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INSTALLATION AND OPERATION
SX TRANSISTOR 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 .................................................................................................................................................... 3
1.1
1.2
1.3
1.4
Section 2.0
FEATURES OF SX FAMILY OF MOTOR CONTROLLERS .................................................................................. 4
2.1
2.1.1
2.1.1.a
2.1.1.b
2.1.2
2.1.3
2.1.4
2.1.4.a
2.1.4.b
2.1.4.c
2.1.5
2.1.6
2.2
2.2.1
SEPARATELY EXCITED (SX) TRANSISTORIZED MOTOR CONTROLLERS
General Electric Company July 2004
Table of Contents
Motor Characteristics ................................................................................................................. 3
Solid-State Reversing .................................................................................................................. 4
Flexible System Application........................................................................................................ 4
More Features with Fewer Components .................................................................................. 4
Performance.................................................................................................................................. 4
Oscillator Card Features.............................................................................................................. 4
Standard Operation................................................................................................... 4
Control Acceleration ................................................................................................... 5
Current Limit .................................................................................................................................. 5
Regenerative Braking to Base Speed ....................................................................................... 5
Auxiliary Speed Control............................................................................................................... 5
Field Weakening ........................................................................................................... 5
Speed Limits ................................................................................................................. 5
Top Speed Regulation ...............................................................................................5
Ramp Start..................................................................................................................................... 5
On-Board Coil Drivers and Internal Coil Suppression ........................................................... 6
System Protective Override ........................................................................................................ 6
Static Return to Off (SRO) .......................................................................................................... 6
FOR NEIGHBORHOOD ELECTRIC VEHICLE APPLICATIONS
INSTALLATION AND OPERATION MANUAL
GE MODEL IC3645SR7A353E1
Page 1
Updated
Sept 2019
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Troubleshooting
Related Manuals for GE IC3645SR7A353E1
Summary of Contents for GE IC3645SR7A353E1
- Page 1 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.
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Page 2: Table Of Contents
INSTALLATION AND OPERATION SX TRANSISTOR CONTROL Page 2 Table of Contents ( Continued ) 2.2.2 Accelerator Volts Hold Off ......................6 2.2.3 Pulse Monitor Trip (PMT)......................6 2.2.4 Thermal Protector (TP)........................ 6 2.2.5 Low Voltage ..........................6 Diagnostics............................ 6 2.3.1 Status Codes.......... - Page 3 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 For GE, the future is now, as we make available a new r start switch closure, and de-e nergize on time out of idle generation of electric traction motor systems for electric ehicle.
- Page 5 This feature requires a system tachometer. The standard 100% ON time. GE system tach is built into the motor and provides four pulses per armature revolution. Once the control has been Section 2.1.3 Regenerative Braking to Zero Speed...
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Page 6: Accelerator Volts Hold Off
BASIC OPERATION AND FEATURES SX TRANSISTOR CONTROL Page 6 This temperature sensitive device is internal to the power This feature provides maximum control torque to restart a transistor (Q1) module. If the transistor's temperature vehicle on an incline. The memory for this function is the begins to exceed the design limits, the thermal protector directional switch. -
Page 7: Odometer Readings
BASIC OPERATION AND FEATURES SX TRANSISTOR CONTROL Page 7 connected incorrectly, the contactors can not be closed electrically. Section 2.3.2 Odometer Readings This feature will transmit the miles of use of the traction control to the Dash Display. Section 2.3.3 RS 232 Communication Port This serial communication port can be used with Interactive Custom Dash Displays to allow changes to vehicle operating parameters by the operator. -
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: Package Size
OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS SX TRANSISTOR CONTROL Page 9 Section 3.2 Outline: Package Size Updated Sept 2019... -
Page 10: Standard Elementary For Neighborhood Electric Vehicle Application
OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS SX TRANSISTOR CONTROL Page 10 Section 3.3 Standard Elementary for Neighborhood Electric Vehicle Application Updated Sept 2019... -
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 PIN MAIN PLUG INPUT/OUTPUT DESCRIPTION BATTERY VOLTS POS FROM KEY BATTERY VOLTS POS FROM KEY BATTERY NEG FROM ACCELERATOR START SWITCH BATTERY VOLTS POS FROM FORWARD SWITCH BATTERY VOLTS POS FROM REVERSE SWITCH BATTERY VOLTS POS FROM TURF SPEED LIMIT SWITCH... -
Page 12: Troubleshooting And Diagnostic Status Codes
The transistor control, like all electrical apparatus, does have some thermal losses. The semiconductor junctions GE does not recommend that any type of welding be have finite temperature limits, above which these devices performed on the vehicle after the installation of the may be damaged. -
Page 13: High Level Signals (Level H)
INSTALLATION AND OPERATION SX TRANSISTOR CONTROL Page 13 • Control common tie customer must apply the general guidelines (section 4.2.3.a), outlined below. • DC buses feeding sensitive analog or digital hardware • 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) •... -
Page 14: Recommended Lubrication Of Pins And Sockets Prior To Installation
Reconnecting the plugs will lubricate the pin (male) EV100/EV200 and Gen II products. Any connection made by terminals. GE to the A, B, X, Y, or Z plugs, includes the lubricant NYE Clean each terminal using Chemtronics contact 760G to prevent fretting of these connections during vehicle cleaner “Pow-R-WasH CZ “... -
Page 15: General Troubleshooting Instructions
INSTALLATION AND OPERATION 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
INSTALLATION AND OPERATION SX TRANSISTOR CONTROL Page 16 Section 4.5 Traction Control Codes 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 >1.4V, with the start switch open (P3 >... - Page 17 INSTALLATION AND OPERATION SX TRANSISTOR CONTROL Page 17 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 when the closure.
- Page 18 INSTALLATION AND OPERATION SX TRANSISTOR CONTROL Page 18 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. less than 2.5 volts when the key switch is closed.
- Page 19 INSTALLATION AND OPERATION SX TRANSISTOR CONTROL Page 19 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Battery voltage is too low at initial key This status code will be displayed when the switch closure. battery volts are less than 68.3 volts at initial key switch on.
- Page 20 INSTALLATION AND OPERATION SX TRANSISTOR CONTROL Page 20 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Accelerator voltage is too high. This status code will be displayed when the accelerator voltage at P7 is greater than 4.5 volts. MEMORY RECALL CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM...
- Page 21 INSTALLATION AND OPERATION 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 key switch is turned on. draw in the motor field is too high on start up.
- Page 22 (Values of less than 1.5 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 status code.
- Page 23 Traction Defective control. Controller • Replace controller unit. GE Sentry for Windows software can be used to monitor control operation, and it will display a value for the motor amps that is less than 123 (corresponding to 2.4V), triggering this status code.
- Page 24 INSTALLATION AND OPERATION SX TRANSISTOR CONTROL Page 24 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 25 INSTALLATION AND OPERATION SX TRANSISTOR CONTROL Page 25 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 less than 1.3 amps and armature current is greater than 100 amps for more than 1.27 seconds during the run mode.
- Page 26 INSTALLATION AND OPERATION SX TRANSISTOR CONTROL Page 26 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Controller “motor current sensor” input This status code will be displayed when the voltage is too low during running. input from the current sensor is too low (less than 1.0V, 416 amps) during running.
- Page 27 INSTALLATION AND OPERATION SX TRANSISTOR CONTROL Page 27 TRACTION DESCRIPTION OF CAUSE OF STATUS INDICATION STATUS CODE STATUS The line coil current is too high This status code will be displayed when the current limit in during the run mode the line coil is exceeded during the run mode.
- Page 28 INSTALLATION AND OPERATION SX TRANSISTOR CONTROL Page 28 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 pedal up regen braking. 1C exceeds 96 volts during the regenerative braking cycle.
- Page 29 INSTALLATION AND OPERATION SX TRANSISTOR CONTROL Page 29 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE No tachometer signal is detected. This status code will be displayed when no tachometer signal is detected. MEMORY RECALL CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM SYMPTOM +72V +72V...
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Page 30: Set Up Functions For Traction Controller
Windows, the user can access any E Prom setting, quickly perform various maintenance, diagnostic, and trouble-shooting Range 2% to 15% on time tasks without the aid of additional test equipment. GE Digital 0 to 255 Expertise for Palm OS and GE Sentry for Windows links Resolution 0.047% per set unit... - Page 31 = 3.3 amps GE and OEM engineers at the time of vehicle development. This setting must not be changed by field personnel without CAUTION: Do not set this function to a value less than 51.
- Page 32 This function allows for the adjustment of the pedal field is present. Adjustment of this function will improve the gain. This value is determined by GE application accuracy of the BDI. In order to determine this setting, the engineering and should be set using the OEM setting voltage drop of the battery under load must first be specifications for this vehicle.
- Page 33 FUNCTION 27 HOUR METER MINUTES 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. This function adjusts the number of 30 second intervals registering in the hour meter.
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Page 34: Memory Map
RS-232 MEMORY MAP TABLES SX TRANSISTOR CONTROL Page 34 Section 6.0 MEMORY MAP Func No. Traction Control Function Access By Restrictions MPH Scaling PC or PDA None Creep Speed PC or PDA None Armature Acceleration Rate PC or PDA None Max Armature Current Limit PC or PDA None... - Page 35 RS-232 MEMORY MAP TABLES SX TRANSISTOR CONTROL Page 35 Func No. Traction Control Function Access By Restrictions BDI 4 PC or PDA Reset to Zero Only Hours (Tens/Ones) 4 PC or PDA Reset to Zero Only Hours (Thou/Hun) 4 PC or PDA Reset to Zero Only Stored Status Code #5 PC or PDA...
- Page 36 Field Offset PC or PDA OEM Read Only Armature Offset PC or PDA OEM Read Only Reserved PC or PDA GE Future Use OEM Use PC or PDA None OEM Use PC or PDA None OEM Use PC or PDA...