GE IC3645SH7R353E2 Installation And Operation Manual Download

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Summary of Contents for IC3645SH7R353E2

Page 1: ...through his normal field service channels Do not contact GE directly for this assistance General Electric Company July 2002 Section 1 0 INTRODUCTION 3 1 1 Motor Characteristics 3 1 2 Solid State Reversing 4 1 3 Flexible System Application 4 1 4 More Features with Fewer Components 4 Section 2 0 FEATURES OF SX FAMILY OF MOTOR CONTROLLERS 5 2 1 Performance 5 2 1 1 Oscillator Card Features 5 2 1 1 a S...

Page 2: ...esponsibility 12 4 2 2 Signal Power Level Definitions 12 4 2 2 a Low Level Signals Level L 12 4 2 2 b High Level Signals Level H 13 4 2 2 c Medium Power Signals Level MP 13 4 2 2 d High Power Signals Level HP 13 4 2 3 Cable Spacing Guidelines 13 4 2 3 a General Cable Spacing 13 4 2 4 Cabling for Vehicle Retrofits 13 4 2 5 RF Interference 13 4 2 6 Suppression 13 4 3 Recommended Lubrication of Pins ...

Page 3: ...torque at low speed characteristic of the series motor is evident In a shunt motor the field is connected directly across the voltage source and is therefore independent of variations in load and armature current If field strength is held constant the torque developed will vary directly with the armature current If the mechanical load on the motor increases the motor slows down reducing the back E...

Page 4: ...ield winding of the motor Bypassing some of the current flowing in the field into the resistor causes the field current to be less or weakened With the field weakened the motor speed will increase giving the effect of overdrive To change the overdrive speed it is necessary to change the resistor value In a separately excited motor independent control of the field current provides for infinite adju...

Page 5: ...y Function 10 and armature plug current can no longer be maintained the braking function is canceled and the control reverts back to motoring All energy produced by the motor during plugging is dumped as heat in the motor in this braking mode Section 2 1 4 Regenerative Braking to Base Speed Regenerative braking to base speed is a function of the vehicle motor design which slows the vehicle to a sp...

Page 6: ... again Automatic look again and reset The PMT circuit will not allow the control to start under the following conditions The control monitors both armature and field FET s at start up and during running The control will not allow the line contactor to close at start up or will drop it out during running if either the armature or field FET s are defective so as to cause uncontrolled truck movement ...

Page 7: ...dicator is present Adjustment of this function will improve the accuracy of the 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 Features and functions Monitor existing system status codes for both traction and pump controls Monitor intermitten...

Page 8: ...umber Argument 02 Control Type SH Separately Excited Control Plugging SR Separately Excited Control Regen to Zero Argument 03 Operating Voltage 1 120 volts 5 36 48 volts 2 24 volts 6 24 36 volts 3 36 volts 7 72 80 volts 4 48 volts Argument 04 Package Size D 6 86 X 6 67 R 6 86 X 8 15 U 8 66 X 8 13 W 8 66 X 10 83 Argument 05 Armature Current 2 characters 22 220 Amps 33 330 Amps 40 400 Amps etc Argum...

Page 9: ...OUTLINE DRAWINGS ELEMENTARY DRAWINGS AND INPUTS OUTPUTS SX TRANSISTOR CONTROL Page 9 July 2002 Section 3 2 Outline SX 2 Package Size ...

Page 10: ...2 FIELD ARMATURE FU1 LINE A1 A2 A1 A2 F2 F1 400A FU3 L TURF SPEED LIMIT SWITCH 10A CHARGER SWITCH KEY SWITCH START SWITCH DIRECTIONAL SWITCH FORWARD REVERSE BUZZER ACCEL POT P1 P2 P3 P4 P5 P11 P10 P15 TACHOMETER P14 P16 P7 P9 P13 P8 P6 RED GREEN BLACK ELEMENTARY DRAWING FOR TYPICAL SEPARATELY EXCITED TRACTION MOTOR CONTROLLER FOR NEV APPLICATIONS PLUG 23 PIN MOTOR CONNECTIONS CUSTOMER SUPPLIED EME...

Page 11: ... ACCELERATOR INPUT VOLTAGE SIGNAL 8 ACCELERATOR NEGATIVE 9 ACCELERATOR POT 5 VOLTS SUPPLY 3 WIRE POT 10 BACK UP ALARM 11 LINE CONTACTOR COIL DRIVER 12 N A 13 PARK BRAKE SWITCH INPUT 14 TACHOMETER INPUT SIGNAL 15 TACHOMETER 12 VOLT OUTPUT 16 NEGATIVE FOR TACH 17 N A 18 N A 19 N A 20 NEGATIVE 21 MOTOR THERMAL SWITCH 22 SERIAL RECEIVE 23 SERIAL TRANSMIT PIN Y PLUG INPUT OUTPUT DESCRIPTION 1 CLOCK OUT...

Page 12: ...procedures recharging before 80 percent discharged with periodic equalizing charges Visual inspection of GE contactors contained in the traction and pump systems is recommended to occur during every 1000 hours of vehicle operation Inspection is recommended to verify that the contactors are not binding and that the tips are intact and free of contaminants GE does not recommend that any type of weld...

Page 13: ...ply the general guidelines section 4 2 3 a outlined below 4 2 3 a General Cable Spacing The following general practices should be used for all levels of cabling All cables and wires of like signal levels and power levels must be grouped together In general different levels must run in separate wire bundles as defined in the different classes identified above Intermixing cannot be allowed unless no...

Page 14: ...per these instructions with the recommended contact cleaner and lubricant which provides a high degree of environmental and fretting protection New and re manufactured control plugs are cleaned and lubricated prior to shipment from the factory However in applications where severe vibration or high temperature cycling and excessive humidity such as freezers are present it is recommended that the pl...

Page 15: ...oblem The same device designations have been maintained on different controls but the wire numbers may vary Refer to the elementary and wiring diagrams for your specific control The wire numbers shown on the elementary diagram will have identical numbers on the corresponding wiring diagrams for a specific vehicle but these numbers may be different from the numbers referenced in this publication WA...

Page 16: ...r Handset FU3 KEY SWITCH P1 P2 NEG CHARGER SWITCH TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 04 Emergency brake switch is open This status code will be displayed when P13 is greater than 2 5 volts MEMORY RECALL NO CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Traction Controller SYMPTOM Control will not operate buzzer will sound POSSIBLE CAUSE Emergency ...

Page 17: ...ITCH TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 06 The accelerator pedal is depressed with no direction selected This status code will be displayed when the accelerator voltage at P7 1 4V and no direction is selected P4 and P5 are both less than 50 of battery volts MEMORY RECALL NO CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Traction Controller SYMPTOM...

Page 18: ...P5 P11 P10 P15 TACHOMETER P14 P16 P7 P9 P13 P8 P6 RED GREEN BLACK PLUG 23 PIN EMERGENCY BRAKE SWITCH P21 MOTOR THERMAL SWITCH TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 09 Both the forward and reverse switches are closed at the same time This status code will be displayed when P4 and P5 are greater than 50 of battery volts MEMORY RECALL NO CORRECTIVE ACTIONS TROUBLE SHOO...

Page 19: ...egative Voltage should be zero If not replace the control L TURF SPEED LIMIT SWITCH CHARGER SWITCH KEY SWITCH START SWITCH DIRECTIONAL SWITCH FORWARD REVERSE BUZZER ACCEL POT P1 P2 P3 P4 P5 P11 P10 P15 TACHOMETER P14 P16 P7 P9 P13 P8 P6 RED GREEN BLACK PLUG 23 PIN EMERGENCY BRAKE SWITCH P21 MOTOR THERMAL SWITCH TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 15 Battery voltag...

Page 20: ...djustment for battery being used See Handset instruction sheet for details Adjust to proper settings Check maximum battery volts at P1 NEG FU3 KEY SWITCH P1 P2 NEG CHARGER SWITCH TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 21 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 NO COR...

Page 21: ...ontroller SYMPTOM Control will not operate POSSIBLE CAUSE Defective control Replace controller unit NO GRAPHIC FOR THIS STATUS CODE TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 24 Motor field current is too high on when the key switch is turned on This status code will be displayed when the current draw in the motor field is too high on start up MEMORY RECALL NO CORRECTIVE...

Page 22: ...ace controller unit FU3 KEY SWITCH P1 P2 NEG CHARGER SWITCH TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 41 Shorted thermal protector TP or transistor over temperature This status code will be displayed when the voltage at the thermal protector is too low MEMORY RECALL YES CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Traction Controller SYMPTOM Reduced or...

Page 23: ...trol operation and it will display a value for the motor amps that is greater than 138 corresponding to 2 7V triggering this status code TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 43 Motor armature offset voltage is too low This status code will be displayed when the value of motor amps is less than 117 corresponding to 2 3 volts with no current flowing in the motor circ...

Page 24: ...s and closes then can only be closed by opening and closing the key switch POSSIBLE CAUSE Defective control Replace controller unit NO GRAPHIC FOR THIS STATUS CODE TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 45 Armature transistor did not turn on properly This status code will be displayed when during control operation the armature transistor fails to turn on properly Thi...

Page 25: ...for short circuit from the motor armature to the frame of the vehicle Defective control Replace controller unit POWER CONNECTIONS TO CONTROL POS A1 F1 NEG A2 F2 FIELD ARMATURE A1 A2 A1 A2 F2 F1 BATT FU1 LINE 400A FU3 10A TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 49 Motor field current is too low during the run mode This status code will be displayed when the current dra...

Page 26: ...use for open circuit condition Replace fuse if necessary Defective control Replace controller unit POWER CONNECTIONS TO CONTROL POS A1 F1 NEG A2 F2 FIELD ARMATURE A1 A2 A1 A2 F2 F1 BATT FU1 LINE 400A FU3 10A TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 57 Controller motor current sensor input is too low during running This status code will be displayed when the voltage inp...

Page 27: ...s accessories are suppressed Excessive motor and control heating control is in thermal cutback L TURF SPEED LIMIT SWITCH CHARGER SWITCH KEY SWITCH START SWITCH DIRECTIONAL SWITCH FORWARD REVERSE BUZZER ACCEL POT P1 P2 P3 P4 P5 P11 P10 P15 TACHOMETER P14 P16 P7 P9 P13 P8 P6 RED GREEN BLACK PLUG 23 PIN EMERGENCY BRAKE SWITCH P21 MOTOR THERMAL SWITCH TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE O...

Page 28: ...the voltage at 1C exceeds 96 volts during motoring MEMORY RECALL YES CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Traction Controller SYMPTOM Line contactor opens and closes then opens and can only close by opening and closing the key switch POSSIBLE CAUSE Defective control Replace controller unit POWER CONNECTIONS TO CONTROL POS A1 F1 NEG A2 F2 FIELD ARMATURE A1 A2 A1 A2 F2 F1 B...

Page 29: ... 36 48 volts is auto ranging Selection of Card Operation Type At the transistor control traction card unplug the Y plug if the dash display is in use and plug in the Handset to the plug location Y on the control card After installing the Handset tool plug the battery in and turn the key switch on The chart at the right details the start up display sequence that will occur START UP DISPLAY SEQUENCE...

Page 30: ...hicle can now be operated with the Handset connected or the Handset can be disconnected before operation NOTE You can return to the segment check mode at any time by holding down the ESC key until 8888 appears in the display Section 5 3 2 Status Code Scrolling The SX family of controllers furnishes a function register that contains the last 16 stored status codes that shut down vehicle operation a...

Page 31: ...etting 203575 11290 Setting 18 FUNCTION 2 CREEP SPEED Push 2 This function allows for the adjustment of the creep speed of the vehicle when the accelerator potentiometer is at its minimum value and the start switch is closed Range 2 to 15 on time Set 0 to 255 Resolution 0 047 per set unit Example Setting of 205 205x0 047 2 11 on time Important Note The function is used to optimize motor and contro...

Page 32: ...imum field current in order to obtain the maximum torque of the motor Range 0 to 32 amps Set 51 to 255 Resolution 0 16 amps per set unit Example Setting of 251 251 51 x0 16 32 amps CAUTION Do not set this function to a value less than 51 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 d...

Page 33: ...ower terminals 3 Calculate voltage drop VDrop as follows VDrop VO VL 4 Use the table below to determine the appropriate setting using the calculated VDrop as a reference INTERNAL RESISTANCE COMPENSATION TABLE Setting VDrop Setting VDrop 2 11 44 17 1 34 3 7 60 18 1 27 4 5 72 19 1 20 5 4 57 20 1 14 6 3 81 21 1 09 7 3 27 22 1 04 8 2 86 23 0 99 9 2 54 24 0 95 10 2 28 25 0 91 11 2 08 26 0 88 12 1 90 27...

Page 34: ...ill 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 FUNCTION 22 ODOMETER CALIBRATION Push CONT 7 This function is used to adjust the number of tachometer pulses divided by 32 that will equal 1 MPH Range 0 to 255 pulses Setting 0 to 255 Example to calculate setting RR Rolling Radius Inches...

Page 35: ... determine which stored status code was the last one recorded read the number stored in Function 28 Using the Memory Map for your logic card match the stored status code pointer number the number shown in bold italics in the HS Handset number column on the memory map with the number obtained from Function 28 This will be the last stored status code recorded Note When scrolling through the stored s...

Page 36: ...housands and hundreds of miles or kilometers on the odometer Range 0 to 99 Set 0 to 99 Example 999999 9 Miles or Kilometers FUNCTION 51 ODOMETER HUNDRED THOUSANDS AND TEN THOUSANDS OF MILES OR KILOMETERS SET Push CONT 4 This function allows for the adjustment of the thousands and hundreds of miles or kilometers on the odometer Range 0 to 99 Set 0 to 99 Example 999999 9 Miles or Kilometers ...

Page 37: ...t setting is adjusted by Function 24 This function sets the armature current at which minimum field current will achieved The ratio setting is adjusted by Function 26 This function sets the ratio between armature and field current when transitioning from minimum field to maximum field current Setting is the value of field current changed for each 100 amps of armature current changed The full load ...

Page 38: ... Discharge Indication and Maintenance Required Code The four LED s above the symbols indicate the active readout mode Connections Connections are made to the Dash Display with five 5 22 gage wires to Plug Y of each control Shielded cable is required to eliminate signal interference Part Number Reference AMP 102241 3 Dash Display mating plug AMP 1 87195 8 Dash Display mating pin 44A723596 G09 Dash ...

Page 39: ...ne Drawings g GE Electric Vehicle Motors Controls PY3 PY4 PY2 PY1 PY5 1 2 3 4 5 5 4 3 2 1 PY3 PY4 PY2 PY1 PUMP TRACTION BACK VIEW OF DISPLAY Wiring connections to Y plugs of Traction Pump controls 2 45 62 2 2 98 75 7 0 19 4 8 2 00 50 8 PUMP TRACTION CONNECTOR OMITTED IF NOT REQUIRED 0 43 10 9 ...

Page 40: ...0 21 21 Armature Current Ramp During Pedal Up Regen HS or PC None 21 22 22 Odometer Calibration HS or PC For DD on power up 22 23 23 Error Compensation HS or PC None 23 24 24 Field Weakening Start or Motor Knee Point HS or PC None 24 25 25 Monitor HS or PC GE Temporary Storage 25 26 26 Ratio of Field to Armature Amps HS or PC None 26 27 27 Hour Meter Minutes HS or PC None 27 28 28 Stored Status Co...

Page 41: ... Only Reset to Zero Only 66 67 Hours Tens Ones 9 PC Only Reset to Zero Only 67 68 Hours Thou Hun 9 PC Only Reset to Zero Only 68 69 36 Stored Status Code 10 PC Only Reset to Zero Only 69 70 BDI 10 PC Only Reset to Zero Only 70 71 Hours Tens Ones 10 PC Only Reset to Zero Only 71 72 Hours Thou Hun 10 PC Only Reset to Zero Only 72 73 38 Stored Status Code 11 PC Only Reset to Zero Only 73 74 BDI 11 PC...

Page 42: ...icable HS or PC None 105 106 57 Not applicable HS or PC None 106 107 58 Not applicable HS or PC None 107 108 59 Not applicable HS or PC None 108 109 60 Not applicable HS or PC None 109 110 61 Not applicable HS or PC None 110 111 62 Not applicable HS or PC None 111 112 63 Not applicable HS or PC None 112 113 Secure HM Tens Ones PC Only OEM Read Only 113 114 Secure HM Thou Hun PC Only OEM Read Only ...

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