This page will describe technical aspects of the Futura SmartControl unit and provide set-up and fault finding information.
Primary functions
Raising Deck
- SmartControl algorithm determines when the deck is raised (smart limit). The algorithm is a determination of f′′(t) derived from a moving average of the winch motor current within dynamic multilevel thresholding based on relative load determination.
- The algorithm also references absolute winch load and shuts down when absolute load limit is reached, or when the safety limit is reached. See beep code table.
- Raising is stopped automatically when either the safety limit or the smart limit is reached.
Lowering Deck
- Deck is lowered for maximum duration. Default 37 seconds (from Firmware 2.2) and can be set to a duration from 25 to 50 seconds.
- The ‘Deck is lowering’ beep will sound for the duration of the lowering process.
- The winch will shut down when the absolute load limit is reached, or when the safety limit is reached, See beep code table.
Recovery Winch Out
- No timers involved.
- The winch will shut down when the absolute safety limit is reached, See beep code table.
Recovery Winch In
- No timers involved.
- The winch will shut down when the absolute safety limit is reached, See beep code table.
Auto Power-Off
The SmartControl with firmware V2.1 and above will automatically power off after 20 minutes. Firmware before V2.1 will power off after 15 minute
The Remote will automatically power off after 5 minutes.
Battery voltage cutoff
High voltage cut-off is 16.5V
The SmartControl will not power any winch for safety (A ‘Voltage too high’ beep will sound instead).
Low voltage cut off is: 8V
The SmartControl will shut off the winch to save damaging the battery, burning out the winch motor, and causing the smart deck raising algorithm to make false detection.
The SmartControl will remain powered on, winches will be disabled (A ‘Voltage too low’ beep will sound instead).
Pairing the remote
Click on this link for SmartControl Remote Pairing Procedure
Setting lowering time
Click on this link for Setting SmartControl lowering timer
Decoding Beeps
|
Item |
Beep Pattern |
|
Start up |
2x 0.05s beeps increasing in pitch |
|
Pairing (repeating) |
3x beeps increasing in pitch with short, shorter, short duration |
|
Auto power off |
1x 0.1s beep |
|
Voltage too low |
3x beeps decreasing in pitch and duration |
|
Voltage too high |
3x beeps increasing in pitch and duration |
|
Temperature warning |
4x 1s beeps with a 1s pause between each |
|
Deck raised limit reached |
1x 0.1s beep |
|
Deck raised absolute load limit |
1x 1s beep |
|
Safety limit reached |
6x 0.1s beeps in two groups of 3 with increasing pitch |
|
Deck already at top position |
2x 0.1s beeps with a short pause in between |
|
Deck is lowering (repeating) |
1x 0.5s beep (repeating every second) |
|
New deck lowering time saved |
1x 1.5s beep |
|
Searching for lowering time |
4x 0.1s beeps with a short pause between each |
Troubleshooting
- SmartControl shutting off during operation.
Check battery low voltage cutoff is not being reached.
- Deck does not lower
Does lowering beeper sound?
YES:
SmartControl powered and ok?
High current power feed components at issue: Battery wire, Relay, winch drive on board, or wires to winch.
The relay can be checked by measuring for voltage on both high current terminals to ground. Both should show battery voltage if the winch board is on (confirm the voltmeter is on). If one high-current relay terminal has no voltage to ground this is most likely a faulty relay.
NO:
SmartControl not powered or damaged
Check power feed wire to SmartControl (low current battery feed)
Check battery voltage is above low voltage cutoff
Deck does not raise / Recovery winch does not operate
Check SmartControl powered (voltmeter on)
Check switch - Try remote instead
Check high-current power feed components: Battery wire, relay, winch drive on board, or wires to winch.
- SmartControl will not enter pairing mode
Confirm switch wiring is correct
Note: It is possible to wire up the recovery winch reversed and combine this with reversed wires to the recovery switch. This results in the recovery winch appearing to work correctly but it reverses the recovery switch direction when performing pairing. This wiring mistake can be confirmed if the combination Deck Up, Recovery in triggers pairing mode instead of the correct Deck Up, Recovery out.
- SmartControl is not charging
Confirm there is enough voltage reaching the SmartControl above the voltage of the winch battery. At Least 1.4V extra is required above the winch battery to begin charging. The current will increase with more voltage.
- Deck switch controls recovery winch or vise versa
Wiring to the winch motor has been reversed
Or
Wiring to the switches has been reversed.
- Remote does not stay on for 5 minutes or the remote behaviour is erratic
Confirm both AAA batteries in remote are above 1.0V. Replace batteries.
- SmartControl enters pairing mode correctly but does not pair to remote.
Confirm remote is on.
Confirm remote within 2 metres of SmartControl for pairing.
Confirm no other remotes for other trailers are being used while the pairing process is being performed, as it may pair to them instead of the intended remote.
Try different remote PCB and/or different SmartControl PCB to isolate fault.
Main relay check/improve/repair
Note: The repair can be done with the relay remaining installed in the box, but care should be taken to ensure the soldering iron does not damage plastics.
Steps to repair Main Solenoid:
Pry open the relay case with a thin flat blade screwdriver
Identify the crimps between each spade terminal and coil wire pins
Soldering complete
Reassemble the relay into the case with the spade terminals aligned with the side of the mounting tab.
Intermittent operation troubleshooting.
*It is recommended to first confirm the relay is not the issue.
If the relay is confirmed functional, the following may help to diagnose an issue causing intermittent operation of the winches.
There are 3 wire groups that could cause intermittent winch function:
-Grey wires
-Pink wires
-Switch wires
Troubleshooting details as follows:
- The grey wire on 24p to the relay ring terminal.
The grey wire provides power to the main control board.
An intermittent connection on the grey wire will cause the entire control board to restart. This can easily be detected because the board will play the startup beep sound every time the intermittent connection is restored. e.g., If the control board plays the startup beep randomly when wires are moved or touched and no button is currently being pressed, then the grey wire likely has a fault. Either the grey wire is broken, the ring terminal crimp is faulty, or the crimp inside the 24p connector is faulty.
- The two pink wires on 24p to relay control terminals.
To determine if the relay is on: measure the voltage between relay pins A and B with a multimeter.
- When the relay is on and working, the meter will read the battery voltage (~12V)
- When the relay is off, the meter will read ~0V, indicating a fault with one of the pink wires.
Technical information:
The two pink wires provide power to the relay. The relay should always be powered if the winch board has power (unless the 20 min timeout-power down has occurred).
An intermittent connection in either of the pink wires will cause the relay to click/energise on or off. An intermittent connection may go off and back on too quickly to read the change in voltage on a meter while it's occurring. However if you use a DMM with a bar graph display (usually below the digits) this should respond fast enough to see an intermittent loss of power. You may have to set the meter to a fixed range to stop it auto-ranging.
If a relay click sound is heard randomly when moving or touching wires, and the SmartControl is NOT also playing the startup beeps each time, then the intermittent issue is likely either the relay itself, the 2 pink wires to the relay or the pink wire crimps inside the 24p connector.
Alternatively, the relay click might be too quiet to hear. Another way to prove this is if the winch motors are not working but you still get the lowering beeps from the SmartControl when lowering the bed. This indicates the winch board has power and is running but the relay is not active so no power gets to the winch motors. This situation is also indicative of being either the relay itself, the 2 pink wires to the relay or the pink wire crimps inside the 24p connector.
- The 6 wires on 24p connected to the two control switches
If the above two options are ruled out, and intermittent winch movement is seen while in operation (e.g., while the switch is being held) this may indicate a faulty switch or faulty wire to the switch. To isolate the issue try using the remote control to confirm if the fault occurs only when using the switch or when using both the switch and the remote.
