LINCS II Presentation

LeTourneau Training 2012

LeTourneau Training

LINCS II• Theory of Operation

• Component Descriptions

• Screen Navigation

• Circuit Descriptions

• Troubleshooting

• Support Software

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THEORY OF OPERATION

“INTRODUCTION”

Theory of Operation

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LINCS LAYOUT

Digital---------Analog

Cards

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HIGHLIGHTS The same software will be used on all GEN 2 loaders. Electrical

wiring is the same to accommodate. Drive system will be functionally the same on all loaders.

Expandable based on requirements. Due to extensive testing there is very little customization and

configurability. Control logic is hidden. Software is programmed to tell you

when the logic is preventing the operators command from being preformed.

Rolling channel log. Always recording all channels. 6 days stored on machine.

Normal and Troubleshooting notices. Automated Calibration of Position Sensors

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COMPONENT DESCRIPTIONS

Component Description

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COMPONENT DESCRIPTIONS


•Low Voltage Control Cabinet•VCU (Vehicle Control Unit)•Digital Interface Card•Analog Interface Card•Fuses & Relays•12v Power Supplies (Dealer options & touch screen)

•Cab• HMI (Human/Machine Interface)•Touch Screen Display•Keypad•Joysticks•User access key reader•USB Port (Download)

•Enclosures•Breakout Boxes•I/O Devices and Cables•Other Cabling

LeTourneau Training Component Description

Low Voltage Control Cabinet


Low Voltage Control Cabinet

12V touch screen display Cartridge fuses

24V/12V converter

Relay panel DIN terminal connections

Digital I/O

VCU

Analog I/O


VCU (VEHICLE CONTROL UNIT) The brains of the loader

Control Protection Safety features

Loader can operate at full production without touch screen and/or HMI EXCEPT:

If an alarm or warning happens you will only see the light and not know what it is

When Park Brake Sw LED is on the VCU is fully booted and engine can be cranked. If no inhibits exist. System is Logging.

Missing modules will be reported except if module 4 is missing. This will prevent LINCS from booting.


VEHICLE CONTROL UNIT (VCU)VEHICLE CONTROL UNIT (VCU)Status LED’s

Power Connector

Not Used

Not Used Not Used

Ethernet Port

DIP Switches(All switches “OFF” by detail)

Port # 1

Port # 0

Analog Input Modules

Digital I/O Modules

CAN (J1939) Modules

C3C1 C4 C5C2 C6 C7 C8


VCU

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Digital I/O

Analog I/O

VCU

1/1004277161

22 OF 29

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ISSUED

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ELECTRIC SCHEMATIC L11502216

22

DIGITAL INTERFACE CARD STATUS LEDs

DIGITAL OUTPUTSLED OFF = 0% DUTY CYCLELED ON = >0% DUTY CYCLE

(BRIGHTNESS VARIES WITH DUTY CYCLE)

1

1

1

1 1

1

11

11

DIG

CAN

DIG

IN1

DIG

IN2

DIG

IN3

DIGOUT1 DIGPWR DIGOUT2

DIGOUT5

DIGOUT4

DIGOUT3

CAN3

CAN2

CAN1

CAN0CARD4 CARD5 CARD6

15V

5V_FP

5V

DO LEDs

DIGITAL INTERFACE CARD(P/N: 425-9228)

DI L

EDs

5V SPEED CONTROL PEDAL SUPPLY

15V CARD SUPPLY

5V CARD SUPPLY

13

FRO

NT

WA

SH

ER

PU

MP

14

PA

RK

BR

AK

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WIT

CH

LIG

HT

16

FRO

NT

WIP

ER

HIG

H17

FRO

NT

WIP

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LO

W18

RE

AR

WIP

ER

LO

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UTP

UT

19 20

AU

TOLU

BE

SO

L21

FLO

AT

SO

L22

DIG

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L O

UTP

UT

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SW

PO

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UT

24

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WA

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15

-----

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0322

1

0322

3

0412

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0321

5

0321

7

0321

9

0224

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5

1122

5

1121

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39383736353433323130292827262512111098765432

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40 41 42 43 44 45 46 47 48

KLE

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2 S

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KLE

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3 S

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KLE

NZ

4 S

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KLE

NZ

5 S

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KLE

NZ

6 S

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7 S

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49

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56

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57

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HTS

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M58 59

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UTP

UT

60

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WL

LIG

HTS

0411

5

0411

7

0411

9

0414

4

-----

-----

-----

-----

-----

-----

-----

0224

9

1121

1

1120

3

1120

9

1120

7

1120

5

1714

1

1714

3

1020

3

1020

7

1020

9

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1

1021

3

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5

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7

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9

1710

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1121

9

1122

1

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8

1712

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04

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-----

-----

0410

3

0410

7

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4

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5

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1310

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13144, 13244, 14139

14115

13111, 13211, 14113

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

UNUSED

17103

10109

11114

10103

11250

02120

02124

02136

02132

02128

-----

-----

-----

-----

-----

-----

-----

-----

-----

02152

03255

02210

02208

11108

02255

11112

06203

13109, 13209, 14111

KEYSWITCH CRANK SWITCH

KEYSWITCH IGNITION

PARK BRAKE SWITCH

AUTOLUBE SWITCHES

FRONT DRIVER LUBE FLOW SWITCH

HV CABINET DOOR SWITCH

STEER SUPPLY PRESSURE SWITCH

ENGINE SAFETY FILTERS

REAR DRIVER LUBE FLOW SWITCH

KLENZ ENABLE SWITCH

STARTER ISOLATION SWITCH

LADDER POSITION SWITCH

CAB E-STOP SWITCH

HV CABINET E-STOP SWITCH

HYD RESERVOIR E-STOP SW

LEFT REAR E-STOP SWITCH

RIGHT REAR E-STOP SWITCH

ENGINE BLUE LAMP

FIRE SYSTEM STATUS

11103

UNUSED

ENGINE YELLOW LAMP

DRIVE COOL RESERVOIR LEVEL SW

HYD RESERVOIR LEVEL SW

5

6

7

8

9

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

29

30

31

32

33

34

35

LINE #FUNCTIONDIENGINE RED LAMP36

DI33

- 36

LED

OFF

= 2

4 V

DC

INP

UT

LED

ON

=

0 V

DC

INPU

T

DI5

- 32

LED

OFF

= 0

VD

C IN

PUT

LED

ON

= 2

4 VD

C IN

PUT

DIG

ITAL

INPU

TS

-----

UN

US

ED


Analog Interface Card


24vdc Fuses


Control Relays


12v Power Supplies

12v Supply for Display

12v Supply for Radio and Power Outlet


CONNECTOR ABBREVIATIONS

CAB - CABLLC - LADDER LIGHT CONTROLPCP - PILOT CONTROL PANELFFR - FRONT FRAMEFPL - FRONT POLE LIGHTMBR - MIRROR BARKLZ - KLENZEST - EMERGENCY STOPRFF - REAR FRAME FORWARDRFM - REAR FRAME MIDDLEEIC- ENGINE INTERFACE CABNETRAX - REAR AXLEDCP - DRIVE COOLING PUMPRCL - REAR COWLCSP - CONTROL SWITCH PANELSRC - SR CABNET

CAB8

CAB7

Low Voltage CabinetConnectors


Cab


Cab


Cab Connections


Display Console


Key Pad


Joy Sticks


HMI FUNCTIONALITY Gauge cluster Channel charting Event viewing Channel forcing Calibrations (sequence of automated channel forces

and data collection) Additional channel and event log storage capacity Software upload Download logs Configure VCU (Service Rep access only) Create user access keys – only down one level


Human MachineInterface (HMI)



BreakoutBoxes

12 PIN FEMALE RECEPTACLE

3 PIN FEMALE RECEPTACLE

PIN-3 PIN-2

PIN-1

PIN COLOR1 ORANGE2 BLUE3 WHITE/BLACK4 RED/BLACK5 GREEN/BLACK6 ORANGE/BLACK7 BLUE/BLACK8 BLACK/WHITE9 GREEN

10 RED11 WHITE12 BLACK

PIN LEGEND

PIN COLOR1 GREEN2 BLACK3 WHITE

PIN LEGEND

5 PIN FEMALE CAN RECEPTACLE

PIN COLOR1 DRAIN2 RED 24V3 BLK GND4 WHT (CAN_H)5 BLU (CAN_L)

PIN LEGEND

PIN-5

PIN-4

PIN-1

CONNECTOR COLOR CODES

PIN-2

PIN-3

PIN-8

PIN-7

PIN-1

PIN-10

PIN-9

PIN-12

PIN-6

PIN-5

PIN-11

PIN-4

PIN-3

PIN-2

BREAKOUT BOX(426-5235)

XXXX: HARNESS NAME / WIRE CODE

24V

GN

D

SIG

NAL 24

V

GN

D

SIG

NAL

SIG

NAL

SIG

NAL

SIG

NAL

SIG

NAL

SIG

NAL

SIG

NAL

XXXX

-05

XXXX

-12

XXXX

-10

XXXX

-11

XXXX

-08

XXXX

-03

XXXX

-09

XXXX

-07

XXXX

-01

XXXX

-02

XXXX

-04

XXXX

-06

SIGNAL

GND

24V

SIGNAL

GND

24V

SIGNAL

GND

24V

SIGNAL

GND

24V

J1-1

J1-2

J1-3

J3-1

J3-2

J3-3

J5-1

J5-2

J5-3

J7-1

J7-2

J7-3 J8-3

J8-2

J8-1

J6-3

J6-2

J6-1

J4-3

J4-2

J4-1

J2-3

J2-2

J2-1

24V

GND

SIGNAL

24V

GND

SIGNAL

24V

GND

SIGNAL

24V

GND

SIGNAL


426-5234

Pressure Sensors

Position Sensors

426-7338

I/O Device Cabling


426-5232

Solenoids

I/O Device Cabling

426-5233


Cable Extensions

3 Pin Extension (From breakout box to device cable) 12 Pin Extension (To breakout boxes)

426-6241 = 10 meter426-6240 = 5 meter426-5213 = 3 meter426-5231 = 2 meter426-4198 = 1.6 meter426-4197 = 1.4 meter426-4196 = 1.2 meter426-5230 = 1 meter

426-6243 = 10 meter426-6242 = 8 meter426-5229 = 6 meter426-5228 = 5 meter426-5227 = 4 meter426-5226 = 3 meter426-5225 = 2.8 meter426-5221 = 2 meter426-5207 = 1.5 meter426-5220 = 1 meter


CAN Cabling

CAN Cables

CAN Tee

426-6253

426-6251 = 10 meter426-4188 = 1.5 meter426-6246 = .5 meter


CAN Cabling

Terminating Resistor

426-6254

120 Ohm



Pressure Transducers

Measuring4-20 mA

Device Range@ 4mA

Low Value*

@ 4mAHigh

Value*

@ 20mALow

Value*

@ 20mAHigh

Value*

Pressure

0 – 15 PSIG -0.3 0.3 14.7 15.30 – 50 PSIG -1 1 49 51

0 – 200 PSIG -4 4 196 2040 – 600 PSIG -12 12 588 612

0 – 1500 PSIG -30 30 147 0 15300 – 5000 PSIG -100 100 4900 51000 – 7500 PSI -150 150 7350 7650

Δ P 0 – 20 IN H 2O -0.4 0.4 19.6 20.4Temperature -10 – 100°c -22.4 -17.6 97.6 102.4

GEN 2 TrainingComponent Description

Position Sensors


Position Sensors


POSITION SENSOR CABLE FAIL

Automatically bypasses limits with manual restore Automatic motion functions will be disabled Bypass limits does not disable inhibits like Park Brake Slip control does not work if steering sensor is

bypassed Load Weight will not work = (Hoist Base)


Steering Interface Card

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Steering Interface CardNeutral


3

Voltage Above Supply Voltage is

Left Steer Command

VoltageIncreases

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Steering Interface CardLeft


3

Voltage Below Supply Voltage is

Right Steer Command

VoltageDecreases

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Steering Interface CardRight


3


24vdc Distribution24vdc Distribution


Enclosures

Engine

Klenz Box

Rear Lights


Air Valves EnclosureAir Valves Enclosure


Optional Equipment Power Source

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CIRCUIT DESCRIPTIONS

Circuit Descriptions

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CIRCUIT DESCRIPTIONS


• DATA RECORDING• IDLE TIMER• USER ACCESS• KEY “ON” POWER UP

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VCU

VCU Event Data

Events

HMI 10,000

Updates every 5 seconds

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HMI

HMI Event Data

1 year

Updates every 5 seconds

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VCU

VCU Channel Data

Channel I/O

50Hz

50Hz1 hr

HMI

5 SEC

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Downloading Log Files

*.L2L

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Offline Viewing Log Files

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IDLE TIMER

Begins the five minute idle count down as soon as low throttle is selected and not just when the key is turned off. Engine must have been running for five minutes.

If the engine has been at idle for four minuets it will count down one minute when the key is turned off.

Red alarm by-passes idle timer automatically


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USER ACCESS KEYS LINCS I key will not work with new system

(it will tell you wrong Key) New LINCS I software is compatible with LINCS II key.

Keys can be programmed on or off loader USB reader (laptop) and serial on loader User cannot create a key of their security level Factory Rep keys are made by Engineering in Longview only. Data on key

Name Password Security level Language 12/24hr clock Unit preference

System changes preferences at log on


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USER ACCESS LEVELS Operator

Display Troubleshooting Notices Adjust Alternate Machine Speed and

Motor Torque Turn Off or On Aux Steer Test, Brake

Test, and Inhibit P.B Released mode. Maintenance

Machine settings screen Software upload, download & restore Calibrations Load bank Create user access keys “Operator” Reset red alarm Configure Drives

Disable drive, swap RPT, Disable phase, Disable panel


Service Force channels Configure VCU to match

machine Create user access keys

“Maintenance” Change system clock

12K

FU 01

10A

TB 2

ESD3-5ESTOP RLY

ESD2-10ESTOP RLY-READ

CR ES

(02241)85 86

0 0A 0AB E-STOP RELAY426-0950 (D4)

CR K1

(06118)85 86

CR HD

(03103)85 86

CR MP

(02226)85 86

CR K2

(05203)85 86

CR K3

(05228)85 86

CR K5

(05247)85 86

CR K4

(06215) (06217)85 86

CR DP

(05107)85 86

CR KS

(02223)85 86

CAB2-04

TB 1

TB 1

TB 1

12K

FU 02

10A

TB 2

CR KA

(02220)85 86

TB 1

TB 1

TB 1

CR KA

(02214)30 87

D3

TB 1CR KS

(02205)30 87

CR ES

(02144)30 87

TB 1

TB 1

CR MP

(02223)30 87

CAB2-05

CAB2-01

KEYSWITCH CRANK SWITCH423-2243 (B4)

KEYSWITCH RELAY426-0950 (D4)

HMI DISPLAY POWER RELAY426-0950 (D4)

KEYSWITCH

MASTER POWER RELAY426-0950 (D4)

KEYSWITCH POWER RELAY 1411-9992 (D4)

DIGITAL OUTPUT POWER411-9992 (D4)

VCU / HMI KEEP ALIVE426-0950 (D4)

0B

0B

0B

0B

0B

0BA

0BB1 0BC

GND

KEYWSITCH POWER RELAY 2411-9992 (D4)



TB 1

0BD

0BD

0BD

0BD

0BD

0BB

0BB

GND

GND

GND

GND

GND

0

3B GND

DRIVE SWITCH POWER OUTPUTKEYSWITCH POWER RELAY 4426-0950 (D4)

DO24

DO23

DO3

KEYSWITCH423-2229 (B4)

KEYSWITCH IGNITION423-2223 (B4)

0BA GNDVEHICLE CONTROL UNIT (VCU) (D4)

DO3 / DIGOUT1-10HIGH SIDEC5-7

DI7 / DIGIN1-7STANDARD C4-7

DI6 / DIGIN1-6STANDARD C4-6

DO2 / DIGOUT1-11LOW SIDE C5-6



(06221)

0BD

DO2

IGNITION KEEP ALIVE OUTPUT

V1 C

(03148)

(VCU)VEHICLE CONTROL UNIT

D3 413-5968 (D4)

0BD

0BB

SW KS

3

2

4

1

(05123)

DI7

24V CAN

24V GENERATOR CONVERTERS

12K

FU 02

10A

TB 2

0

Supplies ground when noE-Stops are pushed (activated)

Supplies 24vcd when LINCS is booted. It will keep(CR KS) energized even when the key switch is turnedoff. It is used as part of the engine idle 5 minute timercircuit.

Switches to ground when LINCS is booted. Supplies 24vdcto Digital interface card output circuits.

Switches to ground when LINCS is booted. Supplies 24vdcto the converters “Ignition circuit”.

Switches to ground when LINCS is booted. Supplies 24vdcto the VCU, HMI, and Display by energizing relay (CR KA).When the key is turned off the software will keep (CR KA)energized for approximately 15 sec to allow for propersoftware shutdown.

Senses the position of the key switch

When key is turned off:1. Looks for engine idle timer required.

2. Removes 24vdc to the ignition keep alive circuit (CR KS)3. Removes 24vdc to the CAN circuit (CR MP)4. Removes 24vdc to the Digital card (CR DP)5. Removes 24vdc to the converters (CR K4)6. Removes groung to keep VCU/HMI alive circuit (CR KA) after 15sec timer

Begins the five minute idle count down as soon as low throttle is selected and not just when the key is turned off. Engine must have been running for five minuets.If the engine has been at idle for four minuets it will count down one minute when the key is turned off.Red alarm by-passes idle timer automatically

When booting:1. Supplies 24vdc to the CAN circuit (CR MP)2. Supplies 24vdc to the Digital card (CR DP)3. Supplies 24vdc to the converters (CR K4)4. Supplies groung to keep VCU/HMI alive circuit (CR KA)5. Supplies 24vdc to the ignition keep alive circuit (CR KS)

LINCS “Key On” start circuit

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SCREEN NAVIGATION

Navigation

Factory Settings System Settings Data Logging Machine Summary

LanguageUnit System

Truck CapacityIdeal Cycle Time

Display Troubleshooting NoticesLamp Test

Zero Tooth to GroundReset Shift ProductionAuxiliary Steering Test

Brake TestInhibit Park Brake Release Mode

Alternate SpeedAlternate Torque

Change Time

LINCSII Menu Structure

Main Operator

HMIVCU

Drives

Change Software

Calibrations

Configure

Load Bank

Machine Settings

Remote Server IP

User Preference

Clean ScreenField AccessLog Off

KLENZ Timing (Low Throttle)KLENZ Timing (High/Med Throttle)

Auto Lube TimingBlower / Fan

Max Machine SpeedMax Machine Torque

Bypass Hoist/Bucket LimitBypass Bucket LimitBypass Steering Limit

Download Logs and Channel DataPrint to PDF

Load Weight DataTons Per Hour

Tons per Load (Bell)Cycle Time (Bell)

Sweet SpotFilter Data

Print to PDF

System Clock

Select Channels to View (Inputs Only)Show Chart form of Selected Channels

View Logs

Speed Control PedalHoist and Bucket

SteeringLoad Weight

Operator

Maintenance

Service

User Access Key

Minimum Security Level Required

User Access

Logging / Monitoring

Production Reports

Select Channels to View/Force (Inputs Only)

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TROUBLESHOOTING

Troubleshooting

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TROUBLESHOOTING

Troubleshooting

• TROUBLESHOOTING NOTICES• RED ALARMS• YELLOW WARNINGS• BLUE EVENTS• LOAD WEIGHT

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TROUBLESHOOTING NOTICES

Can be turned on at any level of access. Will display logic applied limit or inhibit information

For example Raise Hoist Limited by End of Travel


RED ALARMS

Step 1: The cab audible beeper is sounded and the red light on the dash is illuminated. Idle speed is changed to low idle and the drive system if energized will remain energized. This

means top speed is limited to half machine rated speed. If the touch screen is present it will display the alarm text on screen. Pressing the acknowledge switch silences the beeper and removes the text from the screen. A counter on the upper bar of the screen will display the amount of time the operator has until the

machine is shut down. This amount of time will vary based on the alarm. This time can be zero for some alarms. When the counter reaches zero the shut down sequence will begin. At any time during step 1 if the park brake switch is pressed in, it will skip to step 2.

Step 2: Zero speed is commanded to the drive system.

Step 3: When the vehicle has reached .5mph the engine is turned off bypassing the idle timer and the park

brakes are set. The operator can release the computer’s park brake control by pushing the park brake switch in. The engine will not restart until the system is rebooted unless someone with high enough security

access resets the alarm.

Red Alarms indicate something has failed that could result in catastrophic damage or personal injury.


RED ALARMS

Delay to shut down time

Auxiliary Steering System Activated = 30 Sec Auxiliary Steering System Fault = 0 Sec Battery Charging Alternator Voltage Critically Low = 30 Sec Emergency Stop Switch Pressed (Any) = 0 Sec Engine Red Lamp Active = 10 Sec Engine Safety Filter(s) Restricted = 1 Min Fire System Engaged = 10 Sec Detected Five Consecutive Auto Lube Warnings = 15 Min HPD Gearbox Oil Pressure Critically Low = 10 Sec Hydraulic Oil Reservoir Level Low = 30 Sec Hydraulic Reservoir Air Pressure Low = 15 Min Klenz Filter Restriction High At Low Throttle = 5 Min Vehicle Control Unit Critical Over Temperature = 30 Sec


YELLOW WARNINGS

Idle speed is limited to low until boot down (example) Klenz restriction.

Auto Lube cycle long is a progressive warning that after 5 consecutive occurrences becomes a Red Alarm.

Drive faults are yellow, but do not explain cause of fault. You must look at Blue PM alerts in log for details.

Yellow Warnings indicate something that effects how the machine performs has failed or is out of tolerance.

Some Yellow Warnings:

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BLUE PM ALERTS

Blue PM Alerts indicate something is out of tolerance and should be repaired or replaced at the next scheduled PM.

These PM Alerts do not pop up on the screen so they must be checkedusing the view logs screen.

Since many of the PM Alerts are there to assist troubleshooting. You should always look for any PM Alerts related to the circuit you areworking on.


LOAD WEIGH GEN 2 machines incorporate the standard load weigh mechanisms along

with a ‘load and carry’ load weigh function. The load and carry load weigh function is always active and is easy and fun to use.

The standard load weigh mechanism works by calculating the load weight when the Lift Arm angle reaches zero degrees. (Horizontal) However, this calculation is only performed if a load weight does not currently exist. How can a load weight already exist you might ask? Well, if a ‘load and carry’ load weigh was previously calculated, the load weigh software will not re-calculate at 0 degrees. Instead, the software will simply use the current load weigh stored.

To get a ‘load and carry’ load weigh, the lift arms and bucket must be in a certain range. The Lift Arm angle must be greater than -20 degrees and the bucket must be rolled back greater than 30 degrees (Bucket Position). In addition, you must cease any hydraulic functions associated with the right joystick. When this is detected, a ‘load and carry’ weight will register. While in position, if you want to trigger a re-weigh, all you must do is move the right joystick and stop again. If hydraulic commands are active, the software assumes you are still loading.

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SUPPORT SOFTWARE AND TOOLS

Support Software

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SUPPORT SOFTWARE AND TOOLS

Support Software

• DOWNLOAD LOG• UPLOAD NEW Software• USE OF OFF LINE TOOL – Same software as what is on machine• FTP SITE – for Software and downloads

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DOWNLOADING LOG FILES

Put USB drive in USB port

Navigate to download screen under logging and monitoring.

Transfer files to USB drive – (Drive E)

Channel log files can be very large

Date range selected in channel viewer only applies to channels. A maximum of 4 hours can be downloaded

Creates a (.l2l) file

Support Software

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Event Data

6 days of channel data on HMI

Up to 4hrDownloadWindow

End Date\Time

Leng

th o

f Dow

nloa

d

Start Date\Time

4 Hrs

2 Sec

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LOADING NEW SOFTWARE ON LOADER

• Use another computer to put .l2u file on a USB drive• Software will be available on our website at some point• Put USB drive in USB port• Use security key to log on• Navigate to load new software screen• Select correct file and load software

• If drive software has changed it can take over an hour at reboot to program all of the drives

• Perform software spot check

Support Software

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OFF LINE TOOL FUNCTIONALITY

HMI software will run on a lap top computer (1280x1024min resolution)

Has menu bar Channel charting Event viewing Cannot view calibration and

setting screens Create user access keys

Download logs to USB Allows downloading a selected

section of the log small enough to email

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UPLOADING LOG FILES TO OFF LINE TOOL

Put USB stick in Lap top

Open LINCSII application

File then Open on menu bar

Navigate to USB drive

Select file

View data just as on loader

Download must be compatible with version of OFF LINE TOOL.

Support Software

Documents

LINCS II Presentation