Thule TO 5200 Motor Kit 12V - Technical and Operational Guide for Customer Service and Technical Staff

Product Overview:

The Thule TO 5200 Motor Kit 12V is designed for converting manual awnings to electric operation, enhancing ease of use in recreational vehicles.

Specifications:

• Voltage: 12V DC
• Current: Nominal 6A in, 3A out; Peak 20.5A
• Cable Specifications:
  • Red Cable: 2.50m, 1.50mm² for 12V power (+)
  • Black Cable: 2.50m, 1.50mm² for 12V power (-)
  • Grey Cable: 4.00m, 0.75mm² for ignition
  • Door Contact and Override Switch: 4.00m, 2 x 0.75mm²
  • Recommended Cable Length: Max. 10m for optimal performance
  • For distances over 10m, use Ø 4.0mm² cable to prevent voltage drop

Installation Instructions:

1. Control Box Installation:

   • Secure the control box inside the vehicle using screws.
   • Extend motor wires (+ red & - black) to the control unit using Ø 2.5mm² cables. For longer distances, up to Ø 4mm² may be necessary to maintain a minimum of 9V at the motor during peak usage.
   • Connect the awning motor wires to terminals 4 & 5 on the control box. Use a screwdriver to gently open the terminal access and insert the stripped wire ends.

2. Switch Installation (Auto/Open):

   • Install a monostable switch (ON)-OFF-(ON) / (NC)-NO-(NC) at a suitable location.
   • Connect the switch to terminals 1, 2, and 3 of the control box using three Ø 1.5mm² wires.
   • Ensure the awning can only be operated when the vehicle’s ignition is off.

3. Battery Connection:

   • Connect the awning to the vehicle's secondary battery to avoid interference from other devices.
   • Run a 2 x Ø 2.5mm² cable from the control unit to the battery. Include a 20A fuse in the positive line but do not insert the fuse until all connections are complete.
   • Connect the battery to terminals 6 & 7 on the control box.

Safety and Operational Checks:

• Ensure the awning does not operate when the vehicle’s ignition is on.
• Confirm that all connections are secure and correctly polarized to prevent malfunction.
• Regularly check the awning operation to ensure it closes when the vehicle starts.

Troubleshooting:

• Motor Not Connected:

  Check connections at terminals 4 & 5.

• Motor Short Circuit:

  Inspect wiring for damage or shorts and replace if necessary.

• Motor Blocked/End:

  Ensure there are no obstructions in the awning mechanism.

• Voltage Issues:

  Ensure cables are of adequate diameter and the battery is fully charged.

• Switch Issues:

  Verify switch installation and connections at terminals 1, 2, and 3.

Warning Codes LED (Thule Awning Control Box):

• 1 x Blink: Power on
• 2 x Blinks: Motor not connected
• 3 x Blinks: Motor short circuit
• 4 x Blinks: Motor blocked/end
• 5 x Blinks: Motor time out
• 6 x Blinks: Voltage < 9V
• 7 x Blinks: Voltage > 18V
• 8 x Blinks: Button in & out error

Additional Notes:

Ensure all installations and operations comply with Thule's safety guidelines to maintain warranty and prevent damage or injury.
For detailed visual guidance, refer to the figures and diagrams provided in the original manual (e.g., figure p.6 for wire connections).

This guide should serve as a comprehensive reference for customer service and technical staff when addressing inquiries or performing maintenance on the Thule TO 5200 Motor Kit 12V.