Professional Documents
Culture Documents
Copyright 2000, 2003 General Electric Company. All rights reserved. This copyrighted document may be reproduced free of charge by General
Electric Company customers (OEM’s) and their customers, if such reproduction is used exclusively in connection with equipment used in those
customers’ internal operations.
These instructions do not purport to cover all details or variations in equipment nor to provide for every possible contingency to be met in connection with installation, operation, or mainte-
nance. Should further information be desired or should particular problems arise which are not covered sufficiently for the user’s purposes, the matter should be referred to the General
Electric Company. Any applicable Federal, State or local regulations or company safety or operating rules must take precedence over any instructions given in this material. GE has no
obligation to keep the material up to date after the original publication.
CONTENTS
Page
1. OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1. TOOLS AND TEST EQUIPMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2. HANDLING ELECTRONIC PANEL PRINTED CIRCUIT CARDS . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4. CONFIGURATION FILES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.1. GE CONFIGURATION FILE NAME DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
4.2. VIEW TRUCK CONFIGURATION SCREEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
i
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
CONTENTS (Cont’d)
Page
4.3. GE/OEM DEFAULT CONFIGURATION FILES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
4.4. GE/OEM CONFIGURATION OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
4.5. SAVING NEW CONFIGURATION FILES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
4.6. CONFIGURATION FILE DESTINATION DIRECTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
4.7. CONFIGURATION FILE SOURCE DIRECTORY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
ii
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
CONTENTS (Cont’d)
Page
6.19. INVERTER LOAD TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
6.20. FUNCTIONAL GROUND FAULT DETECTION TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
7. STATISTICAL DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
7.1. GENERAL DESCRIPTION AND DEFINITION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
7.2. VIEW STATISTICAL COUNTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
7.3. VIEW STATISTICAL PROFILES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
7.4. VIEW TRUCK STAT SERIAL REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
7.5. RESET STATISTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
7.6. UPLOAD STATISTICAL DATA TO A FILE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
7.7. PROFILE (HISTOGRAM) DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
iii
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
CONTENTS (Cont’d)
Page
10.4. CURRENT MEASURING MODULE CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
10.5. LINK CAPACITANCE TEST MONITORING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
10.6. AUXILIARY INVERTER SCR/IGBT TROUBLESHOOTING (KG498 ONLY) . . . . . . . . . . . . . . 167
10.6.1. Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
10.6.2. SCR Check–Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
10.6.3. IGBT Check–Out . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
11. PHASE MODULE AND GATE DRIVER TROUBLESHOOTING GUIDE . . . . . . . 169
11.1. INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
11.2. TEST/INSPECTION PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
LIST OF TABLES
iv
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
LIST OF ILLUSTRATIONS
v
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
vi
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
vii
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
viii
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
1. OVERVIEW
This document describes the recommended truck start–up and checkout procedures at an Original Equipment
Manufacturer (OEM) facility or a customer’s mine. Special programming of specific mine software requirements, soft-
ware updating, system verification procedures, and troubleshooting information are also included. Refer to Section
14., Software Versions, for current software version features and previous version information.
These instructions cover 320 ton applications of the following GE OHV AC control groups:
17KG498 (2700 HP)
17KG526B (3500 HP)
17KG526C (2700 HP)
NOTE: Screen content of the wPTU* Toolbox display screens may vary slightly for different control
groups.
Information on the screen content and functions of the wPTU Toolbox are also provided. Complete wPTU
Toolbox operational procedures are in the OHV wPTU TOOLBOX USER’S GUIDE, GEK–91712.
NOTE: No revision bars are shown due to this being 100% revised to cover the new wPTU Toolbox
procedures for 320 Ton vehicles from the previous DOS–based PTU covered in GET–6864.
The following are recommended tools and test equipment used in the start–up and troubleshooting of the AC Off–
Highway Vehicle (OHV) propulsion system:
1
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
NOTE: If a need arises to disassemble one of the 104–pin backplane connectors to an electronic control
card panel, a special thin wall socket or nut driver will be required to loosen and remove the assembly
hardware. The socket can be purchased. However, if not purchased, it is recommended that a standard
1/4 in. socket or nut driver be sufficiently machined on a grinder to enable its use in performing the disas-
sembly.
It is not recommended to pull cards from the panel any more times than necessary when starting up, testing, or
welding on the truck. This practice can cause more damage than it prevents because it puts unnecessary cycles on
the connector pins and may cause loose or dirty pins that could cause a control system malfunction.
CAUTION: If cards must be removed from a panel, power to the panel be turned OFF before removing or
inserting cards into the panel.
CAUTION: It is important to note that printed circuit cards in the electronic control card panels are sensi-
tive to static electricity. Handling cards without proper grounding precautions could damage electronic
components mounted on them. Also, when transporting or storing these cards, industry recommended
special static electricity–proof containers should be used.
2
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
The PTU presently used by all GE field personnel is an IBM compatible, portable PC with a hard disk, compact disc
(CD), 3.5” floppy diskette drive(s), and RS232 communication port. Any PC to be used with the wPTU Toolbox
should have a 500 MHz or higher processor speed and at least 128 Meg of random access memory (RAM). The
wPTU Toolbox is for use with software Version 19.03 and higher and 17FB173 Cards Version 3 and higher (this is the
CPLD version that shows up on the wPTU Software Version screen).
All adjustments, setup procedures, and diagnostic troubleshooting of the truck’s control system can be made
through this PTU when loaded with the OHV wPTU Toolbox software.
NOTE: Refer to GEK–91712, OHV wPTU User’s Guide, for complete information on installing and using
the wPTU Toolbox software.
Qualified GE and truck builder (OEM) specialists are able to download new software, troubleshoot system faults,
and establish the control system configuration (horsepower, etc.).
Customers’ qualified mine personnel are able to download new software, troubleshoot system faults, and set spe-
cific mine operating parameters.
Additional terms are defined in Section 13., Glossary of Terms, TABLE 7, Glossary.
The wPTU Toolbox includes the major functions described in this secton.
3
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
2.2.8. Self–Test
The wPTU Toolbox software can be used to initiate or view propulsion system test information. Load–box mode,
the capacitance test, and manual self–test mode can be monitored.
NOTE: Refer to GEK–91712, OHV wPTU User’s Guide, Sections 3.1 and 3.2 for complete information on
installing and starting the wPTU Toolbox software.
The Mode Options are either Normal Mode or Offline/Training Mode. In the Normal Mode the wPTU at-
tempts a connection with the target. When the connection is established, the truck type and truck ID are obtained from
the target. (The mode options can be saved in a settings file.)
In the Offline/Training Mode, the user enters the truck type. If the AC button is selected, the user also selects the
panel type. (If the DC button is selected, the panel type is disabled.)
4
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
NOTE: The Truck Type, Panel Type, and GE System selections are disabled in the Normal Mode. Proce-
dures in this manual are written for the Offline/Training Mode. Some portions of certain procedures will
be performed automatically when in the Normal Mode.
When the LOGIN to wPTU Toolbox button is pressed, the entered password is verified and the user selects the
panel type, TCI or PSC.
The set of screens dedicated to TCI interaction and operation is outlined in Figure 2. The BOLD typeface indicates
a menu screen, whereas normal typeface indicates a dedicated purpose screen.
The set of screens dedicated to PSC interaction and operation is outlined in Figure 3. As in Figure 2, BOLD type-
face indicates a menu screen, whereas normal typeface indicates a dedicated purpose screen.
Most of the truck startup procedures and troubleshooting procedures involve the wPTU toolbox. Figure 1
through Figure 3 in this publication provide a reference to the figures associated with the various wPTU screens to
guide the user to the desired wPTU function screen.
NOTE: A brief description of all wPTU screens is contained in the Help menu. In the Menu Bar, click on
Help –> Applications –> PTU Screen Help –> Desired Screen.
5
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
PTU Screens
TCI
Normal_Operation
Real_Time (Fig. 48)
TCI – Real Time Data (Fig. 49)
TCI – Serial Link Data
TCI – Analog Inputs (Fig. 40)
TCI – Temperatures
Logic (Fig. 15)
Accel Inhibit Logic (Fig. 16)
Configuration
TCI Parameters
TCI Analog Outputs
TCI Truck Configs
TCI Software Versions
TCI Datalog Setup
Special Tasks
Event_Menu (Fig. 92)
TCI Event Summary (Fig. 93)
TCI Trigger Data (Fig. 94)
TCI Datapacks (Fig. 95)
TCI Log Events
Reset TCI Events (Fig. 96)
Erase TCI Events (Fig. 97)
Stat_Menu (Fig. 56)
Stat Serial Report (Fig. 61)
View Counters (Fig. 57)
View Profiles (Fig. 59)
Reset Stats (Fig. 35)
Stat Start Date
Set Time and Date (Fig. 33)
Events & Inv Params (Fig. 98)
Engine_Stopped_Tasks (Fig. 44)
TCI Manual Test (Fig. 51)
Gauge Calibration (Fig. 45)
Ctrl_Z_to_return_to_menu
6
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
PTU Screens
PSC
Normal_Operation
Real_Time (Fig. 41)
PSC – Real Time Data (Fig. 43)
PSC – Serial Link Data
PSC – Analog Inputs (Fig. 42)
PSC – Temperatures (Fig. 10)
Inverter Info
FB173 Card Data (KG526 Groups Only)
Logic (Fig. 11)
Ready Mode (Fig. 12)
Propel Mode (Fig. 13)
Retard Mode (Fig. 14)
Configuration
PSC Parameters
PSC Analog Outputs
FB173 analog Outputs
PSC Truck Configs
Inverter Parameters (Fig. 54)
Custom Parameters
PSC Software Versions (Fig. 36)
PSC Datalog Setup
Tests (Fig. 99)
Self Load Engine Test (Fig. 55)
Temperatures
Capacitance Test (Fig. 100)
Special Tasks (Fig. 46)
Event_Menu
PSC Event Summary
PSC Trigger Data
PSC Datapacks
PSC Log Events
Reset PSC Events
Erase PSC Events
Set Time and Date (Fig. 47)
Events & Inv Params (Fig. 98)
Engine_Stopped_Tasks (Fig. 37)
PSC Manual Test (Fig. 38)
Ctrl_Z_to_return_to_menu
7
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
When in the Offline / Training Mode, options on this screen are selected by clicking in the selection circle (GE
System, Panel Type, or Mode). When in the Normal Mode (connected to a truck), these selections are performed
automatically by the wPTU Toolbox.
After entering a valid password, select any of the functions shown on the right side of the screen by clicking on the
button for the function.
NOTE: Refer to GEK–91712, OHV wPTU User’s Guide, for complete information on installing and using
the wPTU Toolbox software. Information on screen selections, navigation methods, and options is
also included.
8
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
9
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
7. Close the PSC Datalog Setup display screen by clicking on the X in the upper right corner of the screen and
shutdown the wPTU Toolbox.
1. From the Start Menu go to START –> Program Files –> GEOHVPTU 1xx (current version) –> AC Tools –>
Datalog –> Start Datalogger.
2. The Datalog xx.xx (current version) screen is now displayed (Fig. 7). The Datalog xx.xx screen will show how
long the recording can be performed based on the number of variables being recorded, the record rate, and the
available PC memory.
3. In the Menu section of the screen, two options are available as follows:
<W>rite data & quit – This option will stop datalogging and save the data to a file c:\program
files\GEOHVPTU 1xx (current version)\datalog\dlogxxx (xxx is a sequential number)
<A>bort – This option stops datalogging and does not create a file with the data.
The file generated in V19 software is a Space Delimited file that can be opened using any spreadsheet or text
editor. The file generated in V20 software is a Comma Delimited file (*.csv).
10
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
Any real time screen display can be saved for future viewing. Complete procedures for saving screens and data
are provided in GEK–91712, OHV wPTU Toolbox User’s Guide, Section 3.5, MAIN WINDOW MENUS.
A saved screen can be replayed in both online and offline modes. The screens can be saved to a file and then can
be replayed, converted to CSV format, or graphed (screen is saved as a binary file). The user specifies the filename
and location where the file is saved.
2.7. PASSWORDS
The ability to set passwords is provided using the Password Utility for the wPTU toolbox (Fig. 8). Refer to
GEK–91712, OHV wPTU Toolbox User’s Guide, Section 5, PASSWORD UTILITY for complete information on
setting passwords and password privilege levels. It is recommended that supervisors assign passwords and privilege
levels below their own.
11
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
12
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
The following information describes selected screens and functions that are commonly used in the startup and
troubleshooting of the GE OHV AC Propulsion System. Sections 3.1 through 3.5 describe screens that are contained
in the wPTU Configuration Utility. Sections 3.6 through 3.9 describe screens and functions that are contained in
the wPTU Toolbox. The propulsion system’s REST mode function is described in Section 3.9 and the Auxiliary
Blower Control function and monitoring is described in Section 3.10.
This screen is used to create a tracking record for a specific truck or series of trucks (Fig. 27). This record sets a
history as to ship date, where and when the truck was placed in service, and it ties that specific truck to its operational
settings for that period of service.
From the Product Service Data screen, six possible areas may be set or changed for the specific truck or series of
trucks chosen. Only those data items which have been authorized and activated can be set or changed. Perform the
following to change the data settings:
1. Either click in the desired box (outlined in red on the left of screen) or use the TAB key to scroll continuously
down through the boxes.
2. Change the setting by deleting the existing setting (press any key and type the new setting, or simply type over
the existing data).
3. Press Enter to enter the modified setting. (The box color changes from white to blue, indicating that it has been
changed and will remain blue for the present session until the file is saved.)
NOTE: To keep the changes made to the Product Service Data settings, the file must be saved.
4. Click on File and Save. Pop–up messages notify the user that the changed data has been saved, and offer
other Save options.
This screen is used to set the sensitivity and reactivity of the acceleration and retarding controls as desired, based
on specific operating conditions (Fig. 28).
From the Truck Specific Data screen, eight possible parameters may be set or changed for the specific truck
chosen. In addition, the truck ID number may be entered and changed, thus choosing these settings for a specific
truck when saving the file. Only those parameters which have been authorized and activated can be set or changed.
Perform the following to change the data settings
NOTE: Holding the mouse cursor over an item displays Help information for that item.
1. Either click in the desired box (outlined in red on the left of screen) or use the TAB key to scroll continuously
down through the boxes.
2. Change the setting by deleting the existing setting (press any key and type the new setting, or simply type over
the existing data).
3. Press Enter to enter the modified setting. (The box color changes from white to blue, indicating that it has been
changed and will remain blue for the present session until the file is saved.)
13
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
NOTE: If a parameter is out of limits, a warning message appears. Click OK to return to the Truck Specific
Data screen and correct the setting.
NOTE: To keep the changes made to the Truck Specific Data settings, the file must be saved.
4. Click on File and Save. Pop–up messages notify the user that the changed data has been saved, and offer
other Save options.
The Truck Specific Data screen is used to enter the following information:
The View Overspeeds screen displays the current mine speed limit settings for the truck chosen (Fig. 29).
14
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
By entering the codes for the wheel motor models that are being used on this truck, two possible parameters may
be set or changed. Only those items which have been authorized and activated can be set or changed. Perform the
following to change the settings:
1. Either click in the desired box (outlined in red on the left of screen) or use the TAB key to toggle between the
boxes.
2. Change the setting by deleting the existing setting (press any key and type the new setting, or simply type over
the existing data).
3. Press ENTER to enter the modified setting. (The box color changes from white to blue, indicating that it has
been changed and will remain blue for the present session until the file is saved.)
4. Click on File and Save. Pop–up messages notify the user that the changed data has been saved, and offer
other Save options.
NOTE: Refer to Section 13., TABLE 7, Glossary, for definitions of the signal names that appear on this
and other screens.
1. Analogs – This section monitors the status and values of analog signals from devices such as current sensors,
voltage sensors, temperature sensors, etc.
2. Modes – This section provides information regarding the mode of operation, the direction of operation, the
commanded percent of propel or retard effort, communication status with TCI, etc.
15
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
3. Speeds – This section monitors various speed sensor signals and provides a processed truck speed indica-
tion.
NOTE: When discrete signals are active, they are displayed inversed (highlighted). This display method
is used for Digital Inputs, Digital Outputs, and Serial Link Data To and From TCI.
4. Digital Inputs (DI) – This section monitors the status of discrete input signals to PSC such as contactor posi-
tion sensors, electronic connector continuity, etc.
5. Digital Outputs (DO) – This section monitors the status of discrete output signals from PSC such as contactor
commands, panel enabling signals (e.g. GD1E, AFSE), indicating light control, etc.
6. Serial from TCI – This section monitors the status of discrete signals received by PSC from TCI over the PSC–
TCI serial link.
7. Serial to TCI – This section monitors the status of discrete signals provided by PSC to TCI over the PSC–TCI
serial link.
8. Inverters – This section monitors the status of various signals related to inverter operation including run status,
torque command, torque feedback, etc.
Close the PSC – Real Time Data display screen by clicking on the X in the upper right corner of the screen.
16
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
17
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
18
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
19
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
20
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
3. Close the Propel Mode display screen by clicking on the X in the upper right corner of the screen.
4. Click on the Target button to go back to the GE OHV wPTU Toolbox Login screen, close the wPTU Tool-
box, shut down the PTU, and disconnect it from the PSC serial port.
21
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
The TCI Accel Inhibit Logic screen can be accessed by the wPTU user to check the TCI accel inhibit logic. This
screen displays real–time ladder diagrams that show the necessary truck functions and propulsion system operations
that must occur in order for an accel inhibit condition to occur. When activated, the various ladder diagram functions
are displayed reversed (highlighted). In this manner, this logic screen can be used as a troubleshooting aid in diagnos-
ing why an accel inhibit condition has occurred.
Perform the following to access the TCI Accel Inhibit Logic screen:
1. Connect the PTU to the TCI serial port (located in the operator cab), start the GE OHV wPTU Toolbox, enter
password, select TCI Panel, select appropriate truck type, and click on LOGIN to wPTU Toolbox.
2. From the window browser, select PTU Screens –> TCI –> Normal_Operation –> Logic –> Accel Inhibit
Logic (Fig. 15).
3. The Accel Inhibit Logic screen is now displayed (Fig. 16).
4. Close the Accel Inhibit Logic display screen by clicking on the X in the upper right corner of the screen.
5. Click on the Target button to go back to the GE OHV wPTU Toolbox Login screen, close the wPTU Tool-
box, shut down the PTU, and disconnect it from the TCI serial port.
22
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
23
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
To aid in getting the data from the CPU card and into the office computer, the Consolidated Truck Data Save
function has been provided in the wPTU Toolbox. This function puts all the collected statistical data in a file which
can then be processed at a later time.
1. Connect the PTU to the TCI serial port (located in the operator cab), start the GE OHV wPTU Toolbox, enter
password, select TCI Panel, select appropriate truck type, and click on LOGIN to wPTU Toolbox.
2. From the PTU Screens –> TCI screen Menu Bar, select UpLoad –> Consolidated Truck Data Save (Fig 17,
refer to GEK–91712).
3. Select the type of report to be saved from the Reports Type list, choose a Save Directory, then click on the
Begin button to begin uploading (Fig. 18).
4. Click on Close when the uploading is complete, then click on the Target button in the screen Tool Bar to go to
the wPTU startup screen.
5. Close the wPTU Toolbox, shut down the PTU, and disconnect it from the TCI serial port.
FIG. 17. CONSOLIDATED TRUCK DATA SAVE SELECTION FROM TOOLBAR. E–45249.
24
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
25
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
REST mode is commanded by placing the REST rocker switch in the ON position. Placing this switch in the ON
position commands the propulsion system to go to the REST mode of operation, provided that all necessary truck
operating conditions are met, such as truck stopped. Use the REST mode indicating light and the capacitor charged
lights on the main control cabinet to confirm that the REST mode has been successfully achieved after command.
The following are the major reasons for commanding the propulsion system to REST mode:
1. It should always be done when shutting down a truck. The propulsion system should be placed in REST prior to
turning off the engine.
2. It should always be done when the operator leaves the operator’s cab.
3. It is often done when the truck is expected to idle for an extended period of time.
To bring the GE OHV AC propulsion system out of REST mode, place the REST rocker switch in the OFF position.
Provided that truck operating conditions are met, there will be a period of time while the propulsion system energizes
the DC link and gets ready for either accelerating and/or retarding mode truck operation.
The auxiliary blower control system has its own, separate DC link that provides power to the auxiliary blower control
inverter.
WARNING: Whenever the auxiliary blower control system is not shutdown in a controlled manner, such as
during an auxiliary blower control fault, the auxiliary blower DC link may remain energized for an extended
period of time.
Always check for presence of voltage on the auxiliary blower control DC link before servicing this equip-
ment. Auxiliary DC link charged indicating lights are provided on the top of the control capacitor panel for
visual indication. It is recommended that the auxiliary DC link be measured by separate instrumentation as
well before proceeding with maintenance or troubleshooting activities. Failure to do so may result in per-
sonnel injury or death.
The auxiliary blower control speed command (AUXCMD) and the auxiliary blower speed feedback (AUXFB) can
be monitored through the PSC – Real Time Data screen. Perform the following to view:
1. Connect the PTU to the PSC panel (port is located on a bracket under the center dashboard), start the GE OHV
wPTU Toolbox, enter password, select PSC Panel, select appropriate truck type, and click on LOGIN to
wPTU Toolbox.
2. From the window browser, select PTU Screens –> PSC –> Normal_Operation –> Real_Time –> Real Time
Data (Fig. 41).
26
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
3. The Real Time Data screen is now displayed and the auxiliary blower command and feedback can be viewed
(Fig. 43).
AUXOK highlighted on the PSC – Real Time Data screen is an indication that the auxiliary blower control sys-
tem is functioning properly while it is being commanded to run the auxiliary blower.
When the auxiliary blower control system is not commanded to operate the blower, AUXOK will not be high-
lighted on the PSC – Real Time Data screen.
4. Close the PSC – Real time Data display screen by clicking on the X in the upper right corner of the screen.
5. Click on the Target button to go back to the GE OHV wPTU Toolbox Login screen, close the wPTU Tool-
box, shut down the PTU, and disconnect it from the PSC serial port.
27
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
28
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
4. CONFIGURATION FILES
Configuration files are contained in the GE Truck Configuration Utility (CFG AC Vxxxx) (current version). GE con-
figuration file descriptions are displayed when this utility is opened. The configuration utility is opened and files se-
lected as follows:
1. Click the mouse on the AC Configuration Utility icon on the desktop or from the Start Menu go to START –>
Programs –> GEOHVPTU 1xx (current version) –> AC Tools –> CFG AC Vxxxx (current version).
2. Enter an applicable password.
3. Select the appropriate GE configuration file for the truck (refer to Figure 23 for typical View Configuration
Files screen example and refer to TABLE 1 for description of files).
4. Click the on the file to select it and then click OK to go to the PTU Screens –> Configuration Browser.
NOTE: A truck configuration file must be selected before any of the other utility menu choices can be
used except Exit.
Configuration filenames are established using a specific set of guidelines. Each element in a filename represents a
piece of information which describes the application, revision, issue date, etc. (Fig. 19).
To view the Truck Configuration screen, from the window browser, select PTU Screens –> Config –> Truck
Configuration. An example of a typical Truck Configuration screen is shown in Figure 20.
Close the Truck Configuration display screen by clicking on the X in the upper right corner of the screen.
A27005A.903
A27 005 A 9 03
29
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
30
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
There are 20 default GE configuration files for the OHV AC propulsion system. They are described in TABLE 1,
Default Configuration Files and Descriptions.
NOTE: Files that do not apply to 320 Ton vehicles are shaded. Files 1 – 13 are not included in Version 20.
One OEM configuration file should be created by the GE Product Service representative or the OEM representa-
tive for each truck type at the mine location. The GE base configuration files in TABLE 1 should be used. The OEM
files should then be used to create an individual truck configuration file for each truck.
OEM file with OEM options OEM file with OEM options
OEM Files and mine information set and mine information set
OEM006a.903 OEM012a.903
Truck #. . . . Truck #. . . .
Truck #. . . . Truck #. . . .
Truck #. . . . Truck #. . . .
31
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
32
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
These configuration options are adjustable only by an OEM or GE representative, and can only be viewed at the
mine privilege level. Refer to Figure 25 for an example of the Set GE/OEM Options screen.
NOTE: To change GE/OEM Configuration Options requires use of the appropriate privilege level pass-
word.
For Version 20, the features shown in TABLE 2, GE/OEM Configuration Options and Descriptions, are avail-
able as GE/OEM configurable options. Default settings are noted.
33
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
34
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
The activated specific options define the OEM configuration and are normally saved under a filename which can be
used to uniquely identify it at a later time.
Click on File –> Save to save the new configuration (changes) as the same file and overwrite the existing configu-
ration of that filename.
Click on File –> Save As to save the new configuration (changes) as a new file and retain the existing configuration
of the original filename.
35
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
Verify that the desired filename is displayed. Note that the name of the file that was chosen as the valid truck config-
uration is displayed automatically. A new filename is entered by typing the entire new filename. Refer back to Figure
19 for configuration file naming conventions.
This OEM truck configuration file would be the one normally loaded at the beginning of the software download
during a truck startup. It contains the correct option settings and the default truck specific data.
The active wPTU directory where configuration files are saved is displayed on the View Configuration Files
screen (Fig. 23) in the Destination Directory menu. All configuration files that are commanded to be saved will be
saved in this directory.
To change the configuration save directory, click on the Browse button next to the Destination Directory menu
and choose a different existing directory or type in the new full directory path name.
The active PTU directory where configuration files are retrieved from is displayed on the View Configuration
Files screen (Fig. 23) in the Source Directory menu. All configuration files that are available for retrieval and manipu-
lation are in this directory.
36
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
WARNING: Ensure that all mine, OEM, and GE safety procedures are followed during truck software
installation. Ensure the truck is parked in a safe location with the Park Brake applied and the propulsion
system placed in REST mode. Failure to do so could result in personal injury or death, as well as equip-
ment damage and inadvertent truck movement.
Before new software can be loaded into a truck’s propulsion system, configuration files must be created and truck–
specific parameters must be recorded. The following tasks must be completed in the order listed:
NOTE: The OEM file only needs to be created one time. A truck–specific file must be created for each
individual truck. The full installation process takes approximately 40 minutes.
37
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
f. From the PTU Screens –> Configuration Browser, select Product Service Data (Fig. 27). Set the fol-
lowing items in this screen and press ENTER after each change/entry:
(1) Mine Name
(2) GE Mine Code
(3) Model of Truck
g. Name the OEM configuration file according to the following convention and save the file. Replace the first
three digits of the GE configuration file with “OEM”. For example, OEM006a.903 would be the OEM config-
uration file that is derived from GE configuration file A27006a.903.
38
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
39
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
40
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
41
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
42
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
43
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
1. Connect the PTU to the TCI serial port (located in the operator cab), start the GE OHV wPTU Toolbox, enter
password, select TCI Panel, select appropriate truck type, and click on LOGIN to wPTU Toolbox.
2. From the PTU Screens –> TCI screen Menu Bar, select UpLoad –> Consolidated Truck Data Save (Fig 17,
also refer to GEK–91712).
3. Select All Reports, choose a Save Directory, then click on the Begin button to begin uploading (Fig. 18).
5. Click on the Target button to go back to the GE OHV wPTU Toolbox Login screen, close the wPTU Tool-
box, shut down the PTU, and disconnect it from the TCI serial port.
44
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
NOTE: It may be necessary to cycle control power in order to download. Do so by turning the Control
Power Switch or Keyswitch OFF, then back ON.
5. Click on the Exit button when the download is complete to go back to the OHV wPTU Programming Utility
screen.
6. Click on the Exit button again to go back to the GE OHV wPTU Toolbox Login screen, then close the
wPTU Toolbox, shut down the PTU, and disconnect it from the TCI serial port.
45
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
NOTE: It may be necessary to cycle control power in order to download. Do so by turning the Control
Power Switch or Keyswitch OFF, then back ON.
5. Click on the Exit button when the download is complete to go back to the OHV wPTU Programming Utility
screen.
6. Click on the Exit button again to go back to the GE OHV wPTU Toolbox Login screen, then close the
wPTU Toolbox, shut down the PTU, and disconnect it from the PSC serial port.
46
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
NOTE: Throughout the procedures in the remainder of this section, it is required that the inverters be
cutout at various times. The 17KG526 Control Group does not include Inverter Cutout switches. Change
inverter status for the different control groups where necessary as follows:
On KG498 and KG526B Control Groups, place the Inverter #1 and Inverter #2 Cutout switches in the
Down position to CUTOUT or in the Up position for NORMAL operation.
On KG526C Control Groups, use the DID panel to CUTOUT Inverter #1 and Inverter #2 or to place in NOR-
MAL operation. Refer to Section 8., Diagnostic Information Display (DID) Panel.
NOTE: It may be necessary to cycle control power in order to download. Do so by turning the Control
Power Switch or Keyswitch OFF, then back ON.
9. Click on the Exit button when the download is complete to go back to the OHV wPTU Programming Utility
screen.
10. Click on the Exit button again to go back to the GE OHV wPTU Toolbox Login screen and disconnect the
wPTU from the Inverter #1 serial port (CNG, 17FL375 panel or RS11 17FL320 panel).
11. Connect the wPTU to the Inverter #2 serial port (CNH, 17FL375 panel or RS12 17FL320 panel) and repeat
steps 5 through 9 of this procedure.
12. Click on the Exit button again to go back to the GE OHV wPTU Toolbox Login screen, then close the
wPTU Toolbox, shut down the PTU, and disconnect it from the Inverter #2 serial port (CNH, 17FL375 panel or
RS12 17FL320 panel).
47
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
13. Place Inverter #1 and Inverter #2 in the NORMAL mode using the proper method for the control group (KG498
or KG526). and close the control cabinet door.
5.7. CHECKOUT
NOTE: The Truck Type, Panel Type, and GE System selections are disabled in the Normal Mode. Proce-
dures in this manual are written for the Offline/Training Mode. Some portions of certain procedures will
be performed automatically when in the Normal Mode.
1. Connect the PTU to the TCI serial port (located in the operator cab), start the GE OHV wPTU Toolbox, enter
password, select TCI Panel, select appropriate truck type, and click on LOGIN to wPTU Toolbox.
2. From the window browser, select PTU Screens –> TCI –> Normal_Operation –> Configuration –> TCI SW
Versions.
3. The TCI SW Versions screen is now displayed (Fig. 32).
48
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
b. The RESET the Active TCI Events selection screen is now displayed.
c. Click on Yes to reset the events and close the screen.
d. From the window browser, select PTU Screens –> TCI –> Special_Tasks –> Event_Menu –> Erase TCI
Events.
e. The ERASE the Stored TCI Events selection screen is now displayed.
f. Click on Yes to erase the events and close the screen.
NOTE: The following step must be performed the first time V19 or higher software is installed due to the
additional counter categories (yesterday, last month, this month). This step is not required for subse-
quent software downloads.
8. Reset the TCI’s Statistical Information as follows: (Fig. 35)
a. From the window browser, select PTU Screens –> TCI –> Special_Tasks –> Stat_Menu –> Reset Stats.
b. The Reset Stats screen is now displayed.
c. Click on the selection box for Reset ALL <GE AND MINES> Statistics and click on Yes in the question
window that pops up.
49
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
d. Close the Reset Stats display screen by clicking on the X in the upper right corner of the screen.
9. Click on the Target button to go back to the GE OHV wPTU Toolbox Login screen and disconnect the
wPTU from the TCI serial port.
10. Connect the wPTU to the PSC serial port (located in the operator cab) and click on LOGIN to wPTU Tool-
box.
11. From the window browser, select PTU Screens –> PSC –> Normal_Operation –> Configuration –> PSC
SW Versions.
12. The PSC SW Versions screen is now displayed (Fig. 36).
13. Verify the following version information on the display screen:
PSC VER: {current version}
TRUCK TYPE: {applicable HP}
TRUCK ID: {current truck}
INV1 VER: {current version}
INV2 VER: {current version}
14. Close the PSC SW Versions display screen by clicking on the X in the upper right corner of the screen.
15. Reset the PSC’s event information as follows: (similar to Figure 34)
a. From the window browser, select PTU Screens –> PSC –> Special_Tasks –> Event_Menu –> Reset
PSC Events.
b. The RESET the Active PSC Events selection screen is now displayed.
c. Click on Yes to reset the events and close the screen.
d. From the window browser, select PTU Screens –> PSC –> Special_Tasks –> Event_Menu –> Erase
PSC Events.
50
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
e. The ERASE the Stored PSC Events selection screen is now displayed.
f. Click on Yes to erase the events and close the screen.
16. Verify NO events are logged on the DID panel (refer to Section 8.3., Faults Display, for DID panel faults infor-
mation).
17. From the window browser, select PTU Screens –> PSC –> Normal_Operations –> Real_Time –> PSC –
Real Time Data.
18. The PSC – Real Time Data screen is now displayed (Fig. 43).
19. On the PSC – Real Time Data screen, verify the following: (The CPU cards must be reprogrammed with the
pedal percentages prior to verifying these values.)
ACCEL–SEL = 0.00 with the Accel Pedal at rest
ACCEL–SEL = 1.00 with the Accel Pedal fully engaged
NOTE: The following verifications require that Service Brake/Wheel Lock/Load Brake is not applied. En-
sure the Park Brake is applied and the propulsion system placed in REST mode, and that it is safe to
remove the service brakes.
RETRD–SEL = 0.00 with the Retard Pedal and Lever (if equipped) set to the OFF position.
RETRD–SEL = 1.0 with the Retard Pedal at FULL. (If a 1 pedal system, ensure the service brake is not
entered)
RETRD–SEL = 1.0 with the Retard Lever (if equipped) at FULL and the retard pedal OFF.
20. Apply the Park Brake (if not done previously) and place the propulsion system in REST mode by placing the
Park Brake and REST rocker switches in the ON position.
21. Using the appropriate mine procedures, start the diesel engine.
22. Verify the System Mode is REST on the DID panel (refer to Section 8.2., Modes Display, for DID panel modes
information).
23. Release the Park Brake and exit REST mode by placing the Park Brake and REST rocker switches in the OFF
position, and verify the System Mode changes to TEST, then READY within one minute.
51
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
24. With the service brakes applied, move the Direction Selector handle to FORWARD and verify torque is present
on each inverter (TQCMD1, TQCMD2, and TRQFB1, TRQFB2) shown on the PSC – Real Time Data screen.
25. Verify no EVENTS are logged as follows:
a. From the window browser, select PTU Screens –> PSC –> Special_Tasks –> Event_Menu –> PSC
Event Summary.
b. The PSC Event Summary screen is now displayed on top of the PSC – Real Time Data screen.
c. Verify that no EVENTS are logged, then close the PSC Events Summary display screen by clicking on the
X in the upper right corner of the screen.
26. Return the Direction Selector handle to NEUTRAL.
27. Using the appropriate mine procedures, initiate Load Box operation through the wPTU or DID panel (for
wPTU, from the window browser, select PTU Screens –> PSC –> Normal_Operation –> Tests –> Self
Load Engine Test). (Fig. 55) (Refer to Section 8.4., Tests Display, for DID panel tests information.)
28. Maintain Load Box operation at full engine RPM for two minutes and verify that full horsepower is developed.
29. Verify no EVENTS log during Load Box Mode as follows:
a. From the window browser, select PTU Screens –> PSC –> Special_Tasks –> Event_Menu –> PSC
Event Summary.
b. The PSC Event Summary screen is now displayed (on top of the Self Load Engine Test screen if using
wPTU for test).
c. Verify that no EVENTS are logged, then close the PSC Events Summary display screen by clicking on the
X in the upper right corner of the screen.
30. Exit Load Box.
31. Click on the Target button to go back to the GE OHV wPTU Toolbox Login screen, then close the wPTU
Toolbox, shut down the PTU, and disconnect it from the PSC serial port.
52
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
NOTE: Throughout the procedures in this section, it is required that the inverters be cutout at various
times. The 17KG526 Control Group does not include Inverter Cutout switches. Change inverter status
for the different control groups where necessary as follows:
On KG498 and KG526B Control Groups, place the Inverter #1 and Inverter #2 Cutout switches in the
Down position to CUTOUT or in the Up position for NORMAL operation.
On KG526C Control Groups, use the DID panel to CUTOUT Inverter #1 and Inverter #2 or to place in NOR-
MAL operation. Refer to Section 8., Diagnostic Information Display (DID) Panel.
NOTE: An analog meter should be used for link resistance checks because a digital meter may give erro-
neous readings due to the high capacitance of the link.
Circuit/Compo- VOM Connec- VOM Positive VOM Negative VOM Reading VOM Reading
nent tion Note Lead Connec- Lead Connec- in Ohms in Ohms
tion tion (KG498E1 (KG526 Group)
Group) (Approx.)
(Approx.)
DC Link DC+ Link Bus Cabinet Ground 2800 1185
Bar (Top Bus
Bar for KG498)
NOTE: If GNDB1 (ground block) is disconnected from the Ground Resistor Panel
(GRR), both the DC+ and DC– resistance to ground readings will be higher.
DC– Link Bus Cabinet Ground 2800 1185
Bar (Bus Below
DC+ for KG498)
VOM on R1 DC+ Link Bus DC– Link Bus 10000 1500
Scale to avoid Bar Bar
charging capaci-
tors
VOM on R1 DC– Link Bus DC+ Link Bus 5.5 5.5
Scale to avoid Bar Bar
charging capaci-
tors
53
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
NOTE: AFSE P1 adjustment is not required for systems with KG526 Control Groups (FM689 AFSE exciter
panels).
1. Connect the VOM positive lead to the wiper of pot P1 on the 17FM466 AFSE panel.
3. Adjust Pot P1 on the 17FM466 AFSE panel for a VOM reading of 6000 ohms.
CAUTION: Check the polarity of the suppression modules across all coils: relays, contactors and reverser.
If any are reversed, output channels on the digital input/output cards can be damaged during attempts at
energization.
CAUTION: A bell ringer must not be used for wiring checks; use an ohmmeter or light continuity checker.
CAUTION: Before removing any of the cards in the 17FL375, 17FL320, 17FL373, or 17FL349 electronics
panels, turn Battery Power to the control system OFF.
The control equipment circuitry is classified in two major categories: main power circuit and alternator field control.
Both circuit categories must be separately prepared for meggering.
Perform the following procedures to prepare the circuit categories for meggering by either removing wiring connec-
tions, insulating or jumpering, as indicated by the instructions. Use shorting wire for jumpering procedures, however,
be careful not to short devices to ground or to the wrong devices.
1. Ensure that the Park Brake is applied and the propulsion system is placed in REST mode by placing the Park
Brake and REST rocker switches in the ON position.
2. Cutout both Inverter #1 and Inverter #2 using the proper method for the control group (KG498 or KG526).
4. Place the GF Cutout switch, located inside the main control cabinet, in the CUTOUT (down) position.
6. Disconnect the round power plug from the top of each phase and chopper module:
PM1A+, PM1A–, PM1B+, PM1B–, PM1C+, PM1C–, PM2A+, PM2A–, PM2B+, PM2B–, PM2C+, PM2C–,
CM1, CM2
7. Disconnect all PSC panel (17FL320) or Integrated Control Panel (ICP, 17FL375) 104 pin connectors.
54
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
9. Install a jumper between the positive and negative DC link bus bars in the control cabinet.
10. Disconnect the CCLR1 and CCLR2 connectors (located in the center compartment near the top of each vertical
bus bar in KG526 control groups or behind the AFSE panel in KG498 control groups).
11. Disconnect the circular connectors from all VAM’s and disconnect VAM grounds (RTN62 on TB4D for KG498
control groups or VAM4 terminal VH5 for KG526 control groups).
12. Remove all wires from ground block GNDB (located to the left for both control groups).
13. On KG498 Groups Only, install jumper wires between the following cables connection points on the auxiliary
inverter:
AXSNB–1 to AM1
AXSNB–2 to AM2
AXSNB–3 to AM3
14. Remove the GF contactor arc chute and install a jumper between the main contactor tips on GF.
This concludes the megger test. If any readings were below one megohm, an insulation fault is present and must
be located and repaired. If the reading is low because of moisture, the machine must be dried out by heating it for
several hours. Heat can be applied using several methods: 1) heat lamp, 2) hair dryer, 3) passing a controlled current
through the winding for a specific time period, 4) removing the machine from the truck and baking it in an oven at a
controlled temperature for a specific time period.
After repairs are made, remegger that circuit to ensure a good quality repair. To aid in finding a fault, see Section
6.3., Troubleshooting For Grounds.
55
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
1. Remove the jumper wire between the GF contactor tips and reinstall the GF contactor arc chute.
2. Remove the jumper wire from the power circuit DC positive bus bar to ground.
3. Remove the jumper wire between the positive and negative DC link bus bars.
10. Reconnect the power plug to all phase and chopper modules.
3. Once the ground has been isolated to a particular loop, that loop should be broken down into smaller sections
and remeggered.
NOTE: Refer to the overall system schematic to obtain the most convenient points for subsection isola-
tion.
NOTE: This subdividing of the grounded section should continue until the ground is isolated in a
particular cable or piece of equipment. Appropriate measures can then be taken.
4. If the ground occurs in a motorized wheel or alternator, the unit should be checked by removing all connections
and remeggering.
5. Perform a vigorous inspection of the unit following the guidelines of the inspection made in step 1.
6. If no reason for the ground can be determined, or if the problem cannot be corrected, removal of the unit for
repair at an authorized shop will be necessary.
7. If the ground is isolated to the Dynamic Retarding Assembly, disconnect all cables leading to it and remegger
the Dynamic Retarding Assembly.
8. If the ground is still present, thoroughly inspect the Dynamic Retarding Assembly for any obvious problems
such as frayed or rubbing cables and water or debris inside the Dynamic Retarding Assembly.
56
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
9. If the inspection does not locate the cause, isolate the two halves of the Dynamic Retarding Assembly and
remegger to localize the ground to one side or the other.
10. ,If the ground occurs on the blower motor side of the Dynamic Retarding Assembly, disconnect the motor and
check for grounds in the unit once again.
11. If the ground is still present in the Dynamic Retarding Assembly, it will be necessary to disconnect each resistor
section until the grounded section is found.
2. Disconnect all of the PSC (17FL320), TCI (17FL349/373), or ICP (17FL375) cards from their backplane con-
nectors. Verify that all panel connectors are connected.
6.4.2.1. Battery
1. Turn the truck battery switch ON and check polarity of the battery voltage at the location where BATFU was
removed. The BATFU input side should read positive, and the other side should read negative (battery com-
mon).
2. Turn the truck battery switch OFF and reinstall the BATFU fuse.
3. Turn the battery switches and the key switch in the operator’s cab ON to enable control power availability to the
AC OHV propulsion system.
6.4.2.2. Electronic Panel Power Supply (If Applicable, Early KG498 Groups
Only)
1. Turn the Control Power Switch (CPS) ON (located on the side of the main control cabinet).
2. Check for +15V from TB5–A (wire number P15VDC02) to cabinet ground to verify presence of PSC +15V pow-
er supply.
3. Check for –15V from TB5–C (wire number N15VDC02) to cabinet ground to verify presence of PSC –15V pow-
er supply.
57
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
4. Check for +15V from TB29 (wire number 15PV) in the control cabinet where TCI is located to ground to verify
presence of source voltage for pot ref. On systems equipped with 17FL349 TCI panels, this voltage is provided
by the TCI Power Supply Card. On systems equipped with 17FL373 TCI panels, this voltage is provided by the
PSC Power Supply Card.
5. Check for +15V from TB21 (wire number 15V) to ground in the auxiliary cabinet to verify presence of power
supply voltage for gauges. On systems equipped with 17FL349 TCI panels, this voltage is provided by the TCI
Power Supply card. On systems equipped with 17FL373 TCI panels, this voltage is provided by the PSC Pow-
er Supply Card.
6. Check for +11V (approximately) from TB28 (wire number 10V) in the control cabinet where TCI is located to
ground. On systems equipped with 17FL349 TCI panels, this voltage is provided by the TCI Power Supply
Card. On systems equipped with 17FL373 TCI panels, this voltage is provided by the PSC Power Supply Card.
6.4.2.3. System Power Supply (If Applicable, Late KG498 and All KG526
Groups)
1. Turn the Control Power Switch ON (CPS, located in the switch panel on the outside right of the main control
cabinet).
2. On the FH41 Power Supply (located in control area of cabinet left of the ICP panel), view the green status
LEDs. Verify that all five LEDs (+15V, –15V, +5V, +24V, –24V) are illuminated.
6.4.2.4. Sensor Power Supply (If Applicable, Early KG498 Groups Only)
NOTE: Sensor Power Supply (FH36) and FB127 have now been replaced by the FH41 Power Supply.
If the Sensor Power Supply (SPS) is experiencing problems, then check the following voltages referenced to cabi-
net ground:
If a reading is significantly different from the nominal values above, check the input wiring to the SPS. If the wiring
input checks OK, then replace the SPS.
Check that the DID panel is illuminated and shows DISPLAY IS READY message.
58
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
2. Verify that all PSC (17FL320), TCI (17FL349/373), or ICP (17FL375) cards are properly installed and con-
nected to the backplane of the panel.
3. Locate the FAT1 LEDs at the bottom of the PSC CPU card (17FB147) and the TCI CPU card (17FB144) near
the card extractor for each. Turn the CPS ON and observe that both LEDs on both cards should initially turn ON
and then turn OFF. If any LED remains illuminated, it may indicate either a bad CPU card or a problem with the
+5V power supply in that panel. Determine the possible faulty card by turning the CPS OFF, removing one card
from the affected panel, and turning the CPS ON until the faulty card is identified.
CAUTION: Always turn the Control Power Switch (CPS) OFF before either removing or installing control
cards in electronic panels. Failure to do so will result in card and/or panel equipment damage.
1. Apply the Park Brake and place the propulsion system in REST mode by placing the Park Brake and REST
rocker switches in the ON position.
59
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
6. Perform the following digital output checks from the PSC Manual Test screen:
a. In the Toggle Digital Outputs (TDO) section of the screen, click on GF to highlight it (GF Cutout Switch
must be in the NORMAL position). Verify that the GF contactor picks up and that GFFB is highlighted in the
Digital Input (DI) section of this screen. Click on GF again in the TDO section of the screen to deenergize
GF.
b. In the TDO section of the screen, click on GFR to highlight it. Verify (visually) that the GFR contactor picks
up. Click on GFR again in the TDO section of the screen to deenergize GFR.
c. In the TDO section of the screen, click on RP1 to highlight it. Verify that the RP1 contactor picks up and that
RP1FB is highlighted in the DI section of this screen. Click on RP1 again in the TDO section of the screen to
deenergize RP1.
d. In the TDO section of the screen, click on RP2 to highlight it. Verify that the RP2 contactor picks up and that
RP2FB is highlighted in the DI section of this screen. Click on RP2 again in the TDO section of the screen to
deenergize RP2.
60
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
e. On KG498 Groups Only, in the TDO section of the screen, click on RP3 to highlight it. Verify that the RP3
contactor picks up and that RP3FB is highlighted in the DI section of this screen. Click on RP3 again in the
TDO section of the screen to deenergize RP3.
f. In the TDO section of the screen, click on AFSE to highlight it. Verify that there is 24V DC to ground on the
AFSEL wire to ground (+25 on the GFM). Click on AFSE again in the TDO section of the screen to deener-
gize AFSE.
WARNING: When viewed under some conditions, the optical port may expose the eye beyond the maxi-
mum permissible exposure recommended in ANSI z136.2, 1993.
g. In the TDO section of the screen, click on GD1E to highlight it. Verify that the red LED (on the gray fiber–op-
tic port) of each module controlled by the #1 Gate Driver Power Supply is illuminated (remove the gray plug
on the top of each gate driver to observe fiber–optic light from the gate driver port). Click on GD1E again in
the TDO section of the screen to deenergize GD1E. Also check for fiber–optic light on Chopper Module 1.
h. In the TDO section of the screen, click on GD2E to highlight it. Verify that the red LED (on the gray fiber–op-
tic port) of each module controlled by the #2 Gate Driver Power Supply is illuminated (remove the gray plug
on the top of each gate driver to observe fiber–optic light from the gate driver port). Click on GD2E again in
the TDO section of the screen to deenergize GD2E. Also check for fiber–optic light on Chopper Module 2.
NOTE: All LEDs, the Inverter #1 Cutout switch, and the Inverter #2 Cutout switch are not present in the
17KG526Bx Control Group.
NOTE: Steps 6i thru 6l apply only to the 17KG498 Control Group.
i. In the TDO section of the screen, click on SYSRUN to highlight it. Verify that the CONTROL SYSTEM
OKAY LED inside the control area is illuminated. Click on SYSRUN again in the TDO section of the screen
to deenergize SYSRUN.
j. In the TDO section of the screen, click on TEST to highlight it. Verify that the TEST MODE LED inside the
control area is illuminated. Click on TEST again in the TDO section of the screen to deenergize TEST.
k. In the TDO section of the screen, click on REST to highlight it. Verify that the REST MODE LED inside the
control area is illuminated. Click on REST again in the TDO section of the screen to deenergize REST.
l. In the TDO section of the screen, click on SYSFLT to highlight it. Verify that the SYSTEM FAULT LED on
the side of the main control cabinet is illuminated. Click on SYSFLT again in the TDO section of the screen
to deenergize SYSFLT.
7. Perform the following Digital Input checks:
a. With the Keyswitch and the CPS ON, verify that the following Digital Inputs are illuminated: KEYSW,
CPSFB, CNFB, CNXFB (KG498 Only), CNIFB, and GFNCO.
b. On KG498 and KG526C Groups Only, move the Inverter #1 Cutout switch, located inside the control area,
to the CUTOUT position, INV1CO should be highlighted. Move this switch back to the NORMAL position,
INV1CO should then turn OFF.
c. On KG498 and KG526C Groups Only, move the Inverter #2 Cutout switch, located inside the control area
to the CUTOUT position, INV2CO should be highlighted. Move this switch back to the NORMAL position,
INV2CO should then turn OFF.
d. Digital Input BRAKEON will be highlighted if the Service Brake is engaged, otherwise, it will be off. (To
highlight BRAKEON, turn the service brake switch ON with the engine running or apply 24 V dc to wire 44R
[TB26] with the engine OFF.)
61
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
e. Close the PSC Manual Test display screen by clicking on the X in the upper right corner of the screen.
8. Click on the Target button to go back to the GE OHV wPTU Toolbox Login screen, close the wPTU Tool-
box, shut down the PTU, and disconnect it from the TCI serial port.
NOTE: The Truck Type, Panel Type, and GE System selections are disabled in the Normal Mode. Proce-
dures in this manual are written for the Offline/Training Mode. Some portions of certain procedures will
be performed automatically when in the Normal Mode.
The following procedure is for recording and checking the AC OHV propulsion system adjustments for the specific
truck foot pedals and the retard speed control pot:
b. Record the value for ACCEL PEDAL with the pedal FULL OFF (typical value is 1.6 V).
c. Record the value for ACCEL PEDAL with the pedal FULL ON (typical value is 8.5 V).
d. Pull up on the Retard Speed Control Switch, and record the value for RSC POT with the knob turned FULLY
CLOCKWISE (typical value is 0.1 V).
62
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
e. Record the value for RSC POT with the knob turned FULLY COUNTER–CLOCKWISE (typical value is 10.7
V).
f. Close the TCI Analog Inputs display screen by clicking on the X in the upper right corner of the screen.
6. Click on the Target button to go back to the GE OHV wPTU Toolbox Login screen, close the wPTU Tool-
box, shut down the PTU, and disconnect it from the TCI serial port.
7. Connect the PTU to the PSC serial port (located in the operator cab), start the GE OHV wPTU Toolbox, enter
password, select PSC Panel, select appropriate truck type, and click on LOGIN to wPTU Toolbox.
63
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
8. From the window browser, select PTU Screens –> PSC –> Normal_Operation –> Real_Time –> PSC – Ana-
log Inputs (Fig. 41).
9. The PSC – Analog Inputs screen is now displayed (Fig. 42). Perform the following from this screen:
a. Record the value for RETARD PEDAL with the pedal FULL OFF (typical value is 3.3 V).
b. Record the value for RETARD PEDAL with the pedal FULL ON (typical value is 9.5 V).
c. Record the value for RETARD LEVER with the lever FULL OFF (typical value is 0.3 V).
d. Record the value for RETARD LEVER with the lever FULL ON (typical value is 9.5 V).
e. Close the PSC – Analog Inputs display screen by clicking on the X in the upper right corner of the screen.
10. From the window browser, select PTU Screens –> PSC –> Normal_Operation –> Real_Time –> PSC – Real
Time Data (Fig. 41).
11. The PSC – Real Time Data screen is now displayed (Fig. 43). Perform the following from this screen:
64
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
65
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
If it is not, calculate the retard pedal on percent by dividing the recorded value in step 9d of this procedure by
the recorded value in step 5a of this procedure (RETARD PEDAL ON VOLTS / POT REF). Record this as
the new CC_RETARD_LEVER_ON_PCNT parameter value. (This quotient must be multiplied by 100 to
obtain the value to be used in SECTION 5.2., CREATE THE TRUCK/MINE CONFIGURATION FILE.)
g. With retard speed control knob PULLED OUT and knob turned FULLY COUNTERCLOCKWISE (turned to
TURTLE icon), verify that RETSPD = 5.0.
h. With retard speed control knob PULLED OUT and knob turned FULLY CLOCKWISE (turned to RABBIT
icon), verify that RETSPD > 36 (RETSPD = 31 with a 38:1 gear ratio).
i. Close the PSC – Real Time Data display screen by clicking on the X in the upper right corner of the screen.
12. Click on the Target button to go back to the GE OHV wPTU Toolbox Login screen, close the wPTU Tool-
box, shut down the PTU, and disconnect it from the PSC serial port.
66
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
The following is the procedure for recording and checking the AC OHV propulsion system adjustments for the spe-
cific truck gauges:
1. Connect the PTU to the TCI serial port (located in the operator cab), start the GE OHV wPTU Toolbox, enter
password, select TCI Panel, select appropriate truck type, and click on LOGIN to wPTU Toolbox.
2. From the window browser, select PTU Screens –> TCI –> Engine_Stopped_Tasks –> Gauge Calibration
(Fig. 44).
4. Enter a test temperature of 120 in the Type a Hydraulic Brake Fluid Temperature box and verify that the
dashboard Hydraulic Fluid Temperature gauge needle is positioned near the line separating the green and red
background on the gauge.
If it is not, adjust the needle position by clicking on the appropriate Move the Cursor to Increment/Decrement
the Temperature buttons.
When the position is correct, record the Gauge Scale: box reading as the new X_HYDBKTOUT parameter
value.
5. Enter a test temperature of 60 in the Type a Propulsion System Temperature box and verify that the dash-
board Propulsion System Temperature gauge needle is positioned near the line separating the green and yel-
low background on the gauge.
If it is not, adjust the needle position by clicking on the appropriate Move the Cursor to Increment/Decrement
the Temperature buttons.
When the position is correct, record the Gauge Scale: box reading as the new X_PROPELTEMP parameter
value.
6. Enter a test speed of 10, 20, 30, or 40 MPH in the Type a Truck Speed box and verify that the dashboard
speedometer displays that reading. (20 MPH = 32 kPH, 40 MPH = 64 kPH, etc.)
Adjust speeds for best overall reading (use the adjustment screw on the back of the speedometer to calibrate
its reading).
67
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
If, after performing the pedal, lever, pot, and gauge calibration checks, one or more configuration parameters re-
quired change, then do the following:
1. Change the affected truck specific parameters in the truck specific configuration file following the procedure in
the section, CREATE THE TRUCK/MINE CONFIGURATION FILE.
2. Download the software into the AC OHV propulsion system following those same procedures in the sections,
PROGRAM TCI and PROGRAM PSC.
3. After the new configuration has been downloaded, repeat the previous calibration checks to verify the new
settings.
68
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
FIG. 46. PTU BROWSER SET TIME AND DATE SCREEN ACCESS SEQUENCE. E–44366A.
The date and time must be set for the PSC and TCI. The procedure for setting the date and time on either is the
same. In order to set the date and time on a particular computer, you must be connected to the appropriate port in the
operator’s cab. The following procedure is for TCI, but it is the same except for connecting to and selecting PSC:
NOTE: The PSC time is kept synchronized to the TCI time during operation. The TCI is considered the
master clock.
1. Connect the PTU to the TCI serial port (located in the operator cab), start the GE OHV wPTU Toolbox, enter
password, select TCI Panel, select appropriate truck type, and click on LOGIN to wPTU Toolbox.
2. From the window browser, select PTU Screens –> TCI –> Special_Tasks –> Set Time and Date (Fig. 46).
3. The Set Time and Date screen is now displayed (Fig. 47).
4. If the date and time displayed in The CURRENT date and time: line are correct, click on the X in the upper right
corner of the screen to exit without changing.
5. On the Set Time and Date screen (Fig. 47), click within the applicable window (DAY, MONTH, YEAR, HOUR,
MINUTES) and enter the new values, or highlight the existing values in the applicable window and enter the
new values.
6. Repeat step 5 for each of the five windows.
7. Click on the SET CLOCK button at the desired moment for the clock to be set to the time settings entered to set
the new values into memory
8. Verify that the time displayed in The NEW Date and time: line is correct. If not, repeat steps 5 through 7.
9. Close the Set Time and Date display screen by clicking on the X in the upper right corner of the screen.
10. Click on the Target button to go back to the GE OHV wPTU Toolbox Login screen, close the wPTU Tool-
box, shut down the PTU, and disconnect it from the TCI serial port.
69
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
70
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
1. Connect the PTU to the TCI serial port (located in the operator cab), start the GE OHV wPTU Toolbox, enter
password, select TCI Panel, select appropriate truck type, and click on LOGIN to wPTU Toolbox.
2. From the window browser, select PTU Screens –> TCI –> Normal_Operation –> Real_Time –> TCI Real
Time Data (Fig. 48).
3. The TCI Real Time Data screen is now displayed (Fig. 49).
4. In the Modes section of the TCI Real Time Data screen, verify that COMMLINK is OK.
If not, check the RS422 wiring between PSC and TCI. If that does not uncover the problem, remove power from
the control system, then reapply power. If that does not clear the problem, then replace one CPU card at a time
in order to determine the faulty card.
5. Close the TCI Real Time Data display screen by clicking on the X in the upper right corner of the screen.
6. Click on the Target button to go back to the GE OHV wPTU Toolbox Login screen, close the wPTU Tool-
box, shut down the PTU, and disconnect it from the TCI serial port.
7. Connect the PTU to the PSC serial port (located in the operator cab), start the GE OHV wPTU Toolbox, enter
password, select PSC Panel, select appropriate truck type, and click on LOGIN to wPTU Toolbox.
8. From the window browser, select PTU Screens –> PSC –> Normal_Operation –> Real_Time –> PSC – Real
Time Data (Fig. 41).
9. The PSC – Real Time Data screen is now displayed (Fig. 43).
10. In the Modes section of the PSC – Real Time Data screen, verify that COMMLINK is OK.
If not, check wiring between PSC and TCI. If that does not uncover the problem, remove power from the control
system, then reapply power. If that does not clear the problem, then replace one CPU card at a time in order to
determine the faulty card.
71
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
11. Close the PSC – Real Time Data display screen by clicking on the X in the upper right corner of the screen.
12. Click on the Target button to go back to the GE OHV wPTU Toolbox Login screen, close the wPTU Tool-
box, shut down the PTU, and disconnect it from the PSC serial port.
72
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
The following procedure verifies proper TCI analog input signal levels and measurements. If any of the following
measurements differ significantly from their nominal values, check the signal source and wiring interface to TCI. If
those check out OK, replace the TCI analog input card.
1. Connect the PTU to the TCI serial port (located in the operator cab), start the GE OHV wPTU Toolbox, enter
password, select TCI Panel, select appropriate truck type, and click on LOGIN to wPTU Toolbox.
2. From the window browser, select PTU Screens –> TCI –> Normal_Operation –> Real_Time –> TCI Analog
Inputs (Fig. 48).
4. Check the POTREF reading on the TCI Analog Inputs screen. It should be within 1.0 V of the measurement at
TB18 (wire number 10V) in the OEM cab shifter console. (Typical value is 15.0 V.)
5. Measure the voltage at TB18 (wire number 10V) in the OEM electronics cabinet. This processed Pot Refer-
ence voltage should be approximately 11.0 V.
6. Check the CONTROL BATT reading on the TCI Analog Inputs screen. It should be within 1.0 V of the mea-
surement on the battery fuse panel located inside the control cabinet.
7. Check the CRANKING BATT reading on the TCI Analog Inputs screen. It should be within 1.0 V of the mea-
surement at TB28 (wire number 11ST) in the auxiliary cabinet.
8. Check the GROUND reading on the TCI Analog Inputs screen. It should be 0.0 V.
9. Check the GAIN CHECK reading on the TCI Analog Inputs screen. It should be 10.0 V.
NOTE: It is also recommended to check all temperature inputs and control voltages.
10. Close the TCI – Real Time Data display screen by clicking on the X in the upper right corner of the screen.
11. Click on the Target button to go back to the GE OHV wPTU Toolbox Login screen, close the wPTU Tool-
box, shut down the PTU, and disconnect it from the TCI serial port.
The following procedure verifies the proper wiring and component operation of certain discrete devices controlled
by TCI. If any of the following devices do not respond as indicated, check the device and the TCI wiring interface with
that device. If those check out OK, replace the appropriate TCI digital I/O card (consult system schematic to identify
proper card).
1. Connect the PTU to the TCI serial port (located in the operator cab), start the GE OHV wPTU Toolbox, enter
password, select TCI Panel, select appropriate truck type, and click on LOGIN to wPTU Toolbox.
2. From the window browser, select PTU Screens –> TCI –> Engine_Stopped_Tasks –> TCI Manual Test
(Fig. 44).
CAUTION: Do not proceed with TCI Manual Test checks until the Park Brake is applied and the propulsion
system placed in REST mode.
3. The TCI Manual Test Truck Status screen will request truck status; verify correct status and click on OK to
proceed (Fig. 50).
73
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
5. With the Park Brake switch ON, measure zero volts from 52CS (TB26) to ground. Click on PKBRKON to high-
light it and measure 24 volts from 52CS (TB26) to ground.
If voltages are incorrect, troubleshoot per the OEM recommendations.
74
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
NOTE: Refer to the location grid in Figure 52 determine the referenced location for many of the indicating
lights checked in this portion of the procedure. It is an example of the operator cab indicating lights that
are located overhead of the front windshield
NOTE: The ENGCRANK digital output is NOT enabled for manual test, since it potentially could start the
engine.
1 2 3 4 5 6
6. Perform the following digital output checks from the TCI Manual Test screen:
a. In the Toggle Digital Outputs (TDO) section of the screen, click on RESTLT to highlight it. Verify that the
Rest light in operator’s cab turns ON (grid location 6B). Click on RESTLT again in the TDO section of the
screen to turn RESTLT OFF.
b. In the TDO section of the screen, click on PSCNOTRDY to highlight it. Verify that the Propulsion System
Not Ready light in operator’s cab turns ON (grid location 6C). Click on PSCNOTRDY again in the TDO
section of the screen to turn PSCNOTRDY OFF.
75
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
c. In the TDO section of the screen, click on REDUCELT to highlight it. Verify that the Propulsion System
Reduced Power light in operator’s cab turns ON (grid location 6D). Click on REDUCELT again in the TDO
section of the screen to turn REDUCELT OFF.
d. In the TDO section of the screen, click on LINKONLT to highlight it. Verify that the Propulsion System DC
Link Power On light located adjacent to the DID panel in the rear of the operator’s cab turns ON. Click on
LINKONLT again in the TDO section of the screen to turn LINKONLT OFF.
e. In the TDO section of the screen, click on TEMPWARN to highlight it. Verify that the Propulsion System
Temperature Warning light in operator’s cab turns ON (grid location 5C). Click on TEMPWARN again in
the TDO section of the screen to turn TEMPWARN OFF.
f. In the TDO section of the screen, click on NORETARD to highlight it. Verify that the Propulsion System
No Retard Capability light in operator’s cab turns ON (grid location 5A). Click on NORETARD again in the
TDO section of the screen to turn NORETARD OFF.
g. In the TDO section of the screen, click on NOPROPEL to highlight it. Verify that the Propulsion System
No Propel Capability light in operator’s cab turns ON (grid location 6A). Click on NOPROPEL again in the
TDO section of the screen to turn NOPROPEL OFF.
h. In the TDO section of the screen, click on PSCWARNLT to highlight it. Verify that the Propulsion System
PSC Warn light in operator’s cab turns ON (grid location 5B). Click on PSCWARNLT again in the TDO
section of the screen to turn PSCWARNLT OFF.
i. In the TDO section of the screen, click on RTRDCON to highlight it. Verify that the Propulsion System
Retard Effort At Continuous Capability Level light in operator’s cab turns ON (grid location 6E). Click on
RTRDCON again in the TDO section of the screen to turn RTRDCON OFF.
j. In the TDO section of the screen, click on HYDBHOTLT to highlight it. Verify that the Hydraulic Brake
Fluid Hot Temperature light in operator’s cab turns ON (grid location 5D). Click on HYDBHOTLT again in
the TDO section of the screen to turn HYDBHOTLT OFF.
k. In the TDO section of the screen, click on PKBRKON to highlight it. Verify that the Park Brake Solenoid
On light in operator’s cab turns ON (grid location 3A). Click on PKBRKON again in the TDO section of the
screen to turn PKBRKON OFF.
l. In the TDO section of the screen, click on RETARDLT to highlight it. Verify that the Propulsion System
Retard Operation light in operator’s cab turns ON (grid location 3D). Click on RETARDLT again in the TDO
section of the screen to turn RETARDLT OFF.
m. In the TDO section of the screen, click on RETARDXLT to highlight it. Verify that the Propulsion System
Retard Operation light located outside of the operator’s cab turns ON. Click on RETARDXLT again in the
TDO section of the screen to turn RETARDXLT OFF.
7. In the TDO section of the screen, click on BATSPEC to highlight it. Measure the presence of control battery
voltage (24 V) at the coil terminals of the battery separate contactor, located in the battery control box. Click on
BATSPEC again in the TDO section of the screen to turn BATSPEC OFF. Verify that the control battery volt-
age measurement goes to 0 V.
8. In the TDO section of the screen, click on REVERSELT to highlight it. Check that the backup horn sounds and
that the reverse lights are ON. Click on REVERSELT again in the TDO section of the screen to turn REVER-
SELT OFF. Verify that the backup horn no longer sounds and that the reverse lights turn OFF.
76
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
For each digital input check, verify that the input on the Digital Inputs section of the TCI Manual Test screen (Fig.
51) responds appropriately to the input from the external truck device.
1. When the Lamp Test switch in the operator’s cab is activated, LAMPTEST should be displayed.
2. When the Engine System Controller issues an “Engine Caution” output, ENGCAUTION should be displayed.
3. When the Engine System Controller issues an “Engine Warning” output, ENGWARN should be displayed.
4. When the REST switch in the operator cab is placed in the ON position, RESTSW should be displayed.
5. When the Reset switch in the operator cab is actuated, RESET should be displayed.
6. When the Direction Selector handle in the operator cab is moved to the FORWARD position, FORREQ should
be displayed.
7. When the Direction Selector handle in the operator cab is moved to the REVERSE position, REVREQ should
be displayed.
9. When the Data Store switch in the operator cab is activated, DATASTORE should be displayed.
10. When the dump body is down, BODYDWN should be displayed. When the dump body is raised, BODYDWN
should no longer be displayed.
11. When the Park Brake Request switch in the operator’s cab is moved to the Request Brake position,
PRKBRKSW should be displayed.
13. When the Keyswitch is moved to the Engine Start position, ENGSTRTREQ should be displayed.
14. When the Retard Speed Control switch is pulled up, RSC should be displayed.
15. When the Payload Meter indicates that the truck payload is 70% of capacity or greater, MIDPAYLD should be
displayed.
16. When the Payload Meter indicates that the truck payload is 100% of capacity or greater, FULLPAYLD should
be displayed.
17. When the Payload Meter indicates that the truck payload is greater than the truck’s overload rating, OVER-
PAYLD should be displayed.
NOTE: The axle box pressure switch should be adjusted to trip when the axle box door is open 4” at
normal blower speed.
18. When the axle box is pressurized, AXLEP should be displayed (if equipped, OEM Option).
19. When the Control Power Switch is turned to the ON position, CONTROLON should be displayed.
77
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
20. Close the TCI Manual Test display screen by clicking on the X in the upper right corner of the screen.
21. Click on the Target button to go back to the GE OHV wPTU Toolbox Login screen, close the wPTU Tool-
box, shut down the PTU, and disconnect it from the TCI serial port.
NOTE: The HyperTerminal* application program must be running on the wPTU before applying control
power to the propulsion system. If not, the Inverter Fault Checks procedure cannot be performed. Refer
to Section 12.4., Using HyperTerminal To Communicate To 17FB144 and 17FB147 Boards, for additional
information on using the HyperTerminal application program.
NOTE: If at any time, the wPTU locks up or does not operate in an expected manner, type “X” three
times in succession.
2. From the window browser, select PTU Screens –> PSC –> Normal_Operation –> Configuration –> Invert-
er Parameters (Fig. 53).
NOTE: Parameter 25019 can only be changed through the Inverter Parameters screen.
4. In the Inverter Parameter screen, in the Inv # all, Param # field, type in 25019 and press ENTER. The value
will return as 1.
5. Change the parameter by typing 0 in the Inv # all, Value field and press ENTER.
6. Close the Inverter Parameter display screen by clicking on the X in the upper right corner of the screen.
7. Click on the Target button to go back to the GE OHV wPTU Toolbox Login screen and click on Terminal
Emulator Mode to start HyperTerminal.
NOTE: In KG498 Control Groups, the CNG and CNH serial ports are located in the main control cabinet
next to the FL320 panel.
8. Disconnect the wPTU serial cable from the PSC serial port and connect it to the CNG (Inverter #1) serial port.
9. Press T to command the Inverter Test screen.
78
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
79
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
10. Press G to command the GTO test. The screen will display the following:
gto_switch_mode[HNWX1]:
11. Press N to access the GTO/CHOPPER Test, Command and Feedback screen.
NOTE: If any the following GTO module checks fail, check GTO module wiring. If wiring checks OK and
problem persists, replace phase module in question and/or inverter control card(s) until problem is cor-
rected.
12. Perform the following GTO module command and feedback checks:
a. With the wPTU connected to the CNG serial port, move the > sign to the letter F in the test column next to
GTO AUP.
b. Press T with the > sign at the letter F on the screen. Verify that the Fs in the command column and the Fs in
the feedback column should all turn to Ts.
c. Move the > sign to the letter the letter T in the test column next to GTO AUP.
d. Press F with the > sign at the letter T on the screen. Verify that the Ts in the command column and the Ts in
the feedback column should all turn to Fs.
e. Repeat steps a through d for each phase module or chopper in Inverter #1.
a. With the wPTU still connected to the CNG serial port, make certain that all T values are returned to F
values.
b. With the wPTU still connected to the CNG serial port, press X until the prompt invcpu> appears.
c. Disconnect the wPTU serial cable from the CNG (Inverter #1) serial port and connect it to the PSC serial
port.
d. From the window browser, select PTU Screens –> PSC –> Normal_Operation –> Configuration –> In-
verter Parameters (Fig. 54).
e. Reset the parameters for Inverter #1 from the Inverter Parameters screen.
14. Close the Inverter Parameters display screen by clicking on the X in the upper right corner of the screen.
15. With the wPTU connected to the PSC serial port, click on CMCTL to highlight and turn them ON, then press
ENTER.
16. Disconnect the wPTU serial cable from the PSC serial port and connect it to the CNH (Inverter #2) serial port.
17. Repeat steps 2 through 16 for Inverter #2 taking note of the following differences:
– All references to Inverter #1 are now for Inverter #2.
– All references to CNG are now for CNH.
– Shutdown the wPTU Toolbox and turn the PTU off before disconnecting it in step 16, then do not reconnect
it.
80
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
Perform the following steps prior energizing equipment for the purpose of self load testing:
1. Apply the Park Brake and place the propulsion system in REST mode by placing the Park Brake and REST
rocker switches in the ON position.
2. Cutout both Inverter #1 and Inverter #2 using the proper method for the control group (KG498 or KG526).
3. Ensure the engine is shut down and verify that all tape and/or other obstructions are removed from the contac-
tor and control cabinet enclosures for proper air flow to the equipment.
WARNING: If a wheelmotor(s) has been removed, verify that its power cables are properly insulated in the
axle box.
NOTE: Self load testing can also be commanded through the DID panel (see Section 8.6.1., Self Load
Testing). If the DID panel is to be used, proceed to Section 6.18.2., Checks Prior to Self Load Testing.
4. Connect the PTU to the PSC serial port (located in the operator cab), start the GE OHV wPTU Toolbox, enter
password, select PSC Panel, select appropriate truck type, and click on LOGIN to wPTU Toolbox.
5. From the window browser, select PTU Screens –> PSC –> Normal_Operation –> Real_Time –> PSC – Real
Time Data (Fig. 41).
6. The PSC – Real Time Data screen is now displayed (Fig. 43).
2. Ensure that the Park Brake is applied and the propulsion system is placed in REST mode by placing the Park
Brake and REST rocker switches in the ON position.
3. Place the GF Cutout switch, located inside the control area of the main control cabinet, in the CUTOUT (down)
position.
5. Connect a voltmeter across resistor R1 which is located in the power area of the main control cabinet. Connect
the positive lead to the R1 resistor terminal with wire number BAT, and the negative lead to the R1 resistor
terminal with wire number F101.
81
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
9. Apply the Load Brake, release the Park Brake, exit propulsion system REST mode, and note that the voltmeter
will momentarily read approximately 18 V and then drop to zero volts.
NOTE: If the voltmeter reading is significantly different from that stated above, remove voltage from the
propulsion system. After verifying that voltage is removed from the propulsion system, check resistor
R1 and its wiring, replace components and wiring as necessary, then repeat the above portion of the
procedure before continuing.
10. Apply the Park Brake and place the propulsion system in REST mode by placing the Park Brake and REST
rocker switches in the ON position.
11. Place the GF Cutout switch, located on the right hand side of the main control cabinet, in the CUTOUT (down)
position.
13. Verify that all DC link voltage indicating lights are OFF.
14. Disconnect and remove the voltmeter and secure the compartment door.
4. Exit the propulsion system REST mode by placing the REST rocker switch in the OFF position.
5. Verify that the rotation of the auxiliary blower is clockwise as viewed from the Dynamic Retarding Assembly
side of the truck.
NOTE: If the rotation is NOT as indicated above, then shutdown the drive system and the engine in the
normal manner. After verifying that ALL power is removed from BOTH the main propulsion and auxiliary
blower inverter DC links, switch two of the power leads to the auxiliary blower motor and repeat this com-
plete procedure.
6. Place the propulsion system in the REST mode by placing the REST rocker switch in the ON position.
12. Exit the propulsion system REST mode by placing the REST rocker switch in the OFF position.
13. With the direction selector switch in NEUTRAL, depress the accel pedal fully in order to increase the speed of
the auxiliary blower. Verify on the PSC – Real Time Data screen that the AUXCMD and AUXFB both reach
3600 RPM (Fig. 43).
82
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
After the procedures in Section 6.18.1.,Preparation for Self Load Testing and Section 6.18.2., Checks Prior
to Self Load Testing have been completed successfully, conduct the Self Load Test as follows:
2. Ensure that the Park Brake is applied and the propulsion system is placed in REST mode by placing the Park
Brake and REST rocker switches in the ON position.
NOTE: Self load testing can also be commanded through the DID panel (see Section 8.6.1., Self Load
Testing). If the DID panel is to be used without a wPTU, skip the remainder of this procedure and follow
the DID panel self load test procedure.
3. Close the PSC – Real Time Data display screen by clicking on the X in the upper right corner of the screen.
4. From the window browser, select PTU Screens –> PSC –> Normal_Operation –> Tests –> Self Load En-
gine Test (Fig. 41).
5. The Self Load Engine Test screen is now displayed (Fig. 55).
83
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
6. Click on the ENTER LDBX button and verify on the Self Load Engine Test screen that the PSCMODE:
changes to TEST and the SUBSTATE: changes to LOADBOX before proceeding.
7. Press on the accelerator pedal. Engine speed must be above 1200 RPM in order for RP1 to pickup which will
connect retarding grids across the alternator output.
NOTE: In the Loading section of the screen, if the HP ADJ value is consistently minus 400 (–400) or the
ENGLOAD value is 0.0%, that is an indication that the engine load signal is not being communicated to
PSC.
8. Monitor DC link parameters GFAULT and LINKV as engine loading increases. Make certain that the GFAULT
value increases as the LINKV value does. If it does not, abort the test and troubleshoot the ground fault circuit-
ry. (Refer to Section 6.20. Functional Ground Fault Detection Test, Section 6.2. Megger Test For
Grounds, and Section 6.3. Troubleshooting For Grounds for procedures.)
9. Monitor the ENGLOAD value on the Self Load Engine Test screen during load testing. (This is a 0 to 10 V
signal from the engine controller converted to a percentage value.)
b. If the value is below 50% during load testing, this is an indication of a weak engine and the propulsion system
must decrease its load HP.
c. If the value is above 50% during load testing, this is an indication of a strong engine and the propulsion
system can increase its load HP.
10. When self load testing is complete, release the accelerator pedal and click on the EXIT LDBX button. Self load
testing should stop.
11. Close the Self Load Engine Test display screen by clicking on the X in the upper right corner of the screen.
12. Click on the Target button to go back to the GE OHV wPTU Toolbox Login screen, close the wPTU Tool-
box, shut down the PTU, and disconnect it from the PSC serial port.
84
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
The truck cab must be manned at all times, or a means must be provided to stop the truck should motion
occur when an inverter is providing power to a wheel motor.
1. Shut down the engine and ensure the following in preparation for this test, correcting any problems before pro-
ceeding further:
b. The wheel motors are clear for rotation and personnel are aware that wheels will be rotating one at a time.
c. If tires are not installed, verify that the truck is solidly mounted on jack stands and that the truck is stable.
2. Connect the PTU to the PSC serial port (located in the operator cab), start the GE OHV wPTU Toolbox, enter
password, select PSC Panel, select appropriate truck type, and click on LOGIN to wPTU Toolbox.
3. From the window browser, select PTU Screens –> PSC –> Normal_Operation –> Real_Time –> PSC – Real
Time Data (Fig. 41).
4. The PSC – Real Time Data screen is now displayed (Fig. 43).
c. Inverter #2 should be CUTOUT using the proper method for the control group (KG498 or KG526).
d. Inverter #1 should be in NORMAL operating mode using the proper method for the control group (KG498 or
KG526).
7. Release the Park Brake and exit propulsion system REST mode by placing the Park Brake and REST rocker
switches in the OFF position.
CAUTION: Do not accelerate the wheel motors if the truck is on jack stands.
8. Place the Direction Selector handle in the FORWARD position and verify that the truck moves forward if wheels
and tires are installed on the truck.
If the truck is on jack stands due to the absence of tires and/or wheels, view the left wheel motor. It should rotate
in a counter clockwise direction when viewed from the transmission end. The right wheel motor should not be
rotating.
If the truck movement or the wheel rotation is incorrect, stop the truck, stop the engine and correct the problem
before proceeding.
9. Record the following readings on the PSC – Real Time Data screen:
a. Record the torque command and feedback values for Inverter #1 (TQCMD1 and TRQFB1). The minimum
torque command should be around 750 ft–lbs. Note any significant differences.
85
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
b. Record both Inverter #1 (I1LV) and Inverter #2 (I2LV) link voltages. They should be approximately the
same with a maximum allowable difference of 7 V. The DC link volts should be approximately 700 V and the
DC link amps should be less than 50 amps.
11. Apply the Park Brake and place the propulsion system in REST mode by placing the Park Brake and REST
rocker switches in the ON position.
12. Repeat steps 5 through 10 for Inverter #2 (with Inverter #2 placed in NORMAL operating mode and Inverter #1
CUTOUT using the proper method for the control group, KG498 or KG526, in step 5), noting that if wheel rota-
tion must be monitored, the right wheel should be rotating clockwise when viewed from the transmission end
and the left wheel should not be rotating.
13. Apply the Park Brake and place the propulsion system in REST mode, place Inverter #1 and Inverter #2 in the
NORMAL operating mode using the proper method for the control group (KG498 or KG526), then release the
Park Brake and exit propulsion system REST mode.
14. If wheels and tires are installed, verify that truck moves forward in a smooth manner. Stop the truck and move
Direction Selector switch to REVERSE. Again verify that truck moves in reverse in a smooth manner.
If wheels and/or tires are not installed, verify that the wheel motors rotate in an even manner and that the follow-
ing wheel motor rotations as viewed from the transmission side are correct:
a. Direction Selector handle in FORWARD –
NOTE: If problems are encountered during this testing, check the wheel motor speed sensors, the speed
sensor wiring, wheel motor power cabling, and the inverter control card for problems.
15. When inverter testing is complete, move the Direction Selector handle to the NEUTRAL position, apply the
Park Brake and place the propulsion system in REST mode by placing the Park Brake and REST rocker
switches in the ON position, cut out both Inverter #1 and Inverter #2 using the proper method for the control
group (KG498 or KG526), and shut down the engine.
86
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
This is a test procedure to ensure that the ground fault detection circuit is operational by placing a test wire jumper
from the propulsion system section of interest to truck frame ground. It is expected that ground faults will be detected
by the control system during this test.
If, for any reason, this test encounters ground fault detection problems (fails to detect entered fault), immediately
stop any further testing and correct the problem. Each time a ground fault is detected, a ground fault event is logged in
the event summary log and propulsion power will be removed by the control system. Prior to removing the wire jumper,
ensure that the truck is shut down, the engine is stopped, the Parking Brake is applied (propulsion system commanded
to REST mode), and all DC link voltage indicating lights are OFF. With the jumper removed, the ground faults can be
cleared and erased before proceeding further with the test.
The following procedure test the ground fault circuit using the Self Load Testing (Section 6.18.) procedure.
WARNING: When installing or removing the test wire jumper for ground fault detection checking, always
ensure that the truck is shut down, the engine is stopped, the Park Brake is ON, propulsion system is in
REST mode, and ALL DC link voltage indicating lights are OFF. Auxiliary DC link charged indicating lights
are provided on the top of the control for visual indication. It is recommended that the auxiliary DC link be
measured by separate instrumentation as well before proceeding with maintenance or trouble shooting.
Failure to do so may result in personnel injury or death.
1. Install a test wire jumper between the DC bus and a ground point in a convenient location (see WARNING
above).
3. Perform steps 1 – 8 of the procedure in Section 6.18.3., Self Load Test Procedure.
4. A ground fault event with accompanying loss of propel should be generated shortly after the RP1 contactor
closes.
5. If a fault event is not generated, abort the test and troubleshoot the ground fault circuitry. (Refer to Section 6.2.
Megger Test For Grounds and Section 6.3. Troubleshooting For Grounds for procedures.)
6. Shut down the engine and remove the test wire jumper (see WARNING above).
87
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
88
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
7. STATISTICAL DATA
To make data most useful, there are four counters for every Statistical Counter and five for every Statistical Profile.
These counts are named by the method used to reset the count to zero. For the counter, there is a lifetime count,
LCount, which is associated with its date, LCount Start. There are also three other counters, Last Qtr, This Qtr, and
This Day.
A parameter is a defined occurrence. Each parameter has an identification number called Par #, and a short name
called Description. Each parameter is an occurrence that is counted in some unit such as hours or the number of
times the conditions have been correct to declare that the occurrence happened.
The units in which the counters count are listed under Units in TABLE 3, Statistical Data Codes – Counters
(located in this section). TABLE 3 also contains an additional explanation of the conditions that define a statistical
parameter as having occurred in the column titled Count Conditions.
There are two types of parameters: Counters (TABLE 3) and Profiles (TABLE 4, Statistical Data Codes – Pro-
files, located in this section). The profile parameters have one more characteristic, Counter Range, identified by
Profile Number, which segments the possible range of values into a maximum of 17 ranges of values. The number or
count within a particular Counter Range or Profile Number is the time that the parameter had a value that was within
that range.
When examining the number of counts for a parameter, it is often useful to know over what period of time the counts
occurred. To aid in determining how long it took to get a certain number of counts for a Statistical Data Counter param-
eter, the Statistical Data is presented in the form of four counters.
The first counter, LCount, indicates how many counts have occurred since the LCount Start date. This is in-
tended to be a lifetime counter. It can be reset to zero by a privileged user, and the LCount Start will automatically be
set to the date on the CPU board when the user performed the reset.
The second counter, Last Qtr is just the total number of counts for the parameter over the last–fiscal–quarter, also
known as the last–three–months. This counter has the same value in it all quarter long. At midnight on a quarter
change, this counter is overwritten by the “This Qtr” value as this–quarter becomes last–quarter.
The third counter, This Qtr, keeps a moment by moment count of occurrences of the parameter. The counts are
not reset to zero until midnight of the next quarter.
The fourth counter, Last Mnth, keeps a moment by moment count of occurrences of the parameter over the last
month. This counter has the same value in it all month long. At midnight on a month change, this counter is overwritten
by the This Mnth value as this–month becomes last–month.
The fifth counter, This Mnth, keeps a moment by moment count of occurrences of the parameter just as This Qtr,
except the This Mnth count is reset to zero at midnight of the next month.
The sixth counter, Yesterday, keeps a moment by moment count of occurrences of the parameter over the pre-
vious day. This counter has the same value in it all day long. At midnight, this counter is overwritten by the This Day
value as this–day becomes yesterday.
89
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
The seventh counter, This Day, keeps a moment by moment count of occurrences of the parameter just as This
Qtr, except the This Day count is reset to zero every midnight.
If the GE control panel is shut off before midnight, any necessary resetting of counters is done when the panel next
powers up after midnight.
Whenever the truck is programmed, that is, whenever the CPU Card has the contents of the flash proms changed,
the LCount, Last Qtr, and This Qtr counts are not changed. However, the This Day count will be reset to zero.
The wPTU provides the capability to view the current values of the statistical counters as follows:
1. Connect the PTU to the TCI serial port (located in the operator cab), start the GE OHV wPTU Toolbox, enter
password, select TCI Panel, select appropriate truck type, and click on LOGIN to wPTU Toolbox.
2. From the window browser, select PTU Screens –> TCI –> Special_tasks –> Stat_Menu –> View Counters
(Fig. 56).
3. The View Counters screen is now displayed (Fig. 57).
4. Select the COUNTER Group to view from the menu on the screen, then click on View Counter Group.
5. The Mine Counters screen displaying the selected COUNTER Group is now displayed (Fig. 58).
6. Close the Mine Counters display screen by clicking on the X in the upper right corner of the screen.
7. Select a different COUNTER Group if desired by repeating step 4 or close the View Counters screen by click-
ing on the X in the upper right corner of the screen.
90
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
8. Click on the Target button to go back to the GE OHV wPTU Toolbox Login screen, then close the wPTU
Toolbox, shut down the PTU, and disconnect it from the TCI serial port.
91
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
NOTE: It may be desirable to upload Statistical Profiles to a PC for later viewing/analysis. Refer to Sec-
tion 3.8., Consolidated Truck Data Save Function, for procedures.
The wPTU provides the capability to view the current values of the statistical profiles as follows:
1. Connect the PTU to the TCI serial port (located in the operator cab), start the GE OHV wPTU Toolbox, enter
password, select TCI Panel, select appropriate truck type, and click on LOGIN to wPTU Toolbox.
2. From the window browser, select PTU Screens –> TCI –> Special_tasks –> Stat_Menu –> View Profiles
(Fig. 56).
3. The View Mine Profiles screen is now displayed (Fig. 59).
4. Select the profile to view from the SELECT PROFILE TO VIEW menu on the screen, then click on VIEW PRO-
FILES.
5. The Mine Profiles screen displaying the selected profile is now displayed (Fig. 60).
6. Close the Mine Profiles display screen by clicking on the X in the upper right corner of the screen.
7. Select a different profile if desired by repeating step 4 or close the View Mine Profiles screen by clicking on the
X in the upper right corner of the screen.
8. Click on the Target button to go back to the GE OHV wPTU Toolbox Login screen, then close the wPTU
Toolbox, shut down the PTU, and disconnect it from the TCI serial port.
92
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
93
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
94
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
2. From the window browser, select PTU Screens –> TCI –> Special_tasks –> Stat_Menu –> Reset Stats (Fig.
56).
3. The Reset Stats screen displaying the Stat Reset Menu is now displayed (Fig. 62).
4. Reset the desired stat (or stats) on the Reset Stats screen using the following methods:
Enter the counter to be reset in the RESET Individual COUNTER box and click on RESET Individual
COUNTER to perform the reset.
Enter the profile to be reset in the Or, Enter Profile box and click on Or, Enter Profile to perform the reset.
Select an individual profile to reset from the RESET Individual PROFILE menu and the Stat Profile Mine
Reset screen displays. Click on the desired timeframe for the profile to select it (highlighted on screen),
then click in the YES, RESET THE SELECTED PROFILE box at the bottom of the screen to reset (Fig. 63).
Close either display screen by clicking on the X in the upper right corner of the screen.
Click on any of the four reset selection boxes and a question screen displays. Click on Yes to reset the
selected statistics or No to leave the current statistics intact (Fig. 64).
5. Close the Reset Stats display screen by clicking on the X in the upper right corner of the screen.
6. Click on the Target button to go back to the GE OHV wPTU Toolbox Login screen, then close the wPTU
Toolbox, shut down the PTU, and disconnect it from the TCI serial port.
95
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
96
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
In order to use the Statistical Data Collector to monitor maintenance of the vehicle, it is recommended that an office
spread sheet or data base computer program be used to keep periodic records of the statistical data. Also refer to
Section 3.8., Consolidated Truck Data Save Function.
1. Connect the PTU to the TCI serial port (located in the operator cab), start the GE OHV wPTU Toolbox, enter
password, select TCI Panel, select appropriate truck type, and click on LOGIN to wPTU Toolbox.
2. From the PTU Screens –> TCI screen Menu Bar, select UpLoad –> Consolidated Truck Data Save (Fig 17,
refer to GEK–91712).
3. Select the type of report to be saved from the Reports Type list, choose a Save Directory, then click on the
Begin button to begin uploading (Fig. 18).
4. Click on Close when the uploading is complete, then click on the Target button in the screen Tool Bar to go to
the wPTU startup screen.
5. Close the wPTU Toolbox, shut down the PTU, and disconnect it from the TCI serial port.
97
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
98
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
99
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
100
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
101
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
102
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
103
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
104
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
105
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
106
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
107
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
108
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
109
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
110
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
The word histogram is used in the definitions of the various statistical profiles in the following table. A histogram
is a collection of statistical data organized into defined ranges of values. The graphical representation of a histogram
is typically a bar chart.
111
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
112
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
113
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
114
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
115
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
116
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
117
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
118
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
119
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
120
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
121
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
122
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
123
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
124
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
The DID panel (17FM558) indicates the operating condition of the truck and is a primary troubleshooting aid for
maintenance and service personnel.
The AC OHV propulsion system utilizes the message lines and the function keys on the DID panel (Fig. 65). The
message lines provide propulsion system operating information, test status information, and function key label in-
formation, depending upon the DID panel’s mode of display. The function keys assume different functionality depend-
ing upon the DID panel’s mode of display.
The DID panel provides additional functionality with Version 20 software from that available with Version 19. There
is an additional layer of display selections with Version 20 software. Refer to Figure 66 for an overview of the hierarchy
of the displays available. Figures and paragraphs within this section are marked for the applicable software version.
Pressing Menu (F4) from the Normal or Faults display accesses the first layer of selections. This is the only layer
of selections with Version 19 software and a test/information selection is made by pressing the desired function key
(F1, F2, F3, F4). With Version 20 software, pressing Menu (F4) accesses an additional layer of menu selections for
Test, Info, and Inv Cut Out. Pressing the desired function key (F1, F2, F3) then accesses the menu for that function
key. Test/Info/Inv Cut Out selection is then made by pressing the desired function key from this menu layer. Display
selection function keys (soft keys) are shown in Figure 65.
MENU/MESSAGE LINE
125
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
Section 8.4
V19 MENU
F4
Section 8.5
V20 MENU
F4
INV INV
LOAD CAP GD SPEEDO #1 #2
BOX TEST TEST TEST F1 F2
F1 F2 F3 F4
Sec. 8.6.9 Sec. 8.6.9
Sec. 8.6.1 Sec. 8.6.3 Sec. 8.6.5 Sec. 8.6.6
FIG. 66. DID PANEL HIERARCHY FOR V19 AND V20 SOFTWARE. E–45386.
126
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
FIG. 67. DID PANEL EXAMPLE – NORMAL DISPLAY (NO FAULTS). E–45315.
This is the Normal display when there are no active faults and no AC OHV propulsion system tests have been
commanded through the DID panel (Fig. 67).
1. REST – The REST rocker switch is in the ON position and both the AC OHV propulsion system and the truck
are in the appropriate condition for the REST mode to be active.
4. PROPEL – The AC OHV propulsion system is powered up and the Direction Selector switch is either in FOR-
WARD or REVERSE.
5. RETARD – The AC OHV propulsion system is powered up and retard effort is commanded either from the
retard pedal or retard speed control.
127
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
The function keys in the DID panel’s Faults Display mode screen provide the user with the following capabilities:
(Fig. 69)
1. Function key F1 (Up) moves the display UP through the active fault list, thereby displaying detailed information
regarding the fault of interest.
2. Function key F2 (Down) moves the display DOWN through the active fault list, thereby displaying detailed
information regarding the fault of interest.
3. Function key F3 (Return) returns the user to the previous display.
4. Function key F4 (Reset) enables the user to subsequently perform fault reset functions as follows: (Fig. 70)
a. Pressing function key F1 (Reset1) after having pressed function key F4 above will reset the currently dis-
played fault.
b. Pressing function key F2 (RESET*) after having pressed function key F4 above will reset ALL the currently
active faults.
FIG. 69. DID PANEL MESSAGE EXAMPLE – FAULTS DISPLAY FUNCTION KEYS. E–45317.
128
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
FIG. 70. DID PANEL MESSAGE EXAMPLE – FAULT RESET FUNCTION KEYS. E–45318.
c. Pressing function key F5 (cancel) exits the user from the fault reset screen and returns the user to the faults
display screen.
5. Function key F5 displays additional information regarding the currently displayed fault.
The function keys in the DID panel’s Test Display mode provide the user with the test capabilities described.
FIG. 71. DID PANEL MESSAGE EXAMPLE – V19 TEST DISPLAY FUNCTION KEYS. E–45319.
129
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
FIG. 72. DID PANEL MESSAGE EXAMPLE – V20 MENUS DISPLAY FUNCTION KEYS. E–45387.
When function key F4 (MENU) is pressed when the DID panel’s Normal mode display is active, the DID panel’s
Menus Display mode appears to the user (Fig. 72).
The function keys in the DID panel’s Menus Display mode provide selection of the next layer of menus as shown.
130
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
FIG. 73. DID PANEL MESSAGE EXAMPLE – LOAD BOX TEST FUNCTION KEYS. E–45320.
Press the applicable function keys (V19, F4 –> F1 or V20, F4 –> F1 –> F1) to access the Load Box screen. Com-
mands now available to the user are as follows:
1. Pressing function key F2 (Enter) requests Load Box mode of operation (Fig 73). Press F2 to enter the Load-
box mode. With the engine running and the accelerator pedal fully pressed, the engine net horsepower, the
engine load signal, the AC OHV propulsion system horsepower adjust level, and the ground fault current are
displayed to the user (Fig. 74).
2. Pressing function key F5 (Return) stops the Load Box Test and returns the user to the DID Test Display
mode (V19, Fig. 71) or the Test Menu mode (V20, Fig 75).
FIG. 74. DID PANEL MESSAGE EXAMPLE – LOAD BOX TEST DATA. E–45321.
131
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
FIG. 75. DID PANEL MESSAGE EXAMPLE – V20 TEST MENU. E–45388.
Press the applicable function keys (V19, F4 –> F2 or V20, F4 –> F2 –> F1) to access the PSC Software Version
display. This displays the PSC Software Version that is loaded in the AC OHV propulsion system. Subsequent
pressing of the F2 (Next) function key will display the following information in the order listed:
Pressing function key F5 (Return) at any time while in the Software Version display will return the user to the DID
panel Test Display mode (V19, Fig. 71) or the Info Menu mode (V20, Fig 77).
FIG. 76. DID PANEL MESSAGE EXAMPLE – PSC SOFTWARE VERSION DATA. E–45322.
132
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
FIG. 77. DID PANEL MESSAGE EXAMPLE – V20 INFO MENU. E–45389.
Press the applicable function keys (V19, F4 –> F3 or V20, F4 –> F1 –> F2) to invoke the Link Capacitance Test.
The results of the Link Capacitance Test are then automatically displayed (Fig. 78). Commands now available to the
user are as follows:
1. Pressing function key F2 (Start) will start the Link Capacitance Test again.
2. Pressing function key F5 (Return) will return the user to the DID panel Test Display mode (V19, Fig. 71) or the
Test Menu mode (V20, Fig 75).
3. Pressing function key F5 (Return) again will return the user to the DID panel’s Normal mode display (V19, Fig.
67) or the Menus Display mode (V20, Fig 72).
FIG. 78. DID PANEL MESSAGE EXAMPLE – LINK CAPACITANCE TEST DATA. E–45323.
133
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
FIG. 79. DID PANEL MESSAGE EXAMPLE – OVERSPEED SETTING DATA. E–45324.
Press the applicable function keys (V19, F4 –> F4 or V20, F4 –> F2 –> F2) to access the Overspeed Settings
display. This displays the Overspeed Settings that are loaded in the AC OHV propulsion system (Fig. 79).
1. Pressing function key F5 (Return) will return the user to the DID panel Test Display mode (V19, Fig. 71) or the
Info Menu mode (V20, Fig 77).
2. Pressing function key F5 (Return) again will return the user to the DID panel’s Normal mode display (V19, Fig.
67) or the Menus Display mode (V20, Fig 72).
134
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
WARNING: When troubleshooting this truck, unless stated otherwise the truck engine should be shut
down and power removed from the DC link. At 400 RPM engine speed, the DC link is normally commanded
to be energized. DO NOT use the REST mode to remove power while troubleshooting any of the truck cir-
cuits.
Press the applicable function keys (V20, F4 –> F1 –> F3) to display the Gate Driver Test (Fig. 80). The Gate
Driver Test turns the gate drivers ON so that the fiber optics can be manually checked. Commands now available to
the user are as follows:
WARNING: When viewed under some conditions, the optical port may expose the eye beyond the maxi-
mum permissible exposure recommended in ANSI z136.2, 1993.
1. Press function key F2 (Proceed) to start the Gate Driver Test (begin turning on the gate drivers).
2. A Warning displays and F4 (Proceed) must be pressed to acknowledge the Warning and begin turning on the
gate drivers (Fig. 81).
WARNING: When the Gate Drivers are ON, 100 V AC is applied at the module. Follow all standard safety
precautions for checks at this voltage level.
3. The gate drivers will now turn ON (Fig. 82). Press function key F5 (Exit) to turn the gate drivers OFF and return
to the DID panel’s Test Menu mode (Fig. 75).
FIG. 80. DID PANEL MESSAGE EXAMPLE – V20 GATE DRIVER TEST SELECTION. E–45390.
135
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
FIG. 81. DID PANEL MESSAGE EXAMPLE – V20 GATE DRIVER TEST WARNING. E–45391.
FIG. 82. DID PANEL MESSAGE EXAMPLE – V20 GATE DRIVER TEST IN PROGRESS. E–45392.
136
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
FIG. 83. DID PANEL MESSAGE EXAMPLE – V20 SPEEDOMETER TEST SELECTION. E–45393.
Press the applicable function keys (V20, F4 –> F1 –> F4) to display the Speedometer Test (Fig. 83). The
Speedometer Test generates a specific mph reading so that the speedometer can be tested or calibrated (default is
20 mph). Commands now available to the user are as follows:
2. Press function keys F1, F2, F3, F4 as required to calibrate the speedometer (Fig. 84).
3. Press function key F5 (Exit) to exit the Speedometer Test and return to the DID panel’s Test Menu mode (Fig.
75).
FIG. 84. DID PANEL MESSAGE EXAMPLE – V20 SPEEDOMETER TEST IN PROGRESS. E–45394.
137
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
FIG. 85. DID PANEL MESSAGE EXAMPLE – V20 VIEW PARAMETERS SELECTION. E–45395.
Press the applicable function keys (V20, F4 –> F2 –> F3) to display View Parameters (Fig. 85). Enter the known
parameter number (or enter any number) using the 0 – 9 numbered keys, press F3 (Enter), and the parameter value
will be displayed in real time (Fig. 86). (Press F5, Cancel, to cancel the entered number.) Commands now available to
the user are as follows:
1. Press function key F1 (New) to return to the View Parameters display (Fig. 85) and enter a new parameter
number directly.
2. Press function key F2 (Prev) or F3 (Next) to proceed sequentially through the parameter list.
3. Press function key F5 (Exit) to exit View Parameters and return to the DID panel’s Info Menu mode (Fig. 77).
FIG. 86. DID PANEL MESSAGE EXAMPLE – V20 VIEW PARAMETERS DISPLAY. E–45396.
138
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
FIG. 87. DID PANEL MESSAGE EXAMPLE – V20 VIEW STATS SELECTION. E–45397.
Press the applicable function keys (V20, F4 –> F2 –> F4) to display View Stats (Fig. 87). This feature displays the
Mine Level Counters one at a time. Enter the desired number using the 0 – 9 numbered keys, press F3 (Enter), and
the stat value will be displayed in real time (Fig. 88). (Press F5, Cancel, to cancel the entered number.) Commands
now available to the user are as follows:
1. Press function key F1 (New) to return to the View Stats display (Fig. 87) and enter a new stat number directly.
2. Press function key F2 (Prev) or F3 (Next) to proceed sequentially through the statistic list.
3. Press function key F4 (Time) to proceed to the Time Interval display (Fig. 89) and select the desired interval
using the 1 – 7 numbered keys. When the desired key is pressed, that time interval will be selected and the
View Stats display will appear again automatically (function keys F1 – F5 are not active on this display).
4. Press function key F5 (Exit) to exit View Stats and return to the DID panel’s Info Menu mode (Fig. 77).
FIG. 88. DID PANEL MESSAGE EXAMPLE – V20 VIEW STATS DISPLAY. E–45398.
139
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
FIG. 89. DID PANEL MESSAGE EXAMPLE – V20 VIEW STATS INTERVAL CHANGE. E–45399.
140
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
FIG. 90. DID PANEL MESSAGE EXAMPLE – INVERTER CUTOUT SELECTION. E–45400.
Press the applicable function keys (V20, F4 –> F3) to display Inverter Cutout (Fig. 90). This displays the inverter
selections (Inv #1, Inv #2). (Press F5, Return, to return to the DID panel’s Menus mode, Fig. 72). Commands now
available to the user are as follows:
1. Press function key F1 (Inv #1) or F2 (Inv #2) to select the inverter and proceed to the Inverter Status display
(Fig 91).
2. Press function key F4 (Toggle) to change the status of the selected inverter.
3. Press function key F5 (Return) to return to the Inverter Cutout display (Fig. 90).
4. Repeat steps 1 – 3 for the other inverter if desired, then press function key F5 (Return) to exit Inverter Cutout
and return to the DID panel’s Menus mode (Fig. 72).
FIG. 91. DID PANEL MESSAGE EXAMPLE – INVERTER CUTOUT STATUS DISPLAY. E–45401.
141
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
142
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
9. EVENT CODES
WARNING: Lethal Voltages may be present on some circuits. Always turn off and Safety Tag the KEY
SWITCH in the Operator Cab and then verify that ALL lights on either Capacitor Charge Indicating Light
Panel (CCL1 or CCL2) are extinguished before entering the Main Control Cabinet, Retarding Grid Box, or
either Motorized Wheel and/or axle box.
WARNING: When troubleshooting the AC OHV propulsion system, unless stated otherwise, the truck en-
gine should be shutdown and power removed from the DC link. Keep in mind that at 400 RPM engine
speed, the DC link is commanded to be energized. DO NOT use the REST mode to remove power from the
DC link during the troubleshooting of propulsion system circuitry and components.
Restriction Description
NO PROPEL / LOADBOX No Propel (red) light is illuminated in the operator cab. No propulsion effort
is allowed. Retard effort and DC link energization is allowed. Load Box
mode is restricted.
NO POWER No Retard (red) light is illuminated in the operator cab. No propulsion effort
or retard effort is allowed. The DC link is de–energized.
SPEED LIMIT / SYSWARN Propel System Caution (yellow) light is illuminated in the operator cab.
Propel and Retard effort is allowed. The DC link is energized. A speed limit
restriction is imposed on the truck.
INVERTER 1 DISABLE Inverter/wheel motor #1 is disabled. Limited propulsion and retard effort is
available. A speed limit restriction is imposed on the truck.
INVERTER 2 DISABLE Inverter/wheel motor #2 is disabled. Limited propulsion and retard effort is
available. A speed limit restriction is imposed on the truck.
ENGINE SPEED / RP The engine speed is raised and RP1 is closed in response to a potential
Retard circuit problem.
SYSEVENT No restrictions are imposed; the event is logged for information purposes
only.
TABLE 5 lists all the events for the GE OHV AC propulsion system and their associated restriction levels.
143
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
In the following tables, troubleshooting recommendations are provided for each event. Unless noted otherwise,
perform each step in the order listed until the fault is corrected.
TABLE 5 lists all the events for the GE OHV AC propulsion system and their associated troubleshooting recom-
mendations.
NOTE: The following section describes TCI event data access in detail. A similar process is followed for
PSC event data access using the PSC menu and screen hierarchy (refer to Figure 3) for details.
1. Connect the PTU to the TCI serial port (located in the operator cab), start the GE OHV wPTU Toolbox, enter
password, select TCI Panel, select appropriate truck type, and click on LOGIN to wPTU Toolbox.
2. From the window browser, select PTU Screens –> TCI –> Special_Tasks –> Event_Menu (Fig. 92).
3. The Event_Menu list of screens is now displayed. Double–click on the desired screen to display it.
144
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
1. From the Event_Menu, double–click on TCI Event Summary to select that screen (Fig. 92).
2. The TCI Event Summary screen is now displayed (Fig. 93).
This screen contains the following information for each recorded event:
a. The name and number for each event
b. The sub–ID for each event. (Events with only one sub–ID will have 01 as their sub–ID.)
d. The time and date of the reset of the event (If the event is not reset, this column will display all zeroes for the
reset time and date.)
3. Close the TCI Event Summary display screen by clicking on the X in the upper right corner of the screen.
145
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
1. From the Event_Menu, double–click on TCI Trigger Data to select that screen (Fig. 92).
2. The TCI Trigger Data screen is now displayed (Fig. 94).
The TCI Trigger Data screen is a real time screen, similar to Figure 49. It captures the propulsion and truck
system values at the time that the event of interest was detected and logged. This single data capture at the
time of event occurrence is called a “snapshot”. There is one “snapshot” for every event in the TCI summary
list.
3. Close the TCI Trigger Data display screen by clicking on the X in the upper right corner of the screen.
146
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
Data packs are a series of, typically, 100 “snapshots” of the propulsion and truck system real time values taken 50
milliseconds apart. This provides a 5 second long record of propulsion system values before, during, and after an
event occurrence.
There are a limited number of available data packs, and not every event will trigger the recording of a data pack.
Typically, the recurrence of an event that already has a data pack that has NOT been reset, will NOT trigger the cre-
ation of another data pack.
1. From the Event_Menu, double–click on TCI Data Packs to select that screen (Fig. 92).
2. The TCI Data Packs screen is now displayed (Fig. 95).
This screen contains the following information for each data pack:
a. The data pack number
b. The associated event number and sub–ID for the data pack number
c. The time and date when the data pack was created
d. The time and date of the data pack reset (If the data pack is reset, it is enabled to be overwritten by the next
event that would trigger a data pack.)
3. Close the TCI Data Packs display screen by clicking on the X in the upper right corner of the screen.
147
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
The reset of an event is typically done after the conditions for that event occurrence has been investigated and the
propulsion system is ready to resume normal operation.
1. From the Event_Menu, double–click on Reset TCI Events to select that screen (Fig. 92).
2. The Reset TCI Events screen is now displayed (Fig. 96).
3. The user will then be asked if all active TCI events are to be reset. Click on Yes to reset all active TCI events or
No to abort this action. The screen automatically closes upon either selection.
NOTE: When events are reset, their data packs are enabled to be overwritten by subsequent events. Re-
set events remain in the event summary list until they are erased, however.
148
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
The erasure of event data only affects those events that have been reset. The erasure removes those reset events
from the event summary list, removes their associated “snapshots” and removes their data packs, if present.
1. From the Event_Menu, double–click on Erase TCI Events to select that screen (Fig. 92).
2. The Erase TCI Events screen is now displayed (Fig. 97).
3. The user will then be asked if all stored TCI events are to be erased. Click on Yes to erase all stored TCI events
or No to abort this action. The screen automatically closes upon either selection.
NOTE: Only events that have been reset will be erased by this action. Events that are not reset will remain
in the event summary, and any associated data packs will remain as well.
Perform the following to access the Events & Inv Params screen:
1. Connect the PTU to the TCI or PSC serial port (located in the operator cab), start the GE OHV wPTU Toolbox,
enter password, select PSC Panel or TCI Panel, select appropriate truck type, and click on LOGIN to wPTU
Toolbox.
2. From the window browser, select PTU Screens –> TCI or PSC –> Special_Tasks –> Events & Inv Params
(Fig. 92).
3. The Events & Inv Params screen is now displayed (Fig. 98).
4. Click on the desired event list button (PSC Event List, TCI Event List, Inverter Event List) to open. (Use the
scroll bar on the side to navigate through the list).
5. Close the list by clicking on the X in the upper right corner of the screen.
6. Close the Events & Inv Params display screen by clicking on the X in the upper right corner of the screen.
7. Click on the Target button to go back to the GE OHV wPTU Toolbox Login screen, close the wPTU Tool-
box, shut down the PTU, and disconnect it from the serial port.
149
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
150
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
151
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
:02–Link Current
016–PSC CPU Card NO POWER A problem occurred with a PSC CPU card task, as identified by the
following sub–ID:
:01–Message Missing
:02–Bad Tick
:03–Bad CRC
:04–Overflow
:05–Bad Start
:06–Bad Stop
152
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
:01–RP1
:02–RP2
:03–RP3
033–Retard Circuit SPEED LIMIT & STUCK
RP
035–Engine Speed SPEED LIMIT Engine speed signal exceeded upper or lower limit.
Sensor
036–GY19 Grid Blower NO POWER Grid blower failure detected, further identified by the following sub–
ID:
153
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
:01–Chopper 1
:02–Chopper 2
046–Retard Short Circuit SPEED LIMIT & EN- Failure during chopper self test. Link voltage decayed too quickly
GINE SPD when AFSE command set low, prior to starting test.
047–Engine Stall NO POWER Engine stall condition detected.
048–Shorted DC Link NO POWER System detected a potential short on the DC link while attempting to
During Startup charge link.
051–Tach Left Rear INV1 DISABLE Problem occurred with tach on left rear wheelmotor, further defined
by the following sub–ID:
154
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
:01–Inverter #1
:02–Inverter #2
061–Motor Overspeed SYS EVENT Truck exceeded motor overspeed limit.
063–Engine Load Signal SYS EVENT The Engine Load Signal feedback from the engine controller is out-
Fault side of limit, further defined by the following sub–ID:
155
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
085–Auxiliary Cooling SYS EVENT Problem detected with auxiliary blower control system, further identi-
Fault fied by the following sub–ID:
156
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
157
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
158
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
159
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
:01–Missing message
:02–Bad tick
:03–Bad CRC
:04–FIFO overflow
:05–Bad start bit
:06–Bad stop bit
605–Aux Comm Fault None Serial link communication with the Auxiliary Blower Control System
was lost for a persistent time period.
607–Positive 5 volts SPEED LIMIT (10 MPH) +5V Power Supply exceeded limits for a persistent period of time.
608–Positive 15 Volts SPEED LIMIT (10 MPH) +15V Power Supply exceeded limits.
609–Negative 15 Volts SPEED LIMIT (10 MPH) –15V Power Supply exceeded limits.
610–Pot Reference SPEED LIMIT (10 MPH) Pot Reference exceeded limits.
613–Analog Input SPEED LIMIT (10 MPH) An analog signal input on the analog I/O card exceeded its limits for
a persistent period of time, as defined by the following sub–ID:
:01–Ground (A2D)
:02–Gain Check (A2D)
614–Battery Separate SYS EVENT The battery separate contactor failed to operate in an expected man-
Contactor ner as further defined by the following sub–ID:
160
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
619–Engine Warning NO PROPEL The engine warning signal was received when the engine speed is
above the run threshold.
620–Engine Kill while NO PROPEL The engine kill signal was received while the truck was moving.
Moving
622–Park Brake NO PROPEL Unexpected park brake operation defined by the following sub–ID:
:01–Tank
:02– Left Front Outlet
:03– Right Front Outlet
:04– Left Rear Outlet
:05– Right Rear Outlet
624–Body Up and SPEED LIMIT (10 MPH) Simultaneous receipt of both full payload and body up signals for a
Payload Indication persistent time period.
625–Extended Battery None Excessive time has elapsed between battery separate and subse-
Reconnect Time quent battery reconnection.
628–Connected SYS EVENT Battery volts exceeded limits for a persistent period of time, while
Batteries engine speed is greater than idle and control power is ON; further
defined by the following sub–ID:
629–Barometric SYS EVENT Barometric pressure sensor signal exceeded limits for a persistent
Pressure period of time, further defined by the following sub–ID:
630–Motor Blower SPEED LIMIT Motor blower pressure signal exceeded limits, indicating a problem
Pressure with the sensor, duct work, or axle box sensor. Further defined by
the following sub–ID:
631–Ambient SYS EVENT Ambient temperature sensor signal exceeded limits for a persistent
Temperature period of time, further defined by the following sub–ID:
161
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
162
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
When welding on trucks equipped with GE control panels, connect the welder’s ground cable such that welding
current does not flow through the truck’s control wires or cables. This ground connection should be made directly to (or
as close as possible to) the part being welded. For example, if welding is being done on the deck, connect the ground
directly to the deck – not to the control box or cab. If welding is being done on the control box door, connect the ground
to the control box door – not to the box frame.
Extreme care should also be taken to prevent electrical current from passing through bearings in the alternator or
motorized wheel motors as this will result in bearing damage and premature bearing failure.
DO NOT pull any control cards or remove panel connectors. This practice can cause more damage than it pre-
vents. It puts unnecessary cycles on the connector pins and may cause loose or dirty pins which could result in a
control system failure.
WARNING: The following procedure is intended for use under emergency or unusual conditions only and
should not be used in lieu of proper troubleshooting and/or maintenance procedures. In any case, ex-
treme caution must be exercised and all standard safety procedures employed. When using this “special”
procedure, the entire procedure should be read before proceeding.
The following procedure should be followed when it has been determined that either one inverter or one wheel
motor is faulty, and the truck must be moved for servicing using the single, operational inverter/wheel motor.
NOTE: Truck speed is limited to 10 mph by the propulsion system when operating with only one wheel
motor.
1. With truck stopped and the engine running, apply the Park Brake and place the propulsion system in REST
mode by placing the Park Brake and REST rocker switches in the ON position and place the Direction Selector
handle in the NEUTRAL position.
CAUTION: Single inverter/wheel motor operation of the truck should only be done with an empty truck.
Operation of a loaded truck with one inverter/wheel motor may result in damage to that wheel motor.
3. On KG498 systems, move the affected inverter cutout switch to the CUTOUT position. Inverter cutout
switches are located behind the maintenance panel access door on the cab end side of the KG498 control
group. On KG526 systems, cut out the affected inverter using the DID Panel. This will disable that inverter/
wheel motor combination from either accelerating or retarding the truck.
4. Release the Park Brake and exit propulsion system REST mode by placing the Park Brake and REST rocker
switches in the OFF position.
5. Place the Direction Selector handle in FORWARD and move the truck to the desired location.
163
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
With all wiring removed from the suspect VAM, check that a nominal resistance of 2 Megohms exists between the
points in the charts below. Resistance to ground or to any other points on the VAM should be infinite. Refer to the
receptacle and plug diagrams in the system schematic for connector arrangement.
3. With an applied battery voltage of 24 V DC, the A3PV panel output measured between terminals D and F
should be 0.12 V DC (200:1 scaling). If the reading is significantly different from this value, replace the A3PV
and repeat this check.
4. If the A3PV panel output checks OK, remove the jumper wires previously installed in this procedure.
164
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
3. With an applied battery voltage of 24 V DC, the A3PV panel output measured between terminals D and F
should be 0.12 V DC (200:1 scaling). If the reading is significantly different from this value, replace the LINKV
and repeat this check.
4. If the LINKV panel output checks OK, remove the jumper wires previously installed in this procedure.
With all wiring removed from the suspect current measuring module, the following are the nominal resistance val-
ues between the connection points indicated:
The main propulsion DC link capacitance test can be performed through the DID panel (refer to Section 8.6.3.,
Link Capacitance Testing) provided that truck conditions permit this test. Those conditions are as follows:
2. Truck stopped with no direction commanded and accelerator pedal not pressed.
When the DC link capacitance test is run, the AC OHV propulsion system commands the DC link to be charged to
operating level and then it monitors its decay rate from that level. This decay rate is then used to calculate the amount
of DC link capacitance.
The DC link capacitance test can be monitored and its results viewed on a wPTU screen. This screen can be
accessed as follows:
1. Connect the PTU to the PSC serial port (located in the operator cab), start the GE OHV wPTU Toolbox, enter
password, select PSC Panel, select appropriate truck type, and click on LOGIN to wPTU Toolbox.
2. From the window browser, select PTU Screens –> PSC –> Normal_Operation –> Tests –> Capacitance
Test (Fig. 99).
3. The Capacitance Test screen is now displayed and the test data can be viewed (Fig. 100).
4. Close the Capacitance Test display screen by clicking on the X in the upper right corner of the screen.
5. Click on the Target button to go back to the GE OHV wPTU Toolbox Login screen, close the wPTU Tool-
box, shut down the PTU, and disconnect it from the PSC serial port.
165
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
166
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
Use the following procedure to determine whether or not the auxiliary inverter SCRs and/or IGBTs have failed.
NOTE: Refer to GEK–91718, Auxiliary Inverter Panel For 320 Ton OHV AC Troubleshooting and Repair,
for additional troubleshooting procedures and SCR/IGBT replacement procedures.
WARNING: Ensure that all power is removed from the AC OHV propulsion system prior to performing this
procedure. This includes checking that both the propulsion inverter filter capacitors as well as the auxilia-
ry inverter filter capacitors are fully discharged. Failure to do so may result in personnel injury or death.
10.6.1. Preparation
1. Disconnect the auxiliary inverter input power connections at PH+, PH–, IV+ and IV–.
2. Disconnect the auxiliary inverter motor output connections at AM101, AM201 and AM301.
3. Disconnect the following connectors from the Auxiliary Inverter Circuit Card: J1, J2, J3, J4, J6, J7, J8, J10, J11,
J12, J13, J14, J15 and J16.
2. Repeat the above resistance measurement for connectors J11, J12, J14, J15 and J16.
3. Using a hand–held VOM, measure the Anode–to–Cathode and Cathode–to–Anode resistance measurement
for all six (6) SCRs. The nominal value should be greater than 200 Kohm. A resistance reading of less than 100
ohms indicates that the associated SCR has failed.
2. Repeat the above resistance measurement for connectors J2, J3, J4, J7 and J8.
167
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
168
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
11.1. INTRODUCTION
WARNING: Traction motor leads and the DC link may have high voltage present from charged capacitors.
Remove power and discharge capacitors per standard instructions before troubleshooting the equip-
ment. Auxiliary DC link charged indicating lights are provided on the top of the control for visual indica-
tion. It is recommended that the auxiliary DC link be measured by separate instrumentation as well before
proceeding with maintenance or troubleshooting. Failure to do so may result in personnel injury or death.
WARNING: When troubleshooting this truck, unless stated otherwise the truck engine should be shut
down and power removed from the DC link. At 400 RPM engine speed, the DC link is normally commanded
to be energized. DO NOT use the REST mode to remove power while troubleshooting any of the truck cir-
cuits.
Phase module faults can be either related to the phase module itself or its associated gate driver. The fault text will
identify the phase module in question. For example, PM1A+ would refer to phase module (PM) in inverter #1 (1),
phase A (A), positive module (+).
2. Run the Inverter VI Test as follows to determine if the fault occurs again:
a. Apply the Park Brake and place the propulsion system in REST mode by placing the Park Brake and REST
rocker switches in the ON position and place the Direction Selector handle in the NEUTRAL position.
c. When the engine has achieved its idle speed, release the Park Brake and exit propulsion system REST
mode by placing the Park Brake and REST rocker switches in the OFF position.
d. Monitor status messages on the wPTU PSC Real Time Data screen, Inverters section. In the right side
of the Inverters section of the screen, Inverter VI Test State is shown. During the Inverter VI Test, the
status box should read Test. Upon completion, there should be the message Completed.
e. If no faults are logged, and there is no recent history of inverter faults, the truck can be released for service.
If faults are logged proceed with the remainder of this troubleshooting section.
3. Shut down the engine but maintain control power to the propulsion control. Go to the phase module in question
as identified by the fault, and pull out its gray fiber optic connector. The red LED should be ON.
WARNING: When viewed under some conditions, the optical port may expose the eye beyond the maxi-
mum permissible exposure recommended in ANSI z136.2, 1993.
a. If the red LED is ON, the GTO on the phase module is not shorted. Gate drivers, however, can intermittently
fail, therefore, the LED indication does not guarantee that the gate driver is OK.
b. If the red LED is OFF, that is usually an indication that the GTO on the phase module is shorted or the gate
driver has failed.
169
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
WARNING: Electric shock can cause serious or fatal injury. To avoid such injury, personnel should take
and observe proper precautions when making system adjustment or performing system or component
electrical tests.
a. Disconnect the GDPC plug from the gate driver and check for 90 to 100 V AC @ 25 KHz square wave signal
at the circular plug. (A Simpson analog meter is recommended for this measurement.)
b. Verify that the input power to the GDPC is at least 50 volts at its input terminals.
c. If the AC output is less than 90 V AC, unplug all the gate drivers on the inverter in question. Then plug them
in one at a time, waiting about five seconds before reading the AC output voltage as each gate driver is
plugged in.
5. If the gate driver and the GTO test OK, but the truck has a recent history of repeated failures, replace the phase
module.
7. Use a volt–ohm meter to check resistance to ground on the DC link circuit. Using that same meter, check for
short circuits on the DC link from the positive horizontal bus bar to the negative horizontal bus bar.
170
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
12.1. INTRODUCTION
Often, 17FB144 and 17FB147 boards used in 320 ton OHV propulsion systems have no defects found when re-
turned to the factory for unit exchange (UX) repair. It is believed that most of the perceived defects are the result of
problems communicating to the boards with the PTU, combined with a misunderstanding of the light patterns seen on
the bottom edge of the card. This section provides a definition of the light patterns on the card bottom edge and de-
scribes a procedure to use Microsoft HyperTerminal to troubleshoot 17FB144 and 17FB147 boards.
There are two LED indicators on the bottom front edge of the boards defined as follows:
The LED indicators flash during boot–up and can flash if no program is installed in the CPU board. LEDs can also
flash if the 5 V Power Supply is low. Normally, the CPU board is functional and can be communicated with, or down-
loaded to, if the LEDs are flashing.
NOTE: If using HyperTerminal while LEDs are flashing, text will be continuously scrolling with a variable
time delay between messages.
The FATL indicator can be ON solid if the 5 V Power Supply is low or if there is a major failure of the board. Always
check the 5V Power Supply voltage if the FATL indicator is ON solid.
Figure 101 shows the troubleshooting flow chart for both 17FB144 and17FB147 boards.
The flow chart references other figures to provide details where necessary.
171
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
172
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
See Sheet 2 of 2
FIG. 101. 17FB144 AND 17FB147 BOARD TROUBLESHOOTING PROCEDURE (PART 1 OF 2). E–44732.
173
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
See Sheet 1 of 2
FIG. 101. 17FB144 AND 17FB147 BOARD TROUBLESHOOTING PROCEDURE (PART 2 OF 2). E–44732.
174
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
NOTE: The banner at the bottom left hand corner of the main window will say “Connected” and record
connection time if the COM1 port is active.
HyperTerminal saves previous session text (without asking). If it is necessary to verify that the text stored in the
HyperTerminal window is from only the present session only, start a new connection.
175
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
The HyperTerminal screen shows a white background for text that is in the latest window. If the window is scrolled
backwards, the background turns light blue. The boarder between the white and light blue background in no way
indicates anything about the timing of the text displayed, just that the text contained within the present HyperTerminal
connection is more than one window long.
5. After the COM1 properties are set, the main HyperTerminal window will look like that shown in Figure 107, if
HyperTerminal is able to connect to the COM1 port.
176
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
NOTE: The lower left hand banner will say “Connected” and count the connection time. This only indi-
cates that HyperTerminal has access to the COM1 port, NOT that HyperTerminal can talk to the connected
CPU board.
6. If HyperTerminal cannot connect to COM1, a message window appears that says Unable to Open COM1 and
the banner will say Disconnected as shown in Figure 108. If this happens, try to reset the COM1 port by disab-
ling it and re–enabling it at the window previously shown in Figure 102. If this does not work, reboot the comput-
er.
7. Once HyperTerminal is connected to the COM1 port, cycle control power to the connected CPU board. The
screen will appear as shown in Figure 109 if the CPU board is already programmed and running. Only the
17FB144 board will show the text line pertaining to the battery test. Figure 109 shows the HyperTerminal main
window scrolled backwards 1 line to show the complete text that comes out of the CPU board.
NOTE: The HyperTerminal screen shows a white background for text that is in the latest window. If the
window is scrolled backwards, the background turns light blue. The boarder between the white and light
blue background in no way indicates anything about the timing of the text displayed, just that the text
contained within the present HyperTerminal connection is more than one window long.
8. The screen will appear as shown in Figure 110 if the CPU board is not programmed. Only the 17FB144 board
will show the text line pertaining to the battery test.
NOTE: Unit Exchange (UX) cards are not programmed when shipped.
NOTE: The following text message will scroll with a variable time delay between cycles if the LED lights
on the bottom edge of the CPU board are flashing. Lights may or may not flash if no program is installed
in the CPU board.
177
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
FIG. 107. HYPERTERMINAL MAIN WINDOW WHEN CONNECTED TO COM1 PORT. E–44738.
9. To erase the flash memory (program) on a CPU board, the boot–up routine must be interrupted. To do this, hold
down the TAB key and cycle control power to the board. Let the TAB key up when you see the Keyboard
interrupt accepted message as shown in Figure 111.
10. After the boot–up routine has been interrupted, the CPU board flash memory (program) can be erased by typ-
ing ef and hitting ENTER. When typing in the ef characters, they will most likely appear somewhere to the far
right of the =>. This is OK, just type them in and hit ENTER. The message shown in Figure 112 should appear if
the flash memory was erased successfully.
11. An open PTU serial communication ground wire with the PTU connected can cause the CPU board boot–up
(buck) routine to not run during power–up. If this happens, the text in HyperTerminal will stop after the 25MHZ
board detected message as shown in Figure 113.
12. When exiting HyperTerminal, it will ask you if you want to save the session. If you click OK, you can select the
session name the next time you enter HyperTerminal and you will not have to perform the communications
set–up.
NOTE: If you do save the session, any text that was in the HyperTerminal window (including that scrolled
past the view window) will also be saved.
After the initial save, HyperTerminal saves session text (without asking) every time you close it. If it is necessary to
verify that the text stored in the HyperTerminal window is from the present session only, start a new connection.
178
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
Message window
FIG. 108. HYPERTERMINAL MAIN WINDOW WHEN NOT CONNECTED TO COM1 PORT. E–44739.
179
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
FIG. 109. HYPERTERMINAL MAIN WINDOW AFTER CYCLING CONTROL POWER, PROGRAM
INSTALLED AND RUNNING. E–44740.
180
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
FIG. 110. HYPERTERMINAL MAIN WINDOW AFTER CYCLING CONTROL POWER, PROGRAM NOT
INSTALLED. E–44741.
181
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
FIG. 111. HYPERTERMINAL MAIN WINDOW AFTER CYCLING CONTROL POWER, WITH TAB KEY
HELD DOWN (INTERRUPTING BOOT–UP ROUTINE). E–44742.
182
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
183
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
FIG. 113. HYPERTERMINAL MAIN WINDOW WHEN BOOT–UP (BUCK ROUTINE) DOES NOT
RUN DUE TO OPEN PTU SERIAL CABLE GROUND WIRE WITH THE PTU CONNECTED. E–44744.
184
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
NOTE: Those components marked with an asterisk (*) may not be present in all control groups. Refer to
truck specific schematic for configuration details.
TABLE 7. GLOSSARY
Term Description
AFSE Alternator Field Static Exciter panel regulates the current in the alternator field.
AFSER (KG526 Only) Alternator Field Static Exciter Resistor facilitates battery boost to AFSE.
AFSER is used in the low side driver circuit.
ALT Alternator is a salient-pole, three-phase, Y-connected, AC machine that is mounted solidly
to the diesel engine and is driven by the engine crankshaft. The alternator provides electri-
cal power for propulsion and control systems.
AMBTS Ambient Temperature Sensor senses ambient air temperature (located in the air inlet to
the inverters on KG498 groups and in the contactor area on KG526 groups).
ANALOG I/O CARD PSC Analog Input/Output Card provides signal conditioning for analog signals to/from the
(PSC) Propulsion System Control. This card monitors system voltages and currents along with
frequency input from the engine speed sensor. It also contains the digital alternator field
regulator control.
ANALOG I/O CARD TCI Analog Input/Output Card provides signal conditioning for analog signals to/from the
(TCI) Truck Control Interface. This card monitors signals from sensors located throughout the
truck and provides driving signals for operator cab meters.
AXIND (KG498 Only) Auxiliary Power Filter Inductor, along with the Auxiliary Power Filter Capaci-
tor Bank (AXCAP), filter the regulated DC voltage from the Auxiliary Phase Control Rectifi-
er into a smooth DC supply suitable for use by the Auxiliary Power Inverter.
AXINV (KG498 Only) Auxiliary Power Inverter/Phase Control Rectifier contains two major circuit
assemblies: Auxiliary Phase Control Rectifier and the Auxiliary Power Inverter. The Auxil-
iary Phase Control Rectifier converts the three–phase, AC voltage from the Alternator to
regulated DC voltage. This DC voltage is then filtered by Auxiliary Power Filter Capacitor
Bank and Auxiliary Power Filter Inductor. The Auxiliary Power Inverter converts this regu-
lated, filtered, DC voltage into a variable voltage, variable frequency, three–phase output
to power the Auxiliary Blower Motor.
AXSNB (KG498 Only) Auxiliary Power Snubber Panel provides protection to the Auxiliary Power
Inverter/Phase Control Rectifier against electrical transients present in the three–phase,
Alternator output voltage.
ASYN (KG498 Only) Alternator Synchronization Transformer monitors samples of the frequency
of the tertiary winding and provides that sample to the Propulsion System Control Panel,
which uses the input to synchronize the firing pulses sent to the Alternator Field Static Ex-
citer Panel.
A3PV (KG498 Only) Alternator Three–Phase Voltage Measuring Module (17FM458) attenuates
the high voltage from two phases of the Alternator to a level acceptable to the electronics
on the Analog I/O Card, located in the Propulsion Control Panel.
BAROP Barometric Pressure Sensor provides a barometric pressure signal to the control system
used in the calculations of control system cooling requirements.
BATFU Battery Power Fuse provides overload protection to the control equipment.
BATTSW OEM supplied Battery Switch is used to connect/disconnect battery voltage from the truck
control equipment.
185
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
186
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
187
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
188
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
REST is illuminated when the system is in the Rest state with power removed
from the DC link
LINKI Link Current Sensing Module detects the amount of current flow through the DC link (the
DC bus that connects the Alternator output, Chopper Module/Resistor Grid circuits, and
traction Inverters).
LINKV* (KG498 Only) Link Voltage Measuring Module (17FM458) attenuates the high voltage
from the DC link to a level acceptable to the electronics on the Analog I/O Card, located
in the Propulsion Control Panel.
PM1A+, PM1B+, Phase Modules (GTO, 17FM628 on KG498 and KG526C groups, 17FM793 on KG526B
PM1C+ groups) provide the positive driving voltages for each of the three windings of Traction Mo-
tor #1.
PM1A–, PM1B–, Phase Modules (GTO, 17FM629 on KG498 and KG526C groups, 17FM794 on KG526B
PM1C– groups) provide the negative driving voltages for each of the three windings of Traction Mo-
tor #1.
PM2A+, PM2B+, Phase Modules (GTO, 17FM628 on KG498 and KG526C groups, 17FM793 on KG526B
PM2C+ groups) provide the positive driving voltages for each of the three windings of Traction Mo-
tor #2.
PM2A–, PM2B–, Phase Modules (GTO, 17FM629 on KG498 and KG526C groups, 17FM794 on KG526B
PM2C– groups) provide the negative driving voltages for each of the three windings of Traction Mo-
tor #2.
PS (KG498E and KG526 Only) Power Supply (17FH41) which provides +5VDC, ±15VDC,
±24VDC regulated voltage.
PSC Propulsion System Controller, is one of the CPU cards (17FB147) in all control systems,
but is also a panel in KG498 systems.
PS CARD (PSC)* (Early KG498 Only) Power Supply Card (17FB127) in the Propulsion System Control pro-
vides 5 V and 15V power for use by the other control equipment.
PS CARD (TCI)* (Early KG498 Only) Power Supply Card (17FB127) in the Truck Control Interface provides
5 V and 15 V power for use by other control equipment.
RD Rectifier Diode Panel, also denoted as the main rectifier panel, converts the output three–
phase, AC voltage from the Alternator to DC voltage to power the two Inverters. RD is a
single panel on KG498 groups and three separate panels (RDA, RDB, RDC) on KG526
groups.
189
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
190
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
Version 20 was developed to support the 17KG526 Control Group based GETS OHV AC propulsion systems.
Version 20 software is for the 17FL375 Propulsion System Controller panel and a portable PC. It may be applied to
17KG526xx, 17KG527xx, and 17KG531xx Control Groups of GETS OHV AC propulsion systems.
Version 20 includes all application software for the control system panels as well as the MS–Windows based PTU
(wPTU) listed in TABLE 8.
NOTE: Version 20 should not be applied to 17KG498 Control Groups without the specific approval of
GETS OHV engineering.
General information for version 20 and previous versions of software is listed in TABLE 10. Refer to the SMI#
shown in the table for specific information.
191
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
Version 19 was developed to support end–user and OEM requests as well as addressing reliability improvements
and product enhancements to the GE propulsion system.
Version 19 software is for the 17FL320 Propulsion System Controller panel, the 17FL349/17FL373 Truck Control
Interface panel, or the 17FL375 Integrated Control Panel, and a portable PC. It may be applied to all GETS OHV AC
propulsion systems, including the 17KG498xx, 17KG526Bx, and 17KG527xx groups.
Version 19 includes all application software for the control system panels as well as the MS–Windows based PTU
(wPTU) listed in TABLE 9.
NOTE: The FB173 card software is downloaded automatically at startup by the system.
General information for version 19 and previous versions of software is listed in TABLE 10. Refer to the SMI#
shown in the table for specific information.
192
VTI For 320 Ton AC OHV Propulsion Systems, GET–6864A
193
GET–6864A, VTI For 320 Ton AC OHV Propulsion Systems
194
NEW 09/00, FSB PRINTED
IN
REV 05/03, REB U.S.A.
E