Electrical Systems - IQAN Digital Control System. IQAN Control System Components

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1 Section 5.1 Electrical Systems - IQAN Digital Control System IQAN Control System Components IQAN Operational Description: At Machine Startup Before The Machine Can Be Operated During Machine Operation Troubleshooting Hints Form T Electrical System - IQAN Digital Control System

2 NOTE: This diagram is only a simplified overview of the IQAN digital control system. Complete electrical schematics of the system showing wire colors and pin connections can be found at the rear Section 5. Engine Speed operators cab HP Engaged Switch Hydro Pressure Transducer operators cab High Gear Low Gear Gear Box RPM T0830 Figure 1: Simplified IQAN System Layout Electrical System - IQAN Digital Control System Form T055

3 IQAN Control System Components 1) The control box serves as a centralized switching center for the IQAN control system. It contains all the system harness connection points, a power converter, and solid state switching modules. The control box receives incoming signals from control input devices (ie: joysticks) and various sensors (ie: hydraulic oil level) and sends them to the Master Display Module (MDM) for computer processing. Upon receiving command signals from the MDM, the switching modules regulate either a digital ON/OFF or a proportional control signal out to the solenoid coils that control the valves, motors and pumps. 2) The MDM panel houses the Master Display Module (MDM) as well as several switches and indicator lights. One of the switches on the MDM panel is the IQAN system ARM switch. The IQAN system will not operate until armed. The operator must have the cab door closed before arming the system. Opening the cab door will automatically disarm the IQAN system. 3) The Master Display Module (MDM) is the heart of the IQAN digital control system. The MDM contains the computer and program that determines how the control system responds to the operator s input. The MDM performs many auxiliary functions also: A) It is the interface when uploading and downloading programs or attaching a laptop computer for advanced system troubleshooting. B) Serves as a system monitor and can be programmed to display various system variables like engine RPM, hydraulic oil temperature, etc. C) Can be used to monitor and measure control inputs and outputs to the valves, motors and pumps for easy system troubleshooting. D) Used to set a control function s operational characteristics to operator preferences. The MDM can store up to three different custom operator settings along with the system default setting from the factory. NOTE: Additional information on the auxiliary functions of the MDM can be found in the IQAN Training Manual shipped with each machine. 4) The joystick hand controls are actually two different input controls; an upper handle and a lower joystick body. The upper handle contains six push button switches and a trigger switch. The push button switches are ON/OFF except the two most outboard positions (grey switch boot) which are proportional. The trigger switch is also proportional. The lower joystick body is a two-axis control with a centered, neutral position. Control movement along both axis is proportional. 5) Wheel drive speed is controlled by an electronic foot pedal. The foot pedal is a proportional control. 6) The cab door interlock switch is a normallyopen switch that acts as a sensor that won t allow the operator to arm the IQAN system unless the cab door is closed. 7) The VOAC K220/L90 main control valve bank consists of up to eleven valve sections. Each valve section has two proportional solenoids (one for each work port). The solenoid coils are energized with proportional current from the XP modules in the control box. This current creates a proportional pilot pressure change within the valve section that shifts the work spool. Low solenoid current creates low flow from the valve section, high solenoid current creates high flow from the valve section. Form T Electrical System - IQAN Digital Control System

4 8) The Rexroth AAVG125 wheel drive pump feeds the wheel drive hydrostatic circuit. The pump controller is equipped with proportional solenoid coils. When actuated, the solenoid coils shift a controller spool connected to the pump s swash plate. Movement of the controller spool determines travel speed and direction. 9) Various sensors located throughout the machine (hydraulic oil temperature, hydraulic oil level and charge filter bypass shown) provide signal data to the IQAN system. This signal data is used by the IQAN program to help regulate output signals to the valves, motors, and pumps. A good example would be horsepower regulation. On the standard mechanical engine, a speed sensor in the engine s flywheel housing monitors engine RPM. The IQAN system will automatically reduce the signal output to the valves, motors and pumps to avoid stalling the engine, regardless of the operator using full control actuation. 10) On standard machines, where a manual throttle is used, there is a horse power limit switch mounted just ahead of the throttle control. When the throttle control is moved to FULL SPEED the switch is actuated and the IQAN system begins automatic horsepower regulation. When a machine is equipped with an electronic engine, an electronic throttle control is used. The IQAN system monitors the engine ECM feedback for engine torque and regulates hydraulic functions to prevent engine stall. Electrical System - IQAN Digital Control System Form T055

5 IQAN Operational Discription At Machine Startup Electrical power of 24-Volts is supplied to the IQAN digital control system s control box on engine startup. Internal to the control box, the 24-Volt power supply is made available to the Master Display Module (MDM), via harness, and each of the expansion modules located inside the control box. The expansion modules do not have the system program. They allow signal transmissions to the MDM (where the system program is stored) or they respond to signals from the MDM to control outputs to various components. The IQAN system continuously monitors the system sensors. If a control or sensor has a signal outof-range, the error will be displayed on the MDM. These error signals can be generated by any control or sensor. The expansion modules are known as XP and XS modules, See Figure 2. All machine control function inputs, sensor inputs, and valve/motor/pump control outputs are connected to one of the expansion modules by wire harnesses. Each expansion module has its own regulated 5-Volt supply available for system sensors. Fuse Panel Legend F1 10A - XP-A0 F2 3A - MDM supply F3 3A - XP-A1 F4 10A - XS A0 F5 10A - Diagnostic tool F6 3A - Real Time Clock XS Module XP Module Figure 2: IQAN Control Box Internal Components Form T Electrical System - IQAN Digital Control System

6 Before The Machine Can Be Operated The IQAN control system is active on machine startup but before any machine functions will work the IQAN system must be armed. The cab door must be fully closed to arm the IQAN system. There is a normally open cab door safety interlock switch located at the base of the door that is used as a sensor in the IQAN system. See Figure 3. With the cab door open, the switch cannot return the 5-Volt signal it received at startup. The IQAN system cannot be armed until it receives a constant return signal from the switch indicating the cab door is closed. Figure 3: Cab Door Safety Interlock Switch The IQAN control system is armed by actuating the SYSTEM ARM switch on the MDM panel. See Figure 4. This momentary switch actuates a latching relay that will remain closed once the switch is released. If the cab door is opened while the IQAN system is armed, the latching relay loses power and disarms the IQAN system. The cab door has to be closed, and the IQAN system re-armed, before the machine controls will operate again. In addition to the safety interlock switch and arming the IQAN system, the optional charge oil heater and hydraulic oil temperature can either prevent or restrict machine control at startup. Charge Heater The optional charge oil heater helps warm the hydraulic oil during cold weather starts. The charge oil heater circuit is wired to block arming of the IQAN system when the charge oil heater switch is ON preventing operation of the machine. This prevents hydraulic system overheating. See Figure 5. Tempature regulation Figure 4: SYSTEM ARM Switch The IQAN system is also programed to restrict operation of all machine functions when the hydraulic oil is not at a suitable operating temperature, either hot or cold. This is done to prevent system damage from a collapsed filter medium, cavitaion in the pumps or overheating. The IQAN system monitors the hydraulic oil temperature via a sensor in the hydraulic tank. Machine operation restriction is achived by Figure 5: Optional Charge Oil Heater ON/OFF Switch automatically reducing the output signals to the valves/pumps. The reduction scale is determined by the hydraulic oil temperature, less than 50 F and greater than 190 F. Electrical System - IQAN Digital Control System Form T055

7 During Machine Operation Simple Description: The IQAN control system achives machine control by monitoring input signals coming from the machine controls such as the joysticks and foot pedal. Signal monitoring is performed by the XP & XS expansion modules. Input signals are then processed by the IQAN program in the MDM computer and a corresponding output signal is then sent from the expansion modules to the required valve section or pump controller that performs the work. Control Function Input Signals: Each machine control device is sent a 4.5-Volt power signal at machine startup. This signal is returned to the IQAN control box to let the IQAN system know the device is at a ready state. The 5-Volts is also the base voltage for the input signals generated when the control device is actuated. Control function input signals are always measured in volts. A minimum of 0.5-Volts input signal is required to actuate a function. The first 0.5-Volts is a deadband required to help keep the control in a centered, neutral condition and help keep false signals from affecting machine control response. All control function inputs are one of two types of signals: Digital ON/OFF - This signal is either OFF (0- Volts) or FULL ON (+4.5-Volts). The ON/OFF pushbutton switches in the joystick handles are a good example. Analog Proportional - These signals will vary from 0.5-Volts to 4.5-Volts, depending on the control position. The joystick controls work on an axis so they will also return signals of -0.5-Volts to 2.5-Volts and 2.5-Volts to 4.5-Volts, depending on which side of the axis the control movement is on. Control Function Input Signal Processing: All control function input signals are sent back to the control box and then proccessed by the IQAN program in the MDM. The IQAN program determines how the movement of the control by the operator will affect the valve section or pump controller that is required to do the work. Parameters in the program determine many operational characteristics, such as: A) The maximum speed the function will operate. B) How quickly the function starts and stops, or RAMP ON and RAMP OFF. C) How far the control has to be moved before any response is generated, or DEAD BAND. D) How fine or sensitive the control movement is. Some of the above are adjustable by the operator, some are a factory adjustment only. The MDM has the capability to store three different operator modes, each with different settings for all control functions. In addition, one operator mode is always locked as a factory default so any of the other three can be returned back to its original state. After the IQAN program processes the control function input signals, it sends the corresponding output signals to the required valve section or pump controller. Valve/Pump Output Signals: Valve/pump output signals are always measured in milli-amps and typically range from 300 milli-amps to 700 milli-amps. The output signals are sent to a valve section or pump controller s proportional solenoid coils. Energizing the solenoid coil shifts a pilot spool that allows a proportional pilot pressure signal to act on a much larger work spool. In a valve section, the work spool diverts oil flow which actuates the cylinder or motor doing the work. In a pump, the work spool shifts the pump s swash plate and brings the pump onstoke to produce oil flow. The IQAN program has full control over operational characteristics of the valves and pumps by metering the output signals to them. For example; If a control function s parameter has a MAX speed setting at 50% of it s capability, IQAN will only allow half speed operation of that function regardless of how far the control is actuated. Form T Electrical System - IQAN Digital Control System

8 THIS PAGE LEFT BLANK FOR NOTES Electrical System - IQAN Digital Control System Form T055

9 Section 5.2 Electrical Systems - Machine Electrical System and Fuses Electrical System Components Diagrams: Main Electrical Load Center Components Main Electrical Load Center Fuses QSC Engine Electrical Box Components QSC Engine Electrical Box Layout and Fuses Automatic Reversing Engine Fan (PDN# 0026 and below) Optional Pro Heat system Wiring and Fuses Master Electrical Disconnect Master IQAN Control Box Internal Fuses Form T Electrical System - Machine Electrical System

10 NOTE: This diagram is only a simplified overview of the machine electrical system. Complete electrical schematics of the system showing wire colors and pin connections can be found at the rear Section 5. Battery negative (-) and starter negative (-) cables are grounded to the engine block. T0834 Figure 1: Simplified Machine Electrical Layout Electrical System - Machine Electrical System Form T056

11 Electrical System Components 1) Two heavy-duty, 12-volt batteries are connected in series to power the machine s 24-volt electrical system. The batteries are rated at 1000 cold cranking amps each. 2) A master disconnect switch is provided to allow all electrical power to the machine to be cutoff. The disconnect is located on the positive side of the circuit to protect sensitive computer components in the IQAN digital control system and electronic engine. It is recommended that the master electrical disconnect switch be turned off during service of the machine and whenever parking the machine for an extended period, such as the end of the working shift. 3) All machines are equipped with a 75 Amp alternator. There is a 100 Amp fuse located on the alternator mount bracket which protects the electrical system from being over-charged. 4) The starter motor and solenoid have a direct connection to the batteries. A signal wire from the cab energizes a latching relay that allows current from the batteries to turn the motor and start the engine. 5) An inline 100 Amp fuse protects the main electrical load center in the cab. This fuse is located near the left rear vertical leg of the engine house structure. Machines equipped with an electronic engine have this fuse located in the engine control electrical box. 6) Machines equipped with electronic engines have an engine control electrical box that houses the special relays and fuses required for the installation. The engine control electrical box is mounted on the left rear vertical leg of the engine house structure. Major items located in the control box include: A) The inline 100 Amp fuse for the main electrical load center. B) A 100 Amp fuse and latching relay for the air intake grid heater. D) Various fuses for engine command and sensor circuits. A single harness connects the engine control electrical box to all the required points on the engine. The coonection to the machine s electrical system and IQAN digital control system are also made at the control box. 7) The main electrical load center in the cab is the heart of the machine s electrical system. The load center consists of a series of fuse banks, latching relays, harness connection points and an isolated grounding strip for all circuits. There are two 8-position fuse banks on the load center. These main fuse banks use Maxi bus fuses and serve individual high current circuits or feed additional Mini bus fuses found in the auxiliary 28-position fuse bank. Also located on the main electrical load center are auxiliary several 12-volt/5 Amp power connections for equipment such as CB radios, GPS systems, etc. A site map of the main electrical load center showing the location and function of all components is included in this section. 8) The dash panel contains all the system warning gauges, warning lights and function switches. The dash panel is connected to the main electrical load center by a single harness containing the signal wires from the switches and warning lights. Power for the dash panel itself (ie: switch power, switch lights and gauge backlighting) is supplied from the alternator via the auxiliary post on the ignition switch. 9) A 24-volt to 12-volt converter supplies power to the auxiliary equipment power connections and the cab s 12-volt AM/FM radio/cassette player. 10) The IQAN system control box receives power via harness from the main electrical load center. The main IQAN fuse and latching relay are found on the load center. C) Fuse and latching relay for the fuel heater. Form T Electrical System - Machine Electrical System

12 Tan Wire A/C Condensor Fan BRN/YEL Right Outer Hella Lights BRN/RED Right Inner Hella Lights BRN/PNK Left Inner Hella Lights Main Power Supply (24 volts) Main Ground Terminals Dash Panel Connection Fuel Lift Pump Relay Aux Power 1 Relay A/C & Heater Unit Relay Fuel Shut Down Relay Cab Lights Aux Power 2 Ignition Signal Relay Aux Oil Cooler Relay Outer Hella Lights Relay Hydraulic Fill Pump Relay 12 volt Aux Power Connections Starter Relay Ignition Relay A/C Condensor Fans Relay Inner Hella Lights Relay BRN/ORG Left Outer Hella Lights White - Hydraulic Fill Pump Iqan Control System Relay BLK/YEL - Starter Relay Figure 2: Main Electrical Load Center Components Electrical System - Machine Electrical System Form T056

13 3 Fuel Shut Down (pull in) Condensor Fans Relay (out) Aux Power Relay #2 (supply +) Aux Power Relay #1 (supply +) T0835 Figure 3: Main Electrical Load Center Fuses Form T Electrical System - Machine Electrical System

14 00572 Figure 4: QSC Engine Electrical Box Components Electrical System - Machine Electrical System Form T056

15 00573 A: ECU I: Engine Ignition Light B: ECU J: ECU Power Power C: ECU K: ECU Power Power D: ECU L: ECU Power Power Figure 5: QSC Engine Electrical Box Layout Form T Electrical System - Machine Electrical System

16 0588 Figure 7: Automatic Reversing Engine Fan (PDN# 0027 and above) Electrical System - Machine Electrical System Form T056

17 Figure 8: Wiring and Fuses for the Optional Pro heat system Form T Electrical System - Machine Electrical System

18 Master Electrical Disconnect IQAN Control Box Internal Fuses Fuse Panel Legend F1 10A - XP-A0 F2 3A - MDM supply F3 3A - XP-A1 F4 10A - XS A0 F5 10A - Diagnostic tool F6 3A - Real Time Clock On Off XS Module Figure 9: Master Electrical Disconnect Switch XP Module Do not disable the electrical system when the engine is running. Damage to the engine could result. Figure 2: IQAN Control Box Internal Components The master electrical disconnect switch is located behind the perforated swing-out engine guard on the left side of the machine. The switch is mounted on the battery hold-down bracket. See Figure 8. ON - Turn the switch to the ON position to enable the machine s electrical system. The master electrical disconnect switch must be in the ON position for the engine to start. OFF - Turn the switch to the OFF position to disable the machine s electrical system. Always disable the electrical system while servicing the machine or when leaving the machine unattended for an extended period, such as overnight. Disconnect the positive (+) red battery cable if your machine is not equipped with the master electrical disconnect switch. Electrical System - Machine Electrical System Form T056

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