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DIAGNOSTIC STATUS CODES
IT TRANSISTOR CONTROL
Figure 2
5. Reconnect plugs.
Reference
Cleaner
Chemtronics Pow-R-WasH CZ
Contact Cleaner
Lubricant
Nye Lubricants NYOGEL 760G
FSIP Plug Lub Kit
products:
328A1777G1
Section 4.4 Controller Mounting Guidelines
In the design of the FSIP family of motor controls,
performance assumptions were made based on heat
transfer between the control and the ambient
environment. The vehicle mounting surface acts as a
heat sink, which increases the effective surface area
for heat dissipation. If this assumed heat transfer is
not achieved during control installation and operation,
FSIP controllers will fall short of their anticipated
performance. It should be noted that the condition of
the mounting surface, and the quality of the resulting
interface between the control and the vehicle, can
significantly hinder heat transfer from the control.
The presence of contaminants, or of air voids created
by surface inconsistencies in either the vehicle or the
control, degrade the control's capacity for heat
transfer. The control's performance is de-rated
proportionally as its own thermal sensors reduce its
operation to protect it from damage due to excessive
heating.
Contained within the software of the FSIP controls
are several diagnostic status codes related to
controller thermal performance. Failure to follow
these mounting recommendations increases the
likelihood of encountering these status codes,
through no fault of the control itself, thus voiding
Contains both above
controller warranty for units returned solely due to the
presence of these status codes.
Careful surface preparation, including adequate
application of thermal compound, as detailed in the
following paragraphs, must be completed during the
installation of FSIP controls. There are many
techniques for applying thermal compound, and we
have outlined one approach below that has shown to
apply a consistent thickness of material.
Section 4.4.1 Necessary Tools
FSIP recommends the use of the following
components, or equivalent substitutions, during the
control installation process:
a) Thermal compound, (Dow Corning
#340), maintained per the manufacturer's
recommendations and free of
contaminants
b) 3/32" notched trowel, such as a Krusin
adhesive spreader, model 00031
c) Calibrated torque wrench (0 – 15 ft-lbs)
Section 4.4.2 The FSIP Control Mounting Surface
During the manufacture of the FSIP control, the
surface flatness is maintained at 0.005" per linear
inch (not to exceed 0.025" per 10.0 inches). The
surface finish of the FSIP control has an R
roughness) of 64 (microinches), or better. This finish
is consistent with cold rolled or extruded aluminum.
Care should always be taken in the handling and
storage of controllers. The base of the control should
be free from nicks, bumps, protrusions or any other
foreign object that would prevent the control from
sitting flush with the vehicle mounting surface.
Examine the base of the control to verify that it is in
good condition and free from damage or
contamination.
Section 4.4.3 Vehicle Mounting Surface
The quality of the vehicle mounting surface is critical
for the optimum heat transfer between the control
and the ambient environment. Conduction through
the base of the control is the control's only means of
heat rejection. While FSIP controls are highly
efficient, a few percent of the electrical energy will be
converted into heat. As previously mentioned, if this
energy is not dissipated through the base of the
control, a thermal protector will reduce the
performance of the control until the temperature
stabilizes.
For optimal heat transfer from control to vehicle, the
flatness of the vehicle mounting surface should be
Page 17
(average
a
April 2012
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