GE IC3645SR4R333AS1 Installation And Operation Manual Download

Page: 39 / 43

INSTALLATION AND OPERATION MANUAL

SX TRANSISTOR CONTROL

Page 39

April 1999

Section 6.3.3 Connector Reference Numbers
AMP#102241-3 Dash Display mating plug

AMP#1-87195-8 Dash Display mating pin

44A723596-G09 Dash Display plug kit

AMP#175965-2 "Y"

Plug

AMP#175180-1 "Y" Plug receptacle

Section 6.4 Start-Up Display Sequence

START-UP DISPLAY SEQUENCE

Key Switch On

Verify Each LED Segment

8 8 8 8

If Maintenance Code

Active

If Maintenance Code

Is Not

Active

Display Code "-99"

For Four Seconds and

Activate Speed Limit

(if selected)

BDI Display or

Blank Display
(no BDI used)

Diagnostics Override

With Fault

Run Mode

BDI Display or

Blank Display
(no BDI used)

Diagnostics Override

With Fault

Key Switch

Off

Display Traction

Hourmeter

For Four Seconds

Display Pump

Hourmeter

For Four Seconds

Section 6.5 Outline Drawings

For the standard GE traction dash display:

GE Electric Vehicle
Motors & Controls

PY3
PY4
PY2
PY1
PY5

PY3
PY4
PY2
PY1

PUMP

TRACTION

BACK VIEW OF DISPLAY

Wiring connections to "Y"
plugs of Traction & Pump
controls.

2.45 (

62.2)

3.20 (81.3)

0.19
(4.8)

2.00 (

50.8)

PUMP

TRACTION

CONNECTOR OMITTED

IF NOT REQUIRED

0.41

(10.4)

Summary of Contents for IC3645SR4R333AS1

Page 1: ...rough his normal field service channels Do not contact GE directly for this assistance Copyright by General Electric Company April 1999 Section 1 0 INTRODUCTION 4 1 1 Motor Characteristics 4 1 2 Solid State Reversing 5 1 3 Flexible System Application 5 1 4 More Features with Fewer Components 5 Section 2 0 FEATURES OF SX FAMILY OF MOTOR CONTROLLERS 6 2 1 Performance 6 2 1 1 Oscillator Card Features...

Page 2: ... AND DIAGNOSTIC STATUS CODES 13 4 1 General Maintenance Instructions 13 4 2 Cable Routing and Separation 13 4 2 1 Application Responsibility 13 4 2 2 Signal Power Level Definitions 13 4 2 2 a Low Level Signals Level L 13 4 2 2 b High Level Signals Level H 14 4 2 2 c Medium Power Signals Level MP 14 4 2 2 d High Power Signals Level HP 14 4 2 3 Cable Spacing Guidelines 14 4 2 3 a General Cable Spaci...

Page 3: ...isplays 38 6 3 1 Connections 38 6 3 2 Par t Numbers 38 6 3 3 Connector Reference Numbers 39 6 4 Start up Display Sequence 39 6 5 Outline Drawings 39 6 6 Suggested Wiring Configuration for Use of GE Standard Traction Pump Dash Display Motor Traction System 40 Section 7 0 MEMORY MAPS 41 7 1 Typical Memory Map for DM Proportioning Control 41 43 Table of Contents Continued ...

Page 4: ...l performance curves of Figure 1 the high 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 increase...

Page 5: ...mplished by placing a resistor in parallel with the field 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 co...

Page 6: ...r and limits the average current to a value set by Function 4 and Function 8 of the Handset The C L setting is based on the maximum thermal rating of the control Because of the flyback current through 3REC the motor current is usually greater than battery current except at 100 ON time Section 2 1 3 Braking Section 2 1 3 a Regenerative Braking to Zero Speed Slow down is accomplished when reversing ...

Page 7: ... 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 Section 2 2 4 Thermal Protector TP This temperature sensit...

Page 8: ...f a Light Emitting Diode LED display and a keyboard for data entry Note for ordering purposes a separate Handset part is required for SX controls Features and functions Monitor existing system status codes for both traction and pump controls Monitor intermittent random status codes Monitor battery state of charge if available Monitor hourmeter reading on traction and pump controls Monitor or adjus...

Page 9: ...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 10: ...OUTLINE DRAWINGS ELEMENTARY DRAWINGS AND INPUTS OUTPUTS SX TRANSISTOR CONTROL Page 10 April 1999 Section 3 2 Outline SX 2 Package Size ...

Page 11: ... P6 P3 P4 P5 FOOT SW DIRECTION SW TRAVEL ENABLE SW P21 P13 ACC POT P14 P11 P18 1A OR SP DVR P7 P6 P2 P1 P3 P4 P5 LEFT CONTROL MASTER RIGHT CONTROL SLAVE P11 P13 LINE P16 PY7 12V 48V P16 PY7 P21 P12 LEFT TURN SW P12 RIGHT TURN SW B P10 3 1 2 JACK RABBIT SW BOOM UP SW LEFT TACH TILT SW P14 RIGHT TACH PIN 1 2 3 4 5 6 7 8 9 10 11 12 DESCRIPTION CLOCK OUT TMM7A POWER SUPPLY 5V Y PLUG CONNECTIONS DATA O...

Page 12: ...TS SUPPLY 10 BRAKE DRIVER SIGNAL 11 CROSS TALK SEND 12 TURN SWITCH 13 TILT SENSOR 14 TACHOMETER INPUT SIGNAL 15 TACHOMETER 12 VOLTS SUPPLY 16 MOTOR CURRENT COMPENSATION 17 LINE CONTACTOR DRIVER AND SUPPRESSION 18 N A 19 N A 20 N A 21 CROSS TALK RECEIVE 22 SERIAL RECEIVE 23 SERIAL TRANSMIT MOTOR TRACTION Y PLUG PIN INPUT OUTPUT DESCRIPTION 1 CLOCK OUT DASH DISPLAY 4 2 DATA OUT DASH DISPLAY 3 3 ENAB...

Page 13: ... discharged with periodic equalizing charges Visual inspection of GE contactors contained in the traction and pump systems is recommended to occur during every 160 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 welding be performed on the vehicle after th...

Page 14: ...on 4 2 3 a outlined below Section 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 noted by exception Interco...

Page 15: ...ollowing 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 location and then reading the status code With the status code number follow the procedures outlined in the status code instruct...

Page 16: ...ose connection going from the Y plug and the Dash Display or Handset Defective Dash Display or Handset Replace Dash Display or Handset NEG FU3 KEY SWITCH P1 P2 P6 FOOT SWITCH 12V TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 01 No foot switch or deadman switch input no voltage to P6 This status code will be displayed when P6 is less than 12 battery volts MEMORY RECALL NO CO...

Page 17: ...ol Replace the controller unit KEY SWITCH P1 P2 P3 P17 P5 TRAVEL ENABLE SW DIRECTIONAL SW P4 FOOT SW P6 L BOOM SW JACK RABBIT SW TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 03 Travel enable switch is closed on initial power up This status code will be displayed when P5 is greater than 12 of battery voltage at initial key switch on MEMORY RECALL NO CORRECTIVE ACTIONS TROUB...

Page 18: ...RABBIT SW TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 07 Accelerator input voltage too high on power up after initial key switch closure This status code will be displayed when the accelerator input voltage at P7 is higher than 3 7 volts and travel enable switch is selected MEMORY RECALL NO CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Traction Controller...

Page 19: ...s Defective control Disconnect wire from P7 Measure voltage from TB1 to negative Voltage should be greater than 4 5 volts if not replace control P7 P8 ACC POT P9 P7 P8 ACC POT TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 09 The travel enable switch is open and the directional switch is closed This status code will be displayed when P5 is less than 12 of battery volts and P...

Page 20: ...settings Check minimum battery volts at P1 and NEG NEG FU3 P1 NOMINAL BATTERY VOLTAGE MINIMUM LIMIT VOLTS AT 1 95 VDC PER CELL 24 80 48 72 36 23 4 78 0 46 8 70 2 35 1 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 16 Battery voltage is too high or control card is mis adjusted This status code will be displayed when the battery volts are greater than 2 4 volts per cell at ini...

Page 21: ... Controller 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 high on start up in the forward direction This status code will be displayed when the current draw in the motor field is too high at start up in the forward direction MEM...

Page 22: ...oltage may be dropping below 10 Volts DC under load Loose connection at P1 Insure that the wire connection at P1 is tight Defective control Replace controller unit NEG FU3 KEY SWITCH P1 P2 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 41 Open thermal protector TP or transistor over temperature This status code will be displayed when the voltage at the thermal protector is t...

Page 23: ...on Controller 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 43 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 ME...

Page 24: ... 2 FU3 DRIVER BLOCK FU1 LINE 12V P21 P11 RIGHT CONTROL SLAVE POWER CONNECTIONS LEFT CONTROL POS A1 F1 NEG A2 F2 FIELD ARMATURE 48V 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 This will result in a PMT condition ...

Page 25: ...NE 12V P21 P11 RIGHT CONTROL SLAVE POWER CONNECTIONS LEFT CONTROL POS A1 F1 NEG A2 F2 FIELD ARMATURE 48V TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 47 The PMT enable signal from the opposite control dropped below 5V during motoring This status code will be displayed when the voltage at PL2 21 drops below 5V during motoring MEMORY RECALL NO CORRECTIVE ACTIONS TROUBLE SHOO...

Page 26: ... CAUSE OF STATUS INDICATION 51 Capacitor volts are low before the line contactor closes This status code will be displayed during key on when the capacitor volts is less than 85 of battery volts at initial key switch on MEMORY RECALL NO CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Traction Controller SYMPTOM Line contactor does not close when capacitor does not precharge POSSIBLE...

Page 27: ...TION OF STATUS CAUSE OF STATUS INDICATION 68 The PMT enable signal from the opposite control from the one displaying the 68 fault code drops below 5V This status code will be displayed when the voltage at PL21 drops below 5V MEMORY RECALL YES CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Traction Controller SYMPTOM Control will not operate POSSIBLE CAUSE Auxiliary control shut dow...

Page 28: ...V 72 80V KEY SWITCH L P1 P17 P2 P6 FOOT SW P18 1A OR SP DVR LEFT CONTROL MASTER P12 LEFT TURN SW B P10 3 1 2 FU3 DRIVER BLOCK FU1 LINE 12V P21 P11 RIGHT CONTROL SLAVE POWER CONNECTIONS LEFT CONTROL POS A1 F1 NEG A2 F2 FIELD ARMATURE 48V TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 77 Motor current is detected during regenerative braking This status code will be displayed w...

Page 29: ...YES CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Traction Controller SYMPTOM Control will not operate POSSIBLE CAUSE Bad tachometer Replace tachometer Lost wire from tachometer Verify tach connections Motor has stalled Defective control Replace controller unit KEY SWITCH L P1 P17 P2 P6 FOOT SW P18 1A OR SP DVR LEFT CONTROL MASTER P12 LEFT TURN SW B P10 3 1 2 FU3 DRIVER BLOCK FU1 ...

Page 30: ... Voltage 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 ...

Page 31: ... a blank display if BDI is not used and there are no fault codes The vehicle 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 cont...

Page 32: ... HIGH SPEED MODE Push 3 This function allows for the adjustment of the rate of time it takes for the control to accelerate to 100 applied battery voltage to the motor on hard acceleration in high speed mode Range 0 1 to 25 5 seconds Set 1 to 255 Resolution 0 1 seconds per set unit Example Setting of 20 2 0 seconds C A 2 2 seconds FUNCTION 4 ARMATURE CURRENT LIMIT Push 4 This function allows for th...

Page 33: ... 6 28 amps 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 FUNCTION 9 REGEN BRAKING CURRENT LIMIT Push 9 This function allows for the adjustment of the regen braking current limit Resolutio...

Page 34: ...he Battery Discharge Indication function In order for the BDI to operate properly the setting as shown in the table must be entered Battery Volts Set Units 24 volts Between 0 and 31 36 volts Between 32 and 44 48 volts Between 45 and 69 36 48 volts Between 184 and 250 No BDI Between 251 and 255 FUNCTION 16 FIELD RAMP DOWN RATE WHILE IN REGENERATIVE BRAKING MODE Push CONT 1 Important Note This funct...

Page 35: ... minimum field to maximum field current The setting represents the quantity of field current changed for each 1 amp of armature current changed Max Max Resolution Example Fld Ref Change Set Per unit value If set at 5 20 24 0 to 10 0 024 amps 0 12 amps 30 24 0 to 10 0 024 amps 0 12 amps 40 27 0 to 10 0 027 amps 0 135 amps 50 48 0 to 10 0 048 amps 0 24 amps 60 48 0 to 10 0 048 amps 0 24 amps FUNCTIO...

Page 36: ...hould not be adjusted FUNCTION 56 NOT APPLICABLE This function is not applicable to this type of control and should not be adjusted FUNCTION 57 NOT APPLICABLE This function is not applicable to this type of control and should not be adjusted FUNCTION 58 NOT APPLICABLE This function is not applicable to this type of control and should not be adjusted FUNCTION 59 NOT APPLICABLE This function is not ...

Page 37: ...justed 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 transition poin...

Page 38: ... and 4 Speed Limit levels These interactive modes are pre set using the Handset Functions 48 63 or a personal computer Functions 97 112 This feature allows the operator to select the best vehicle performance for changing factory task conditions The table below outlines the normal logic flow for pre setting the four interactive modes Value Logic Table Mode 1 Turtle Mode 2 Mode 3 Mode 4 Rabbit C A M...

Page 39: ...ode 99 For Four Seconds and Activate Speed Limit if selected BDI Display or Blank Display no BDI used Diagnostics Override With Fault Run Mode BDI Display or Blank Display no BDI used Diagnostics Override With Fault Key Switch Off Display TractionHourmeter For Four Seconds Display PumpHourmeter For Four Seconds Section 6 5 Outline Drawings For the standard GE traction dash display g GE Electric Ve...

Page 40: ... with Dual Motor Traction System 1 2 3 4 5 5 4 3 2 1 BACK VIEW OF DISPLAY T P PY3 PY4 PY2 PY1 PY5 Y PLUG CONNECTIONS LEFT CONTROL CONNECTIONS RIGHT CONTROL CONNECTIONS Y PLUG CONNECTIONS BARE WIRE NEGATIVE CONNECTION PY1 PY2 PY4 PY3 BARE WIRE NEGATIVE CONNECTION NOTE USE SHIELDED CABLE FOR DASH DISPLAY CONNECTIONS WITH THE BARE WIRE CONNECTED TO PY4 BATTERY NEGATIVE ...

Page 41: ... PC None 17 18 18 Armature Current Ramp Up Rate in Regen HS or PC None 18 19 19 Not Used HS or PC None 19 20 20 Not Used HS or PC None 20 21 21 Not Used HS or PC None 21 22 22 Not Used HS or PC For DD on power up 22 23 23 Error Compensation HS or PC None 23 24 24 FW Start HS or PC None 24 25 25 Monitor HS or PC GE Temporary Storage 25 26 26 Ratio HS or PC GE Temporary Storage 26 27 27 Not Used HS ...

Page 42: ...C 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 P...

Page 43: ...PC None 106 107 58 Dash Display Min Fld 3 HS or PC None 107 108 59 Dash Display If Im Ratio 3 SL 3 HS or PC None 108 109 60 Dash Display CA 4 HS or PC None 109 110 61 Dash Display FWS 4 Ratio2 4 HS or PC None 110 111 62 Dash Display Min Fld 4 HS or PC None 111 112 63 Dash Display If Im Ratio 4 SL 4 HS or PC None 112 113 Secure HM Tens Ones PC Only OEM Read Only 113 114 Secure HM Thou Hun PC Only O...

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