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INSTALLATION AND OPERATION
SX TRANSISTOR CONTROL
SEPARATELY EXCITED (SX) TRANSISTORIZED TRACTION DUAL MOTOR 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 SX 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
2.1.3.d
2.1.4
2.1.4.a
2.1.4.b
INSTALLATION AND OPERATION MANUAL
(IC3645SR3R404R2, IC3645SR3R404R3 and IC3645SR3R404R4)
Copyright by General Electric Company March 2000
Table of Contents
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
Controlled Acceleration and 1A Time......................................................................6
Current Limit.........................................................................................................................6
Braking .................................................................................................................................6
Regenerative Braking to Zero Speed........................................................................6
Pedal Position Plug Braking......................................................................................6
Auto Braking................................................................................................................6
Brake Pedal Regenerative Braking...........................................................................6
Auxiliary Speed Control......................................................................................................6
Field Weakening..................................................................................................................6
Speed Limits ........................................................................................................................7
Page 1
March 2000
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Table of Contents
Troubleshooting
Related Manuals for GE IC3645SR3R404R2
Summary of Contents for GE IC3645SR3R404R2
- 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.
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Page 2: Table Of Contents
INSTALLATION AND OPERATION SX TRANSISTOR CONTROL Page 2 Table of Contents ( Continued ) 2.1.5 Ramp Operation........................7 2.1.5.a Ramp Start........................7 2.1.5.b Anti-Rollback.......................7 2.1.6 On-Board Coil Drivers and Internal Coil Suppression ..........7 System Protective Override......................7 2.2.1 Static Return to Off (SRO) ....................7 2.2.2 Accelerator Volts Hold Off....................7 2.2.3... - Page 3 TMM7A Typical Brush Wear Sensor Connections ..............39 5.4.3 TMM Pump Control Connections ....................40 TMM7A Outline Drawings .........................40 Section 6.0 SX FAMILY - GE HANDSET INSTRUCTIONS....................41 General Features ..........................41 Purpose/Setup Functions ........................41 Setup Function Procedures ......................42 6.3.1 Setup Mode ..........................42 6.3.2...
- Page 4 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 2 KHZ. For GE, the future is now as we make available a new The line contactor is normally the only contactor required generation of electric traction motor systems for electric for the shunt motor traction circuit.
- Page 6 1 volt. It is important to note that this Section 2.1.3 Braking function is used to optimize motor and control performance, and this setting will be determined by GE and Section 2.1.3.a Regenerative Braking to Zero Speed OEM engineers at the time of vehicle development. This setting must not be changed by field personnel, without the permission of the OEM.
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Page 7: Ramp Operation
BASIC OPERATION AND FEATURES SX TRANSISTOR CONTROL Page 7 will not operate. This feature assures that the control is This feature provides a means to control speed by limiting calling for low speed operation at start up. motor volts utilizing three "adjustable speed limits. This motor volt limit regulates top speed of the transistor Section 2.2.3 Pulse Monitor Trip (PMT) controller, but actual truck speed will vary at any set point... -
Page 8: Status Codes
This is a multi-functional tool used with the LX, ZX, and SX occurs, a status code will be displayed on the Dash Series GE solid state controls. The Handset consists of a Display for vehicles so equipped, or be available by Light Emitting Diode (LED) display and a keyboard for data plugging the Handset into the “y”... -
Page 9: Truck Management Module (Tmm)
Section 2.3.8 Truck Management Module (TMM) The Truck Management Module is a multifunction accessory card, or an integral function of the GE Pump controls when used with the SX Traction control. The Module provides the OEM the ability to initiate status... -
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: Series Control (Pump) -
Page 11: Traction Elementary
OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS SX TRANSISTOR CONTROL Page 11 Section 3.3 Traction Elementary... - Page 12 OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS SX TRANSISTOR CONTROL Page 12 Section 3.4 Traction Control Input and Output List...
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Page 13: Traction Control Input / Output List
OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS SX TRANSISTOR CONTROL Page 13 CONNECTIONS TO MAIN PLUG (23 PIN) AND "Y" PLUG (12 PIN) TRACTION 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 SEAT SWITCH ACCELERATOR INPUT VOLTAGE SIGNAL... -
Page 14: Troubleshooting And Diagnostic Status Codes
For these reasons, normal maintenance should guard against any action which will expose the GE does not recommend that any type of welding be components to excessive heat and/or those conditions performed on the vehicle after the installation of the which will reduce the heat dissipating ability of the control(s) in the vehicle. -
Page 15: High Level Signals (Level H)
DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 15 The following are specific examples of level L signals used customer must apply the general guidelines (section in drive equipment cabling: 4.2.3.a), outlined below. ?? Control common tie 4.2.3.a General Cable Spacing ?? DC buses feeding sensitive analog or digital hardware ?? All wiring connected to components associated with The following general practices should be used for all... -
Page 16: Recommended Lubrication Of Pins And Sockets Prior To Installation
EV100/EV200 and Gen II products. Any Clean each terminal using Chemtronics? contact connection made by GE to the A, B, X, Y, or Z plugs will cleaner “Pow-R-WasH CZ “ as shown in Figure 1. have the lubricant NYE 760G added to prevent fretting of these connections during vehicle operation. - Page 17 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 17 Trouble-shooting the SX 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"...
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Page 18: Traction Controller Status Codes
DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 18 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Segments do not illuminate on the Dash No input voltage to the control card or the display unit. NONE Display and/or the Handset. 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 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 20 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 20 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. MEMORY RECALL CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM...
- Page 21 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 21 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Accelerator input voltage too high during This status code will be displayed when the run mode. accelerator input voltage at P7 is higher than 4.2 volts, and a directional contactor is picked up.
- Page 22 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 22 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Both the forward and reverse directional This status code will be displayed when P4 and P5 are switches are closed at the same time. greater than 60% of battery volts at the same time.
- Page 23 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 23 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Battery voltage is too low or control card This status code will be displayed when the battery is mis-adjusted. volts are less than 1.95 volts per cell at initial key switch on.
- Page 24 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 24 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 25 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 25 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 26 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 26 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 27 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 27 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Motor armature offset voltage is too low. This status code will be displayed when the voltage at the current sensor input is less than 2.4 volts with no current flowing in the motor circuit.
- Page 28 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 28 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Armature transistor did not turn on This status code will be displayed when, during control properly. operation, the armature transistor fails to turn on properly.
- Page 29 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 29 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 3.1 amps, while the armature current is greater than 100A for 2.0 seconds during run mode.
- Page 30 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 30 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Controller “motor current sensor” input This status code will be displayed when the voltage input too low during running. from the current sensor is too low during running. MEMORY RECALL CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM...
- Page 31 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 31 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE The line coil current is too high during This status code will be displayed when the current the run mode limit in the line coil is exceeded during the run mode. The line contactor will drop out and the key switch will have to be recycled to reset the control.
- Page 32 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 32 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE The 1A coil current is too high during This status code will be displayed when the current in the run mode. the 1A driver circuit exceeds current limit during the run mode.
- Page 33 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 33 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.
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Page 34: Tmm Module Status Codes
DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 34 Section 4.6 TMM Codes TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Traction motor temperature has This status code will be displayed when the voltage at exceeded maximum temperature limit. the respective terminal of the TMM or Pump Logic Card is at zero volts. - Page 35 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 35 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Steering pump motor brush wear This status code will be displayed when the voltage at indicator has detected worn brush. the respective terminal of the TMM or Pump Logic Card is at battery volts.
- Page 36 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 36 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Traction motor brush wear indicator has This status code will be displayed when the voltage at detected worn brush. the respective terminal of the TMM or Pump Logic Card is at battery volts.
- Page 37 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 37 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Pump motor brush wear indicator has This status code will be displayed when the voltage at detected worn brush. the respective terminal of the TMM or Pump Logic Card is at battery volts.
- Page 38 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 38 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Maintenance alert and speed limit. This status code will be displayed when the “normal” hour meter exceeds the “maintenance alert hours” setting for the vehicle. MEMORY RECALL CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM...
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Page 39: Truck Management Module (Tmm)
INSTALLATION AND OPERATION MANUAL Page 39 SX TRANSISTOR CONTROL Section 5. TRUCK MANAGEMENT MODULE (TMM) IMPORTANT NOTE: Status Codes 93, 94 and 95 are only checked when a neutral signal is present (i.e., open Section 5.1 General Features start switch or open F/R switch). The status code is displayed and the speed limit enabled when the control The Truck Management Module is a multi-functional is returned to the run mode. -
Page 40: Tmm Pump Control Connections
INSTALLATION AND OPERATION MANUAL Page 40 SX TRANSISTOR CONTROL PUMP CONTROL CONNECTIONS BATTERY NEGATIVE TRACTION PL2-14 BATTERY POSITIVE TRACTION PL2-20 Section 5.5 TMM7A Outline Drawings 1.60 (40.6) (20.3) March 2000... -
Page 41: Sx Family - Ge Handset Instructions
INSTRUCTIONS Section 6.1 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 42: Setup Function Procedures
This will place you in the set-up 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 6.3.1 Setup Mode Key Switch Off... -
Page 43: Setup Functions For Traction Controller
Important Note: This function is used to optimize motor provided. and control performance and this setting will be determined by GE and OEM engineers at the time of Range 2% to 15% on time vehicle development. This setting must not be changed... - Page 44 0.314 amps 6.28 amps and control performance and this setting will be determined by GE and OEM engineers at the time of Important Note: The function is used to optimize motor vehicle development. This setting must not be changed and control performance and this setting will be by field personnel without the permission of the OEM.
- Page 45 ADJUSTABLE FEATURES SX TRANSISTOR CONTROLS Page 11.44 01.34 To disable the pedal position plug function, adjust this current value to the same current value as the plug 07.60 01.27 distance current. 05.72 01.20 04.57 01.14 Example: If plug distance current, Function 5, is set at 350 03.81 01.09 amps, then set pedal plug current at 350 amps.
- Page 46 0 to 99 to be known, this function should not be used without Example 9999 Hours detailed instructions from the GE application engineer. FUNCTION 20 MAINTENANCE CODE THOUSANDS AND This function should only be adjusted by the vehicle HUNDREDS HOURS SET OEM.
- Page 47 ADJUSTABLE FEATURES SX TRANSISTOR CONTROLS Page This FIELD WEAKENING START takes effect when the To determine which stored status code was the last one Mode 1 settings are called for by the Interactive Dash recorded, read the number stored in Function 28. Using the Display.
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Page 48: Summary Of Current Limit Adjustments
ADJUSTABLE FEATURES SX TRANSISTOR CONTROLS Page Same as Function 51. This FIELD WEAKENING START takes effect when the Mode 2 settings are called for by the Interactive Dash This RATIO takes effect when the Mode 3 settings are Display. called for by the Interactive Dash Display. FUNCTION 54 MODE 2 MINIMUM FIELD CURRENT FUNCTION 60... - Page 49 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.
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Page 50: Dash Displays
Part Number IC3645LXTDD T=Traction Only P=Traction & Pump The GE Standard Dash Display is a four segment Light Emitting Diode (LED) instrument that displays the GE LX, ZX, and SX Status Codes, Hourmeter Readings, Battery 3=Round Face with four Discharge Indication, and Maintenance Required Code. -
Page 51: Start-Up Display Sequence
SX TRANSISTOR CONTROL Page 51 START-UP DISPLAY SEQUENCE Section 7.5 Outline Drawings Key Switch On Verify Each LED Segment GE Electric Vehicle Motors & Controls 8 8 8 8 If Maintenance Code If Maintenance Code Is Active Is Not Active 0.41... -
Page 52: Memory Maps
For DD on power up Regen Cancel HS or PC None FW Start HS or PC None Monitor HS or PC GE Temporary Storage Ratio HS or PC GE Temporary Storage HS or PC GE Temporary Storage Fault Count Pointer HS or PC None... - Page 53 RS-232 MEMORY MAP TABLES SX TRANSISTOR CONTROL Page 53 Function Hours (Thou/Hun) 3 PC Only Reset to Zero Only 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 Stored Status Code #5 PC Only...
- Page 54 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...