threshold 20A 30A 50A

VS2 Brush 2 motor protection threshold 20A 40A 50A

VDEAD Paddle potentiometer dead zone 0.0V 0.1V 1.0V

INOM Nominal drive current 10A 15A 15A

IMAX Maximum drive current 10A 45A 45A

TMAX Protection trip time for IMAX 0 sec. 12 sec. 60 sec.

Maximum deceleration ramp (sec.)

Maximum deceleration ramp in reverse (sec.)

REV 0.5 sec. 2.5 sec. 8 sec.

Min.

Value

0.5 sec. 0.5 sec. 5 sec.

Factory Setting

0 0 1000

Max.

Value

Meaning

Set to a value X greater than 0 if you wish the “Service Advisory” icon to be displayed every X hours of machine running time (according to the main operating time counter). To reset the hour counter for the icon display countdown (until the next service advisory), press the BURST and vacuum buttons for 10 seconds with the display on the “SERVICE MENU” page.

Increase to obtain a less abrupt response when accelerating, and vice versa.

Increase to obtain a less abrupt response when decelerating, and vice versa.

WARNING: increasing this value increases the

braking distance.

This is the maximum current which can be supplied to the disc brush deck.

WARNING: increasing this value increases the risk

of the motors overheating.

This is the maximum current which can be supplied to the disc brush deck.

WARNING: increasing this value increases the risk

of the motors overheating.

This is the maximum current which can be supplied to the cylindrical brush deck.

WARNING: increasing this value increases the risk

of the motors overheating.

Increase if the alarm T3 appears in the rest position and it is not possible to adjust the system’s mechanics. (Speed regulation will, however, be more difficult to modulate)

This is the maximum continuous current which can be supplied to the electric wheel drive unit.

WARNING: increasing this value increases the risk

of the motor overheating.

This is the maximum instantaneous current which can be supplied to the electric wheel drive unit.

WARNING: increasing this value increases the risk

of the motor overheating.

This is the reaction time of the electric wheel drive unit protection device when overloaded: this parameter is used in conjunction with IMAX to obtain the most appropriate response curve for the overload protection motor actuation system.

WARNING: increasing this value increases the risk

of the motor overheating.

Page 35

Display, Operating Time Counter Screen

The operating time counter screen (Figure 10) function allows you to check the total accumulated hours of work for each machine subsystem:

• (A) TOTAL counter (machine running time): same counter display on screen after starting machine.

• (B) DRIVE counter (drive system usage time).

• (C) BRUSH counter (brush rotation system usage time).

• (D) VACUUM counter (vacuum system usage time).

35Service Manual – SC500 04 - Control System

Figure 10:

Time Counter Reset

To reset the time counter see the table below for the procedure:

PUSH-BUTTON (> 10 SEC.) TIME COUNTER RESET

(A) TOTAL counter (*)

(B) DRIVE counter

(D) VACUUM counter

(*) When the TOTAL counter is reset, it is automatically reset also all partial ones (B, C, D) and deleted all

LOG memory.

To return to the main screen (Figure 7), press the One-Touch button

Page 36

System for Flow Rate Regulation as Function of Speed

Solution ow levels 1, 2 and 3 regulate the ow of detergent solution on the basis of the machine speed so as to keep the quantity of solution dispensed per square metre of oor treated constant.

The reference ow level is level 3: based on the setting of the corresponding parameter P3, the opening time of the solenoid valve (and of the detergent pump when tted) is regulated so that the quantity of solution in

centiliters per metre travelled by the machine is constant and equal to the value set in the parameter.

For example, for P3 = 3.0, the machine will dispense 3 centiliters of solution per metre travelled, which

equates (for the standard deck width of 530 mm) to 5.7 centiliters per square metre of oor treated.

Levels 1 and 2 are dened via the corresponding parameters P1 and P2 as a % of level 3.

For example, for P1 = 25 and P2 = 50, P1 and P2 are respectively ¼ (25%) and ½ (50%) of the reference ow

rate P3.

The default values (the same as in the example above) are summarized in the table, with the corresponding

ow rate values in liters per minute, dependent on machine speed, given as a reference.

SC500 DISC detergent ow (as a function of speed) (standard setting)

Level 1 Level 2 Level 3

Liters/minute @ 1 km/h 0.2 0.3 0.5

Liters/minute @ 3 km/h 0.4 0.8 1.5

Liters/minute @ 5 km/h 0.6 1.3 2.5

Centiliters per metre cleaned (constant) 0.75 1.5 3

Centiliters per meter

cleaned (Ø530 deck) 1.4 2.8 5.7

36Service Manual – SC500 04 - Control System

Level 4 (when enabled) is independent of any parameter and supplies the maximum possible quantity of solution as it keeps the solenoid valve of the supply system constantly open (with the brush rotating).

SC500 DISC detergent ow rate

Level 4

Liters/minute - Tank full 3.5

Liters/minute - Average 2.5

Page 37

Removal and Installation

Main machine controller (EB1)

1. Drive the machine on a level oor, remove the ignition key, and disconnect the red battery connector.

2. Lift the recovery tank.

3. Remove the 7 screws and remove the electronic component compartment cover.

4. Disconnect the following connections sequentially (Figure 11):

◦ (A) and (B) Main machine controller power supply connection (B+) and (B-).

◦ (C) and D) Brush motor connection (BR+) and (BR-).

37Service Manual – SC500 04 - Control System

Figure 11:

5. Disconnect the following connections sequentially (Figure 12):

◦ (E) and (F) Drive system motor connection (M1) and (M2).

◦ (G) and (H) Vacuum motor connection (VA+) and (VA-).

E E

G G

H H

F F

Figure 12:

Page 38

6. Disconnect the following connections sequentially (Figure 13):

◦ (I) Deck actuator and detergent pump connection (J1).

◦ (J) Solenoid valve connection (J2).

◦ (K) Display controller connection (J3).

◦ (L) Battery charger connection (J4).

◦ (M) Detergent level sensor connection (J5).

◦ (N) Connection (J6).

38Service Manual – SC500 04 - Control System

Figure 13:

7. Unscrew the 4 retaining screws (O) and carefully remove the Main machine controller (Figure 14).

Figure 14:

8. Assemble the components in the reverse order of disassembly.

Page 39

Display Controller (EB2) and User interface controller (EB3)

39Service Manual – SC500 04 - Control System

Display Controller (EB2)

1. Drive the machine on a level oor.

2. Remove the ignition key.

3. Disconnect the red battery connector.

4. Unscrew the 2 screws (A) (Figure 15).

5. Release the retaining tab (B), then lift up and remove the Main machine controller cover (C).

6. Disconnect the following connections sequentially (Figure 16):

◦ (A) Speed potentiometer connection (J4).

◦ (B) Display controller power supply

connection (J1).

◦ (C) Flat connection (J2).

◦ (D) Flat connection (J3).

7. Unscrew the 4 screws (E), then remove the display controller (F).

Figure 15:

Figure 16:

Page 40

User interface controller (EB4)

8. Perform points 1 to 5 for removal of the display controller.

9. Disconnect the following connections sequentially (Figure 17):

◦ (A) Flat connection J2.

◦ (B) Flat connection J3.

10. Carefully raise the User interface controller (C), detaching it from the cover (D).

Assembly

11. Assemble the components in the reverse order of disassembly and note the following:

◦ Before fastening the User interface controller (C), ensure that the at connections (A) and (B) are

correctly run through the slots in the cover (D), then glue the User interface controller to the cover itself.

40Service Manual – SC500 04 - Control System

Figure 17:

Page 41

Specications

Main machine controller (EB1) Connectors

(Figure 18) Power connections (Ø6mm male RADSOK terminals - AMPHENOL SK 200800532 101 or

equivalent)

Ref. Description

B+ Main machine controller power supply + in 24V 125A BAT+

B- Main machine controller power supply - in 24V 125A BAT-

Controller

in/out

V ref. I max. Connected to

41Service Manual – SC500 04 - Control System

Figure 18:

(Figure 19) Drive connections (Ø3.6mm male RADSOK terminals - AMPHENOL P/N N01 036 6501 001 or

equivalent)

Ref. Description

BR+ Brush motor + out 24V 50A M1+

BR- Brush motor - out 24V 50A M1-

Controller

in/out

V ref. I max. Connected to

Figure 19:

Page 42

(Figure 20) Drive connections (2-way male faston T-connectors, 6.3x0.8 – spacing 7.4mm)

Ref. Description

Controller

in/out

V ref. I max. Connected to

M1 Drive system motor + out 0-24V 45A M3+

M2 Drive system motor - out 0-24V 45A M3-

42Service Manual – SC500 04 - Control System

Figure 20:

(Figure 21) Vacuum connections (2-way male parallel faston connectors, 6.3x0.8 – spacing 6.5mm)

Ref. Description

Controller

in/out

V ref. I max. Connected to

VA+ Vacuum system power supply + out 10-24V 30A M2+

VA- Vacuum system power supply - out 0V 30A M2-

Figure 21:

Page 43

(Figure 22) J1: MOLEX MINIFIT type, 8-ways vertical

PIN Description Controller

V ref. I max. Connected to

in/out

1 Detergent pump power supply + out 24V <1A M4

2 Detergent pump power supply - out 0V <1A M4

3 Deck actuator power supply +/- out 0/24V 8A M5

4 Deck actuator power supply -/+ out 0/24V 8A M5

5 Power supply for ADV versions configurator out 0V <1A J1.6

6 ADV versions configurator return in 0V <1A J1.5

7 Power supply for deck configurator out 0V <1A J1.8

8 Deck configurator return in 0V <1A J1.7

43Service Manual – SC500 04 - Control System

Figure 22:

(Figure 23) J2: MOLEX MINIFIT type, 2-ways vertical

PIN Description Controller

V ref. I max. Connected to

in/out

1 Solenoid valve power supply + out 24V 1A EV1

2 Solenoid valve power supply - out 0V 1A EV1

Figure 23:

Page 44

(Figure 24) J3: MOLEX MINIFIT type, 6-ways vertical

PIN Description Controller

V ref. I max. Connected to

in/out

1 User interface controller power supply + out 24V <1A EB2.1

2 User interface controller serial + in/out 5V <1A EB2.2

3 User interface controller serial - in/out 0V <1A EB2.3

4 User interface controller power supply - out 0V <1A EB2.4

5 Return from key in 24V <1A EB2.5

6 Return from key (repetition) out 24V <1A -

44Service Manual – SC500 04 - Control System

Figure 24:

(Figure 25) J4: MOLEX MINIFIT type, 4-ways vertical

PIN Description Controller

V ref. I max. Connected to

in/out

1 Enabling from battery charger in 24V <1A CH.1

2 Power supply from battery charger in 24V <1A CH.2

3 Battery charger enabling power supply out 24V <1A CH.3

4 Battery charger data communication In/out 5V <1A CH.4

Figure 25:

Page 45

(Figure 26) J5: JST VHR-3N vertical 3-way

PIN Description Controller

V ref. I max. Connected to

in/out

1 Power supply for water level sensor + out 24V <1A S1.1

2 Water level sensor return in 0V <1A S1.2

3 Power supply for water level sensor - out 0V <1A S1.3

45Service Manual – SC500 04 - Control System

Figure 26:

(Figure 27) J6: JUMPER, 2-ways vertical

Figure 27:

Page 46

(Figure 28) J7: TYCO MODU II vertical 6-way

PIN Description Controller

V ref. I max. Connected to

in/out

1 +24V power supply out 24V <1A TRK.RD

2 +5V power supply out 5V <1A -

3 iButton input (CAN H channel) In (Out) 0V (0-5V) <1A TRK.YE

4 Ext. operating time counter enable (CAN L

(In) Out 0V (0-24V) <1A TRK.WH

channel)

5 Power supply - out 0V <1A TRK.BU

6 Machine on signal out 24V <1A TRK.BN

46Service Manual – SC500 04 - Control System

Figure 28:

Page 47

Connectors of the Display Controller (EB2)

(Figure 29) J1: MOLEX MINIFIT type, 6-ways vertical

Ref. Description

1 Power supply + in/out 24V <1A CFD12.J3.1

2 Main machine controller serial + in/out 5V <1A CFD12.J3.2

3 Main machine controller serial - in 0V <1A CFD12.J3.3

4 Power supply - out 0V <1A CFD12.J3.4

5 Key signal return (KEY0) out 24V <1A CFD12.J3.5

6 Key signal return (KEY0)

Controller

in/out

V ref. I max. Connected to

24V <1A -

47Service Manual – SC500 04 - Control System

Figure 29:

(Figure 30) J2: FCI DUFLEX (2.54 pitch) 9-way, male pins

Ref. Description

Controller

in/out

V ref. I max.

1 Power supply - common out 0V <1A

2 ON/OFF button (P0) in 0V <1A

3 DETERGENT MIX button (P4) in 0V <1A

4 EDS button (P3) in 0V <1A

5 VACUUM button (P2) in 0V <1A

6 VACUUM function LED (LD2)

7 SPOT function LED (LD1)

8 SPOT button (P1)

9 DS versions configurator

out

5V <1A

0V <1A

Figure 30:

Page 48

(Figure 31) J3: FCI DUFLEX (2.54 pitch) 8-way, male pins

Ref. Description

Controller

in/out

V ref. I max.

1 Power supply - common out 0V <1A

2 SP / EXTRAPR function LED (red) (LD3R) out 5V <1A

3 SP / EXTRAPR function LED (green)

out 5V <1A

(LD3V)

4 BRUSH RELEASE function LED (LD4) out 5V <1A

5 BRUSH RELEASE switch (P6) in 0V <1A

6 INCREASE SPEED button (P7)

7 DECREASE SPEED button (P8)

8 ONETOUCH / EXTRAPR. button (P5)

0V <1A

48Service Manual – SC500 04 - Control System

Figure 31:

(Figure 32) J4: JST VH vertical, 3-way (B 3P-VH)

PIN Description

Controller

in/out

V ref. I max. Connected to

1 VR1 potentiometer power supply + Out 3V <1A VR1.1

2 VR1 potentiometer return In 0-3V <1A VR1.2

3 VR1 potentiometer power supply - out 0V <1A VR1.3

Figure 32:

Page 49

Shop Measurements

The following tables contain some “real world” shop voltage measurements to help you recognize what “normal” looks like. All voltage values were measured with the black (Negative) voltmeter lead connected to

the main battery negative unless otherwise specied.

Shop Measurements - Main machine controller (EB1)

Battery volts at battery, key on = 25.03V

Power Supply

49Service Manual – SC500 04 - Control System

Figure 33:

PIN Color Description Measured Comments

B+ Red Main machine controller power supply + 24.5v Vacuum on

B- Black Main machine controller power supply - 0.035vV Vacuum on

Page 50

Brush Motor

Figure 34:

PIN Color Description Measured Comments

BR+ Red Brush motor + 24.4V (off),

24.2V (on)

BR- Blue Brush motor - 24.4V (off),

0.15v (on without RPM control activated)

Constant Positive

PWM Battery Negative

50Service Manual – SC500 04 - Control System

5.8v (on with RPM Control Active – set at 20)

Drive System Motor

Figure 35:

PIN Color Circuit Description Measured

Neutral Fwd - Initial Reverse -

Initial

M1 Red Drive system motor + 5.62v 12.7v 10.9v 21.8v 8.7v

M2 Gray Drive system motor - 5.61 1.95 16.00 8.9v 13.5v

M1 to M2 0.001v 6.1v -2.5v 22.6 -7.4

FWD Max REV Max

Page 51

Vacuum Motor

Figure 36:

PIN Color Description Measured Comments

VA+ Red Vacuum system power supply + 24.8v (off)

24.4v (on)

VA- Blue Vacuum system power supply - 24.56 (off)

1.36v (on High)

Constant Positive

1.02 Running, 9.56 Quiet Mode

51Service Manual – SC500 04 - Control System

9.69v (on Quiet mode VRID parameter = 1)

Page 52

J1 - 8 Ways

Figure 37:

PIN Color Circuit Description Measured Comments

1 Red Detergent pump power supply + 24.9v (off) No change seen on

voltmeter when the pump pulsed.

2 Gray Detergent pump power supply - 24.9v (off) Momentary drop to 0 when on. Voltmeter reading

momentarily jumped. Too fast to settle into a range and value.

3 White Deck actuator power supply +/- 24.8v (Stationary)

52Service Manual – SC500 04 - Control System

0.18v (going up)

12v (going up near top)

24.8v (going down to scrub or Ex press)

12.6v (Reset Up)

Stationary: 0v

Transport to Scrub: 24.8v

Scurb to Ex Press: 24.8v then 12v near end of travel.

Ex Press to Scrub: -24.8v

Scrub to Transport: -24.8v then -12v near end of travel

Reset to transport:-12.5v entire range

4 Blue Deck actuator power supply -/+ 24.8v (stationary)

0.03v (Transport to scrub)

Scrub to EX Press – Initial 0.03v then 12v near bottom

24.8v( Ex press to scrub)

Scrub to Transport – 24.8v

5 Green Power supply for ADV versions

configurator

6 Green ADV versions configurator return 0.001 (Loop not cut)

0.001

Reference to J1.3

Loop not cut

7 Red Power supply for deck configurator 0.001

8 Red Deck configurator return 0.001 (Loop not cut)

4.98v (Open loop)

Loop not cut

4.98v (Open loop)

Page 53

J2 - 2 Ways

Figure 38:

PIN Color Circuit Description Measured Comments

1 Yellow Solenoid valve power supply + 24.4 (Off and On)

2 Purple Solenoid valve power supply - 24.4 (off)

Momentary drop (on)

Momentarily drops to 0v when on but it is too fast for a DVOM to read. The value just momentarily changes.

53Service Manual – SC500 04 - Control System

J3 - 6 Ways

Figure 39:

PIN Color Circuit Description Measured Comments

1 Red Main machine controller power supply + 24.9v On or Off

2 White Main machine controller serial + 4.62v key on

0v key off

3 Blk/Wh Main machine controller serial - 4.13v key on

0v key off

4 Black Main machine controller power supply - 0.001v key on

5 Orange Return from key 24.3v key inserted and power “on” Either the yellow or

6 Empty

gray key has the same result. Note: if no key, jumping +24v here turns the machine on.

Page 54

J4 - 4 Ways

Figure 40:

PIN Color Circuit Description Measured Comments

1 White Enabling from battery charger 24.8v Not Charging May see residual

voltage back-feeding from the main controller here when charging.

2 Yellow Power supply from battery charger 0.136v Not charging

54Service Manual – SC500 04 - Control System

26.1v Charging

3 Brown Battery charger enabling power supply 24.8v key on or off Constant power

4 Green Battery charger data communication 4.98v when charger is first plugged in. Then

dropped to 4.6

whether charging or not. Key on or off.

J5 - 3 Ways

Figure 41:

PIN Color Circuit Description Measured Comments

1 Brown Power supply for water level sensor + 24.7v Key on

2 Black Water level sensor return 4.98

3 Blue Power supply for water level sensor - 0.001

0.03v

Tank < ½ full

Tank > ½ full

Page 55

Figure 42:

Two way vertical jumper.

• What is this for? The J6 Jumper is used to congure the Main machine controller for the EcoFlex option.

• What does it mean if it is jumped? The Main machine controller is set for no EcoFlex

55Service Manual – SC500 04 - Control System

• What does it mean if it is open? The Main machine controller is set for EcoFlex

• Is there a measurable voltage on either of the pins when not jumped? Yes. 4.98v on pin near the LEDS on the Main machine controller.

J7 - 6 Ways

Measured machine did not have a wiring connector. Measurements were taken at each pin on the Main machine controller.

Figure 43:

PIN Color Circuit Description Measured Comments

1 +24V power supply 24.6

2 +5V power supply 5.00

3 iButton input (CAN H channel) 4.98

4 Ext. operating time counter enable (CAN

L channel)

5 Power supply - 0.001

6 Machine on signal 23.68

24.6

Page 56

Shop Measurements - Display Controller (EB2)

Measure and record the voltage at each of the Main machine controller pins. Always use battery negative as your reference point for your black voltmeter lead.

J1 - 6 Ways

Figure 44:

56Service Manual – SC500 04 - Control System

PIN Color Circuit Description Measured Comments

1 Red Power supply + 24.6

2 White Main machine controller serial + 4.62

3 Blk/Wh Main machine controller serial - 4.12

4 Black Power supply - 0.003

5 Orange Key signal return (KEY0) 24.23

Page 57

J2 - 9 way ribbon connector

Figure 45:

PIN Color Circuit Description Measured Comments

1 Power supply - common 0.003v

2 ON/OFF button (P0) 24.2v Key off or key on

3 DETERGENT MIX button (P4) 3.14v Not pressed

0.02v pressed

4 EDS button (P3) (Solution Button) 3.14v Not pressed

57Service Manual – SC500 04 - Control System

0.02v pressed

5 VACUUM button (P2) 3.14v not pressed

0.05v pressed

6 VACUUM function LED (LD2) 0.007v LED off

7 SPOT function LED (LD1) 0.007v LED off

8 SPOT button (P1) (EcoFlex – Burst of

power)

9 DS versions configurator 3.14v

3.14v Not pressed

0.02v pressed

Page 58

J3 - 8 Ways ribbon connector

Figure 46:

PIN Color Circuit Description Measured Comments

1 Power supply - common 0.003v

2 SP / EXTRAPR function LED (red)(LD3R) 1.78v Red LED on

0.032v Red LED off

3 SP / EXTRAPR function LED (green)

(LD3V)

4 BRUSH RELEASE function LED (LD4) 0.07v LED off

1.95v Grn LED on

0.032v Grn LED off

58Service Manual – SC500 04 - Control System

Pulsing when flashing

5 BRUSH RELEASE switch (P6) 3.14v not pressed

0.03v pressed

6 INCREASE SPEED button (P7) 3.14v not pressed

0.02v pressed

7 DECREASE SPEED button (P8) 3.14v not pressed

0.02v pressed

8 ONETOUCH / EXTRAPR. button (P5) 3.16v not pressed

0.04v pressed

Page 59

J4 - 3 Ways Potentiometer Connector

Figure 47:

PIN Color Circuit Description Measured Comments

1 Red VR1 potentiometer power supply + 2.675

2 White VR1 potentiometer return 1.45 (Neutral) 2.48 (Full Fwd Pin 2),

0.44 (Full Rev Pin 2)

3 Black VR1 potentiometer power supply - 0.41 (Ground)

59Service Manual – SC500 04 - Control System

Page 60

05 - Control System, Magnetic Smart Key

Product Nr.: 9087403020, 9087404020, 9087400020,9087401020, 9087405020, 9087402020

Functional Description

60Service Manual – SC500

The architecture of the electronic control system for the machine’s electrical components is composed of a Main machine controller (EB1) and a Display controller (EB2), in turn connected to the User interface controller (EB3) which represents the main user interface.

The Main machine controller (EB1) manages all components and drives the following components directly:

• Drive system motor (M3)

• Vacuum system motor (M2)

• Deck actuator (M5)

• Brush motor (M6)

• Solution ow solenoid valve (EV1)

• Detergent pump (M4)

The Display controller (EB2) serves mainly as an aggregator for all input signals (buttons) and outputs (LEDs) from the User interface controller (EB3),

which it is connected to via 2 at cables.

The Magnetic key reader (IB) is connected to the Display controller (EB2). The display controller (EB2) check the presence of the Magnetic smart key and drive the switch on/off of the system accordingly.

The Display controller (EB2) sends all the input and output signals of these components to the Main machine controller (EB1) using 2-wire 2-way serial communications protocol.

Display controller (EB2)

Main machine

controller (EB1)

User interface controller (EB3)

Smart key reader (IB)

Flat calbes from

(EB2) to (EB3)

Smart key reader (IB)

Page 61

Wiring Diagram

SMART KEY (IB)

J5.1

J5.2

Microprocessor

USER INTERFACE CONTROLLER (EB3)

DISPLAY CONTROLLER (EB2)

User interface contr. serial +

User interface contr. serial -

User interface contr. power supply -

FCI DUFLEX (2.54 pitch) 8-way, male pins

FCI DUFLEX (2.54 pitch) 9-way, male pins

cpower supply +

Return from key

BATT +

J1.1

J1.2

J1.3

J1.4

J1.5

BATT -

Power supply +

B+

J3.1

User interface contr. power supply +

J3.2

User interface contr. serial +

J3.3

User interface contr. serial -

J3.4

User interface contr. power supply -

J3.5

Return from key

B-

MAIN MACHINE CONTROLLER (EB1)

61Service Manual – SC500 05 - Control System, Magnetic Smart Key

SIGNAL CIRCUITS FUSE (F2)

Microprocessor

Power supply -

Figure 1:

Page 62

Component Locations

62Service Manual – SC500 05 - Control System, Magnetic Smart Key

Main machine

controller (EB1)

Figure 2:

Display controller (EB2)

Smart key reader (IB)

Flat calbes from

(EB2) to (EB3)

User interface

controller (EB3)

Figure 3:

Page 63

Troubleshooting

Main machine controller (EB1) Alarm Codes

The Main machine controller (EB1) indicates a series of alarms in case of malfunction of one or more systems, and in case of abnormal conditions detected in the input signals.

The alarms are shown on the display in the following format: ALARM <XX> <DESCRIPTION> (Figure 4).

63Service Manual – SC500 05 - Control System, Magnetic Smart Key

Figure 4:

In case the display is malfunctioning, the alarms are also repeated by the yellow and red diagnostic LEDs (Figure 5) on the Main machine controller (EB1), as indicated in the following tables.

Figure 5:

General alarms

Alarm on Main machine controller - FLASHING YELLOW + RED LEDS

Alarm code

--------------------------

Description

-----------------------

EEPROM ERROR

No.

Flashes

Meaning Condition Effect

2 EEPROM error EEPROM error Function block

+ Default setting reset

Service Suggestions

If the machine continues to function after G2 has been displayed, this may have been caused by a signicant external electromagnetic disturbance.

1. Check that the settings and parameters (see pages 71 - 72) are correct (they may have returned to their defaults). If the error persists, the Main machine controller must be replaced.

Page 64

General alarms

Alarm on Main machine controller - FLASHING YELLOW + RED LEDS

Alarm code

--------------------------

Description

-----------------------

MAIN FUSE FAILURE

No.

Flashes

Meaning Condition Effect

3 Blown F1 fuse. Blown F1 fuse. Function block.

Broken battery.

64Service Manual – SC500 05 - Control System, Magnetic Smart Key

Service Suggestions

F1 is a safety fuse primarily included to prevent a short circuit or serious damage to the Main machine controller causing currents such as to melt cables and/or cause smoke or re. If F1 has blown, this is usually indicative of serious damage to the Main machine controller.

1. Removing the cover should allow you to understand the extent of the damage, but the solution in any case should be to replace the Main machine controller.

2. Try replacing fuse F1 only if there is no clear damage to the Main machine controller and wiring.

3. Ensure you tighten the fuse contacts correctly.

It could happen also if a battery is broken:

-----------------------

BATTERY LOW VOLTAGE

-----------------------

BATTERY OVERVOLTAGE

-----------------------

HARDWARE FAILURE

-----------------------

HARDWARE FAILURE

4 Undervoltage. The battery voltage

5 Excessive battery

voltage.

6 Serial

communication error with User interface controller.

7 General relay

fault.

remains below 18.4V for over 10 seconds (for WET CELL batteries, 19.6V for GEL-AGM batteries).

Battery voltage over 32V. Function block.

No signal or error in communications decoding between the Main machine controller (EB1) and the Display controller (EB2).

Relay closes or closed at start-up.

Function block.

No block.

Function block.

Check the battery voltage under load.

1. Check the battery voltage under no-load conditions and under load. Replace the faulty battery/batteries if necessary.

2. Recharge the batteries by performing a complete charging cycle.

Check the voltage of the installed batteries and that the terminals are correctly tightened.

1. Check the 5 cables from the 6-way User interface controller connector to connector J3 pins 1, 2, 3, 4.

2. If there is continuity, the User interface controller must be replaced.

Replace the Main machine controller.

Page 65

Main machine controller alarms

Alarm on Main machine controller - FLASHING RED LED

Alarm code

--------------------------

Description

-----------------------

BRUSH MOTOR OVERLOAD

-----------------------

VACUUM MOTOR OVERLOAD

-----------------------

DECK ACTUATOR FAILURE

-----------------------

HARDWARE FAILURE

-----------------------

PRESSURE GAUGE FAILURE

-----------------------

OVERHEATING

-----------------------

No.

ashes

Meaning Condition Effect

2 BRUSH motor

amperometric protection.

3 VACUUM

SYSTEM

amperometric protection.

4 DECK

ACTUATOR overcurrent.

5 Short circuit on

the vacuum or brush motor drive MOSFET.

6 PRESSURE

GAUGE FAILURE

(Not used)

7 Motor drive

section thermal cut-out.

8 Brush motor

output short circuit.

The motor current is greater than the value of the parameter (see page

72) VS1

The current draw of the vacuum motor is greater than 30A for over 10 seconds.

Current greater than 4A detected for more than 1 second.

MOSFET short circuit. Function block.

- -

The heatsink on the Main machine controller has reached a temperature of 194°F (90°C).

I > 150A for 20µsec. Function block.

Brush motor output stop.

Vacuum system block.

Brush function block.

Function block.

65Service Manual – SC500 05 - Control System, Magnetic Smart Key

Service Suggestions

Check the current draw of the brush motor. It should remain below the value set in the parameter “VS1” during operation.

1. Check for any debris in the vacuum motor.

2. Check that the motor rotor turns freely.

3. Replace the vacuum motor if necessary.

1. Check that there is no friction on

the brush deck linkage; lubricate if necessary.

2. Check that the actuator and deck travel is not blocked by mechanical obstructions.

3. If the problem persists, replace the actuator.

1. Check that there are no short circuits in the motor wiring.

2. Replace the Main machine controller.

Check the vacuum and brush motor power draw and that the openings of the electrical compartment are not blocked.

Check for short circuits in the wiring or motor.

BRUSH MOTOR FAILURE

-----------------------

VACUUM MOTOR FAILURE

9 Vacuum

motor output overcurrent.

I > 150A for 20µsec. Function block.

Check for short circuits in the wiring or motor.

Page 66

Drive system alarms

Alarm on Main machine controller - FLASHING YELLOW LED

Alarm code

--------------------------

Description

-----------------------

DRIVE MOTOR OVERLOAD

-----------------------

RELEASE THE PADDLE !

-----------------------

PADDLE INPUT FAILURE

-----------------------

HARDWARE FAILURE

No.

ashes

Meaning Condition

2 Amperometric

protection intervention.

3 Paddle not in rest

position when the machine is turned

on.

4 Incorrect voltage

measured at the paddle potentiometer input.

5 Drive system

power section damage

Drive motor current draw greater than the parameter (see page 72) “INOM” for more than the parameter (see page 72) “TMAX”.

Voltage on J1.2 of the Display controller (EB2) out of range 1.29V - 1.49V with respect to - BAT.

Voltage on J1.2 of the Display controller (EB2)

above 3V.

MOSFET short circuit.

Effect

Drive blocked. Check the current draw of the drive motor

Drive blocked. Check that the paddle moves correctly,

Drive blocked. 1. Check the connection of the

Drive blocked. 1. Check that the cables of the gear motor

66Service Manual – SC500 05 - Control System, Magnetic Smart Key

Service Suggestions

(this should be around 6-8amps without load and remain below 10-12amps during operation).

lubricating if necessary; check the linkage and potentiometer.

potentiometer to the Display controller.

2. Replace the potentiometer.

3. Replace the Display controller.

are not short circuited (try disconnecting the connectors from contacts M1 and M2) and try starting the machine and pressing the pedal again

2. If the alarm persists, replace the Main machine controller

-----------------------

DRIVE MOTOR FAILURE

-----------------------

OVERHEATING

6 Overcurrent

(motor D.C.)

7 Drive motor drive

section thermal cut-out.

Drive motor current draw greater than 1.5 times the value of the parameter (see page 72) “IMAX”.

The heatsink on the Main machine controller has reached a temperature of 194°F (90°C).

Drive blocked. 1. Check that the gear motor cables are

not short circuited

2. Check that the motor of the gear motor unit is not short circuited (the impedance of the motor should be around 0.6 – 0.8 Ohm)

3. If necessary, replace the gear motor unit motor

Drive blocked. 1. Check the drive motor power draw

and that the openings of the electrical compartment are not blocked.

errors, the one with greater priority is shown rst (priority order is opposite to the number of ashes).

Page 67

On-board Battery Charger Alarms

Alarm code

67Service Manual – SC500 05 - Control System, Magnetic Smart Key

--------------------------

Description

-----------------------

CHARGER COMMUNICAT.

-----------------------

BATTERY OVERVOLTAGE

-----------------------

CHARGING TIME I EXPIRED

-----------------------

CHARGING TIME II EXPIRED

-----------------------

Meaning Condition

Communication problem between the battery charger and the Main machine controller.

Battery overvoltage.

Charging phase I expired.

Charging phase II expired.

Battery charger internal short circuit.

No signal from battery charger via gate J4.4 for over 3 seconds.

Battery voltage over 32V.

Battery excessively discharged or at end of life cycle.

Battery charger internal short circuit.

Effect

The battery charger is performing the standard recharging cycle for generic GEL/ AGM batteries.

Battery charger block. 1. Check the connections of the batteries and

Battery charger block. If the problem persists, replace the batteries.

Battery charger block. Replace the battery charger.

Service Suggestions

Check the wiring between the battery charger and the Main machine controller (EB1).

the voltage of the installed batteries.

2. Disconnect and reconnect the battery charger.

CHARGER FAULT

Page 68

Black-box: Recording of Alarms, Parameters (see pages 71-72), Partial Operating Time Counter

The alarms activated during normal machine operation are stored and can be read in the corresponding log (Alarm Log Screen).

Display, Main Screen

1. Place the Supevisor key (yellow) (Figure 6), then press the the button to access the main screen (Figure 7) of the display.

68Service Manual – SC500 05 - Control System, Magnetic Smart Key

Figure 6:

2. Press One-Touch push-button to change the machine settings (see Machine Settings Screen section).

3. Press the brush release button Alarms Log Screen section).

4. Press the “hare” button Screen section).

5. Press the “tortoise” button

to check the machine’s hours of operation (see Operating Time Counter

or REV button to check for any stored machine alarms (see

to manage the magnetic smart keys..

Figure 7:

Page 69

Display, Alarms Log Screen

The alarms log screen (Figure 8) function allows you to check any alarms stored on the machine.

69Service Manual – SC500 05 - Control System, Magnetic Smart Key

To return to the main screen (Figure 6), press the One-Touch button

repeatedly.

Figure 8:

The memory holds up to 20 alarm records, after which the oldest are overwritten when new alarms occur.

Improper uses of the batteries or battery charger are also recorded, as in the following table:

On-board Battery Charger Alarms

Alarm code

--------------------------

Description

GB-N

-----------------------

CONTINUOUS LOW BATTERY VOLTAGE

-----------------------

CHARGER DISCONN BEFORE END CYCLE

GD-N

-----------------------

CHARGING TIME LESS THAN 4 HOURS

Meaning Condition

Time of continuous use with discharged batteries

Charging cycle interrupted before completion

Charging phase duration

“N” is the number of hours from key on to off when the battery level is below 20.4V for WET CELL (21.6 for AGM) batteries. This event is not recorded if the usage time is below 10 minutes.

Disconnection of battery charger before stage IV = battery symbol with 3 segments lit steadily.

N = Number of hours from battery charger connection to completion of PHASE II (red LED on) if < 4

Effect

Incorrect use by customer. Risk of reduced battery life.

Page 70

Display, Machine Settings Screen

70Service Manual – SC500 05 - Control System, Magnetic Smart Key

The machine settings screen (Figure 9) functions

value of the current parameter.

allow you to customise some parameters described in

the following table of modiable parameters.

3. Press the One-Touch button

to move to

the next parameter.

1. Press the “hare” button value of the current parameter.

2. Press the “tortoise” button

Figure 9:

to increase the

to decrease the

4. To return to the main screen (Figure 6), press

the brush release button

Modiable Parameters

Code Description Min. Value

CHM1 Detergent concentration level 1

CHM2 Detergent concentration level 2 1:400 (0.25 %) 1:125 (0.80 %) 1:33 (3 %)

Level 1 solution ow rate in relation to level 3

P1/P3

P2/P3

P3 Level 3 solution ow rate

P4 Level 4 solution ow enabling (2.8 l/min regardless of speed) OFF OFF ON

SPT EcoFlex function timer 0 (disabled) 60 sec. 300 sec.

XPRES Brush deck extra pressure enable OFF ON ON

FVMIN Minimum forward speed 0 % 25 % 100 %

FVMAX Maximum forward speed 10 % 100 % 100 %

RVMAX Maximum reverse speed 10 % 30 % 50 %

BAT Installed battery type 0 1 5

TOFF Automatic shut-off time 0 (disabled) 300 sec. 600 sec.

BRGH Display contrast 5 20 50

VRID Vacuum power in silent mode 1 1 5

RPM (*) Reduced brush rpm activation threshold 5 9 20

RESET (**) Restore factory settings for all parameters OFF OFF ON

(see section “System for Flow Rate Regulation as Function of Speed”)

Level 2 solution ow rate in relation to level 3

(see section “System for Flow Rate Regulation as Function of Speed”)

DISC 1.0 cl/m 3.0 cl/m 5.0 cl/m

REV 1.0 cl/m 1.5 cl/m 5.0 cl/m

1:400 (0.25 %) 1:400 (0.25 %) 1:33 (3 %)

0 % 25 % 100 %

0 % 50 % 100 %

Factory

Setting

Max. Value

Page 71

The following parameters are displayed only when, on reaching the last parameter RESET, the One-Touch

button is pressed together with the EcoFlex and vacuum buttons.

If only the One-Touch button is pressed, the system will return to the rst parameter CHM1.

Hidden Parameters

Code Description

TSERV Service advisory timer

AR Maximum acceleration ramp (sec.) 0.5 sec. 1.5 sec. 5 sec.

DISC 0.5 sec. 1.5 sec. 8 sec.

VS1 Brush 1 motor protection threshold 20A 30A 50A

VS2 Brush 2 motor protection threshold 20A 40A 50A

VDEAD Paddle potentiometer dead zone 0.0V 0.1V 1.0V

Maximum deceleration ramp (sec.)

Maximum deceleration ramp in reverse (sec.)

REV 0.5 sec. 2.5 sec. 8 sec.

Min.

Value

0.5 sec. 0.5 sec. 5 sec.

Factory Setting

0 0 1000

Max.

Value

Meaning

Increase to obtain a less abrupt response when accelerating, and vice versa.

Increase to obtain a less abrupt response when decelerating, and vice versa.

WARNING: increasing this value increases the braking distance.

This is the maximum current which can be supplied to the disc brush deck.

WARNING: increasing this value increases the risk of the motors overheating.

This is the maximum current which can be supplied to the disc brush deck.

WARNING: increasing this value increases the risk of the motors overheating.

This is the maximum current which can be supplied to the cylindrical brush deck.

WARNING: increasing this value increases the risk of the motors overheating.

Increase if the alarm T3 appears in the rest position and it is not possible to adjust the system’s mechanics. (Speed regulation will, however, be more

di󰀩cult to modulate)

71Service Manual – SC500 05 - Control System, Magnetic Smart Key

Continues

Page 72

Hidden Parameters

Code Description

INOM Nominal drive current 10A 15A 15A

IMAX Maximum drive current 10A 45A 45A

TMAX Protection trip time for IMAX 0 sec. 12 sec. 60 sec.

PDET Detergent pump type PST PER PER

Min.

Value

Factory Setting

Max.

Value

72Service Manual – SC500 05 - Control System, Magnetic Smart Key

Meaning

This is the maximum continuous current which can be supplied to the electric wheel drive unit.

WARNING: increasing this value increases the risk

of the motor overheating.

This is the maximum instantaneous current which can be supplied to the electric wheel drive unit.

WARNING: increasing this value increases the risk

of the motor overheating.

WARNING: increasing this value increases the risk

of the motor overheating.

Select “PST” for piston pump (factory installed on Product Nr.: 9087352020, 9087354020, 9087350020, 9087351020, 9087353020, 9087355020)

Select “PER” for peristaltic pump (factory installed on Product Nr.: 9087403020, 9087404020, 9087400020,9087401020, 9087405020, 9087402020)

Page 73

Display, Operating Time Counter Screen

The operating time counter screen (Figure 10) function allows you to check the total accumulated hours of work for each machine subsystem:

• (A) TOTAL counter (machine running time): same counter display on screen after starting machine.

• (B) DRIVE counter (drive system usage time).

• (C) BRUSH counter (brush rotation system usage time).

• (D) VACUUM counter (vacuum system usage time).

73Service Manual – SC500 05 - Control System, Magnetic Smart Key

Figure 10:

Time Counter Reset

To reset the time counter see the table below for the procedure:

PUSH-BUTTON (> 10 SEC.) TIME COUNTER RESET

(A) TOTAL counter (*)

(B) DRIVE counter

(D) VACUUM counter

(*) When the TOTAL counter is reset, it is automatically reset also all partial ones (B, C, D) and deleted all

LOG memory.

To return to the main screen (Figure 7), press the One-Touch button

Page 74

Display, Magnetic Smart Keys Management Screen

The Magnetic Smart Keys Management Screen (Figure 11) allows you to dene if the machine can be used with whatever user key (factory setting) or only with one or more specic user keys.

74Service Manual – SC500 05 - Control System, Magnetic Smart Key

To switch on the operator mode press the “hare” button

Identify a specic user key to be used for the

machine:

1. Remove the supervisor key (if present) from the key reader.

2. Place the user key on the key reader, then press

the One-Touch button

Remove a specic user key from the list of the keys

to be used for the machine:

1. Remove the supervisor key (if present) from the key reader.

2. Place the user key on the key reader, then press

the brush release button

Replace the factory setting (whatever user key can be used for the machine):

1. Remove the supervisor key (if present) from the key reader.

2. Press the brush release button

3. Conrm the command pressing the One-Touch

button

Figure 11:

To return to the main screen (Figure 7), press the “tortoise” button .

Page 75

System for Flow Rate Regulation as Function of Speed

centiliters per metre travelled by the machine is constant and equal to the value set in the parameter.

For example, for P3 = 3.0, the machine will dispense 3 centiliters of solution per metre travelled, which

equates (for the standard deck width of 530 mm) to 5.7 centiliters per square metre of oor treated.

Levels 1 and 2 are dened via the corresponding parameters P1 and P2 as a % of level 3.

For example, for P1 = 25 and P2 = 50, P1 and P2 are respectively ¼ (25%) and ½ (50%) of the reference ow

rate P3.

The default values (the same as in the example above) are summarized in the table, with the corresponding

ow rate values in liters per minute, dependent on machine speed, given as a reference.

SC500 DISC detergent ow (as a function of speed) (standard setting)

Level 1 Level 2 Level 3

Liters/minute @ 1 km/h 0.2 0.3 0.5

Liters/minute @ 3 km/h 0.4 0.8 1.5

Liters/minute @ 5 km/h 0.6 1.3 2.5

Centiliters per metre cleaned (constant) 0.75 1.5 3

Centiliters per meter

cleaned (Ø530 deck) 1.4 2.8 5.7

75Service Manual – SC500 05 - Control System, Magnetic Smart Key

SC500 DISC detergent ow rate

Level 4

Liters/minute - Tank full 3.5

Liters/minute - Average 2.5

Page 76

Removal and Installation

Main machine controller (EB1)

1. Drive the machine on a level oor, remove the ignition key, and disconnect the red battery connector.

2. Lift the recovery tank.

3. Remove the 7 screws and remove the electronic component compartment cover.

4. Disconnect the following connections sequentially (Figure 12):

◦ (A) and (B) Board power supply connection (B+) and (B-).

◦ (C) and D) Brush motor connection (BR+) and (BR-).

76Service Manual – SC500 05 - Control System, Magnetic Smart Key

Figure 12:

5. Disconnect the following connections sequentially (Figure 13):

◦ (E) and (F) Drive system motor connection (M1) and (M2).

◦ (G) and (H) Vacuum motor connection (VA+) and (VA-).

E E

G G

H H

F F

Figure 13:

Page 77

6. Disconnect the following connections sequentially (Figure 14):

◦ (I) Deck actuator and detergent pump connection (J1).

◦ (J) Solenoid valve connection (J2).

◦ (K) Display controller connection (J3).

◦ (L) Battery charger connection (J4).

◦ (M) Detergent level sensor connection (J5).

◦ (N) Connection (J6).

77Service Manual – SC500 05 - Control System, Magnetic Smart Key

Figure 14:

7. Unscrew the 4 retaining screws (O) and carefully remove the Main machine controller (Figure 15).

Figure 15:

8. Assemble the components in the reverse order of disassembly.

Page 78

Display Controller (EB2), User interface controller (EB3) and Smart Key Reader (IB)

78Service Manual – SC500 05 - Control System, Magnetic Smart Key

Display Controller (EB2)

1. Drive the machine on a level oor.

2. Remove the ingition key.

3. Disconnect the red battery connector.

4. Unscrew the 2 screws (A) (Figure 16).

5. Lift up and remove the User interface controller cover (B).

6. Disconnect the following connections sequentially (Figure 17):

◦ (A) Speed potentiometer connection J4.

◦ (B) Display controller power supply

connection J1.

◦ (C) Smart key connection J6.

◦ (D) Flat connection J2.

◦ (E) Flat connection J3.

7. Unscrew the 4 screws (F), then remove the Display controller (G).

Figure 16:

Figure 17:

Page 79

User interface controller (EB4)

8. Perform points 1 to 5 for removal of the Display controller.

9. Disconnect the following connections sequentially (Figure 18):

◦ (A) Flat connection J2.

◦ (B) Flat connection J3.

10. Carefully raise the User interface controller (C), detaching it from the cover (D).

Smart Key Reader (IB)

11. Perform points 1 to 5 for removal of the Display controller.

12. Disconnect the Smart key reader connection J6 (E).

13. Loosen the exagon (F) then remove the Smart key reader (G).

Assembly

79Service Manual – SC500 05 - Control System, Magnetic Smart Key

14. Assemble the components in the reverse order of disassembly and note the following:

◦ Before fastening the User interface controller (C), ensure that the at connections (A) and (B) are

correctly run through the slots in the cover (D), then glue the User interface controller to the cover itself.

Figure 18:

Page 80

Specications

Main machine controller (EB1) Connectors

(Figure 18) Power connections (Ø6mm male RADSOK terminals - AMPHENOL SK 200800532 101 or

equivalent)

Ref. Description

B+ Main machine controller power supply + in 24V 125A BAT+

B- Main machine controller power supply - in 24V 125A BAT-

Controller

in/out

V ref. I max. Connected to

80Service Manual – SC500 05 - Control System, Magnetic Smart Key

Figure 19:

(Figure 19) Drive connections (Ø3.6mm male RADSOK terminals - AMPHENOL P/N N01 036 6501 001 or

equivalent)

Ref. Description

BR+ Brush motor + out 24V 50A M1+

BR- Brush motor - out 24V 50A M1-

Controller

in/out

V ref. I max. Connected to

Figure 20:

Page 81

(Figure 20) Drive connections (2-way male faston T-connectors, 6.3x0.8 – spacing 7.4mm)

Ref. Description

Controller

in/out

V ref. I max. Connected to

M1 Drive system motor + out 0-24V 45A M3+

M2 Drive system motor - out 0-24V 45A M3-

81Service Manual – SC500 05 - Control System, Magnetic Smart Key

Figure 21:

(Figure 21) Vacuum connections (2-way male parallel faston connectors, 6.3x0.8 – spacing 6.5mm)

Ref. Description

Controller

in/out

V ref. I max. Connected to

VA+ Vacuum system power supply + out 10-24V 30A M2+

VA- Vacuum system power supply - out 0V 30A M2-

Figure 22:

Page 82

(Figure 22) J1: MOLEX MINIFIT type, 8-ways vertical

PIN Description Controller

V ref. I max. Connected to

in/out

1 Detergent pump power supply + out 24V <1A M4

2 Detergent pump power supply - out 0V <1A M4

3 Deck actuator power supply +/- out 0/24V 8A M5

4 Deck actuator power supply -/+ out 0/24V 8A M5

5 Power supply for ADV versions congurator out 0V <1A J1.6

6 ADV versions congurator return in 0V <1A J1.5

7 Power supply for deck congurator out 0V <1A J1.8

8 Deck congurator return in 0V <1A J1.7

82Service Manual – SC500 05 - Control System, Magnetic Smart Key

Figure 23:

(Figure 23) J2: MOLEX MINIFIT type, 2-ways vertical

PIN Description Controller

V ref. I max. Connected to

in/out

1 Solenoid valve power supply + out 24V 1A EV1

2 Solenoid valve power supply - out 0V 1A EV1

Figure 24:

Page 83

(Figure 24) J3: MOLEX MINIFIT type, 6-ways vertical

PIN Description Controller

V ref. I max. Connected to

in/out

1 User interface controller power supply + out 24V <1A EB2.1

2 User interface controller serial + in/out 5V <1A EB2.2

3 User interface controller serial - in/out 0V <1A EB2.3

4 User interface controller power supply - out 0V <1A EB2.4

5 Return from key in 24V <1A EB2.5

6 Return from key (repetition) out 24V <1A -

83Service Manual – SC500 05 - Control System, Magnetic Smart Key

Figure 25:

(Figure 25) J4: MOLEX MINIFIT type, 4-ways vertical

PIN Description Controller

V ref. I max. Connected to

in/out

1 Enabling from battery charger in 24V <1A CH.1

2 Power supply from battery charger in 24V <1A CH.2

3 Battery charger enabling power supply out 24V <1A CH.3

4 Battery charger data communication In/out 5V <1A CH.4

Figure 26:

Page 84

(Figure 26) J5: JST VHR-3N vertical 3-way

PIN Description Controller

V ref. I max. Connected to

in/out

1 Power supply for water level sensor + out 24V <1A S1.1

2 Water level sensor return in 0V <1A S1.2

3 Power supply for water level sensor - out 0V <1A S1.3

84Service Manual – SC500 05 - Control System, Magnetic Smart Key

Figure 27:

(Figure 27) J6: JUMPER, 2-ways vertical

Figure 28:

Page 85

(Figure 28) J7: TYCO MODU II vertical 6-way

PIN Description Controller

V ref. I max. Connected to

in/out

1 +24V power supply out 24V <1A TRK.RD

2 +5V power supply out 5V <1A -

3 iButton input (CAN H channel) In (Out) 0V (0-5V) <1A TRK.YE

4 Ext. operating time counter enable (CAN L

(In) Out 0V (0-24V) <1A TRK.WH

channel)

5 Power supply - out 0V <1A TRK.BU

6 Machine on signal out 24V <1A TRK.BN

85Service Manual – SC500 05 - Control System, Magnetic Smart Key

Figure 29:

Page 86

Connectors of the Display Controller (EB2)

(Figure 29) J1: MOLEX MINIFIT type, 6-ways vertical

Ref. Description

1 Power supply + in/out 24V <1A CFD12.J3.1

2 Main machine controller serial + in/out 5V <1A CFD12.J3.2

3 Main machine controller serial - in 0V <1A CFD12.J3.3

4 Power supply - out 0V <1A CFD12.J3.4

5 Key signal return (KEY0) out 24V <1A CFD12.J3.5

6 Key signal return (KEY0)

Controller

in/out

V ref. I max. Connected to

24V <1A -

86Service Manual – SC500 05 - Control System, Magnetic Smart Key

Figure 30:

(Figure 30) J2: FCI DUFLEX (2.54 pitch) 9-way, male pins

Ref. Description

Controller

in/out

V ref. I max.

1 Power supply - common out 0V <1A

2 ON/OFF button (P0) in 0V <1A

3 DETERGENT MIX button (P4) in 0V <1A

4 EDS button (P3) in 0V <1A

5 VACUUM button (P2) in 0V <1A

6 VACUUM function LED (LD2)

7 SPOT function LED (LD1)

8 SPOT button (P1)

9 DS versions congurator

out

5V <1A

0V <1A

Figure 31:

Page 87

(Figure 31) J3: FCI DUFLEX (2.54 pitch) 8-way, male pins

Ref. Description

Controller

in/out

V ref. I max.

1 Power supply - common out 0V <1A

2 SP / EXTRAPR function LED (red) (LD3R) out 5V <1A

3 SP / EXTRAPR function LED (green)

out 5V <1A

(LD3V)

4 BRUSH RELEASE function LED (LD4) out 5V <1A

5 BRUSH RELEASE switch (P6) in 0V <1A

6 INCREASE SPEED button (P7)

7 DECREASE SPEED button (P8)

8 ONETOUCH / EXTRAPR. button (P5)

0V <1A

87Service Manual – SC500 05 - Control System, Magnetic Smart Key

Figure 32:

(Figure 32) J4: JST VH vertical, 3-way (B 3P-VH)

PIN Description

Controller

in/out

V ref. I max. Connected to

1 VR1 potentiometer power supply + Out 3V <1A VR1.1

2 VR1 potentiometer return In 0-3V <1A VR1.2

3 VR1 potentiometer power supply - out 0V <1A VR1.3

Figure 33:

Page 88

(Figure 34) J5: MOLEX MICROFIT vertical, 2 ways

PIN Description

Controller

in/out

V ref. I max. Connected to

1 Smart Key reader signal GND In/Out 0V <1A KEY.1

2 Smart key reader signal IN/OUT In/Out 0-3V <1A KEY.2

Figure 34:

88Service Manual – SC500 05 - Control System, Magnetic Smart Key

(Figure 35) J6: MOLEX MINIFIT vertical, 2 ways

PIN Description

Controller

in/out

V ref. I max. Connected to

1 CAN H In/Out 0-5V <1A TRACK.WH

2 CAN L In/Out 0-5V <1A TRACK.PK

Figure 35:

Page 89

Shop Measurements

the main battery negative unless otherwise specied.

Shop Measurements - Main machine controller (EB1)

Battery volts at battery, key on = 25.03V

Power Supply

89Service Manual – SC500 05 - Control System, Magnetic Smart Key

Figure 36:

PIN Color Description Measured Comments

B+ Red Main machine controller power supply + 24.5v Vacuum on

B- Black Main machine controller power supply - 0.035vV Vacuum on

Page 90

Brush Motor

Figure 37:

PIN Color Description Measured Comments

BR+ Red Brush motor + 24.4V (off),

24.2V (on)

BR- Blue Brush motor - 24.4V (off),

0.15v (on without RPM control activated)

Constant Positive

PWM Battery Negative

90Service Manual – SC500 05 - Control System, Magnetic Smart Key

5.8v (on with RPM Control Active – set at 20)

Drive System Motor

Figure 38:

PIN Color Circuit Description Measured

Neutral Fwd - Initial Reverse -

Initial

M1 Red Drive system motor + 5.62v 12.7v 10.9v 21.8v 8.7v

M2 Gray Drive system motor - 5.61 1.95 16.00 8.9v 13.5v

M1 to M2 0.001v 6.1v -2.5v 22.6 -7.4

FWD Max REV Max

Page 91

Vacuum Motor

Figure 39:

PIN Color Description Measured Comments

VA+ Red Vacuum system power supply + 24.8v (off)

24.4v (on)

VA- Blue Vacuum system power supply - 24.56 (off)

1.36v (on High)

Constant Positive

1.02 Running, 9.56 Quiet Mode

91Service Manual – SC500 05 - Control System, Magnetic Smart Key

9.69v (on Quiet mode VRID parameter = 1)

Page 92

J1 - 8 Ways

Figure 40:

PIN Color Circuit Description Measured Comments

1 Red Detergent pump power supply + 24.9v (off) No change seen on

voltmeter when the pump pulsed.

2 Gray Detergent pump power supply - 24.9v (off) Momentary drop to 0 when on. Voltmeter reading

momentarily jumped. Too fast to settle into a range and value.

3 White Deck actuator power supply +/- 24.8v (Stationary)

92Service Manual – SC500 05 - Control System, Magnetic Smart Key

0.18v (going up)

12v (going up near top)

24.8v (going down to scrub or Ex press)

12.6v (Reset Up)

Stationary: 0v

Transport to Scrub: 24.8v

Scurb to Ex Press: 24.8v then 12v near end of travel.

Ex Press to Scrub: -24.8v

Scrub to Transport: -24.8v then -12v near end of travel

Reset to transport:-12.5v entire range

4 Blue Deck actuator power supply -/+ 24.8v (stationary)

0.03v (Transport to scrub)

Scrub to EX Press – Initial 0.03v then 12v near bottom

24.8v( Ex press to scrub)

Scrub to Transport – 24.8v

5 Green Power supply for ADV versions

congurator

6 Green ADV versions congurator return 0.001 (Loop not cut)

0.001

Reference to J1.3

Loop not cut

7 Red Power supply for deck congurator 0.001

8 Red Deck congurator return 0.001 (Loop not cut)

4.98v (Open loop)

Loop not cut

4.98v (Open loop)

Page 93

J2 - 2 Ways

Figure 41:

PIN Color Circuit Description Measured Comments

1 Yellow Solenoid valve power supply + 24.4 (Off and On)

2 Purple Solenoid valve power supply - 24.4 (off)

Momentary drop (on)

Momentarily drops to 0v when on but it is too fast for a DVOM to read. The value just momentarily changes.

93Service Manual – SC500 05 - Control System, Magnetic Smart Key

J3 - 6 Ways

Figure 42:

PIN Color Circuit Description Measured Comments

1 Red Main machine controller power supply + 24.9v On or Off

2 White Main machine controller serial + 4.62v key on

0v key off

3 Blk/Wh Main machine controller serial - 4.13v key on

0v key off

4 Black Main machine controller power supply - 0.001v key on

5 Orange Return from key 24.3v key inserted and power “on” Either the yellow or

6 Empty

gray key has the same result. Note: if no key, jumping +24v here turns the machine on.

Page 94

J4 - 4 Ways

Figure 43:

PIN Color Circuit Description Measured Comments

1 White Enabling from battery charger 24.8v Not Charging May see residual

voltage back-feeding from the main controller here when charging.

2 Yellow Power supply from battery charger 0.136v Not charging

94Service Manual – SC500 05 - Control System, Magnetic Smart Key

26.1v Charging

3 Brown Battery charger enabling power supply 24.8v key on or off Constant power

4 Green Battery charger data communication 4.98v when charger is rst plugged in. Then

dropped to 4.6

whether charging or not. Key on or off.

J5 - 3 Ways

Figure 44:

PIN Color Circuit Description Measured Comments

1 Brown Power supply for water level sensor + 24.7v Key on

2 Black Water level sensor return 4.98

3 Blue Power supply for water level sensor - 0.001

0.03v

Tank < ½ full

Tank > ½ full

Page 95

Figure 45:

Two way vertical jumper.

• What is this for? The J6 Jumper is used to congure the Main machine controller for the EcoFlex option.

• What does it mean if it is jumped? The Main machine controller is set for no EcoFlex

95Service Manual – SC500 05 - Control System, Magnetic Smart Key

• What does it mean if it is open? The Main machine controller is set for EcoFlex

• Is there a measurable voltage on either of the pins when not jumped? Yes. 4.98v on pin near the LEDS on the Main machine controller.

J7 - 6 Ways

Measured machine did not have a wiring connector. Measurements were taken at each pin on the Main machine controller.

Figure 46:

PIN Color Circuit Description Measured Comments

1 +24V power supply 24.6

2 +5V power supply 5.00

3 iButton input (CAN H channel) 4.98

4 Ext. operating time counter enable (CAN

L channel)

5 Power supply - 0.001

6 Machine on signal 23.68

24.6

Page 96

Shop Measurements - Display Controller (EB2)

Measure and record the voltage at each of the Main machine controller pins. Always use battery negative as your reference point for your black voltmeter lead.

J1 - 6 Ways

Figure 47:

96Service Manual – SC500 05 - Control System, Magnetic Smart Key

PIN Color Circuit Description Measured Comments

1 Red Power supply + 24.6

2 White Main machine controller serial + 4.62

3 Blk/Wh Main machine controller serial - 4.12

4 Black Power supply - 0.003

5 Orange Key signal return (KEY0) 24.23

Page 97

J2 - 9 way ribbon connector

Figure 48:

PIN Color Circuit Description Measured Comments

1 Power supply - common 0.003v

2 ON/OFF button (P0) 24.2v Key off or key on

3 DETERGENT MIX button (P4) 3.14v Not pressed

0.02v pressed

4 EDS button (P3) (Solution Button) 3.14v Not pressed

97Service Manual – SC500 05 - Control System, Magnetic Smart Key

0.02v pressed

5 VACUUM button (P2) 3.14v not pressed

0.05v pressed

6 VACUUM function LED (LD2) 0.007v LED off

7 SPOT function LED (LD1) 0.007v LED off

8 SPOT button (P1) (EcoFlex – Burst of

power)

9 DS versions congurator 3.14v

3.14v Not pressed

0.02v pressed

Page 98

J3 - 8 way ribbon connector

Figure 49:

PIN Color Circuit Description Measured Comments

1 Power supply - common 0.003v

2 SP / EXTRAPR function LED (red)(LD3R) 1.78v Red LED on

0.032v Red LED off

3 SP / EXTRAPR function LED (green)

(LD3V)

4 BRUSH RELEASE function LED (LD4) 0.07v LED off

1.95v Grn LED on

0.032v Grn LED off

98Service Manual – SC500 05 - Control System, Magnetic Smart Key

Pulsing when ashing

5 BRUSH RELEASE switch (P6) 3.14v not pressed

0.03v pressed

6 INCREASE SPEED button (P7) 3.14v not pressed

0.02v pressed

7 DECREASE SPEED button (P8) 3.14v not pressed

0.02v pressed

8 ONETOUCH / EXTRAPR. button (P5) 3.16v not pressed

0.04v pressed

Page 99

J4 - 3 Ways Potentiometer Connector

Figure 50:

PIN Color Circuit Description Measured Comments

1 Red VR1 potentiometer power supply + 2.675

2 White VR1 potentiometer return 1.45 (Neutral) 2.48 (Full Fwd Pin 2),

0.44 (Full Rev Pin 2)

3 Black VR1 potentiometer power supply - 0.41 (Ground)

99Service Manual – SC500 05 - Control System, Magnetic Smart Key

Page 100

10 - Chassis System

Chassis (main parts)

The chassis function is primarily performed by the solution tank, the support housings for the wheels and working mechanisms are integrated in the gear motor unit and the rear frame.

Reference to Figure 1

Deck raising levers (see also Brush System, Disc and Brush System, REV)

Frame integrated in the drive motor (see also Wheels System, Drive)

Rear pivoting wheels support frame with squeegee raising/lowering system (see also Squeegee System)

Brush deck raising levers

100Service Manual – SC500

Rear pivoting wheels support frame with

squeegee raising/lowering system

Figure 1:

Drive gear motor with

integrated frame