GE IC3645SR3R404P2 Installation And Operation Manual
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GE IC3645SR3R404P2 Installation And Operation Manual

Separately excited (sx) transistorized dual motor controllers
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INSTALLATION AND OPERATION
SX TRANSISTOR CONTROL
SEPARATELY EXCITED (SX) TRANSISTORIZED DUAL MOTOR CONTROLLERS
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 SX FAMILY OF MOTOR CONTROLLERS .............................................. 5
2.1
2.1.1
2.1.2
2.1.3
2.1.4
2.1.5
INSTALLATION AND OPERATION MANUAL
(IC3645SR3R404P2 & IC3645SR3R404P3)

Table of Contents

Copyright by General Electric Company July 1999
Motor Characteristics.................................................................................. 4
Solid-State Reversing.................................................................................. 5
Flexible System Application ........................................................................ 5
More Features with Fewer Components ........................................................ 5
Performance............................................................................................... 5
Oscillator Card Features........................................................................ 5
Standard Operation......................................................................... 5
Proportional Operation for Dual Motor Vehicles .................................. 6
Creep Speed .................................................................................. 6
Control Acceleration and 1A Time .................................................... 6
Current Limit ........................................................................................ 6
Braking................................................................................................ 7
Plug Braking .................................................................................. 7
Regenerative Braking to Zero Speed ................................................. 7
Pedal Position Plug Braking ............................................................ 7
Auxiliary Speed Control......................................................................... 7
Field Weakening............................................................................. 7
Speed Limits ................................................................................. 7
Ramp Operation ................................................................................... 7
Ramp Start .................................................................................... 7
Anti-Rollback.................................................................................. 7
Page 1
July 1999

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Summary of Contents for GE IC3645SR3R404P2

  • Page 1: Table Of Contents

    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.
  • Page 2 Recommended Lubrication of Pins and Sockets Prior to Installation ...... 15 General Troubleshooting Instructions ..............16 Traction Controller Status Codes ................ 17-44 Section 5.0 SX FAMILY - GE HANDSET INSTRUCTIONS ..............45 General Features ..................... 45 Purpose/Setup Functions ................. 45 Setup Function Procedures ................45 5.3.1...
  • Page 3 INSTALLATION AND OPERATION SX TRANSISTOR CONTROL Page 3 Table of Contents ( Continued ) 5.3.2 Status Code Scrolling................. 46 5.3.3 SX Handset Plug Connections & Outline Drawing.......... 46 Setup Functions for Traction Controller .............. 47-51 Summary of Current Limit Adjustments............... 52 Section 6.0 DISPLAYS........................

  • Page 4: Introduction

    SPEED new advances on the horizon. GE has introduced a second generation system using separately excited DC shunt wound motors. The separately excited DC motor system offers many of the features that are generally found on the advanced AC systems.

  • Page 5: Solid-State Reversing

    For GE, the future is now, as we make available a new The line can be energized and de-energized by the various generation of electric traction motor systems for electric logic combinations of the vehicle, i.e.

  • Page 6: Proportional Operation For Dual Motor Vehicles

    BASIC OPERATION AND FEATURES SX TRANSISTOR CONTROL Page 6 The oscillator section of the card has two adjustable predetermined angle of approximately 70 . At this point, the features, creep speed and minimum field current. With the inside wheel will stop. As the steer angle is increased accelerator at maximum ohms or volts, the creep speed toward the 90 point, the inside wheel will reverse direction...

  • Page 7: Braking

    Section 2.1.3.a Plug Braking setting will be determined by GE and OEM engineers at the time of vehicle development. This setting must not be changed by field personnel without the permission of the Slow down is accomplished when reversing direction by OEM.

  • Page 8: Accelerator Volts Hold Off

    BASIC OPERATION AND FEATURES SX TRANSISTOR CONTROL Page 8 Section 2.2.2 Accelerator Volts Hold Off Along with the status code display from the TMM, the SX control is capable of reducing the current to the motor, This feature checks the voltage level at the accelerator alerting the operator of a critical fault condition.

  • Page 9: 4.A Internal Resistance Compensation

    This is a multi-functional tool used with the LX, ZX, and SX Function 100 Function 101 Function 110 Series GE solid state controls. The Handset consists of a of Computer of Computer of Computer Light Emitting Diode (LED) display and a keyboard for data...

  • Page 10: Ordering Information, Elementary And Outline Drawings

    OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS SX 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: Separately Excited Control ( Plugging )

  • Page 11: Outline: Sx-2 Package Size

    OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS SX TRANSISTOR CONTROL Page 11 Section 3.2 Outline: SX-2 Package Size July 1999...

  • Page 12: Dual Motor Proportioning Drive Elementary

    OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS SX TRANSISTOR CONTROL Page 12 Section 3.3 Dual Motor Proportioning Drive Elementary July 1999...

  • Page 13: Dual Motor Proportioning Drive Input / Output List

    OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS SX TRANSISTOR CONTROL Page 13 Section 3.4 Dual Motor Proportioning Drive Control Input/Output List Connections to Main Plug (23 Pin) and “Y” Plug (12 Pin) STANDARD DUAL MOTOR PROPORTIONING MAIN PLUG INPUT/OUTPUT DESCRIPTION BATTERY VOLTS FROM BATTERY BATTERY VOLTS FROM KEY BATTERY VOLTS FROM START SWITCH BATTERY VOLTS FROM FORWARD SWITCH...

  • Page 14: Troubleshooting And Diagnostic Status Codes

    The semiconductor junctions in the vehicle. GE will not honor control failures during the have finite temperature limits, above which these devices warranty period when such failures are attributed to may be damaged.

  • Page 15: High Level Signals (Level H)

    4.2.3.a), outlined below. of a lubricant to all connections using pins and sockets on EV100/EV200 and Gen II products. Any connection made by GE to the A, B, X, Y, or Z plugs will have the lubricant NYE July 1999...

  • Page 16: General Troubleshooting Instructions

    GE recommends the addition of this Tools and test equipment required are: clip leads, volt-ohm lubricant to the 12 pin and 23 pin plugs of all new Gen II meter (20,000 ohms per volt) and basic hand tools.

  • Page 17: Traction Controller Status Codes

    DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 17 Section 4.5 Traction Control Status 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 unit. NONE Dash Display and/or the Handset.
  • Page 18 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 18 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Forward directional switch is closed on This status code will be displayed when P4 is greater initial power up. than 60% of battery voltage at initial key switch on. MEMORY RECALL CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM...
  • Page 19 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 19 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Brake pedal depressed while motoring This status code will be displayed when P13 is .25 volts greater than the low learn point and 5 seconds have timed out in motoring.
  • Page 20 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 20 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Accelerator depressed with no This status code will be displayed while P4 and P5 direction selected. are less than 60% of battery volts, and the accelerator (P7) is calling for greater than 40% on-time.
  • Page 21 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 21 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 22 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 22 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Start switch closed on power up after This status code will be displayed when P3 is greater initial key switch closure. than 60% of battery voltage when the key switch is closed.
  • Page 23 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 23 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE The brake switch is open with the This status code will be displayed when the brake brake pot voltage at some percentage switch is open and the brake pot voltage is some greater than the brake low learn setting percentage (defined by function setting) greater than...
  • Page 24 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 24 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Battery voltage is too high or control This status code will be displayed when the battery card is mis-adjusted. volts are greater than 2.4 volts per cell at initial key switch on.
  • Page 25 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 25 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Battery voltage is dropping too low This status code will be displayed when the battery during motoring. volts drops below 16 volts during motoring. MEMORY RECALL CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM...
  • Page 26 DIAGNOSTIC STATUS CODES SX 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 current the reverse direction. draw in the motor field is too high at start up in the reverse direction.
  • Page 27 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 27 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Armature current compensation This status code will be displayed when the voltage at calibration fault. P16 of the master control is less than 2.4 V or greater than 2.6V at start up.
  • Page 28 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 28 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Motor field current is too high during This status code will be displayed when the current in the run mode. the motor field is sustained above a preset limit for longer than 70 seconds.
  • Page 29 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 29 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE The first byte of data sent from the This status code will be displayed when the slave master to the slave “timed out”. control is expecting to receive the first byte of data and does not.
  • Page 30 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 30 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Either the master or the slave control This status code will be displayed when either the “timed out” while waiting for data after master or slave control did not receive any data.
  • Page 31 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 31 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE The first byte of data sent to the This status code will be displayed when the master “master” control has timed out. control does not receive the first byte of data when expected.
  • Page 32 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 32 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Indicates that the user needs to cycle This status code will be displayed when the user exits the key switch after exiting the handset the handset routine and the key switch is still on.
  • Page 33 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 33 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Open thermal protector (TP) or This status code will be displayed when the voltage at transistor over temperature. the thermal protector is too high. MEMORY RECALL CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM...
  • Page 34 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 34 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 35 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 35 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 36 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 36 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 37 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 37 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Controller “motor current sensor” input This status code will be displayed when the voltage too low during running. input from the current sensor is too low during running.
  • Page 38 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 38 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE There is an open circuit in the line This status code will be displayed when P17 does not contactor coil. see battery voltage while the contactor is open. MEMORY RECALL CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM...
  • Page 39 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 39 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 specific current limit. The line contactor will drop out and the key switch will have to be recycled to restart the control.
  • Page 40 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 40 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Capacitor (1C) voltage too high. This status code will be displayed when the voltage on the capacitor goes above 96 volts during the regenerative braking cycle.
  • Page 41 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 41 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE No data is received from the opposite This status code will be displayed when no data has control when expected. been received from the opposite control in over 3 seconds.
  • Page 42 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 42 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE A “time out” fault occurred in the This status code will be displayed when either control potentiometer auto calibration routine. does not receive RS232 data from the opposite control during the potentiometer auto calibration routine.
  • Page 43 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 43 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE The control cannot complete the This status code will be displayed when any of the potentiometer auto calibration routine potentiometer values do not meet the criteria outlined due to potentiometer settings which are below during the potentiometer auto calibration out of range.
  • Page 44 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 44 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Both controls will display status codes This status code will be displayed in both the master -2XX in the -2xx series, i.e. -201 to -299, and the slave controls, indicating a fault has occurred indicating a status code mismatch.

  • Page 45: Sx Family - Ge Handset Instructions

    START-UP DISPLAY SEQUENCE Section 5.1 General Features Key Switch On The GE Handset is a multi-functional tool to be used with the LX, ZX, and SX 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 46: Setup Mode

    ADJUSTABLE FEATURES SX TRANSISTOR CONTROLS Page 46 Section 5.3.1 Setup Mode ACCESSING STORED STATUS CODES WITH GE HANDSET SET-UP MODE Key Switch Off DISPLAY ACTION REMARKS SHOWS Hold Down CONT Segment Check 8 8 8 8 Push ESC and CONT...

  • Page 47: Setup Functions For Traction Controller

    Important Note: The function is used to optimize motor and HANDSET control performance and this setting will be determined by GE and OEM engineers at the time of vehicle development. This setting must not be changed by field personnel without the permission of the OEM.
  • Page 48 ADJUSTABLE FEATURES SX TRANSISTOR CONTROLS Page 48 FUNCTION 6 NOT APPLICABLE Example Setting of 75 = 73.5% of battery volts This function is not applicable to this control type and should not be adjusted. FUNCTION 13 NOT APPLICABLE FUNCTION 7 NOT APPLICABLE This function is not applicable to this control type and should not be adjusted.
  • Page 49 Because absolute memory locations need opens the line and steer pump contactors. to be known, this function should not be used without detailed instructions from the GE application engineer. Range 0 to 64 seconds Setting...
  • Page 50 ADJUSTABLE FEATURES SX TRANSISTOR CONTROLS Page 50 FUNCTION 28 STORED STATUS CODE COUNT This C/A TIME takes effect when the Mode 1 settings are POINTER called for by Function 1. ( Push CONT 13) FUNCTION 49 MODE 1 FIELD WEAKENING START (Push CONT 2) This register contains the location of the last stored status code recorded of the 16 stored status codes.
  • Page 51 ADJUSTABLE FEATURES SX TRANSISTOR CONTROLS Page 51 Range 52 to 364 amps This FIELD WEAKENING START takes effect when the 32 to 224 Mode 3 settings are called for by Function 1. Example: Setting of 50 = 78 amps FUNCTION 60 MODE 3 MINIMUM FIELD FUNCTION 53 MODE 2 CONTROLLED ACCELERATION...

  • Page 52: Summary Of Current Limit Adjustments

    ADJUSTABLE FEATURES SX TRANSISTOR CONTROLS Page 52 Section 5.5 Summary of Current Limit Adjustments The " maximum field current" setting is set at 38 amps. This function, along with the "maximum armature current" (Function 4), sets the maximum torque of the motor.

  • Page 53: Displays

    With Fault (no BDI used) Run Mode BDI Display or Diagnostics Override The GE Standard Dash Display is a four segment Light Blank Display With Fault Emitting Diode (LED) instrument that displays the GE LX, ZX, (no BDI used) and SX Status Codes, Hourmeter Readings, Battery Discharge Indication, and Maintenance Required Code.

  • Page 54: Outline Drawings

    INSTALLATION AND OPERATION MANUAL SX TRANSISTOR CONTROL Page 54 Section 6.4 Outline Drawings GE Electric Vehicle Motors & Controls 0.41 (10.4) 3.20 (81.3) CONNECTOR OMITTED IF NOT REQUIRED PUMP 0.19 TRACTION (4.8) PUMP Wiring connections to "Y" plugs of Traction BACK VIEW OF DISPLAY and Pump controls.

  • Page 55: Turn Angle Potentiometer Installation

    TURN ANGLE POTENTIOMETER INSTALLATION SX TRANSISTOR CONTROL Page 55 Section 7.0 TURN ANGLE POTENTIOMETER INSTALLATION Section 7.1 General The potentiometer used for the turn angle must be a 270 degree rotation device that is attached to the steer wheel in a manner to cause a 1:1 rotation ratio between the two devices.

  • Page 56: 270 Degree Potentiometer Input

    TURN ANGLE POTENTIOMETER INSTALLATION SX TRANSISTOR CONTROL Page 56 Section 7.2 270 Degree Potentiometer Input 270 DEGREE POTENTIOMETER FOR STEER ANGLE INPUT 4.30V Over Travel 3.52V Reverse Direction and Re-Accelerate 3.28V 3.20V Proportionally Reduces The Speed of the Right Motor As Steer Angle Increases 2.40V No Speed Change...

  • Page 57: Turn Angle Input Volts Vs. Steer Wheel Degrees Vs. Handset Reading

    TURN ANGLE POTENTIOMETER INSTALLATION SX TRANSISTOR CONTROL Page 57 Section 7.3 Turn Angle Input Volts vs. Steer Wheel Degrees vs. Handset Readings 270 Degree Potentiometer 270 Degree Potentiometer Left Right Left Right Volts Deg HS Volts Deg HS Actions Volts Deg HS Volts Actions 2.15 Ctr...

  • Page 58: Auto Calibration Of Accelerator, Brake And Steer Angle Potentiometers

    TURN ANGLE POTENTIOMETER INSTALLATION SX TRANSISTOR CONTROL Page 58 SECTION 8.0 AUTOCALIBRATION OF ACCELERATOR, mode. Cycle the key switch on and off to store the function setting. BRAKE AND STEER ANGLE POTENTIOMETERS When returning the key switch to the “ON” position, make Section 8.0 General sure that the forward, reverse and start switches are open, and that the seat switch is closed.
  • Page 59 TURN ANGLE POTENTIOMETER INSTALLATION SX TRANSISTOR CONTROL Page 59 Return the forward switch to the open position, and the dash display should show two “-“ ’s: Close the forward switch again while fully depressing the “-“ brake pedal. Only one should be displayed: Reopen the forward switch.

  • Page 60: Memory Maps

    Not Applicable HS or PC None Not Applicable HS or PC None Monitor HS or PC GE Temporary Storage Not Applicable HS or PC GE Temporary Storage Not Applicable HS or PC GE Temporary Storage Stored Status Code Count Pointer...
  • Page 61 RS-232 MEMORY MAP TABLES SX TRANSISTOR CONTROL Page 61 Func No. Traction Control Access By Restrictions Function Not Applicable PC Only Reset to Zero Only Not Applicable PC Only Reset to Zero Only Not Applicable PC Only Reset to Zero Only (26) Not Applicable PC Only...
  • Page 62 PC Only OEM Read Only Not Applicable PC Only OEM Read Only Not Applicable PC Only OEM Read Only GE Use PC Only OEM Read Only GE Use PC Only OEM Read Only GE Use PC Only OEM Read Only...

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