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GE IC3645SR4T405CT1 Installation And Operation Manual

Separately excited transistorized traction control.
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INSTALLATION AND OPERATION
IT/IP TRANSISTOR CONTROL
SEPARATELY EXCITED TRANSISTORIZED TRACTION CONTROL
Note: The information contained herein is intended to assist OEM's, Dealers and Users of electric vehicles in the
application, installation and service of GE solid-state controllers. This manual does not purport to cover all
variations in OEM vehicle types. Nor does it provide for every possible contingency to be met involving vehicle
installation, operation or maintenance. For additional information and/or problem resolution, please refer the matter
to the OEM vehicle manufacturer through his normal field service channels. Do not contact GE directly for this
assistance.
Section 1.0
INTRODUCTION .................................................................................................................. 4
1.1
1.2
1.3
1.4
Section 2.0
FEATURES OF IT FAMILY OF MOTOR CONTROLLERS................................................. 6
2.1
2.1.1
2.1.1.a
2.1.1.b
2.1.1.c
2.1.2
2.1.3
2.1.3.a
2.1.3.b
2.1.3.c
2.1.4
2.1.4.a
2.1.4.b
2.1.5
INSTALLATION AND OPERATION MANUAL
IC3645SR4T405CT1 and IC3645SR7T405CT1
Table of Contents
General Electric Company January 2008
Motor Characteristics ........................................................................................ 4
Solid-State Reversing ....................................................................................... 5
Flexible System Application .............................................................................. 5
More Features with Fewer Components........................................................... 5
Performance...................................................................................................... 6
Oscillator Card Features............................................................................. 6
Standard Operation.............................................................................. 6
Creep Speed ........................................................................................ 6
Control Acceleration ............................................................................ 6
Current Limit ............................................................................................... 6
Braking........................................................................................................ 6
Regenerative Braking to Zero Speed................................................... 6
Pedal Position Plug Braking................................................................. 6
Auto Braking......................................................................................... 6
Auxiliary Speed Control .............................................................................. 6
Field Weakening .................................................................................. 6
Speed Limits ........................................................................................ 7
Ramp Operation ......................................................................................... 7
Page 1
January 2008

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   Summary of Contents for GE IC3645SR4T405CT1

  • Page 1 OEM vehicle types. Nor does it provide for every possible contingency to be met involving vehicle installation, operation or maintenance. For additional information and/or problem resolution, please refer the matter to the OEM vehicle manufacturer through his normal field service channels. Do not contact GE directly for this assistance.
  • Page 2: Table Of Contents

    Recommended Lubrication of Pins and Sockets Prior to Installation...... 16 Controller Mounting Guidelines ................17 4.4.1 Necessary Tools....................17 4.4.2 The GE Control Mounting Surface ..............17 4.4.3 Vehicle Mounting Surface ................. 17 4.4.4 Application of Thermal Compound..............18 4.4.5 Mounting the GE Control...................
  • Page 3 INSTALLATION AND OPERATION IT/IP TRANSISTOR CONTROL Page 3 Table of Contents ( Continued ) Section 5.0 IT FAMILY - GE HANDSET INSTRUCTIONS ..............37 General Features ....................37 Purpose/Setup Functions ..................37 Setup Function Procedures ..................38 5.3.1 Setup Mode ..........
  • Page 4: Section 1.0 Introduction

    (Figure 2). advantage of today’s technology, while looking forward to new advances on the horizon. GE has introduced a second generation system using SPEED separately excited DC shunt wound motors. The...
  • Page 5: Solid-state Reversing

    The line can be energized and de-energized by the various logic combinations For GE, the future is now as we make available a of the vehicle, i.e. activate on key, seat or start switch new generation of electric traction motor systems for closure, and de-energize on time out of idle vehicle.
  • Page 6: Performance

    BASIC OPERATION AND FEATURES IT400 TRANSISTOR CONTROL Page 6 motor current is usually greater than battery current, Section 2. FEATURES OF IT FAMILY OF except at 100% ON time. TRANSISTOR MOTOR CONTROLLERS Section 2.1 Performance Section 2.1.3 Braking Section 2.1.1 Oscillator Card Features Section 2.1.3.a Regenerative Braking to Zero Speed Section 2.1.1.a Standard Operation...
  • Page 7: Ramp Start

    GE and OEM engineers at the time opening of the seat switch, if a bump is encountered. of vehicle development. This setting must not be Section 2.2.2 Accelerator Volts Hold Off...
  • Page 8: Diagnostics

    This is a multi-functional tool used with the LX, ZX, The IT traction control has over 30 Status Codes that SX and IT Series GE solid state controls. The assist the service technician and operator in trouble Handset consists of a Light Emitting Diode (LED) shooting the vehicle.
  • Page 9: Circuit Board Coil Driver Modules

    BASIC OPERATION AND FEATURES IT400 TRANSISTOR CONTROL Page 9 Field Current levels, and (4) Top Speed Regulation levels. These interactive modes are "pre-set" using the Handset (Functions 48-62) or a personal computer (Functions 97-112). This feature allows the operator to select the best vehicle performance for changing tasks or conditions.
  • Page 10: Section 3.0 Ordering Information, Elementary And Outline Drawings

    OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS IT TRANSISTOR CONTROL Page 10 Section 3.0 ORDERING INFORMATION, ELEMENTARY AND OUTLINE DRAWINGS Section 3.1 Ordering Information for Separately Excited Controls Example: Part Number: IC3645 Argument Number: Argument 01: Basic Electric Vehicle Control Number Argument 02: Control Type: Series Control (Pump)
  • Page 11: Outline: It400 Package Size

    OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS IT TRANSISTOR CONTROL Page 11 Section 3.2 Outline: IT400 Package January 2008...
  • Page 12: Traction Elementary

    OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS IT/IP TRANSISTOR CONTROL Page 12 Section 3.3 Traction Elementary January 2008...
  • Page 13: Traction Control Input / Output List

    OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS IT/IP TRANSISTOR CONTROL Page 13 Section 3.4. Traction Control Input and Output List INPUT/OUTPUT DESCRIPTION BATTERY VOLTS FROM BATTERY BATTERY VOLTS FROM KEY BATTERY VOLTS FROM START SWITCH BATTERY VOLTS FROM FORWARD SWITCH BATTERY VOLTS FROM REVERSE SWITCH BATTERY VOLTS FROM MOTOR THERMOSTAT SWITCH ACCELERATOR INPUT VOLTAGE SIGNAL POT NEGATIVE...
  • Page 14: Section 4.0 Troubleshooting And Diagnostic Status Codes

    GE does not recommend that any type of welding be The following Do’s and Don’ts should be performed on the vehicle after the installation of the control(s) in the vehicle.
  • Page 15: Low Level Signals (level L)

    DIAGNOSTIC STATUS CODES IT TRANSISTOR CONTROL Page 15 4.2.2.a Low-Level Signals (Level L) 4.2.2.d High Power Signals (Level HP) Low-level signals are designated as level L. These Power wiring is designated as level HP. This consists consist of: of DC buses and motor wiring with currents greater •...
  • Page 16: 4.2.5 Rf Interference

    1. Disconnect plug from controller or mating plug. and sockets on EV100/EV200 and Gen II products. Any connection made by GE to the A, B, X, Y, or Z 2. Locate the plug that contains the socket (female) plugs will have the lubricant NYE 760G added to terminals.
  • Page 17: Controller Mounting Guidelines

    64 (microinches), or better. This finish Section 4.4 Controller Mounting Guidelines is consistent with cold rolled or extruded aluminum. In the design of the GE family of motor controls, performance assumptions were made based on heat Care should always be taken in the handling and transfer between the control and the ambient storage of controllers.
  • Page 18: Application Of Thermal Compound

    Move the control slightly in all directions to conductivity, thermal compound must be applied eliminate voids and enhance the distribution between the GE control base plate and the vehicle of the thermal compound. mounting surface. The function of this compound is...
  • Page 19: Maintenance

    DIAGNOSTIC STATUS CODES IT TRANSISTOR CONTROL Page 19 With the status code number, follow the procedures outlined in the status code instruction sheets to determine the problem. Important Note: Due to the interaction of the logic card with all vehicle functions, almost any status code or control fault could be caused by the logic card.
  • Page 20: Traction Controller Status Codes

    DIAGNOSTIC STATUS CODES IT TRANSISTOR CONTROL Page 20 Section 4.6 Traction Control Codes TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Segments do not illuminate on the No input voltage to the control card or the display NONE Dash Display and/or the Handset.
  • Page 21 DIAGNOSTIC STATUS CODES IT TRANSISTOR CONTROL Page 21 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Forward directional switch is closed on initial This status code will be displayed when P4 is power up. greater than 60% of battery voltage at initial key switch on.
  • Page 22 DIAGNOSTIC STATUS CODES IT TRANSISTOR CONTROL Page 22 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Start switch fails to close. This status code will be displayed when P7 is less than 2.5 volts and P3 is less than 60% of battery volts.
  • Page 23 DIAGNOSTIC STATUS CODES IT TRANSISTOR CONTROL Page 23 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Accelerator input voltage too high on This status code will be displayed when the power up after initial key switch closure. accelerator input voltage at P7 is higher than 4.2 volts.
  • Page 24 DIAGNOSTIC STATUS CODES IT TRANSISTOR CONTROL Page 24 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Both the forward and reverse This status code will be displayed when P4 and P5 directional switches are closed at the are greater than 60% of battery volts at the same same time.
  • Page 25 DIAGNOSTIC STATUS CODES IT TRANSISTOR CONTROL Page 25 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Battery voltage is too low or control card is mis- This status code will be displayed when the adjusted. battery volts are less than 1.95 volts per cell at initial key switch on.
  • Page 26 DIAGNOSTIC STATUS CODES IT TRANSISTOR CONTROL Page 26 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Motor field current is high on start up in This status code will be displayed when the offset the reverse direction. voltage is too high at start up in the reverse direction. MEMORY RECALL CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM...
  • Page 27 DIAGNOSTIC STATUS CODES IT TRANSISTOR CONTROL Page 27 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Control’s power supply is less than 10 This status code will be displayed when the control’s Volts DC. power supply is less than 10 volts. MEMORY RECALL CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM...
  • Page 28 DIAGNOSTIC STATUS CODES IT TRANSISTOR CONTROL Page 28 Open thermal protector (TP) or This status code will be displayed when the voltage transistor over temperature. at the thermal protector is too high. MEMORY RECALL CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM YES * Circuits valid SYMPTOM Reduced or no power to traction motor.
  • Page 29 DIAGNOSTIC STATUS CODES IT TRANSISTOR CONTROL Page 29 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Motor armature offset voltage is too This status code will be displayed when the voltage at low. the current sensor input is less than 2.4 volts with no current flowing in the motor circuit.
  • Page 30 DIAGNOSTIC STATUS CODES IT TRANSISTOR CONTROL Page 30 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Armature transistor did not turn on This status code will be displayed when, during properly. control operation, the armature transistor fails to turn on properly.
  • Page 31 DIAGNOSTIC STATUS CODES IT TRANSISTOR CONTROL Page 31 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Motor field current is too low during the This status code will be displayed when the current run mode. draw in the motor field is too low during the run mode. MEMORY RECALL CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM...
  • Page 32 DIAGNOSTIC STATUS CODES IT TRANSISTOR CONTROL Page 32 TRACTION DESCRIPTION OF CAUSE OF STATUS INDICATION STATUS CODE STATUS Controller “motor current This status code will be displayed when the voltage input sensor” input too low during from the current sensor is too low during running. running.
  • Page 33 DIAGNOSTIC STATUS CODES IT TRANSISTOR CONTROL Page 33 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE The line driver input (P2-17) is less This status code will be displayed when the control than 12% of battery volts detects that the line driver input (P2-17) is less than 12% battery volts when the key switch is turned on.
  • Page 34 DIAGNOSTIC STATUS CODES IT TRANSISTOR CONTROL Page 34 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE The field current exceeds the current This status code will be displayed when the field limit of the field transistor. transistor exceeds its current limit. The line contactor will drop out and the key switch will have to be recycled to restart the control.
  • Page 35 DIAGNOSTIC STATUS CODES IT TRANSISTOR CONTROL Page 35 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE This status code will be displayed when the current in the The brake coil current is too high brake driver circuit exceeds current limit during the run mode. during the run mode.
  • Page 36 DIAGNOSTIC STATUS CODES IT TRANSISTOR CONTROL Page 36 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Motor current is detected during This status code will be displayed when motoring regenerative braking. current is detected during the regenerative braking cycle.
  • Page 37: It Family - Ge Handset Instructions

    INSTRUCTIONS Section 5.1 General Features Key Switch On The GE Handset is a multi-functional tool to be used with the LX, ZX, SX and IT Series GE solid-state controls. The Handset consists of a Light Emitting Diode (LED) display Verify Each LED Segment and a keyboard for data entry.
  • Page 38: Setup Function Procedures

    This will place you in the set- up mode, ready to monitor or adjust control function ACCESSING STORED STATUS CODES settings. WITH GE HANDSET NOTE: The term “Push” means to depress key for approximately one second. Key Switch Off Section 5.3.1 Setup Mode...
  • Page 39: Setup Functions For Traction Controller

    MPH SCALING motor and control performance, and this setting will (Push 1) be determined by GE and OEM engineers at the time of vehicle development. This setting must not be This function allows for the pulses from the tachometer to...
  • Page 40 Please refer to the specification sheets and current limit motor and control performance, and this setting will curves for the control used in your vehicle. be determined by GE and OEM engineers at the time of vehicle development. This setting must not be Range...
  • Page 41 Indicator is present. Adjustment of this function will be determined by GE and OEM engineers at the time improve the accuracy of the BDI. In order to determine of vehicle development. This setting must not be...
  • Page 42 ADJUSTABLE FEATURES IT TRANSISTOR CONTROLS Page This function allows for the adjustment of the time delay for the brake or line contactor coil drop out when the control receives a neutral signal from the direction switch Battery volts Set units or the start switch opens.
  • Page 43 RAM of the Setting of 255 = Least aggressive braking microprocessor. Because absolute memory locations need to be known, this function should not be used without detailed instructions from the GE application FUNCTION 22 OVERSPEED DECREASE RATE FOR engineer. FIELD/ARMATURE CURRENT...
  • Page 44 ADJUSTABLE FEATURES IT TRANSISTOR CONTROLS Page To determine which stored status code was the last one Setting 0 to 255 recorded, read the number stored in Function 28. Using Resolution 1.63 amps per unit the Memory Map for your logic card, match the "stored Example: Setting of 100 = 163 Amps status code pointer number"...
  • Page 45: Summary Of Current Limit Adjustments

    The value for this function will be defined by the GE application engineer. The " minimum field current" setting is adjusted by Function 7.
  • Page 46: Dash Displays

    Shielded cable is required to eliminate signal interference. Part Number IC3645LXTDD The GE Standard Dash Display is a four segment Light Emitting Diode (LED) instrument that displays T=Traction Only the GE LX, ZX, and SX Status Codes, Hourmeter P=Traction & Pump Readings, Battery Discharge Indication, and Maintenance Required Code.
  • Page 47: Interactive Dash Displays

    INSTALLATION AND OPERATION MANUAL IT TRANSISTOR CONTROL Page 48 Section 6.4 Start-Up Display Sequence Section 6.5 Outline Drawings START-UP DISPLAY SEQUENCE GE Electric Vehicle Motors & Controls Key Switch On Verify Each LED Segment 8 8 8 8 0.41 (10.4) 3.20 (81.3)
  • Page 48 HS = 14 or GE Sentry None HS = 15 or GE Sentry None Battery Volts Select HS = CONT 1 or GE Sentry None Line and Brake Coil Pickup Voltages HS = CONT 2 or GE Sentry None Card Type Selection...
  • Page 49: Memory Maps

    See Manual for HS Access Reset to Zero Only Hours (Tens/Ones) 4 Hours (Thou/Hun) 4 See Manual for HS Access Reset to Zero Only GE SENTRY ONLY None M1 Reverse Speed Limit GE SENTRY ONLY None M1 Electric Brake Apply speed...
  • Page 50: January

    RS-232 MEMORY MAP TABLES IT TRANSISTOR CONTROL Page 51 Func Access By Restrictions GE SENTRY ONLY None M3 Armature Acceleration Rate GE SENTRY ONLY None M3 Pedal Up Regen Rate GE SENTRY ONLY None M3 Accelerator Slope Select GE SENTRY ONLY...

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