GE OHV AC Electric Drive System Software Modification Instruction - AC Release 21 41A322501BF Rev. B December 15, 2005

g GE - Transportation
GE OHV AC Electric Drive System

Dec 15, 2005 Software Modification Instruction – AC Release 21 41A322501BF
Rev. B
Software Modification Instruction – AC Release 21
41A322501BF
Rev. B
December 15, 2005
Author: T. Brown Approval: A. Hamilton 41A322501BF
Issued: GET Engineering BUS. AREA: OHV DIST: N/A Sheet 1 of 43

This Drawing is the Property of GENERAL ELECTRIC COMPANY, This drawing is loaned upon the express condition that it shall not be
reproduced in any manner, and shall be returned upon demand. It is submitted for evaluation purposes and it, and the information
contained therein, shall not be otherwise used nor disclosed to third parties without written permission of General Electric Co.(Made on Word –41a322501bf.doc)

Rev. B
Revision History
REV DATE BY REVISION DESCRIPTION

0 03/31/05 Tim Brown Initial Creation for Release 21
A 04/27/05 Tim Brown Updated For Field Test
B 12/15/05 Tim Brown Final Revision of Official wPTU 3.01 release
NOTICE
The information contained in this document is not to be used for other than the purpose
for which this document is furnished by the General Electric Company, nor is this
document (in whole or in part) to be reproduced or furnished to third parties or made
public without the prior express written permission of the General Electric Company.
Neither the General Electric Company nor any of the contributors to this document
makes any warranty or representation (expressed or implied) with respect to the
accuracy, completeness, or usefulness of the information contained in this document.
General Electric Company assumes no responsibility for liability or damage of any kind
which may result from the use of the information contained in this document.


Rev. B
Table of Contents
1 OHV AC ELECTRIC DRIVE APPLICATION SOFTWARE – RELEASE 21 5
1.1 Compatibility 5
1.2 Description 5
1.3 Definitions 6
1.4 Applicable Documents 6
1.5 Change Instructions and Authorization 6
1.6 Software Versions 7
2 RELEASE OVERVIEW 8
2.1 Operator Changes 8
2.2 Specific Changes 10

2.2.1 PSC / TCI / Inverter 10
2.2.2 AC pocketPTU changes 13
2.2.3 wPTU Toolbox Changes 13
3 POCKETPTU 14
3.1 System Requirements 15
3.2 Handhelds tested 16
3.3 pocketPTU Installation. 17

3.3.1 Installation via PC. 17
3.3.2 Installation via storage Medium 17
4 WPTU TOOLBOX 19
4.1 Toolbox Releases 19
4.2 Computer Requirements 19
4.3 Installation of wPTU Toolbox onto a Laptop 20


Rev. B
4.3.1 Installing wPTU Toolbox 20

4.3.2 Starting the wPTU Toolbox 20
5 GE DEFAULT CONFIGURATION FILES 21
6 GE / OEM CONFIGURATION OPTIONS 23
7 INSTALLATION OF TRUCK SOFTWARE 27
7.1 Quick Startup Procedure 27
7.2 Creating an GE/OEM configuration File 28

7.2.1 Starting OEM tool. 29
7.3 Set TCI Time 36
7.4 Saving Existing Truck data 37

7.4.1 Event Data 37
7.5 Download Inverters 38
7.6 Download PSC 39
7.7 Download TCI 39
7.8 Calibrate Pedals 41
7.9 Truck ID 41
7.10 Checkout 42


Rev. B
1 OHV AC ELECTRIC DRIVE APPLICATION SOFTWARE – RELEASE 21
1.1 Compatibility
Release 21 software may be applied to the following GE Off Highway Vehicle AC

Drive systems.
Drive System Control Mandatory

Type Group Upgrade
GTO 2700HP 17KG498 NO
GE320AC - 3500HP 17KG526Bx YES
GE320AC - 2700HP 17KG526Cx YES
GE240AC 17KG531 NO
IGBT GE150AC 17KG527 NO
GE200AC 17KG537 YES
1.2 Description
This document describes the changes made to the OHV AC Wheel software since
the release of Version 20 in September 2003. It also documents the installation and
downloading procedures for the drive system software and associated diagnostic
tools. For details on previous releases, reference the SMI’s for the desired version.
Release GET Drawing #

16 41A322501BA
17 41A322501BB
18 41A322501BC
19 41A322501BD
20 41A322501BE
This software is for the 17FL320(PSC), 17FL349(TCI), 17FL373(TCI), 17FL375

(ICP) or 17FL386 (ICP2) electronics panels, a portable PC and a handheld Pocket
PC based device.


Rev. B
1.3 Definitions
DID = Diagnostic Information Display
GET = GE -Transportation
ICP = Integrated Control Panel – 17FL375
ICP2 = Integrated Control Panel 2 – 17FL386
NTF = No Trouble Found
PC = Personal Computer
pocketPTU = Pocket PC based software application to interface with Drive System.
PSC = Propulsion System Controller
TCI = Truck Controller Interface
SMI = Software Modification Instruction
wPTU Toolbox = Microsoft Windows based software app to interface to Drive system
1.4 Applicable Documents
The documents that form a part of this document are listed in Table 1.5.
Title of GETS Referenced Documents GE Document Number
wPTU Users Manual GEK-91712

pocketPTU Users Manual GEK-91730A
1.5 Change Instructions and Authorization
This document was originally released as revision 0. Revision letters (A, B, C, etc.)
will be used to identify the latest revision of this document.


Rev. B
1.6 Software Versions
Release 21 includes all application software for the control system electronics panels
as well as the MS-Windows based wPTU Toolbox and Pocket PC based
pocketPTU listed in Table 1.
Software Name Version SW Location

On Truck Controller Software
Propulsion System Controller – (PSC) 21.00b 17FB147 or 17FB174 Card
Truck Control Interface – (TCI) 21.00b 17FB144 or 17FB174 Card
Inverter – 17FB138 01.xx.24.10 17FB138 Card
wPTU Toolbox (Release 3.01)
AC PTU 21.00 laptop
AC Mine and OEM Configuration Utility 21.00 laptop
OHV Download Utility 3.01 laptop
OHV Data-logger Utility X18, Sept 2002 laptop
DC PTU 2.01 laptop
DC Mine and OEM Configuration Utility 2.01 laptop
pocketPTU
AC pocketPTU  2.01 Pocket PC
DC pocketPTU 1.0 Pocket PC
Table 1: Software Versions


Rev. B
2 RELEASE OVERVIEW
Release 21 Software was developed to include support for the 17KG535 and 17KG537
Dual IGBT Drive Systems. It also supports end-user and OEM requested improvements
as well as addressing reliability improvements and product enhancements to the GE
drive systems.
2.1 Operator Changes
The following changes are items that the driver may notice while operating the truck.
• Overloaded Speed Limit Entry (If enabled)

Due to differences in Payload meters and the variations in when an overload is
annunciated, the initial response to an overload has been modified. Previously if
the speed limit overload option was enabled, and the payload meter annunciated
an overload, the Drive system would instantly apply the desired speed limit.
This could cause retarding to be strongly applied to quickly get down to speed.
In v21, when an overload is announced, propel will be inhibited until the truck
speed coasts down to the desired overload speed. Then speed control will be
enabled.
• Flash Continuous Retard Light prior to Entry.

On drive systems that have a Standard and Short Time retarding level, the PSC
will flash the Continuous retarding light for 15 seconds prior to initiated the
standard level of retarding.
• Event 20 Pre-Warning
On drive systems that have the event 20 torque timeout enabled, the drive
system will flash a new output light prior to logging event 20 and removing
propel.
• DDC Ramp down for GE150AC

The DDC 4000 Ramp down logic, which has been running on all DDC 4000-16V
engines, was also applied to DDC 4000-12V engines. This logic allows the PSC
to drop the engine load prior to reducing the engine speed command. This
avoids potential turbo stall issues.


Rev. B


Rev. B
2.2 Specific Changes
These changes are general changes that support additional features or address
reliability improvements. The operator does not directly see these changes.
2.2.1 PSC / TCI / Inverter

• Support for GE360AC Drive System
Version 21 software includes support for the GE360AC drive system using a
17KG535 main control group.


17KG535 main control group on both KAC and Terex Haul Trucks.
.
• Inverter Software Versions

The number of different inverter software versions has been reduced. In v21 there
is one inverter software version per inverter CPU card type. The PSC will then
instruct the inverter what type of Phase Modules / Motor it should be configured for.
• OEM Settable default Gross Engine Horsepower.

The ability to reduce the GHP rating for a particular truck type has been added. This
should reduce the total number of config files and speed response for locations
where engines with reduced HP are installed.
• GY19 Grid Blower Monitoring


Rev. B
The logic for Event 36-5 has been modified to avoid nuisance loggings due to current
feedback delta. The PSC now learns the natural current delta between the 2 motors
and looks for changes to that delta.
• Inverter Speed Resolution

The resolution on the traction motor speed signal has been increased, which should
aid in overall control resolution.
• Transition Time
Changes to reduce the Propel to Retard transition time.
• Reverse Speed limit correction

Changes to allow the reverse speed limit option to work correctly. Previously
released as PSC 20.02c
• Spin Slide Improvements

Improvements to the spin/slide logic which allow greater levels of creep to improve
gradability
• Pedal Cal NTF Event

Changes to event 650 to avoid false loggings on trucks where the profile does not
guarantee 100% retard call is ever reached.
• Event 33-1 NTF Improvement

Changes to avoid false loggings of Event 33-1, when the engine is off.
• Inverter Background Communication Event.

Changes to avoid logging inverter background communication events during VI tests.
• Front Wheel Speed Sensor Logic

Additional logic to detect erroneous front wheel speed signals.


Rev. B
• Engine Warm-up Option

Changes to allow option with only parking brake instead of both parking and wheel
brake.
• Control Group Pressure Sensor Logic

Added support for the addition of a Control Group Pressure Sensor. If installed, and
the option enabled, the system expects that Input to be present at engine speeds >
1800 rpm.
• Speedometer Output Driver

Split output driver schemes for KAC, Terex.


Rev. B
2.2.2 AC pocketPTU changes

The following changes have been made to the pocketPTU application.
• New Screens – Added the following new screens

o Custom Monitor
o Pedal Calibration (TCI)
o Set Truck ID (TCI)
• Choosing COM port – Added the ability to select the specific communication port
to be used.
• PSC Logic Screens – Simplified the PSC logic screens.
2.2.3 wPTU Toolbox Changes

2.2.3.1 Installation
The following changes have been made to the wPTU Toolbox Installation Utility
• Installation – Enforced password sensitivity to only install components necessary.

• Components – Added pocketPC install,
2.2.3.2 AC PTU Application

The following changes have been made to the PTU application.
• Publications – Updated to Latest Versions

• Truck types – Added Support for Dual IGBT Drive Systems
• Revised Screens – Absoluted the Value of GY19 Grid Blower Currents
• New Screens - add the following new screens
o READY mode
o PROPEL Mode
o RETARD Mode
2.2.3.3 Configuration Utility Changes

The following changes have been made to the wPTU Configuration Utility.
• Horsepower – Added the ability to set the Engine GHP value.

• New OEM Options – Added additional OEM options. (See OEM option table)
2.2.3.4 Software Downloading Utility

The following changes shall be made to the wPTU Download Utility.
• Updated for Single Inverter version per card logic


Rev. B
3 POCKETPTU
The pocketPTU software application for AC Drive Systems was introduced with the
version 20 software release. The pocketPTU application allows the end user to
interface with the AC Drive System utilizing the “Pocket PC” platform.
The pocketPTU software is similar in function to the wPTU Toolbox software that
runs on portable computers. The pocketPTU can perform 70% of the functions
that the wPTU Toolbox can accomplish. The ease of use, size and other inherent
advantages of the Pocket PC platform make this an invaluable tool.
Note: The DC pocketPTU program is being released as part of wPTU Toolbox

3.01. It is a separate software program though it is installed and used in a similar
fashion to the AC pocketPTU


Rev. B
3.1 System Requirements
In order to run the pocketPTU software, the handheld device should meet the
following requirements:
• Operating System - Microsoft Windows CE Version 2.0 or higher. Note: the

PalmOS operating system is NOT supported.
• Processor Speed - All of the existing devices are sufficient to run the
software.
• Memory - 32MB of ROM with 32MB of RAM is recommended. The

pocketPTU application is small (< 700K). To utilize the software-
downloading feature an additional 10 Mbytes is required to store the PSC,
TCI, and Inverter object code and configuration files. Additionally, the
amount of Drive System data that can be saved will be dependant upon the
size of the device’s RAM and the frequency of “hot syncs”. (A hot sync will
transfer the saved data from the Handheld to a PC.)
• Ports - A built-in RS-232 Serial Port. Ensure that the port is a true RS-232
serial port and does not need to be powered from the connecting device.
• Expansion Memory (Optional) - The pocketPTU is cable of utilizing expansion

memory. Each device is different, but common memory types are SD
Memory and Compact Flash Cards. If one of these cards is present, the
pocketPTU will utilize this storage first.
• Serial Cable – A Serial cable to connect the handheld computer to the PSC,
TCI, or inverter. These cables vary per device and will have a device-specific
connector on one end and a male DB9 connector on the other. Please note
that the typical “serial hot sync” cable that is normally included with devices is
considered a “null modem” cable. This means that the transmit and receive
pins are swapped to allow the two “computers”, the handheld and the PC, to
talk to each other. In order to communicate to the Drive System computers, a
standard serial cable must be obtained. These cables are available from the
handheld manufacturer or other 3rd party suppliers. The other option is to
modify the hot sync serial cable by adding a “null modem” adapter and a
“gender changer” which are both readily available.


Rev. B
3.2 Handhelds tested
The PocketPTU has been tested on various handheld models including:
• HP (Compaq) iPAQ 3650, 3950, 3955
• ViewSonic V35 ***
• DELL Axim
• TDS – Recon 400
A complete list of available devices, from consumer to industrial, is maintained at the

Microsoft Pocket PC website: www.pocketpc.com


Rev. B
3.3 pocketPTU Installation.
The pocketPTU software may be installed via a PC or directly via a storage medium
such as a SD Memory or compact flash card.
3.3.1 Installation via PC.

Perform the following steps to install via a PC.
1) With the handheld device in its cradle and connected to the PC. (i.e. the
Microsoft ActiveSync software running). Click on the
PocketPtuSetupAC_rel201.exe or PocketPtuSetupAC_rel201_with_v21.exe
file. Note: The installations are provided with and without the v21 object code. If
you wish to download using the device and your device has sufficient space,
choose the latter file.
2) Read and accept or reject the license agreement
3) The PC will then transmit the software to the device. When the transfer is
complete the device will complete the installation.
3.3.2 Installation via storage Medium

Perform the following steps to install via a storage medium that contains the
software.
1) Insert the Storage card into the device.
2) Tap on Start -> File Explorer
3) Pull down and tap on My Device.
4) Tap on Storage Card
5) Tap on the appropriate installation file for Pocket PC 2000 or Pocket PC 2002.
Ac2002_201.cab – For Pocket PC 2000 OS
Ac2002_201obj.cab – For Pocket PC 2000 OS, with v21 object files
Ac2000_201.cab – For Pocket PC 2002/2003 OS
Ac2000_201obj.cab – For Pocket PC 2002/2003 OS, with v21 object files


Rev. B
The software will expand and install


Rev. B
4 WPTU TOOLBOX
4.1 Toolbox Releases
The DOS based PTU and toolbox was replaced with an MS-Windows based software
program during AC Release 19.
wPTU Release AC Software DC Software Date

1.0 19.03 1.19 July 2002
2.01 20.02 1.57 September 2003
3.01 21.00 2.01 December 2005
The term PTU or wPTU Toolbox refers to both a MS-Windows based software
package and the computer hardware that it executes on.
4.2 Computer Requirements
In order to run the wPTU Toolbox software, the laptop computer used should meet the
following requirements:
Minimum Recommended
Operating Windows 95/98/ME or Windows 2000/XP
System NT/2000/XP
Processor 500Mhz 1.5Ghz
Speed
Memory 128Mbytes 512 Mbytes
Hard Drive 300 Mbytes 500 Mbytes
Space
Ports Built in RS-232 or USB to Build in RS-232
Serial adapter


Rev. B
4.3 Installation of wPTU Toolbox onto a Laptop
4.3.1 Installing wPTU Toolbox

The wPTU Toolbox release includes the PTU, configuration utility, password utility,
control software, publications, configuration files and pocketPTU installs.
The entire release is available on a CD or as one large setup file. (Approx 228 Mbytes).
A Serial Number is required to install the CD. Serial numbers should be obtained from a
GE or OEM Representative.
CD Install
Insert the CD into the CD bay of the computer. Use File Manager to browse to the CD
drive and click on the setup.exe file on the CD.
At the end of the installation procedure, the utility will request that the computer be re-
booted to complete the installation.
4.3.2 Starting the wPTU Toolbox

The installation procedure creates a shortcut on your desktop to start the wPTU Toolbox
program. The configuration utilities and the password utility can be launched via the
START menu.


Rev. B
5 GE DEFAULT CONFIGURATION FILES
GE Filename Notes Description

GE150AC – (17KG527)
a15001a.21 Detroit GE150AC for Terex MT3300AC, DDC-12V engine
GE200AC – (17KG537)
A20001a.21 Detroit GE200AC for Terex MT3700AC, DDC 4000 Engine
A20002a.21 Cummins GE200AC for Terex MT3700AC, QSK60 Engine
GE240AC – GTO (17KG531)
a24001a.21 Detroit Diesel GE240AC for Terex MT4400AC with a DDC 4000 Engine
a24002a.21 Cummins GE240AC for Terex MT4400AC with a QSK60 Engine
GE240AC – IGBT (17KG535)
A24011a.21 Standard GE240AC for KAC 830E-AC
A24021a.21 Detroit Diesel GE240AC for Terex MT4400AC with a DDC 4000 Engine
A24022a.21 Cummins GE240AC for Terex MT4400AC with a Cummins QSK60 Engine
GE320AC - 2700 HP -- MTU Engine (17KG498)
A27005a.21 Standard KAC 930E Standard MTU Engine, 31.5 Gear ratio
GE320AC - 2700 HP -- DDC 4000 ENGINE (17KG498)
A27006a.21 Standard KAC 930E Standard DDC 4000 Engine, 31.5 Gear ratio
a27007a.21 Oil Sands KAC 930E Oil Sands, DDC 4000 Engine 38.8 Gear ratio
a27008a.21 10,000Ft KAC 930E DDC 4000 Engine, 31.5 Gear ratio, 10,000 Ft
a27009a.21 14,000Ft KAC 930E DDC 4000 Engine, 31.5 Gear ratio 14,000 Ft
a27010a.21 14,000ft KAC 930E DDC 4000 Engine, 38.5, Gear ratio 14,000 Ft
GE320AC – 2700 HP – CUMMINS QSK60 Engine (17KG498)
a27012a.21 Standard KAC 930E Standard QSK60 Engine, 31.5 Gear ratio
a27013a.21 Oil Sands KAC 930E Oil Sands, QSK60 Engine, 38.8 Gear ratio
a27014a.21 10,000 KAC 930E QSK60 Engine, 31.5 Gear ratio, 10,000 Ft
a27015a.21 14,000Ft KAC 930E QSK60 Engine, 31.5 Gear ratio 14,000 Ft
a27016a.21 14,000Ft KAC 930E QSK60 Engine, 38.8 Gear Ratio, 14,000 Ft
a27011a.21 Torque Boost KAC 930E QSK60 Engine, with boosted Torque (GDY106 only)


Rev. B
GE320AC – (17KG526) – Cummins QSK60 Engine

a27e01a.21 Standard GE320AC for KAC 930E-3
a27e02a.21 Oil Sands - Boost GE320AC for KAC 930E-3, at Oil Sands with Torque Boost
a27e03a.21 10,000 FT GE320AC for KAC 930E-3 at 10k elevation
A27e04a.21 14k or SA GE320AC for KAC930E-3 at 14k…
A27e05a.21 Oil Sands GE320AC for KAC 930E-3, At Oil Sands
GE320AC – 3500HP (17KG526) – Cummins QSK78 Engine
a35001a.21 Standard GE320AC-3500HP for KAC 930E-3SE
A35002a.21 15k GE320AC-3500HP for KAC 930E-3SE at 15k
GE320AC – (17KG535)
A32001a.21 Standard GE320AC for KAC 930E (igbt)
A32002a.21 Oil Sands Boost GE320AC for KAC 930E (igbt)
A32003a.21 14k GE320AC for KAC 930E (igbt)
GE360AC – (17KG535)
a36001a.21 w / GEB16’s GE360AC for KAC 960E, with GEB16 Traction Motors
a36002a.21 w / GEB26’s GE360AC for KAC 960E, with GEB26 Traction Motors
Table 2 – GE Default Configurations


Rev. B
6 GE / OEM CONFIGURATION OPTIONS
For version 21, the following features can be set as GE/OEM configuration options.
Default settings are listed.
# Option Name Description Default

OEM Output FET Options
1 OEM Speed Option 1 Speed @ which Digital output #6 (TCI) is energized, 10 mph
Intended to be wired to external light to give indication of
truck speed.
2 OEM Speed Option 2 Speed @ which Digital output #5 (TCI) is energized, 25 mph
similar purpose as Speed option 1.
3 Engine OEM speed option Speed @ which Digital output #22 (TCI) is energized. 1700 rpm
Can be used to drive other OEM devices based on
engine speed.
Dump Body UP Speed Options
4 Dump Body Up Speed Limit Speed Limit applied to truck while Dump Body is UP 5 mph
5 Dump Body Up Speed Limit (With Speed Limit Applied to truck while Dump Body is UP 15 mph
Override) and Override Button is pressed
6 Dump Body Up RETARD Enable Allows full speed control (Propel and Retard effort 1 - Enabled
at max speed modulation) at the max dump body up speed. If
disabled, retard is not automatically applied to maintain
speed, only propel effort is removed.
Add-on Options
7 Hydraulic Brake Outlet Temp Option to enable the Monitoring of the hydraulic Brake 0 - Disabled
Monitor outlet cooling temperatures on a KAC 930E. To enable
this option, the Kit which includes an updated FB160
card and the additional hydraulic sensors must be
installed.
8 External OEM ACCEL Inhibit Option to enable the external OEM ACCEL Inhibit logic. 0 = Disabled
If this flag is set to 1, PSC Digital input 16 is read to
initiate an accel inhibit.
9 Autonomous Mode Option to configure GE Drive system for Autonomous 0 = Disabled
operation in conjunction with OEM supplied equipment.


Rev. B

Hardware Configuration Options
10 Axle Box Sensor Type Option to set which type of axle box pressure sensor is 0 = None
installed on the system. Set to 1 if the analog sensor is 1 = Analog
installed. Set to 2 if the Digital Sensor is installed.
2 = Digital
Setting to 0 should be avoided since without this turned
on, the propulsion system is unable to detect a loss of
cooling air to the traction motors.
11 Auxiliary Blower Type Option to set which type of Auxiliary cooling system is 0 = Aux Inv
present on the truck. Set to 0 if an Aux Inverter System 1 = Alt Blwr
is present. Set to 1 if an alternator blower System is
2 = Hydraulic
present. Set to 2 if a hydraulic blower is present. Set to
3 is a combination Alternator blower and Hydraulic 3 = Alt/Hyd
blower are present. combo
12 VHMS System Present Option to indicate the KAC VHMS system is installed on cfg dependant
the truck.
13 Engine Load Signal Option to set which type of engine load signal is cfg dependant
present. Set to 0 if the 0 to 10 volt analog system is
present. Set to 1 if the Engine Speed System is used.
Set to 2 if the PWM signal is present.
14 Control Group Pressure Sensor Option to enable the use of a Control Group Blower 0 = Not
pressure Sensor. Present
Protection Options
15 Engine Cranking Protection Option to enable the engine cranking protection 0 – Disabled
Enabled strategy, (i.e. 20 second max crank, with cool-down
periods). NOTE: May be enabled on all trucks with an
MTU or DDC engine. The Cummins QSK60 engine has
a pre-lube feature that takes additional time and will
cause the crank to timeout. Only QSK60 engines on
trucks with KAC Truck number 186 or greater should
have this feature enabled
16 RP1 Hold-in Strategy Option to indicate which RP1 hold-in strategy to use. 1 = Retard
The RP1 Hold-in feature reduces the cycles during
RETARD and helps reduce both RP1 and GY19 Grid
Blower Life.


Rev. B

The three options are:
0 = None
1 = RETARD mode
2 = READY Mode
The Default setting is 1, RETARD Mode.
Engine Warmup Option
17 Engine Warm-up Mode Option to enable the Engine Warm-up mode. This 0 = Disabled
feature is for trucks parked in cold environments. The
system enters loadbox mode to place an additional load
on the engine to keep it at its normal operating
temperature.
18 Engine Warm-up Speed Engine Speed setting to use during engine warm-up 1200 RM
mode. The higher the engine speed the greater the HP
load.
Other Options
19 DID – LINK ON Min Engine Option to allow the Minimum engine speed with the DC 0 - Disabled
Speed Link energized to be entered via the DID panel. This
allows individual truck adjustment. This option is meant
for high altitude operation where engines have low HP
at lower RPM’s in situations such as bed raising.
20 Mine Adjustable Speed Limit Enables Mine Settable Over-speed Limits 1 - Enabled
21 Spanish Option on DID Panel Option to enable the Spanish language support on the 1 – Enabled
DID panel (Option Disabled will hide the ESPANOL key)
22 GE Lockout Option Specialized GE Option. 0 – Disabled
23 930E-3SE Engine Speed Option Option to adjust Engine Speed on 3500HP systems to Cfg
allow for additional Cooling. dependant
Overloaded Options
24 Overload Response Indicates the desired Truck Response to an Overloaded 0 = No
condition response
0 = No response
1 = Apply a Mine adjustable Speed Limit
2 = Apply a No Propel Restriction


Rev. B

25 Overload Sense Indicates the sense of the Overload digital input 1
0 = 0 volts indicates Active
1 = 24 Volts indicates Active
Wheel Motor Options
26 Left Wheel Motor Type Flag to indicate the wheel motor type of the Cfg
Left (Driver side) wheel. dependant
1 = GDY85 A or B
2 = GDY85C
3 = GDY85D
4 = GDY85E
5 = GDY85F or J
11 = GDY106A
21 = GEB23 A or B
22 = GEB23 C or E
31 = GEB25A
32 = GEB25C
41 = GDY108A
42 = GDY108B
51 = GEB25B (GE200AC –40R57)
52 – GEB25B (GE200AC - 37R57)
27 Right Wheel Motor Type Flag to indicate the wheel type on the (Grid box side) Cfg
wheel. dependant
Horsepower
28 Engine Gross HP Indicates the GHP rating of the installed diesel engine. Cfg
dependant
Table 3 – GE / OEM Options


Rev. B
7 INSTALLATION OF TRUCK SOFTWARE
NOTE: Ensure all MINE, OEM, and GE Safety procedures are followed during this
procedure. This document does not authorize overriding any existing procedures
that are in place at your location.
The full installation process takes approximately 40 minutes. Ensure the truck is located
is a safe location with the parking brakes applied
7.1 Quick Startup Procedure
The following chart summarizes the v21 installation steps. These procedures are
described in detail in the following sections.
V21 Upgrade Steps
1 Create Configuration Files For Mine Site (Section 7.2)
2 Verify and set TCI Time (Section 7.3)
3 Save Existing PSC and TCI Event and Statistical Data (Section 7.4)
4* Program Inverters (Section 7.5)
5* Program PSC (Section 7.6)
6* Program TCI (Section 7.7)
7 Calibrate Pedals through DID panel (Section 7.8)
8 Set Truck ID through DID Panel (Section 7.9)
9 Reset Active Events through the DID Panel
10 Reset All Statistics using the TCI
11 Perform Checkout (Section 7.10)
* The panels should be downloaded in the order defined here.


Rev. B
7.2 Creating an GE/OEM configuration File
One OEM Configuration file should be created by the GE Product Service

representative or the OEM representative for each truck type at the mine location.
The GE base configurations described earlier should be used.
For example if a location contained AC Trucks of the following types:
GE320AC - standard with DDC 4000
GE320AC - standard with Cummins QSK60
The Configuration files would look like this:
GE Defaults GE Default file for Standard GE Default file for Standard

GE320AC with DDC4000 GE320AC with QSK60
A32006a.21 A32012a.21
OEM / Mine FilesOEM File with OEM options OEM File with OEM options
and mine information set and mine information set
OEM6a.21 OEM12a.21


Rev. B
7.2.1 Starting OEM tool.

• Click on the AC Configuration Utility icon on the desktop, or on the START menu go
to START->Programs->GE wPTU Toolbox 3.01->AC Tools -> Config Utility AC
v21.00
• A password is required to enter the GE / OEM tool.
• Choose the appropriate GE Default Configuration File as described in Table 2.


Rev. B
On the Menu Browser Choose, SET GE /OEM Options(1). Set the appropriate options
for your mine location. The options are described in table 3.


Rev. B
On the Menu Browser Choose, SET GE /OEM Options(2). Set the appropriate options
for your mine location. The options are described in table 3.


Rev. B
• On the Menu Browser choose View/Set Wheel Motor Types. Set the Left and right
wheel motor type.


Rev. B
• On the Menu Browser Choose, HORSEPOWER. Set the Following items in the
OEM config file.
- Engine Gross Horsepower


Rev. B
• On the Menu Browser Choose, Change/View GE Product Service Data. Set the
Following items in the OEM config file.
- Mine Name
- GE Mine Code


Rev. B
If Mine settable speed limit is enabled, Set the proper settings under Overspeeds.
When finished setting the options, save the file to an OEM specific file name; recommend
oemxxx.210, where xxx is the base configuration number.


Rev. B
7.3 Set TCI Time
Verify the TCI’s Time is set correct and adjust if necessary.
Perform the following steps:
1. Connect the cable to the TCI serial channel and start the TCI wPTU.
2. Login with the appropriate Password
3. On the Side Menu, Choose Stat_menu -> Set Time and Date.
4. Verify Time.
5. If Necessary, enter new time and press SET CLOCK


Rev. B
7.4 Saving Existing Truck data
7.4.1 Event Data

Perform the following Steps:
6. Connect the cable to the TCI serial channel and start the TCI wPTU.
7. Login with the appropriate Password
8. Choose UPLOAD TASKS -> CONSOLIDATED TRUCK DATA.
9. Choose All Reports and press BEGIN.


Rev. B
7.5 Download Inverters
1. Place the TRUCK in REST Mode

2. Open the Side Cabinet on the control group and set the GF Cutout Switch to
CUTOUT.
3. Check the link charged lights and verify the link is discharged.
4. Determine if your system has a 2-card inverter set with a 17FB138 & 17FB134 or a
1–card inverter set with a 17FB172 or 17FB179 card. If unsure of the Inverter CPU
type, perform the following steps:
- Open the Right most Control Cabinet door
- Open the Electronics Panel Door.
- Verify the Card names in Slots 9 and 11, for an FL320 panel, Slots 11
and 12 for an FL375 panel or Slots 10 and 11 for an FL386 panel.
- Close the electronics panel
5. Connect the serial port from the laptop to Inverter #1 serial Port located inside the
group.
6. Start the PTU and choose Program Panel
7. Choose the appropriate inverter version type.
17FB138 Card
17FB172 Card
17FB179 Card
8. Wait for download to complete
9. Move the serial cable to the Inverter #2 serial port located inside the group.
10. Repeat steps 6-8 for Inverter #2.


Rev. B
7.6 Download PSC
1) Connect the Laptop’s serial cable to the PSC port.

2) Start the PTU and choose Program Panel
3) Verify the correct panel and files are selected
4) Choose the appropriate Configuration file by hitting Browse.
5) Press Begin Download
NOTE: After the PSC is downloaded; it will set configuration options on each of the inverters. After doing
so, the inverter will reset. The PSC will log loss of inverter communications events during this time. The
events should reset on their own.
7.7 Download TCI
1) Connect the serial cable from the laptop to the TCI serial port.
2) Start the PTU and choose, PROGRAM PANEL
3) Verify the correct panel and files are selected
4) Choose the appropriate Configuration file by hitting Browse.
5) Press Begin Download


Rev. B


Rev. B
7.8 Calibrate Pedals
Upon initial power-up after a software download, Event 650-4 will be logged indicating a
Calibration is required. To calibrate the pedals perform the following steps:
1. On the DID Panel, press
F4 – Menu
F4 – Truck Config
F1 – Pedal Cal
2. When ready to calibrate press F2
3. Press the Accel Pedal to FULL and then Release
4. Press the Retard Pedal to FULL and then Release.
5. If equipped, move the Retard Lever to full and then release
6. Press F4 when finished.
If the Pedal calibration was successful the DID will indicate it. If not, Repeat steps 2 through
6.
Event 650-4 will automatically reset when a successful calibration has occurred.
7.9 Truck ID
Upon initial power-up after a software download, Event 651-1 will be logged indicating the truck
ID is set to 0.. To set the Truck ID, perform the following steps:
1. On the DID Panel, press
F4 – Menu
F4 – Truck Config
F2 – Truck ID
2. Enter a unique truck ID between 1 and 99,999
3. When finished press F2.


Rev. B
7.10 Checkout
To verify proper software Installation perform the following steps:

1. Connect the PTU to the TCI’s serial port. Verify the following version information on
the TCI Software Versions Screen.
TCI VER: 21.00b
TRUCK TYPE: Varies (Matches Truck)
TRUCK ID: {current truck}
2. Verify the TCI’s time is set correctly:
Choose Set Date and Time from the menu browser.
3. Reset the TCI’s event information:
RESET TCI EVENTS
ERASE TCI Events
1. Reset the TCI’s Statistical Information
RESET STATS -> RESET ENTIRE (GE and MINE) STATISTICS.
4. Connect the PTU to the PSC’s serial port. Verify the following version information on
the PSC’s software Version screen
PSC VER: 21.00b
TRUCK TYPE: Varies (Matches Truck)
TRUCK ID: {current truck}
INV1 VER: 0x.yy.24.10
INV2 VER: 0x.yy.24.10
5. Reset the PSC’s Event information:
RESET PSC EVENTS
ERASE Events
6. Verify NO events are logged on the DID.
7. Change to the PSC real time menu, PSC REAL TIME DATA
8. While viewing the PSC Real Time Screen. Verify the following:


Rev. B
• ACCEL-SEL = 0.00 with the accel pedal at rest

• ACCEL-SEL = 1.00 with the accel pedal fully engaged
Note: The following will require that Service Brake/ Wheel Lock/Loadbrake is not
applied. Ensure the parking brake is applied and it is safe to remove the service
brakes.
• RETRD-SEL = 0.00 with the Retard Pedal and Lever (if equipped at their off
positions)
• RETRD-SEL = 1.0 with the Retard Pedal at Full. (If a 1 pedal system, ensure the
service break is not entered)
• RETRD-SEL = 1.0 with the Retard Lever at Full and the retard pedal off.
9. Set the rest switch to ON.
10. Using the appropriate Mine procedures, start the diesel engine.
11. Verify the System mode is REST on the DID.
12. Exit REST mode. Verify the System mode changes to TEST, then READY within 1
minute.
13. With the Brakes applied move the direction handle to forward. Verify torque is
present on each inverter. (TQCMD1, TQCMD2, and TRQFB1, TRQFB2)
14. Verify no EVENTS are logged.
15. Return the direction handle to neutral.
16. Using the appropriate mine procedures, initiate a loadbox session through the PTU
or DID.
17. Loadbox at full RPM and verify that full horsepower is developed.
18. Verify no EVENTS log during load box mode.
19. Exit load box.
20. Enter REST Mode.


GE OHV AC Electric Drive System Software Modification Instruction - AC Release 21 41A322501BF Rev. B December 15, 2005

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GE OHV AC Electric Drive System Software Modification Instruction - AC Release 21 41A322501BF Rev. B December 15, 2005

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GE OHV AC Electric Drive System

GE OHV AC Electric Drive System

Software Modification Instruction – AC Release 21

December 15, 2005

Author: T. Brown Approval: A. Hamilton 41A322501BF

Issued: GET Engineering BUS. AREA: OHV DIST: N/A Sheet 1 of 43

GE OHV AC Electric Drive System

REV DATE BY REVISION DESCRIPTION

Author: T. Brown Approval: A. Hamilton 41A322501BF

Issued: GET Engineering BUS. AREA: OHV DIST: N/A Sheet 2 of 43

GE OHV AC Electric Drive System

1 OHV AC ELECTRIC DRIVE APPLICATION SOFTWARE – RELEASE 21 5

1.4 Applicable Documents 6

1.5 Change Instructions and Authorization 6

1.6 Software Versions 7

2.1 Operator Changes 8

2.2 Specific Changes 10

3.1 System Requirements 15

3.2 Handhelds tested 16

3.3 pocketPTU Installation. 17

4.1 Toolbox Releases 19

4.2 Computer Requirements 19

4.3 Installation of wPTU Toolbox onto a Laptop 20

Author: T. Brown Approval: A. Hamilton 41A322501BF

Issued: GET Engineering BUS. AREA: OHV DIST: N/A Sheet 3 of 43

GE OHV AC Electric Drive System

4.3.1 Installing wPTU Toolbox 20

5 GE DEFAULT CONFIGURATION FILES 21

6 GE / OEM CONFIGURATION OPTIONS 23

7 INSTALLATION OF TRUCK SOFTWARE 27

7.1 Quick Startup Procedure 27

7.2 Creating an GE/OEM configuration File 28

7.3 Set TCI Time 36

7.4 Saving Existing Truck data 37

7.5 Download Inverters 38

7.6 Download PSC 39

7.7 Download TCI 39

7.8 Calibrate Pedals 41

Author: T. Brown Approval: A. Hamilton 41A322501BF

Issued: GET Engineering BUS. AREA: OHV DIST: N/A Sheet 4 of 43

GE OHV AC Electric Drive System

1 OHV AC ELECTRIC DRIVE APPLICATION SOFTWARE – RELEASE 21

Release 21 software may be applied to the following GE Off Highway Vehicle AC

Drive System Control Mandatory

Release GET Drawing #

This software is for the 17FL320(PSC), 17FL349(TCI), 17FL373(TCI), 17FL375

Author: T. Brown Approval: A. Hamilton 41A322501BF

Issued: GET Engineering BUS. AREA: OHV DIST: N/A Sheet 5 of 43

GE OHV AC Electric Drive System

DID = Diagnostic Information Display

ICP = Integrated Control Panel – 17FL375

ICP2 = Integrated Control Panel 2 – 17FL386

NTF = No Trouble Found

pocketPTU = Pocket PC based software application to interface with Drive System.

PSC = Propulsion System Controller

TCI = Truck Controller Interface

SMI = Software Modification Instruction

1.4 Applicable Documents

Title of GETS Referenced Documents GE Document Number

wPTU Users Manual GEK-91712

1.5 Change Instructions and Authorization

Author: T. Brown Approval: A. Hamilton 41A322501BF