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INSTALLATION AND OPERATION
SX TRANSISTOR CONTROL
SEPARATELY EXCITED (SX) TRANSISTORIZED 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 ........................................................................................................................................................ 3
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
2.1.6
2.2
2.2.1
2.2.2
2.2.3
2.2.4
FOR NEIGHBORHOOD ELECTRIC VEHICLE APPLICATION
INSTALLATION AND OPERATION MANUAL
(GE MODEL IC3645SH7R353T1)
General Electric Company August 2001
Table of Contents
Motor Characteristics .............................................................................................................. 3
Solid-State Reversing ............................................................................................................... 4
Flexible System Application..................................................................................................... 4
More Features with Fewer Components ................................................................................ 4
Performance.............................................................................................................................. 5
Oscillator Card Features .................................................................................................. 5
Standard Operation................................................................................................... 5
Control Acceleration ................................................................................................ 5
Current Limit ...................................................................................................................... 5
Plug Braking ...................................................................................................................... 5
Auxiliary Speed Control.................................................................................................... 5
Field Weakening........................................................................................................ 5
Speed Limits .............................................................................................................. 5
Top Speed Regulation ...............................................................................................5
Ramp Start ......................................................................................................................... 6
On-Board Coil Drivers and Internal Coil Suppression ................................................. 6
System Protective Override ..................................................................................................... 6
Static Return to Off (SRO) ............................................................................................... 6
Accelerator Volts Hold Off............................................................................................... 6
Pulse Monitor Trip (PMT)................................................................................................. 6
Thermal Protector (TP)..................................................................................................... 6
Page 1
August 2001
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Table of Contents
Troubleshooting
Related Manuals for GE IC3645SH7R353T1
Summary of Contents for GE IC3645SH7R353T1
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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. For additional information and/or problem resolution, please refer the matter to the OEM vehicle manufacturer through his normal field service channels. - Page 2 Recommended Lubrication of Pins and Sockets Prior to Installation........14 General Troubleshooting Instructions ................... 15 Traction Controller Status Codes ....................16-27 Section 5.0 SX FAMILY - GE HANDSET INSTRUCTIONS ...................... 28 General Features ........................28 Purpose/Setup Functions ......................28 Setup Function Procedures ....................29 6.3.1...
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Page 3: 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 4: Solid-State Reversing
For GE, the future is now, as we make available a new problems that would cause a full motor torque condition. -
Page 5: Performance
GE and OEM engineers at the time of Function 24 and the accelerator input voltage is less than 1 vehicle development. -
Page 6: Ramp Start
BASIC OPERATION AND FEATURES SX TRANSISTOR CONTROL Page 6 Section 2.1.5 Ramp Start armature or field FET's are defective, so as to cause uncontrolled truck movement. This feature provides maximum control torque to restart a vehicle on an incline. The memory for this function is the Section 2.2.4 Thermal Protector (TP) directional switch. -
Page 7: Stored Status Codes
BDI. Section 2.3.5 Handset This is a multi-functional tool used with the LX, ZX, and SX Series GE solid state controls. The Handset consists of a Light Emitting Diode (LED) display and a keyboard for data entry. -
Page 8: Ordering Information, Elementary And Outline Drawings
OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS SX TRANSISTOR CONTROL Page 8 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 9: Outline: Sx-2 Package Size
OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS SX TRANSISTOR CONTROL Page 9 Section 3.2 Outline: SX-2 Package Size August 2001... -
Page 10: Standard Elementary For Neighborhood Electric Vehicle Application
ELEMENTARY DRAWING FOR TYPICAL MOTOR CONNECTIONS SEPARATELY EXCITED TRACTION MOTOR * CUSTOMER SUPPLIED CONTROLLER FOR NEV APPLICATIONS CHARGER SWITCH * KEY SWITCH * DIRECTIONAL LINE * SWITCH * 400A P2 P3 P11 P10 PLUG (23 PIN) P15 P14 P16 P7 P9 POWER CONNECTIONS TO CONTROL... -
Page 11: Standard Neighborhood Electric Vehicle Application Input/Output List
OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS SX TRANSISTOR CONTROL Page 11 Section 3.4 Neighborhood Electric Vehicle Application Input/Output List Connections to Main Plug (23 Pin) and “Y” Plug (8 Pin) MAIN PLUG INPUT/OUTPUT DESCRIPTION BATTERY VOLTS FROM BATTERY BATTERY VOLTS FROM KEY BATTERY VOLTS FROM ACCELERATOR START SWITCH BATTERY VOLTS FROM FORWARD SWITCH BATTERY VOLTS FROM REVERSE SWITCH... -
Page 12: Troubleshooting And Diagnostic Status Codes
The semiconductor junctions have finite temperature limits, above which these devices GE does not recommend that any type of welding be may be damaged. For these reasons, normal maintenance performed on the vehicle after the installation of the should guard against any action which will expose the control(s) in the vehicle. -
Page 13: High Level Signals (Level H)
DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 13 •= Control common tie customer must apply the general guidelines (section •= DC buses feeding sensitive analog or digital hardware 4.2.3.a), outlined below. •= All wiring connected to components associated with 4.2.3.a General Cable Spacing sensitive analog hardware with less than 5V signals (for example, potentiometers and tachometers) •= Digital tachometers and resolvers... -
Page 14: Recommended Lubrication Of Pins And Sockets Prior To Installation
EV100/EV200 and Gen II products. Any connection made by Clean each terminal using Chemtronics contact GE to the A, B, X, Y, or Z plugs, includes the lubricant NYE cleaner “Pow-R-WasH CZ “ as shown in Figure 1. 760G to prevent fretting of these connections during vehicle operation. -
Page 15: General Troubleshooting Instructions
DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 15 Section 4.4 General Troubleshooting Instructions Trouble-shooting the ZX family of controls should be quick and easy when following the instructions outlined in the following status code instruction sheets. If mis-operation of the vehicle occurs, a status code will be displayed on the Dash Display (for vehicles equipped with a Dash Display) or made available by plugging a Handset into the plug "Y"... -
Page 16: Traction Controller Status Codes
DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 16 Section 4.5 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 unit. NONE Dash Display and/or the Handset. - Page 17 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 17 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Start switch fails to close. This status code will be displayed when the accelerator voltage at P7 is >2.5V, with the start switch open (P3<...
- Page 18 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 18 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Accelerator voltage input is too high on This status code will be displayed when the power up after initial key switch accelerator input voltage at P7 >0.9V and either the closure.
- Page 19 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 19 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Start switch closed on power up after initial This status code will be displayed when P3 is key switch closure. greater than 50% of battery volts when the key switch is closed.
- Page 20 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 20 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Battery voltage is too high at initial key This status code will be displayed when the switch closure. battery volts are greater than 86 volts at initial key switch on.
- Page 21 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 21 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Motor field current is too high when the This status code will be displayed when the current start switch is closed and the reverse draw in the motor field is too high on start up in the direction is selected.
- Page 22 (Values of greater than 4 V at the thermal protector are typically indicative of a failed control.) GE Sentry for Windows software can be used to monitor control operation, and it will display a value for the thermal protector that is greater than 84 (corresponding to 1.65V), triggering this...
- Page 23 Defective control. •= Replace controller unit. Controller GE Sentry for Windows software can be used to monitor control operation, and it will display a value for the motor amps that is greater than 138, (corresponding to 2.7V), triggering this status code.
- Page 24 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 24 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Armature transistor did not turn off This status code will be displayed when, during properly. control operation, the armature transistor fails to turn off.
- Page 25 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 25 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE “Look Ahead” test for A2 volts is less This status code will be displayed when the voltage at than 12.5% of battery volts. A2 is less than 12.5% of battery volts and I is greater than 52 amps, when the control is in the neutral state,...
- Page 26 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 26 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Capacitor volts are low before the line This status code will be displayed during “key on” contactor closes. when the capacitor volts is less than 85% of battery volts at initial key switch on.
- Page 27 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 27 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Capacitor (1C) voltage too high during This status code will be displayed when the voltage at regenerative braking. 1C exceeds 96 volts during the regenerative braking cycle.
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Page 28: 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 29: Setup Function Procedures
This will place you in the setup mode, ready to monitor or adjust control function settings. ACCESSING STORED STATUS CODES NOTE: The term “Push” means to depress key for WITH GE HANDSET approximately one second. Section 5.3.1 Setup Mode Key Switch Off... -
Page 30: Sx Handset Plug Connections And Outline Drawing
Important Note: The function is used to optimize motor and 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 31 Resolution 0.8125 amps per unit GE and OEM engineers at the time of vehicle development. Example Setting of 20 = 26 + (20 X .8125) = This setting must not be changed by field personnel without the permission of the OEM.
- Page 32 ADJUSTABLE FEATURES SX TRANSISTOR CONTROLS Page 32 Example: Setting of 0 = no speed limit 3. Calculate voltage drop (V ) as follows: Drop Setting of 170 = maximum speed Drop reduction 4. Use the table below to determine the appropriate setting Setting of 110 =100%-((110-51) - (creep val/8)) x 0.78 using the calculated V as a reference.
- Page 33 ( Push CONT 3 ) control performance and this setting will be determined by GE and OEM engineers at the time of vehicle development. This function allows for the adjustment of the time This setting must not be changed by field personnel without allowable for the start switch to be opened before the line the permission of the OEM.
- Page 34 HS (Handset) number column] on the memory map, GE and OEM engineers at the time of vehicle development. with the number obtained from Function 28. This will be the This setting must not be changed by field personnel without last stored status code recorded.
- Page 35 ADJUSTABLE FEATURES SX TRANSISTOR CONTROLS Page 35 FUNCTION 48 ODOMETER TENTH OF MILE OR KILOMETER SET ( Push CONT 1) This function allows for the adjustment of the tenth of a mile or kilometer on the odometer. Range 0 to 9 0 to 9 Example 999999.9 Miles or Kilometers...
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Page 36: 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. The function sets the top speed of the motor. -
Page 37: Displays
Plug "Y" of each control. Shielded cable is required to eliminate signal interference. Part Number IC3645LXTDD The GE Standard Dash Display is a four segment Light T=Traction Only Emitting Diode (LED) instrument that displays the GE LX, ZX, P=Traction & Pump and SX Status Codes, Hourmeter Readings, Battery Discharge Indication, and Maintenance Required Code. -
Page 38: Outline Drawings
INSTALLATION AND OPERATION MANUAL SX TRANSISTOR CONTROL Page 38 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 0.43 (10.9) 2.98 (75.7) -
Page 39: Memory Map
HS or PC None Field Weakening Start (or Motor Knee Point) HS or PC None Monitor HS or PC GE Temporary Storage Ratio of Field to Armature Amps HS or PC None Hour Meter Minutes HS or PC None Stored Status Code Count Pointer... - Page 40 RS-232 MEMORY MAP TABLES SX TRANSISTOR CONTROL Page 40 Func No. Traction Control Access By Restrictions Function BDI 4 PC Only Reset to Zero Only Hours (Tens/Ones) 4 PC Only Reset to Zero Only Hours (Thou/Hun) 4 PC Only Reset to Zero Only (26) Stored Status Code #5 PC Only...
- Page 41 OEM Read Only Secure Aux HM (Tens/Ones) PC Only OEM Read Only Secure Aux HM (Thou/Hun) PC Only OEM Read Only Reserved PC Only GE Future Use Reserved PC Only GE Future Use Reserved PC Only GE Future Use Reserved PC Only...