GE IC3645SR4R333AS2 Installation And Operation Manual Download Page 27

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DIAGNOSTIC STATUS CODES

SX TRANSISTOR CONTROL

Page

TRACTION

STATUS CODE

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

-57

Controller “motor current sensor” input
too low during running.

This status code will be displayed when the voltage
input from the current sensor is too low during
running.

MEMORY RE ALL

YES

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

Circuits valid

for

Traction

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

-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 RE ALL

YES

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

Circuits valid

for

Traction

Controller

SYMPTOM

Control will not operate.

POSSIBLE CAUSE

Auxiliary control shut down.

Check Auxiliary control for stored faults.

Verify the connection between the master
control P21 and the auxiliary/slave control
P11.

KEY SWITCH

P17 P2 P6

FOOT SW.

P18

1A OR

SP DVR

LEFT CONTROL (MASTER)

P12

LEFT TURN SW.

P10

FU3

DRIVER

BLOCK

FU1

LINE

12V

P21

P11

RIGHT

CONTROL

(SLAVE)

POWER CONNECTIONS

LEFT CONTROL

POS

NEG

FIELD

ARMATURE

48V

May 2000

Summary of Contents for IC3645SR4R333AS2

Page 1: ... normal field service channels Do not contact GE directly for this assistance Table of Contents Copyright by General Electric Company May 2000 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 F...

Page 2: ... 0 TROUBLESHOOTING 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 G...

Page 3: ... Dash Displays 39 6 2 1 Connections 38 6 2 2 Par t Numbers 38 6 2 3 Connector Reference Numbers 39 6 3 Start up Display Sequence 40 6 4 Outline Drawings 40 6 5 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 ...

Page 4: ...nce 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 increases the moto...

Page 5: ...y 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 control of t...

Page 6: ...ts 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 direction ...

Page 7: ...lting PMT should open the Line contactor in the event of a failure Section 2 1 6 On Board Coil Drivers Internal Coil Suppression Coil drivers for the LINE and SP or BYPASS contactors are on board the control card These contactors must have coils rated for the vehicle battery volts Section 2 2 System Protective Override Section 2 3 Diagnostics Section 2 2 1 Static Return to Off SRO Section 2 3 1 Sy...

Page 8: ... 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 adjust...

Page 9: ...ment 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 Argument 06 Fie...

Page 10: ...OUTLINE DRAWINGS ELEMENTARY DRAWINGS AND INPUTS OUTPUTS SX TRANSISTOR CONTROL Page 10 Section 3 2 Outline SX 2 Package Size May 2000 ...

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 OU...

Page 12: ...S 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 ENABL...

Page 13: ... 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 the installat...

Page 14: ...nd higher levels should never encircle each other or run parallel for long distances Medium power signals are designated as level MP These signals consist of It is practical to use existing wire runs or trays as long as the level spacing see section 4 2 2 can be maintained for the full length of the run DC switching signals greater than 15 V Signals with currents greater than 250 mA and less than ...

Page 15: ...he 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 instruction sheets...

Page 16: ... going from the Y plug and the Dash Display or Handset Defective Dash Display or Handset Replace Dash Display or Handset NEG 48V 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 R CALL E NO CORRECTIVE...

Page 17: ...e 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 R CALL E NO CORRECTIVE ACTIONS TROUBLE SHOO...

Page 18: ...SW JACK 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 R CALL E NO CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Traction ...

Page 19: ... than 4 7K ohms Defective control Disconnect wire from P7 Measure voltage from P7 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 batter...

Page 20: ...heck 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 initial key s...

Page 21: ...r 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 MEMORY R CALL...

Page 22: ... 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 too high ME...

Page 23: ...ler 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 MEMORY R CAL...

Page 24: ...VER BLOCK FU1 LINE 12V P21 P11 RIGHT CONTROL SLAVE POWER CONNECTIONS LEFT CONTROL POS A1 F1 NEG A2 F2 FIELD ARMATURE 48V May 2000 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 M...

Page 25: ... 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 R CALL E NO CORRECTIVE ACTIONS TROUBLE SHOOTING DIA...

Page 26: ...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 R CALL E NO CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Traction Controller SYMPTOM Line contactor does not close when capacitor does not precharge POSSIBLE CAUSE D...

Page 27: ...ATUS 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 RE ALL C YES CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Traction Controller SYMPTOM Control will not operate POSSIBLE CAUSE Auxiliary control shut down Check ...

Page 28: ...VER BLOCK FU1 LINE 12V P21 P11 RIGHT CONTROL SLAVE POWER CONNECTIONS LEFT CONTROL POS A1 F1 NEG A2 F2 FIELD ARMATURE 48V May 2000 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 75 Regen fault with capacitor 1C voltage too high This status code will be displayed when the voltage on the capacitor is greater than battery voltage plus 6 volts during the regenerative braking cycl...

Page 29: ...EY 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 May 2000 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 77 Motor current is detected during regenerative braking This status code will be displayed wh...

Page 30: ...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 31: ...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 S...

Page 32: ...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 conta...

Page 33: ...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 the adjustment of the arma...

Page 34: ...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 Resolution...

Page 35: ...he 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 function is used to optimize motor and control performance a...

Page 36: ...GE application engineer To ensure optimum operation of the control this function must be left with zero stored in this register FUNCTION 26 RATIO Push CONT 11 This function sets the ratio between armature and field current when transitioning from 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 Re...

Page 37: ...ould not be adjusted FUNCTION 55 NOT APPLICABLE This function is not applicable to this type of control and should 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 a...

Page 38: ...usted 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 point...

Page 39: ...bols indicate the active readout mode Section 6 2 1 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 Section 6 2 2 Part Number IC3645LXTDD T 3 T Traction Only P Traction Pump 3 Round Face with four display symbols For Custom Dash Displays contact your vehicleOEM g GE Electric Vehicle...

Page 40: ...0 81 3 0 19 4 8 2 00 50 8 PUMP TRACTION CONNECTOR OMITTED IF NOT REQUIRED 0 41 10 4 Section 6 5 Suggested Wiring Configuration for Use of GE Standard Traction Pump Dash Display 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...

Page 41: ...re Current Ramp Up Rate in Regen HS or PC None 18 19 19 Tach Loss Trip Time HS or PC None 19 20 20 Hill Climbing Speed Limit 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...

Page 42: ... 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 43: ...C 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 OE...

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