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Black Bruin CTR101 Operation Manual

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  • Page 1 Operation manual CTR101 control system...

  • Page 2: Table Of Contents

    Contents Contents General instructions................. 4 About the manual............................4 Intended use..............................4 Warranty................................4 Product identification............................. 4 Revision comments............................5 Safety instructions................6 Warning symbols..............................6 Product description................7 Operating modes..............................7 Driving mode..............................7 Driving mode with HDC function (Hill descent control) (option)............8 Freewheeling mode............................
  • Page 3 Contents Setup....................46 User parameters............................46 Automatic freewheeling conditions......................50 Setting the values for the automatic freewheeling................51 Troubleshooting................53 Display status indicator LED........................58 Control device segment-display....................... 59 Operation manual...

  • Page 4: General Instructions

    General instructions General instructions About the manual This manual contains the instructions for the operation of Black Bruin CTR101 control system. Obey these instructions when you use the product. Black Bruin CTR101 control system is part of the On-Demand Drive System transmission solution.

  • Page 5: Revision Comments

    General instructions Model Part number Serial number Figure 1. Identification plate of the control system. Revision comments 06.06.2024 (Software version 04.01.00) - This manual is published. Operation manual...

  • Page 6: Safety Instructions

    Safety instructions Safety instructions The instructions that follow apply to all procedures related to the product. Read these instructions fully and follow them carefully. • Use necessary personal protective equipment when you do work with the product. • Use correct support with the product. Make sure that the product cannot accidentally fall or turn.

  • Page 7: Product Description

    Product description Product description Operating modes The Black Bruin On-Demand Drive System can use hydraulic motors in the operating modes that follow: • Driving mode • Driving mode with HDC function (Hill descent control) (option) • Freewheeling mode. The chapters that follow give the working principles of these modes.

  • Page 8: Driving Mode With Hdc Function (Hill Descent Control) (Option)

    Product description • Driving on slippery or soft surfaces. Driving mode with HDC function (Hill descent control) (option) The HDC function helps when you drive the vehicle down on steep slopes, in both forward and reverse driving modes. HDC is active when the tractor brakes. When the HDC function is active, the wheel motors resist the wheel movement to the driving direction.
  • Page 9 Product description If the pressure level is not sufficient due to increased driving speed, the control system automatically switches to freewheeling. This protects the motor from overloading. The operator can also manually change the mode to freewheeling. Typical situations to operate in the freewheeling mode are: •...

  • Page 10: User Interface

    User interface User interface This manual includes all different CTR101 control system options. When the information in the section relates to an option, the icons that follow are used: Four-wheel drive Hill Descent Control Speed and direction sensors DISPLAY System that has a display as the user interface...

  • Page 11: Display

    User interface 4.1.1 Display DISPLAY The functions of the F1 – F4 buttons change together with the view and the mode. The icons that show at the bottom of the display refer to the related functions of the F1 – F4 buttons. The background color of the icon shows if the mode of the function is ON or OFF.

  • Page 12: Operating Panel

    User interface 4.1.2 Operating panel PANEL The operating panel has buttons L1 – L3, R1 – R3 and a control Knob with a Segmented LED ring. Figure 3. The operating panel elements. L1: Forward R1: D2 (two-speed function) L2: Neutral / AUX R2: ATC •...
  • Page 13 User interface Dim white Backlight, function is not on or is not selected Green Function is on or is selected Blue Alternative function is on Yellow Warning Alarm Operation manual...

  • Page 14: Getting Started

    Getting started Getting started Power up the control system The brake-signal check activates at each power-up, after which the system is in the freewheeling (N) mode. Operating functions are not available until you press the brake and the system detects the brake signal. If the brake-signal check stays active when you press the brake, see chapter Troubleshooting.
  • Page 15 Getting started DISPLAY After the system detects the brake signal, the main view comes into view. Symbols on the display may be different from the figure depending on the system configu- ration and options. PANEL After the power-up the backlight color of the R3 button is green and it flashes in one-sec- ond intervals.

  • Page 16: Menu

    Getting started Menu DISPLAY 1. Main menu To open the main menu from the main view, push the F4 button ( ). Note: The main menu is available only when the system is in the free- wheeling mode. Operation manual...
  • Page 17 Getting started 2. Main settings • Arrow buttons up/down: Select the value Settings you want to adjust. Brightness • Arrow buttons left/right: Adjust the val- Language English ues. Manual mode You can adjust the display brightness and Show sensor values change the control system language from the main menu.
  • Page 18 Getting started 4. Parameter selections Parameter names are in the same language as Parameters the user interface. See chapter 8.1 User pa- 2-speed function rameters for the detailed information on the ATC max. time [s] parameters and their possible values. Minimum pressure level [bar] •...
  • Page 19 Working hours This information is necessary for example for troubleshooting and support requests. Forward Backward • Model series: Control system model: CTR101 • Sw Version: Software version numbers are as follows: Control device software version Display software version Auxiliary control device software version (only in 4WD and systems with speed sensors).

  • Page 20: Main View Elements

    Main view elements Main view elements Main view at the initial state DISPLAY You can manage the operating functions from the main view. Figure 4. The main view. If the system does not have the 2-speed motors, the D2 icon does not show.

  • Page 21: Alarms And Warnings

    Main view elements PANEL Figure 6. Indication of the initial state in the operating panel. The operating panel does not have indication of the drive-control mode. Alarms and warnings DISPLAY The status bar at the top of the main view shows all alarms and warnings. The background color of the status bar is: •...

  • Page 22: Tractive Power And Hdc Level Indication

    Main view elements PANEL In the control panel the backlight color of the R3 button gives the indication for an alarm or a warning. The backlight color of the R3 button is: • Red for the alarms • Yellow for the warnings. LED segment colors around the knob identify which alarm or warning is active.

  • Page 23: Operating Mode Indication

    Main view elements Mode: PWR/HDC Selected level: Shows the active mode on the display: • The number shows the set value. • The grey arrow above the colored • PWR: Tractive power adjustment. The power bar shows the set value. values on the display show the trac- tive power level.
  • Page 24 Main view elements Arrows Color of the trailer wheels Show the operation and operating modes Show the hub motor operation modes as as follows: follows: • No arrows: Freewheeling • The color of the front wheel icon • Green arrows: changes.
  • Page 25 Main view elements System without speed sensors is always Current gear in the manual drive-control mode. • N: Freewheeling • D1: Drive forward, speed range 1 Drive-control mode indication • D2: Drive forward, speed range 2 Drive-control mode indication is only visi- •...

  • Page 26: Operating Functions

    Symbol Description Manual drive-control mode Manual drive control mode is available in all CTR101 systems. The system without the speed sensors only has the manual drive- control mode. In this mode the drive activation and most of the operations are manual.

  • Page 27: Tractive Power Level Selection

    Operating functions Table 2: Drive-control mode comparison System configuration CTR101 without CTR101 with speed sensors speed sensors Mode Manual Automatic Manual (not possible to change) Display symbol No symbol Drive activation Manual Automatic Manual with restric- tions • When the vehicle...
  • Page 28 Operating functions 28/25 Figure 11. Tractive power level selection. Measured value/set value: 28/25. PANEL You can rotate the knob to adjust the power level. The power level changes in 5% steps of the maximum power level. You can set the value in the freewheeling mode and change it during the driving mode.

  • Page 29: Driving And Freewheeling Functions In The Manual Drive-Control Mode

    Operating functions Driving and freewheeling functions in the manual drive-con- trol mode Note: Do not activate the drive if the driving speed is above the working speed range. The system prevents this automatically. Note: If you drive forward, you can change directly from freewheeling to D2 speed range.
  • Page 30 Operating functions DISPLAY The gear indicator at the bottom of the screen shows the current mode of the drive system. Use the up/down arrows and the F2 button to change between the freewheeling (N) and the driving modes (D1, D2 and R). 49/50 49/50 0/50...
  • Page 31 Operating functions Figure 13. Operating mode selection from the operating panel. Automatic freewheeling (N) If the pressure level is not sufficient due to increased driving speed, the system automatically switches to the freewheeling mode. DISPLAY The status bar at the top of the main view shows the warning Pressure_low when the system automatically switches to freewheeling.

  • Page 32: Driving And Freewheeling Functions In The Automatic Drive-Control Mode

    Operating functions Figure 14. Operating panel warning indication. Driving and freewheeling functions in the automatic drive- control mode In the automatic drive-control mode the system can perform the following driving functions automatically: • Activate the drive towards the direction of movement •...
  • Page 33 Operating functions Figure 15. The main view of the automatic drive-control mode after the power-up. Activating and deactivating automatic driving functions Push the F2 button to toggle the automatic driving functions ON and OFF. When the background color of the power icon is red the driving functions are enabled. When the background color of the power icon is black and the driving mode indicator shows OFF, the driving functions are disabled.
  • Page 34 Operating functions Figure 16. Indication of active motion detection cycle on the display. Operation mode indicator shows the pause icon and the flashing green / grey arrows point out. Figure 17. Indication of active motion detection cycle on the operating panel. Yellow lights on L1 and L3 buttons flash very quickly.
  • Page 35 Operating functions Danger: When you press the brake pedal, the drive can activate again. Deactivate the automatic driving functions when you do not need to use the drive. Danger: Automatic drive-control mode can activate the drive. Use automatic drive- control mode only when you have full attention to driving operations. Motion detection function activates the drive in the direction of movement.

  • Page 36: Braking In Driving Mode Without The Hdc

    Operating functions Figure 19. Indication of timeout during motion detection on the operating panel. Yellow lights on L1 and L3 buttons flash in one-second intervals. Manual drive activation commands In the automatic drive-control mode you can also manually activate the drive in the selected direction.

  • Page 37: Operation During Braking

    Operating functions 7.5.1 Operation during braking When the vehicle brakes the tractive power reduces to the lowest level. DISPLAY The brake icon comes into view and the trailer wheel color changes to red. The direction arrows flash which is an indication that the minimum power level is in use. 8/25 Figure 20.

  • Page 38: Operation After Releasing The Brake

    Operating functions 7.5.2 Operation after releasing the brake After the braking, the tractive power level stays at the minimum level. To return the tractive power to the selected level: DISPLAY • If the vehicle moves forward, push the arrow button up •...
  • Page 39 Operating functions 32/38 Figure 22. Braking in driving mode with the HDC function. PANEL Green flashing light on the selected driving direction button (L1 or L3) is an indication of reduced power level due to braking. Red LED segments show the selected intensity of the HDC.

  • Page 40: Operation After Releasing The Brake

    Operating functions Speed range selection during HDC You can use the HDC during all driving speeds. If the flow to the motors is not sufficient for the driving speed, the vehicle loses the deceleration power. If the speed is too high during the HDC function, the system shows a warning of the low flow level: •...

  • Page 41: Assisting Traction Control (Atc)

    Operating functions Assisting traction control (ATC) The assisting traction control (ATC) helps the vehicle to move in difficult conditions. The ATC function restricts the flow to the wheels that do not have enough traction. This increases the torque on the wheels that have more traction. Note: The use of the ATC functions for long periods when the wheels have no traction can cause the hydraulic fluid temperature to increase.
  • Page 42 Operating functions driving mode. When the ATC times out, the background color of the ATC icon becomes red. Push the F3 button to switch ON the ATC again for the set time. When the system switches to freewheeling the switch-off delay resets. When you activate the forward driving mode again, the ATC is ON.

  • Page 43: Auxiliary Valve Control (Aux) (Option)

    Operating functions You can also activate the continuous operation of the ATC in the automatic drive- control mode. DISPLAY Push the F3 button to start the continuous operation of the ATC in the automatic drive-control mode. The ATC function is in the automatic operation mode when the background color of the function icon is black.

  • Page 44: Keypad Lock

    Operating functions The machine manufacturer sets whether the AUX output connection is energized or de-energized during function. DISPLAY Push the F1 button in the main view to toggle the AUX function on and off. 0/50 PANEL Push the L2 button to toggle the AUX func- tion on and off.
  • Page 45 Operating functions DISPLAY Push and hold the OK button for 2 seconds in the main view to lock and unlock the display keypad. Lock screen is an indication that the keypad lock is in use. Locked: hold OK to unlock PANEL Push and hold the R3 button for 2 seconds in the freewheeling mode to lock or unlock the...

  • Page 46: Setup

    Setup Setup User parameters DISPLAY You can only set the parameters from the display. Adjust the listed parameters before you use the system for the first time. Parameter Description Possible values 2-speed function Shows if the 2-speed function is 0 / 1 available to use (speed range selec- 0: No 2-speed function.
  • Page 47 Setup Parameter Description Possible values Power change Ramp time that has an effect on the 0 – 4 ramp power level adjustment from the 0: The shortest time – fastest pow- display. er level change. 4: The longest time – the smooth- est power level change.
  • Page 48 Setup Parameters for the speed sensor option Parameter Description Possible values Disengagement Sets the maximum speed for the 1 – 30 km/h speed [km/h] driving in the automatic drive-con- The flow capacity and the displace- trol mode. If the speed reaches this ment of the motors have an effect value, the control system automat- on the applicable value.
  • Page 49 Setup Parameters for the speed sensor option Parameter Description Possible values Disengagement Sets the delay for the Disengage- 0 – 4 speed, delay ment speed [km/h] condition. 0: The shortest delay. Longer disengagement delay can 4: The longest delay. be useful when driving in slippery conditions.

  • Page 50: Automatic Freewheeling Conditions

    The CTR101 control system can use the measured vehicle speed and pressure level to automatically switch to freewheeling. The parameters for the speed condition are the Disengagement speed [km/h] and the Disengagement speed, delay.

  • Page 51: Setting The Values For The Automatic Freewheeling

    Setup speed range. The system automatically calculates a lower maximum speed value for the reverse driving. The Disengagement speed [km/h] parameter also has an effect on the automatic speed range shift and the automatic drive activation functions. Thus, it is important to set the parameter correctly.
  • Page 52 Setup automatic drive-control mode, the low pressure condition must also activate the freewheeling. 11. In the manual drive-control mode, activate the drive forward in D2 speed range. 12. Slowly increase the speed while you monitor the vehicle speed. 13. Record the speed when the warning Pressure_low shows and the freewheeling activates.

  • Page 53: Troubleshooting

    Troubleshooting Troubleshooting The table that follows gives the causes of the alarms and warnings, and procedures to correct them. DISPLAY The status bar at the top of the main view indicates the active alarm or warning. PANEL R3 button light is red in case of an alarm and yellow in case of a warning. LED segments around the knob indicate the active alarm or warning.
  • Page 54 Troubleshooting DISPLAY Alarm/warning message Cause Procedures PANEL Segment indica- tion 5: Pressure_high Examine the main pressure relief valve (on the pump or as a separate valve). Make sure that it operates The working pressure is more than and is adjusted correctly. the maximum system pressure, 350 If you use the CVM120 valve, make bar.
  • Page 55 Troubleshooting DISPLAY Alarm/warning message Cause Procedures PANEL Segment indica- tion 8: SW_ver- Examine the software versions sion_mismatch from the system information view. 4WD: The software versions of the Replace the device that has the in- primary control device and the aux- correct software version.
  • Page 56 Troubleshooting DISPLAY Alarm/warning message Cause Procedures PANEL Segment indica- tion 14: Overspeed The flow to the motors is not suf- ficient because of the speed. Use the brake to decrease the speed. In forward driving, use the D2 speed HDC: Low working pressure during range, if available.
  • Page 57 Troubleshooting DISPLAY Alarm/warning message Cause Procedures PANEL Segment indica- tion 29: 1L frequency too low 30: 1R frequency Examine the sensor cable connec- too low tions. Use "Show sensor values" op- 31: 2L frequency Unexpected, low, speed signal from tion from the menu to verify the too low the named signal.

  • Page 58: Display Status Indicator Led

    Troubleshooting Fault Cause and procedures Drive functions are not correct, for example, Examine the valve connections to the control driving direction functions operate in the op- device. posite direction. Wiring diagrams for different systems are in the On-Demand Drive System product man- ual.

  • Page 59: Control Device Segment-Display

    Troubleshooting Control device segment-display Figure 28. Control device status LEDs and segment display. Status LED LED/status Description No LED No operating voltage PWR + DIA, 1 flash Device starts PWR, 5 Hz The device has no software PWR, 2 Hz Usual status PWR, continuous Software error...
  • Page 60 Troubleshooting Segment display text, a system with two control devices Figure 29. Segment displays in a system with two control devices. Display text Description The system does not recognize the 4WD-auxiliary control device. Empty, no text The system does not operate correctly. One device "A", the Correct status in a system with two control devices, "A"...
  • Page 61 Operation manual...
  • Page 62 +358 50 419 3484 P.O. Box 633, FI-40101 JYVÄSKYLÄ, FINLAND www.blackbruin.com info@blackbruin.com All the information contained in this publication is based on the latest information available at the time of publication. Black Bruin Inc. reserves the right to make changes without prior notice.

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