025 aladdin troubleshooting

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05151 KS

Service Repair Procedure Aladdin™ System Troubleshooting

2003Monaco: SignatureSafari: PantherBeaver: Marquis, Patriot, Contessa, Monterey

2004Monaco: Signature, Dynasty, Executive, Windsor, CamelotHoliday Rambler: Navigator, Scepter, ImperialSafari: PantherBeaver: Marquis, Patriot, Monterey

2005Monaco: Signature, Dynasty, Executive, Windsor, CamelotHoliday Rambler: Navigator, Scepter, ImperialSafari: Panther, GazelleBeaver: Marquis, Patriot, Monterey

2006Monaco: Signature, Dynasty, Executive, Windsor, CamelotHoliday Rambler: Navigator, Scepter, Imperial, Ambassador, EndeavorBeaver: Marquis, Patriot, Monterey

025

ALADDIN SYSTEM TROUBLESHOOTING • 2

SERVICE REPAIR PROCEDURE

The Aladdin™ System

Introduction

The Aladdin™ System uses the dash monitor and television to display various house and chassis information. A joystick is used to navigate the main menu and various submenus. Sensors are located throughout house and chassis systems. Sensors relay the information to interface modules that digitize the information. The interface modules use bus taps to relay data to the Aladdin video source. The Aladdin Systems will display version and revision numbers upon initial power up. It is essential when replacing components to specify version and revision numbers to obtain the correct component.

The joystick is used to navigate the main menu and various submenus. Versions and revisions have different features, therefore main menus and submenus will vary. To operate the system, the house battery power must be on.

System Components

The Aladdin System consists of the following modules or components all tied together via RS485 data busses. All modules receive their power from the Aladdin Controller whether it is switched power or continuous power.

• Controller - (model numbers 100,211,400,413,431,440): This unit is the main processor and display unit. It receives information via two data busses. One data bus is tied to the engine and transmission to receive data for display while driving. The other data bus is called the house bus and is used to communicate to all the interface modules and joysticks. The controller also contains all the video switching and on-screen display electronics. Location: Depending on coach model, either on the passenger or driver side under the dash access panel.

NOTE:Fuses for the Aladdin Video Coach Monitor (VCM) brain are located in the front run box. All modules receive power from the VCM.

video mon.tif



• Joystick - Used to navigate the system menus by moving the joystick up, down, right and left. There may be single or multiple joysticks in the system. Location: One in the drivers or center console, one in the galley area, and some models use a third in the bedroom.

• Bus Tap - Junction for interface modules. Location: One is on the VCM brain in the dash, two are mounted on the module board in the cargo bay area, and some models have an additional bus tap underneath the bed deck.

• ACI (AC Interface) - Module used to measure AC voltages and currents for legs one and two. Location: On the module board in the cargo bay area.

• ATSM (Automatic Transfer Switch Interface Module 2005 Beaver Products) - The ATSM connects the Surge Guard Automatic Transfer Switch to the Aladdin System displaying AC power status in a readable form. Location: On the module board in the cargo bay area.

• DCI (DC Interface) - Module measures voltage and current of the house batteries and solar panels. Location: On the module board in the cargo bay area.

• TLI (Tank Level Interface 2003 version) - This module is used to read the fresh, gray and black holding tank pressure sensors. The unit also stores the calibration data for these sensors. Location: On the module board in the cargo bay area.

• TIM (Tank Interface Module 2004-2006 versions) - This module is used to read the fresh, grey and black holding tank pressure sensors. The unit also stores the calibration data for these sensors. The TIM also interfaces with an LP resistive sensor to provide propane tank levels to the system. This module has the added feature of providing automatic fresh water tank fi lling when combined with a 12VDC water valve/solenoid. Location: On the module board in the cargo bay area.

• LPI (LP Interface 2003 version) - This module measures a 0-90 ohm sensor mounted to the LP-Gas tank. Location: On the module board in the cargo bay area.

080377d



• TMI (Temperature Module Interface 2003 version) - Module uses two thermistors to measure outside temperature and bay temperature. Location: On the module board in the cargo bay area.

• TCM (Temperature/Compass Module 2004-2006 versions) - Module interfaces up to three thermistors. In addition, the TCM also contains an electronic compass that provides the Aladdin system with magnetic bearing. Location: On the module board in the cargo bay area or behind the dash.

• Optional Camera and Video amp power control module (Used on model 100 & 2xx only) - Module is used to control power to the rear camera and video distribution amplifi er. The video amplifi er is powered by house power. The rear camera receives power from the controller. Location: Depending on coach model, either on the passenger or driver side under the dash access panel.

Viewing From the Dash Monitor

NOTE:The Aladdin power/reset switch and interior house power must be on for the Aladdin system to operate.

• Sony Monitor: Turn the VCM and dash monitor on. With joystick, navigate up to Select Video Source. Press the joystick to the right and select Backup Camera. There should be an image on the dash monitor.

• Panasonic Flat Screen Dash Monitor: Operation with this monitor is the same as above, with the exception of units equipped with the GPS Navigation system. For these units, the display will toggle between the Aladdin and the Navigation screens by pressing the NAVI button on the lower left on the monitor, or the NAVIGATION button on the Panasonic remote control.

• See Vision (2004 product): If the motorhome has this option and a single dash monitor, selection of the various cameras is done through the VCM with the joystick. Navigate with the joystick to Select Video Source then scroll up or down to the desired camera (i.e. Left, Right, Interior, Backup Camera). See Vision (2003 product): Camera selection on 2003 model year product is done via the See Vision control brain with a dash mounted black push-button switch.

• 2003 Dual Monitor Systems: 2003 model year units with dual monitors use the Sony monitor in the lower part of the dash to view the Backup Camera and See Vision side view cameras if so equipped. These motorhomes still use the See Vision control brain and a separate dash mounted black push-button switch to manually select camera inputs to the display.

Aladdin data (no video sources)/GPS Navigation systems are viewed on the Panasonic fl at screen dash monitor. For these units, use the NAVI button to toggle between Aladdin data and the Navigation system.

NOTE:Shifting the transmission into Reverse will select the backup camera. When equipped with See Vision, engaging the turn signal will select the corresponding camera. When in reverse, selecting a turn signal will change view from backup camera to the corresponding camera. After the transmission is taken out of reverse, or the turn signals are cancelled, the display will default to the last selected view after a short delay.



Component Troubleshooting

Controller & Joystick

The four-pin engine buss connector on the controller is powered from the Aladdin Power/Reset switch by a fuse in the front run bay. The Power/Reset is used to reset the system if a lock-up should occur. Constant power allows the system to be turned on from any joystick position. Constant power is required to keep the internal time clock operating. If power is removed from the controller for more than four minutes, the clock will need to be reset. All other data is stored in non-volatile memory and will not be lost when power is removed.

The controller also provides constant power to the joysticks and switched power to the interface modules. Power provided by the controller is surge protected and contains 0.5A over-current protection. If a short circuit occurs, it will reset itself automatically once the short is removed.

NOTE:Interface module LEDs; The 2003 modules use three status LEDs, one is the “+ 12 V DC Good” LED and should be illuminated any time the Aladdin system is on. Next is a “Data Good” LED and should be blinking indicating that the module communications are functioning properly. The third one is called “Sensor Good” and is illuminated when internal self tests and sensor tests pass.

The 2004 modules use a single indicator LED that should be illuminated when the Aladdin system is on. The LED should blink rapidly indicating that power and data is present. If the status LED is on solid, then power is present but data communication is missing.

• Problem 1 - No engine data displayed or is not up-dated.• Solution - The ignition switch must be on to communicate with the engine or transmission. Check all

related wiring, data wires may be damaged.

NOTE:All data for Engine/Trans Status screens is obtained from a twisted pair of yellow and blue wires that hook to the 1587 wire in the Hillam harness. The M100 plug located underneath the instrument panel access hatch connects the engine buss to the twisted pair.

RM03A0006c



• Problem 2 - No house data is available, shows xxxx or is intermittent.• Solution - Check status LEDs on the Interface modules. LEDs should illuminate as described. If the

Data or + 12V Good LEDs are not lit, troubleshoot for a short or open in the data bus/power cables. If +12 V Good LED is lit, disconnect all measurement sensors. Begin plugging in sensors until the system locks up, that module is suspect as bad.

NOTE: Some earlier controllers (model 100 with a fi rmware revision prior to 1.04 and model 100-AC prior to fi rmware revision 1.22) may require a power reset to clear the locked bus.

• Problem 3 - Joystick locks up and cannot control the system. May be intermittent or solid failure.• Solution - Ensure that power is getting to the joysticks. If there is no power, troubleshoot for a short

or open in the data bus/power wiring cables. Since the joysticks use the same data bus as the Interface modules, it may be an Interface module causing the problem. Disconnect all Interface modules from the house bus (for model 100 perform a power reset of the controller). If joystick function resumes, the failure may be in one of the modules. Perform the procedures as described in Problem 2.

If the system is still unresponsive, plug one joystick directly into the Control Box using a known good cable. Try this with all joysticks to see if the problem is just one of the joysticks. If system is still unresponsive, replace the controller. The joystick LED should blink about once every 4 seconds indicating that it is communicating with the controller. The joystick LED will blink once any time the joystick is moved, indicating that it has transmitted the movement to the controller. The joystick LED will be off when the system is in sleep mode.

NOTE:Joysticks prior to revision A may be susceptible to high static discharge and lock up. Replace these joysticks with revision A or later. Check the joystick label (on back of unit) to see if it is a revision A.

• Problem 4 (Model 100) - Video image “tears” on the top of the dash display when viewing a text only display.

• Solution - Some LCD and KRT TV displays are sensitive to sync levels and color burst frequencies on the video. Check the label on the controller to see if it is a revision “D” suffi x or later (Model 100, 2xx); or revision “A” suffi x (Model 4xx). If the controller is a prior revision, replace with a newer version. If the controller is a later revision, check the video cable to the monitor. It should be a good quality 75-ohm video cable. Check the monitor itself for proper operation.

• Problem 5 (Models 200,400,413,431,440) - Unable to get into the Tank calibration screen, system asks for Maintenance Code.

• Solution - Enter Maintenance Code 1218. Only authorized maintenance personnel should have this code. Authorized personnel should be following the calibration procedures, which also requires the maintenance code.



ACI Troubleshooting

The ACI is powered from switched 12 V Good from the controller and is only powered up when the Aladdin system is on and running. The ACI measures AC (Alternating Currents) voltages and currents by the use of instrument transformers. These transformers provide AC isolation and reduces power to a safe level for measuring. The transformers are mounted inside a J-Box that is physically connected to the transfer relay assembly. Current is measured via 2" diameter 60:5 ratio current transformers (2003 version only); for the 2004 systems, two small Hall-effect sensors are used. Voltage is measured via voltage transformers with a 7.5:1 ratio. This means if 120 VAC is applied to the primary, 16 VAC will be output on the secondary. Fuses on the primary side protect the voltage transformers. These fuses are also located in the same J-Box, connected to the transfer switch.

Since a 240 VAC system is used in the coaches, two current and two voltage transformers are used, one set for each leg of 120 VAC. All calibrations are done during manufacture; there are no user adjustments.

• Problem 1 - No AC data is displayed or is xxxx and all other modules are working.• Solution - Check to see if the Interface module has power. Look on the ACI, the status LED should be

blinking indicating that module communications are working. Check data bus connection of ACI. Swap data cable with an adjacent working module if you suspect a bad data cable. If all attempts to get the Interface module communicating fail, replace the ACI module.

• Problem 2 - One leg of AC indicates OFF when it should be displaying approximately 120 VAC.• Solution - Remove the ACI connector for leg 1 or leg 2, whichever is not functioning. Using a Digital

Multimeter, measure 16VAC between the voltage input pins on the removed connector. (The label on the ACI will show the correct pin out for the connector.)

CAUTION:Lethal voltage is present inside the instrument transformer J-box. Only a qualifi ed service technician should make the following measurements.

If AC is not present on the correct pins, remove the cover from the instrument transformer J-Box which is attached to the transformer relay assembly. Measure the voltage on the primary side of each voltage transformer, (the bottom 2 terminals of the transformer), this should indicate the line voltage (117-120 VAC). If the primary voltage is not present, check the fuses in the J-Box and the connections between the transformers and the contactor inside the transfer relay box.

Current Transformers

Voltage Transformers

Transfer Relay Box.tif



Transfer Relay Junction Box:If primary voltage is present, the secondary voltage on each transformer (upper outside two terminals)

should be about 16 Volts AC. If the secondary voltage is not present, replace the voltage transformer and check the wiring between the transformer and ACI for shorts. If the secondary voltage is present, trace and continuity test wiring between the instrument transformers and the ACI. If the 16 VAC is present on the correct pins and the ACI still shows the leg as being OFF, replace the ACI module.

• Problem 3 (2003 style system only) - One leg of AC current always indicates 0 when it should display a load.

• Solution - Remove the ACI connector for Leg 1 or Leg 2, which ever is not functioning. Remove AC power from the coach. Using a Digital Multimeter, measure approximately 2 ohms between the current input pins on the removed connector. (The label on the ACI will show the correct pin out for the connector.)

If the wires do not show continuity (i.e. open), trace the wires between the current transformers in the instrument transformer J-Box and the removed ACI connector.

If the wires show continuity and are pinned correctly, confi rm that the current transformer “doughnut” is around a single primary AC cable inside the instrument transformer J-Box. If this is all correct, do the following:

CAUTION:Lethal voltage is present inside the instrument transformer J-box, only a qualifi ed service technician should make the following measurements.

Reconnect any removed ACI connectors. Reapply power to the coach and turn on some AC loads on both legs of AC. Use a clamp-on amp meter to measure the current fl owing through the AC leg that is not reading. Turn on enough loads to draw at least 5 Amps. If the ACI still does not read any current, replace the ACI.

NOTE:The current transformers are nearly impossible to destroy outside of physical damage. Replacement of these units is very rare.

ATSM Troubleshooting

The Aladdin Automatic Transfer Switch Module (ATSM) is powered by switched +12 Volt DC from the Aladdin controller and is only powered up when the Aladdin system is on. There are no user adjustments or calibrations for the ATSM.

The Automatic Transfer Switch (ATS) performs normally whether the Aladdin system is on or off. The ATSM receives serial communications from the ATS for display on the Aladdin system. The Aladdin system does not control functions of the ATS, but only reports the system status of the AC system.

• Problem 1 - No AC data is displayed or is xxxx and all other modules are working.• Solution - Check to see if the module has power. Look on the side of the ATSM. The system status

LED should be blink rapidly indicating power and data are present. If the Status LED is on solid, power is present but the data communication is missing or wired backwards. Check the data bus to the ATSM. Swap the data cable with a known working module if a bad data cable is suspect. If all attempts to get the module communicating fail, replace the ATSM or return for repair.



• Problem 2 - “No AC Power Present” status line is always displayed. It is normal for this message to be displayed when no AC power is present in the coach. If AC power is present proceed to the solution.

• Solution - If the ATS is supplying power to the coach then the problem lies in the communications between the ATS and the ATSM. Check the data cable between the ATS and the ATSM for damage or bad connections.

• Problem 3 - Aladdin AC status messages indicate a problem with the AC power or the Transfer switch.• Solution - Review the following status messages for cause and effect.

ALADDIN STATUS MESSAGE CAUSE EFFECT

AC INPUT REVERSE POLARITY

The ATS has detected that Neutral has been swapped with a HOT leg in the AC supply to the coach. AC power will not be applied to the

coach until problem is rectifi ed.

If power was being supplied to the coach when this error occurred, AC would be immediately removed from the coach without delay.

Check the AC input wiring to the ATS and repair as necessary.

AC INPUT OPEN NEUTRAL

The ATS has detected an open Neutral condition in the AC supply to the coach.

AC INPUT OPEN GROUND

The ATS has detected an open Ground condition in the AC supply to the coach.

AC INPUT LEG 1 OPEN The ATS does not detect power on Leg 2 in the AC supply to the coach.

AC INPUT LEG 2 OPEN The ATS has detected an open HOT Leg in the AC supply to the coach.

AC INPUT LOW FREQ AC input frequency is below the nominal 60 Hz. (<52 Hz)

If this condition exists for an abnormal period of time, power will not be applied to the coach.

Delays are built in to the ATS to accommodate normal generator sags and peaks.

AC INPUT HIGH FREQ AC input frequency is above the nominal 60 Hz. (>68 Hz)

AC INPUT LEG 1 HIGH AC Leg voltage is above the nominal 12OVAC. (>132 VAC)

AC INPUT LEG 2 HIGH AC Leg voltage is above the nominal 12OVAC. (>132 VAC)

AC INPUT LEG 1 LOW AC Leg voltage is below 102 Volts AC. (<102 VAC)

AC INPUT LEG 2 LOW AC Leg voltage is below 102 Volts AC. (<102 VAC)



DCI Troubleshooting

The DCI (DC Interface) module is powered by switched 12 Volt DC from the controller and is only powered up when the Aladdin system is on. The DCI measures house battery and solar voltage. Solar and battery current are measured via the use of Hall effect current sensors. The solar current sensor is hard wired to the module and cannot be removed or replaced without replacing the DCI module. The battery current sensor is connected to the DCI via a corresponding connector. 5 Volt DC and ground are supplied to the current sensor and a signal wire returns the current reading. The battery current sensor can be damaged if wired incorrectly.

• Problem 1 - No DC data is displayed or is xxxx and all other Interface modules are working.

• Solution - Check to see if the module has power. Check the status lights on the DCI. The status LED should blink to indicate that the module communications are working. Check data bus connection of the DCI. Swap the data cable with an adjacent working module if the data cable is suspected as bad. If all attempts to get the module to communicate fail, replace the DCI module.

NO AC POWER PRESENT The ATS has no AC input power and therefore cannot communicate with the ATSM Aladdin system.

This is a normal operation of the ATS and is not considered a fault condition.

Also see problem 2 above if “NO AC POWER PRESENT” is the only message displayed.

GEN-SET POWER SELECTED Generator is operating the 120/240 Volt

AC system.SHORE POWER SELECTED

NO AC POWER SELECTED The ATS has elected not to apply power to the coach due to an error condition or a required delay period.

POWER DELAY ACTIVE The ATS is going through a delay period prior to switching AC power sources.

SURGE FAIL The ATS has detected a failure in the surge protection circuitry.

Normal switching operation of the ATS will resume, however the ATS requires servicing to repair the internal surge protection circuitry.

The DCI Solar Voltage Sensors are located at the Solar Controller in the bay. One Amp fuses protect the wiring.

solar charge cont.tif



• Problem 2 - (Only applies to 2003 style system) House DC or Solar voltage reading incorrectly. • Solution - Both the house and solar voltage use the same reference ground and it must be connected to

a solid house battery ground point. The voltage inputs to the DCI must have an in-line fuse if the wires are in excess of 18" in length between the DCI and the supply termination. A common place to connect the DCI voltage inputs is the solar regulator. The solar regulator typically has a solid ground, battery and solar positive connections.

Using a Digital Multimeter, measure the voltage at the ground and positive input of the DCI with the plug connected. The voltage displayed on the Digital Multimeter should match what is displayed on the Aladdin system.

If the two readings do not agree, measure the voltage between the ground input and a known good battery ground with the plug connected. There should be no more than a 100mV (millivolts) differential. If more, a poor ground is suspected and must be repaired or replaced.

If the Digital Multimeter and Aladdin readings agree but are not what is expected, troubleshoot the battery or solar positive inputs. The battery positive input should have a fuse located near the battery. Make sure the connection is clean and tight.

• Problem 3 - Solar current always reads zero or much

lower than expected.• Solution - The solar current sensor is normally placed

around the positive or negative lead of the solar panel or the negative battery lead of the solar regulator. This sensor is not polarity sensitive. The current sensor can measure up to 60 Amps.

Use a known good clamp-on amp meter or series amp meter to measure the current fl owing through the same conductor that passes through the current sensor. The readings of the amp meter should closely match the readings on the Aladdin system. If the two readings do not agree, and the amp meter is known accurate, replace the DCI module.

• Problem 4 - House battery current always reads inaccurate or backwards.• Solution - The house current sensor is normally placed around the positive lead close to the house

battery bank. This sensor is polarity sensitive and must face the proper direction. The small cable lead connected to the current sensor should always point towards the battery positive terminal. If the Aladdin system reads discharge when it should be charging, the sensor may be installed backwards on the battery cable. Use a clamp-on meter to verify the current fl ow.

The Aladdin system should match the meter +/- 5 Amps. The current sensor can read 200 Amps charge/discharge. Currents above this will not damage the sensor.

If the Aladdin does not come close to matching the clamp-on meter, then the sensor may be damaged. The damage can either be physical or electrical. The sensor is made of a fragile torrid core and must be handled with care. A sensor wired backwards may be permanently damaged. The red wire should be 5 Volts DC, the black wire should be ground; and the white wire should be the signal lead.

house current sensor.tif

Current Sensor Lead

Solar Panel Current Sensor is located near the Solar Controller.

current sensor.tif



To check for proper sensor excitation, unplug the current sensor from the harness. Use a Digital Multimeter and measure the voltage between the red and black wires at the connection. Reading should be 5 Volts DC +/- 0.2 Volts. If the voltage reading is incorrect check the wiring between the sensor and the DCI for shorts or opens. If wiring is good, check the 5 Volt excitation directly on the DCI connector J3 with the harness disconnected. If the voltage is still out of tolerance, replace the DCI module.

If the excitation is normal, plug the current sensor back into the harness and use the Digital Multimeter to measure voltage between the black wire and the white wire. This reading should be approximately 2.5 Volts with no current fl owing through the battery cable. If the Digital Multimeter readings are near 5 Volts DC or near 0 Volts (with no current fl ow), the sensor may have been connected improperly and damaged. Replace the current sensor. If all voltage checks and cables test normal, replace the DCI module.

TIM (Temperature Interface Module)

The TIM is powered by switched 12 Volts DC from the controller and is only powered when the Aladdin system is operating.

• Problem 1 - No holding tank data is displayed or is xxxx and all other modules are working.• Solution - Check to see if the + 12 V Good LED is lit on the Interface module. The Status LED should

blink rapidly to indicate power and data is present. If the Status LED is on solid, power is present but data communication is missing. Check the wiring. If the wiring is good, check the data bus to Interface module by swapping the data cable with an adjacent working module if the data cable is suspect. If all attempts to get the Interface module operating fail, replace the TIM module.

• Problem 2 - Gallons and Percentages are off on one or more tanks.• Solution - Check for proper installation and calibration.

Common Problems:1. The cables used on the pressure sensors are fl at

telephone cord. The color code is: Red - 5 Volts DC; Black - ground; and Green - signal wire. Verify that the fl at phone cord is not damaged. Keep this wire away from noisy high-current cables, such as inverter battery cables and high-current AC wire.

2. All tanks must freely vent to the atmosphere. Blocked tank vents will raise pressure to tank sensors and cause erroneous readings. Ensure that any anti-siphon plumbing or vents do not trap water or affect the internal pressure of the tank.

3. Tank readings inaccurate. Perform the calibration procedure (requires an access code). Calibrate empty with the tank empty from normal use. Calibrate full only when the tank is full, not fl ooded. By default, the capacities are set to 75 gallons for the gray and black tanks, 100 gallons for the fresh tank. Make sure to set gallons to match tank capacities of the motorhome. Follow the calibration procedures for setting tank capacities.

holding tank sensor 2.tif

Tank Pressure Sensor



• Problem 3 - LP-Gas tank level always indicates, “FAIL” or reads higher than normal.• Solution - Check for an open circuit between the connector on the interface module and the tank

sensor. Disconnect the 2-pin connector from the module. Using a Digital Multimeter, take an ohm reading between the two wires - the resistance should be between 0 and 90 ohms. If not, check the wiring and the tank sensor. Also check for continuity between the sensor wires and chassis ground. There should be no continuity.

• Problem 4 - (Marquis only) Auto-Fill overfi lls or under fi lls the fresh tank• Solution - Auto-fi ll works in conjunction with calibration settings for the fresh water tank. Perform

calibration procedure.

• Problem 5 - Auto-Fill does not work; manual mode may work.• Solution - Set the Auto-Fill switch from AUTO to OFF and back to AUTO. The Aladdin Tank display

should indicate “AF” next to Fresh Tank status line.

See the following for the “AF” display defi nitions:AF is not displayed - Auto-Fill is turned off. If incorrect, check the wiring and switch(s).

AF is solid green - Auto-Fill is turned on. Fill valve keeps tank level between 80% and 100%.

AF is blinking green - The system has energized the tank fi ll valve and is attempting to fi ll the tank.

AF is solid red - An error has occurred while attempting to fi ll the tank. Check the water supply, wiring and fi ll valve.

Tank Level Interface (TLI) Troubleshooting (2003 Version)

The TLI is powered from switched 12 Volt DC from the controller and is only powered when the Aladdin system is operating. The TLI measures tank levels with the use of pressure sensors mounted at the bottom of holding the tanks.

Two different type pressure sensors were used in model year 2003. TLI P/N 38030058 uses Setra pressure sensors P/N 16616612. TLI P/N 38030267 uses Catcon pressure sensors P/N 16618613.

NOTE:The Setra pressure sensors were used on early model year Beaver coaches only. Later production coaches all use the Catcon sensors.

• Problem 1 - No holding tank data is displayed or is xxxx and all other modules are working.• Solution - The 12 V Good LED is lit on the Tank Interface Module indicating the module has power.

The status LED should blink to indicate that the module communications are working. Check the data bus connection of the module. If the data cable is suspect, swap the data cable with an adjacent working module. If all attempts to get the module to communicate fail, replace the TLI module.

• Problem 2 - Gallons and percentages are way off on one or more tanks.• Solution - Check for proper installation and calibration.



Common Errors:The cables used with the Setra sensors are 16 AWG. The

cables used on the Catcon sensors are fl at telephone cord. The color code is the same: Red - 5 Volts DC; Black - ground; and Green - signal wire. Keep this wire away from inverter battery cables and high current AC wires. Make sure the fl at phone cord is not damaged.

• Problem 3 - Fail High or Fail Low message appears on the display for the tank levels.• Solution - A Fail High message indicates that the excitation voltage for the sensors is too high. This is

usually caused by a regulator failure in the Interface module. A sensor wire shorted to another voltage source could cause the same message. Check the wiring. A shorted sensor wire usually causes the Fail Low message. Disconnect all sensors from the Interface module and plug one sensor in at a time until the failure reappears; check the wiring for this sensor. If the Fail Low message remains even though all sensors are unplugged from the Interface module, replace the module.

LP-Gas Interface Module (LPI) Troubleshooting (2003 Version)

The Interface module is powered by switched 12 Volt DC from the controller and is only powered when the Aladdin system is operating. The module measures the LP-Gas level in the tank using a 0-90 ohm sensor mounted to the tank. At 0 ohms the tank is empty and at 90 ohms the tank is 80%, which is considered full.

• Problem 1 - No LP-Gas data is displayed or is xxxx and all other modules are working.• Solution - The 12 V Good LED is lit on the Tank Interface Module indicating the module has power.

The status LED should blink to indicate that the module communications are working. Check the data bus connection of the module. If the data cable is suspect, swap the data cable with an adjacent working module. If all attempts to get the module to communicate fail, replace the LPI module.

• Problem 2 - LP-Gas level always says “FAIL.”• Solution - Check for an open circuit between the Interface module and the tank sensor. Disconnect the

2-pin connector from the Interface module. Using a Digital Multimeter, take an ohm reading between the two wires. Resistance should be between 0 and 90 ohms. If not check the wiring and the tank sensor.

Temperature Module Interface (TMI) Troubleshooting (2003 version)

The Interface module is powered from switched 12 Volts DC from the controller and is only powered when the Aladdin system is operating. The Interface module uses thermistors to measure temperature. The thermistors have a resistance of 10,000 ohms at room temperature. As temperature rises, resistance will decrease. There are two thermistors in the system: One to measure the outside temperature and the other to measure bay temperature. On Monaco products the outside temperature sensor is located on the front fi rewall near the A/C plenum. The bay temperature sensor is located near the fresh water tank. On Beaver products the outside temperature sensor is mounted inside the driver or passenger outside mirror arm. The bay temperature sensor is usually mounted near the fl esh water tank or pump plumbing. The Aladdin temperature system has a typical accuracy of +/- 1° F.

setra sensor.tif



• Problem 1 - No temperature data is displayed or is xxxx and all other modules are working.• Solution - The 12 V Good LED is lit on the Interface module indicating the module has power. The

status LED should be blinking indicating the module communications are working. Check the data bus connection on J1 of the TMI. Swap the J1 data cable with an adjacent working module if you suspect a bad data cable. If all attempts to get the module to communicate fail, replace the TMI module.

• Problem 2 - Temperature always reads extremely cold and never changes.• Solution - The wiring to the thermistor sensor is open or the thermistor assembly is damaged. Check

the wiring.

• Problem 3 - Temperature always reads extremely hot and never changes.• Solution - The wiring to the thermistor sensor is shorted or the thermistor assembly is damaged and

shorted. Check the wiring.

• Problem 4 - Temperature always reads hotter than it really is, but does change.• Solution - The thermistor may be mounted in a position that exposes it to direct sunlight where radiant

heat causes a rise in temperature. The sensor may also be mounted near another heat source like a generator, engine, water heater etc. Relocate the sensor to a sheltered position that has free airfl ow around it and is not exposed to any radiant heat sources.

Temperature Compass Module (TCM) Troubleshooting

The Interface module is powered by switched 12 Volt DC from the controller and is only powered when the Aladdin system is operating. The TCM measures temperature with the use of thermistors. At room temperature (68° - 77° F), the thermistors have a resistance of 10,000 ohms. As temperature increases, resistance decreases. There are two thermistors usually installed in the system: one to measure the outside temperature and the other to measure bay temperature (for freezing conditions).

• Problem 1 - No temperature or compass data is displayed or is xxxx and all other modules are working.• Solution - The 12 V Good LED is lit on the Interface module to indicate the module has power. The

status LED should blink to indicate that the module communications are working. Check the data bus connection on J1 of the TMI. Swap the J1 data cable with an adjacent working module if you suspect a bad data cable. If all attempts to get the module to communicate fail, replace the TMI module.

• Problem 2 - Temperature always reads extremely cold and never changes.• Solution - The wiring to the thermistor sensor is open, or the thermistor assembly is damaged and

open. Check the wiring.

• Problem 3 - Temperature always reads extremely hot and never changes.• Solution - The wiring to the thermistor sensor is shorted, or the thermistor assembly is damaged and

shorted. Check the wiring.

• Problem 4 - Temperature always reads hotter than it really is but does change.• Solution - The thermistor may be mounted in a position that exposes it to direct sunlight where radiant

heat causes a rise in temperature. The sensor may also be mounted near another heat source like a generator, engine, water heater etc. Relocate the sensor to a sun-sheltered position that has free airfl ow around it and is not exposed to any radiant heat sources.



• Problem 5 - Compass direction is erratic when certain equipment is turned on.• Solution - The TCM module may be mounted too close to high-current wiring. Check the installation

requirements and correct problems. Recalibrate the system.

• Problem 6 - Compass direction seems off by 90 degrees or more.• Solution - Recalibrate the TCM module. The system may indicate “Calibration Successful” even when

the coach is driven in a partial circle; therefore, it is important to complete one full circle or more during calibration.

Calibration Procedure

Direct Current Interface Module (2004 Version)

The Aladdin System DC voltage and current accuracy is ensured when component interface and calibration is properly performed. All DC calibration information is stored in non-volatile memory within the Interface module. Non-volatile memory retains calibration information regardless of power status.

Calibration for the 2004-2006 Aladdin Systems are protected by a maintenance code (1218) to guard against tampering. The code must be entered in order to access the calibration screens. Only authorized personnel should perform system calibrations.

• DC Volts Calibration: DC Volts calibration is performed during the manufacture of the DC Interface module (DCI). No

fi eld calibrations are required. Errors in voltage display are likely related to wiring problems. Good solid connections help to guarantee accurate results. The module is calibrated at 12.00 Volt DC. This provides accurate readings (+/- 0.05 VDC) in the 9-15 Volt DC range.

• Solar Current Calibration: The solar current sensor plugs into the Interface module. Due to manufacturing tolerances an “offset”

calibration must be performed for best accuracy. Each sensor is slightly different with respect to offset voltage output. The sensor typically has an offset output of ½ Vss (one half the sensors supply voltage i.e. Vss = 5VDC) when the current being measured is zero. The offset may be different for each sensor and the calibration procedure will compensate for errors.

1. Disconnect the Solar fuse or the solar panel positive output wire to ensure that solar output current is zero.

2. Using the Aladdin joystick, navigate to the SYSTEM OPTIONS screen. Select the SYSTEM SETUP screen.

3. When prompted, enter the maintenance code 1218.

4. Select Electrical Calibration.

5. Select Solar Amps to calibrate. Solar Amps Calibration screen will appear.



6. Select Calibrate. The screen will change back and Solar Amps will be fl ashing. Solar Amps should indicate 0.0. At the bottom of the screen the Solar Amps Cal value should be 0 +/- 15 bits. If the Cal Value is out of tolerance, check wiring and ensure zero current is fl owing through the sensor.

a) A Solar Cal value of -400 or more indicates the current sensor signal is shorted to the 5V supply. Sensor may be damaged or wired incorrectly.

b) A Solar Cal value of +400 or more indicates the current sensor signal is shorted to ground or is unplugged. Sensor may be damaged or wired incorrectly.

7. Navigate back to the Coach Electrical Status Screen. Solar current should read 0.0 Amps +/- 0.2 Amps.

8. Reconnect all Fuses and cables that were disconnected in Step 1.

9. Verify Solar panels are operating. If in full sun, check that solar current and voltage are reading properly.

• Battery/Aux Current Calibration: The solar current sensor plugs into the Interface module. Due to manufacturing tolerances an “offset”

calibration must be performed for best accuracy. Each sensor is slightly different with respect to offset voltage output. The sensor typically has an offset output of ½ Vss (one half the sensors supply voltage i.e. Vss = 5VDC) when the current being measured is zero. The offset may be different for each sensor and the calibration procedure will compensate for errors.

NOTE:In the following steps there are two battery current sensor calibrations available. One is house battery current; the other is Aux battery current. If Aux battery current is not used, do not calibrate it. Otherwise the same procedure is used for both sensor calibrations.

1. Turn off all battery charging sources.

2. Using a known accurate DC clamp-on amp meter, measure the battery current on the same cable that the current sensor is attached to. Verify the meter is properly zeroed prior to use.

3. Add or remove coach loads (such as lights) so the meter indicates there is a constant 5 to 10 Amp draw.

4. Using the Aladdin joystick, navigate to the SYSTEM OPTIONS screen and then to the SYSTEM SETUP screen.

5. When prompted, enter the maintenance code 1218.

6. Select Electrical Calibration. If the system is properly operating, the Electrical Calibration screen should indicate a discharge (negative) current reading on the battery current to be calibrated.

a) If Battery current agrees with clamp meter +/- 0.5 Amp, no calibration is necessary. b) If battery current does not agree with the clamp meter +/- 0.5 Amp, proceed with calibration.

7. Select Battery Current to calibrate (House or Aux). Battery Amps calibration screen will appear.

8. Adjust battery current up or down to equal the value (+/- 0.5 Amp) on the Clamp Meter. Press SELECT when fi nished. (Note: A negative value indicates discharge.)



9. The system will automatically take you back to the Electrical Calibration screen. Battery current (House or Aux) should now equal the current displayed (+/- 0.5 Amps) on the clamp-on meter. At the bottom of the screen the Battery Amps Cal value should be 0 +/- 20 bits. If the Cal Value is out of tolerance, check wiring and ensure the current reading on the clamp meter is correct.

a) A Battery Cal value of -400 or more indicates the current sensor signal is shorted to the 5 Volt supply. Sensor may be damaged or wired incorrectly.

b) A Battery Cal value of +400 or more indicates the current sensor signal is shorted to ground or is unplugged. Sensor may be damaged or wired incorrectly.

10. Navigate to the Coach Electrical Status Screen and verify battery current is operating properly for both charge and discharge conditions.

Tank Interface Module Calibration (2004-2006 Version)

The tank level indications are accurate when component interface and calibration is properly performed. All calibration information is stored in non-volatile memory within the Interface module. Non-volatile memory retains calibration information regardless of power status.

Calibration for the 2004-2006 Aladdin systems are protected by a maintenance code to guard against tampering. The code must be entered in order to access the calibration screens. Only authorized personnel should perform system calibrations.

• Auto-fi ll Calibration (Marquis): The Fresh Water Auto-fi ll requires no calibration or set up. Auto-Fill is pre-programmed to keep the

water level between 80% and 100% when activated.

• LP-Gas Level Calibration: LP-Gas level calibration is done during production of the Tank Interface Module. There are no fi eld

calibrations required. The only setting required is tank capacity. Any observed errors in the LP-Gas tank readings are most likely related to the tank sender or the wiring. Good solid connections are the best way to guarantee accurate results. Use waterproof connections when connecting the LP-Gas sensor wires to the LP-Gas tank sender. This will prevent corrosion from affecting the LP-Gas tank readings.

• Holding Tank Calibration: Two calibrations settings are required for each holding tank on 2003 systems. One is Empty and the

other is the Full. For 2004-2006, the joystick can be used to select numeric calibration settings. The 2004-2006 system can also be calibrated by fi lling the tanks with water (like the 2003 system). The Empty calibration is set so the system can reference the value. No two pressure sensors measure pressure identically. The Empty calibration must be performed for each tank: Fresh, Grey and Black. After setting the Full calibration, the system can reference the numeric differences between empty and full of each tank to allow precise measurement.

Calibration can be performed two different ways. Wet Full calibration requires fi lling the tank to the normally full position and entering in the calibration number. The Dry Full calibration does not require the tank to be fi lled; however, Empty must be fi rst calibrated. Calculations are performed to generate the proper Full calibration value entered into the system. During both the Empty and Full calibration procedures, numbers entered represent 1 bit each. Each bit is equal to 1mm of fl uid level change.



Empty Calibration:1) Determine the location of the tank pressure sensor. If the sensor

is located on the end of the holding tank, drain the tank as indicated in Figure 5. There will be no pressure on the tank sensor. If the pressure sensor is located in a drainpipe, drain the tank as indicated in Figure 6. The pressure on the sensor from the water remaining in the pipe will be the 0 or empty setting.

2) Use the Aladdin joystick to navigate to SYSTEM OPTIONS screen and then to SYSTEM SETUP screen.

3) When prompted, enter the maintenance code 1218.

4) Select Tank Calibration.

5) Select the tank you would like to calibrate Empty.

6) Enter the Empty calibration value, which should be equal to the RAW value displayed at the bottom of the screen. Exit the screen by moving the joystick left or right.

7) The system should be back on the Tank Calibration screen and the value just entered should appear next to the tank that was calibrated empty. Repeat this process for all tanks that require EMPTY calibration.

Wet Full Calibration (Requires Filling Tank):1) Fill the tank to the normally full position. This is usually 3/4”

down from the top of the tank (see Fig. 7).

2) Use the Aladdin joystick to navigate to SYSTEM OPTIONS screen and then to SYSTEM SETUP screen.



5) Select the tank you would like to calibrate FULL.

6) Enter the Full Calibration value, which should be equal to the RAW value displayed at the bottom of the screen. Exit the screen by moving the joystick left or right.

7) The system should be back on the Tank calibration screen and the value you just entered should appear next to the tank that was calibrated Full. Repeat this process for all tanks that require FULL calibration.



Dry Full Calibration (Tank at any level):This method does not require fi lling the tank to perform FULL calibration. An Empty calibration must

be performed prior to this method being used.

1) Measure the tank height from the center of the sensor to the top of the tank (see Fig. 8). If the sensor is mounted on a drainpipe or other plumbing, measure the height of the tank (see Fig. 9). The tank height measured must be 36" (914mm) or less.

2) Convert this measurement to millimeters (mm) mm = inches X 25.4

1/8" = 0.125" = 3mm1/4" = 0.250" = 6mm3/8" = 0.375" = 10mm1/2" = 0.500" = 13mm5/8" = 0.625" = 16mm3/4" = 0.750" = 19mm7/8" = 0.875" = 22mm

3) Subtract 19mm from the tank height measurement (This gives us the 3/4" air gap above the full water level). The factored number is the Full Cal Factor used in the following steps.

4) Using the Aladdin Joystick, navigate to the SYSTEM OPTIONS screen and then to the SYSTEM SETUP screen.

5) When Prompted, enter the maintenance code 1218.


7) Select the tank you would like to calibrate FULL.

8) Enter the Full Calibration value. The value entered for the selected tank is:

Full Cal Value = Full Cal Factor + Empty Cal Value Exit the screen by moving the joystick left or right.

9) The system should be back on the Tank calibration screen and the value you just entered should appear next to the tank that was calibrated Full. Repeat this process for all tanks that require FULL calibration using this method.

Example Calculations: Tank Height = 20.625” = 524mm Full Cal Factor = 524mm - 19mm = 505 Empty Cal Value = 45 Full Cal Value = 505 + 45 = 550



Setting Tank Capacities:Proper setting of the tank capacities allows the system to accurately calculate the fl uid volume in

gallons. Setting of the tank capacities will not affect the tank calibrations performed earlier. The gallons for the Fresh, Grey, Black and LP-Gas levels are stored inside the tank Interface module. The values are stored in non-volatile memory.

1) Using the Aladdin Joystick, navigate to the SYSTEM OPTIONS screen and then to the SYSTEM SETUP screen.


3) Select Set Tank Capacities.

4) Select the tank you would like to set the capacity on.

NOTE:Fuel tank capacity is also on this screen. The gallons value entered here is stored in the Aladdin controller and not in the Tank Interface Module.

5) Enter the Tank Capacity value. Exit the screen by moving the joystick left or right.

NOTE:The LP-Gas level is the total volume of the tank in gallons. Do not subtract the upper 20% used for expansion.

6) The system should be back on the Tank Capacity screen and the value just entered should appear next to the tank that was set.

Repeat this process for all tanks that require capacity changes.

Tank Level Interface Calibration (2003 Version Only)

The Tank Level Interface module (TLI) utilizes a pressure sensor in the bottom of the holding tanks to measure the depth of water within the tank. This sensor needs to be calibrated after installation to ensure accuracy. With proper calibration the Interface module will measure tank levels to 1/8" providing accurate measurements.

The 2003 system requires calibrating both empty and full. Once calibrated, the system can determine the height of the tank. Measured depth and height gives percentage full, and tank capacity in gallons.



Empty Calibration Procedures:Step 1 - Prepare the tank for an empty calibration: Empty the tank to be calibrated. If the pressure sensor is mounted below the bottom of the tank, such as on a drain tube, drain the tank to the bottom edge.

Step 2 - Set the VCM to system calibration screen:From the MAIN MENU navigate to SYSTEM OPTIONS and then to SET SYSTEM CALIBRATION.

Step 3 - Perform the empty calibration:Using the joystick, select the tank to calibrate empty and move the joystick to the right. The empty calibration number will fl ash while calibrating and then goes solid.

Step 4 - Record Results:Record the Empty Cal value in the following form where indicated. This information is used for future reference and may be used to calculate the correct Full Cal value.

Repeat steps 1 through 4 for all tanks requiring empty calibration. If no further calibrations are to be performed, navigate back to the main menu.

Full Calibration Procedures:Full calibration is performed with the tank full. Tank material or access can make it diffi cult to know

when a tank is full. If the tank level can not be determined, it is possible for the pressure sensor to tell when it is full. To do this, measure the height of the tank from the center of sensor vertically to the top edge of tank. Convert this measurement to 1/8" increments and fi ll in the following worktable. (Example: 11-5/8" height = 93 eighths.)

TankEmpty CAL

Value

Tank Height in 8ths

Subtract 6 for a 3/4” safety margin

so we do not overfi ll the tank!

Full Calibration Value

Calculated Actual

Fresh + = - 6 =Gray + = - 6 =Black + = - 6 =

example 32 + 93 = 125 - 6 = 119 119



From the Main Menu navigate to SYSTEM OPTIONS, then to SET SYSTEM CALIBRATION. To fi ll the tank, there are three options: A, B or C. Perform the option that applies to that particular installation and then proceed to Step 1.

Option A: If you can see the level in the tank, fi ll to about ¾" from the top to leave an air gap in the tank. Motorhomes with auto-fi ll water systems may fi ll the fresh tank until it automatically stops, this will be the FULL CAL point on the fresh tank. Proceed to Step 1.

Option B: If you cannot see the tank level and the SET SYSTEM CALIBRATION screen does show the RAW tank level data at the very bottom of the screen. Fill the tank to be calibrated until its raw value is equal to the Calculated Full calibration value determined in the worksheet above. Proceed to Step 1.

Move the joystick right until RAW mode is displayed. Return to the main menu by moving the joystick left. Select TANK LEVELS from the MAIN MENU. All of the tank levels are listed in RAW data mode. Fill the tank to be calibrated until its raw value is equal to the calculated full value determined in the worksheet above. Return the system to NORMAL sensor mode by selecting SYSTEM OPTIONS from the main menu. Select SYSTEM CONFIGURATION. The system should be in RAW sensor mode. Move the joystick right until NORMAL mode is displayed. Return to the main menu by moving the joystick left. From the MAIN MENU navigate to SYSTEM OPTIONS and then to SET SYSTEM CALIBRATION. Proceed to Step 1.

Step 1 - Fill the tank to be calibrated.

Step 2 - Perform the full calibration: Using the joystick, select the tank to calibrate full and move the joystick to the right. The full calibration number will fl ash while calibrating. When calibrated the number will stop fl ashing.

NOTE:Do not accidentally select empty calibration or you will have to start all over.

Step 3 - Record Results: Record the Full calibration value from the worksheet for future reference. Repeat steps 1 through 3 for all tanks requiring full calibration. If no further calibrations are to be performed, verify system operation. Set Tank Capacities.

Option C: If you cannot see the tank level and the SET SYSTEM CALIBRATION screen does not show the RAW tank level data at the very bottom of the screen, usie the data from the worksheet above to set the system to RAW display mode by selecting SYSTEM OPTIONS from the main menu. Select SYSTEM CONFIGURATION. The system is now in NORMAL sensor mode.

Step 1 - Fill the tank to be calibrated.

Step 2 - Set the Aladdin system to the Tank Capacity screen. From the main menu, navigate to System Options and then to Set Tank Capacities.

Step 3 - Select tank to adjust capacity: Using the joystick, select the tank to adjust capacity and move the joystick to the right. A new screen will appear. Enter each digit from 1 to 255 gallons. An entry of 75 gallons would be entered as 075. When fi nished, move the joystick right or left until the Set Tank Capacities screen displays. Verify the gallons are correct. Repeat steps 1 and 2 to set capacities for the other tanks, otherwise return to the main menu. After system calibration, verify system operation.



Temperature/Compass Interface Module Calibration (2004 version)

All calibration information for the compass and temperature is stored in non-volatile memory within the Interface module. Even when power is removed for extended periods of time the calibration information will stay in non-volatile memory.

Temperature Calibration:Temperature calibration is preset in the Interface module. There are no calibrations required. Any

observed errors in temperature are most likely related to the sensor location or wiring.

Compass Calibration:Compass calibration is required to compensate for the “magnetic signature” of the motorhome. Each

motorhome will have a different magnetic fi eld. The term “Hard Iron Effects” is a magnetic fi eld affecting the compass caused by the manufacturing process. Each magnetic signature is slightly different from motorhome to motorhome.

Along with hard iron effects are soft iron effects. These are changes in the magnetic fi eld of the motorhome caused by the Earth’s magnetic fi eld. While traveling, compass readings will change with location due to the Earth’s radiating magnetic fi eld.

NOTE:The Interface module compensates for the magnetic fi eld in the motorhome during calibration.

If the Interface module board is moved or the Temperature/Compass module is moved, the compass will need to be recalibrated.

To Calibrate the Compass:1. Using the Aladdin Joystick, navigate to the Systems Options screen and then to the Compass

Calibration screen.2. Select Start Calibration and then select Confi rm Start Calibration.3. Stop Calibration will blink on the display. While this is occurring, drive slowly clockwise or

counterclockwise to complete a 360º circle one or two times. The surface should be level. Stay at least 10 feet away from metal buildings or other large metal objects, such as other vehicles.

4. Bring the motorhome slowly to a stop and select Stop Calibration.5. The display should indicate Calibration Successful. If Calibration Fail appears, one of the following

two-digit codes will display.

In all cases, try Steps 1-5 again.

1n - Severe magnetic fi eld right or left of TCM (Hex min limit)2n - Severe magnetic fi eld right or left of TCM (Hex max limit)4n - Severe magnetic fi eld or complete circle not performed (Hex Diff limit)n1 - Severe magnetic fi eld fore or aft of TCM (Hey min limit)n2 - Severe magnetic fi eld for or aft of TCM (Hey max limit)n4 - Severe magnetic fi eld or complete circle not performed (Hey Diff limit)(n can be 0,1,2 or 4)

6. Navigate to any of the engine status screens to view the magnetic heading. Slowly drive in a circle checking that all eight quadrants display (N, NE, E, SE, S, SW, W, NW). The display is the magnetic heading and not true heading.



A declination chart of the United States (Fig. 10) shows the difference between a magnetic heading and a true heading. A magnetic reading in central Oregon for example, would indicate 19º to the right (East) of true North when the motorhome is pointing toward true geographic North.

020116bFig. 10

025 aladdin troubleshooting

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