GE IC3645SR4R404U2 Installation And Operation Manual Download

Page: 59 / 68

ADJUSTABLE FEATURES

SX TRANSISTOR CONTROLS

Page 59

October 1998

This MINIMUM FIELD CURRENT takes effect when the

Mode 4 settings are called for by the Interactive Dash

Display.

FUNCTION 63

MODE 4 RATIO

(Push

CONT

16)

Same as Function 51.

This RATIO takes effect when the Mode 4 settings are

called for by the Interactive Dash Display.

Summary of Contents for IC3645SR4R404U2

Page 1: ...nufacturer through his normal field service channels Do not contact GE directly for this assistance Copyright by General Electric Company October 1998 Section 1 0 INTRODUCTION 4 1 1 Motor Characterist...

Page 2: ...Section 3 0 ORDERING INFORMATION ELEMENTARY AND OUTLINE DRAWINGS 11 3 1 Ordering Information for Separately Excited Controls 11 3 2 Outline SX 2 Package Size 12 3 3 Outline SR 2 Package Size 13 3 4 Du...

Page 3: ...unction Procedures 52 6 3 1 Setup Mode 52 6 3 2 Status Code Scrolling 52 6 3 3 SX Handset Plug Connections Outline Drawing 52 6 4 Setup Functions for Traction Controller 53 59 6 5 Summary of Current L...

Page 4: ...cal 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 therefor...

Page 5: ...he 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...

Page 6: ...sically identical and it is only software that separates a right from a left control or differentiates a control for a dual motor application from one intended for a single motor vehicle As the steer...

Page 7: ...the value set by this function as the accelerator is returned to the creep speed position Maximum plug current is obtained with the accelerator in the top speed position This feature is adjustable by...

Page 8: ...into the seat switch input to allow momentary opening of the seat switch if a bump is encountered Section 2 2 2 Accelerator Volts Hold Off This feature checks the voltage level at the accelerator inp...

Page 9: ...r terminal Section 2 3 3 Hourmeter Readings This feature will display the recorded hours of use of the traction and pump control to the Dash Display each time the key switch is turned off Section 2 3...

Page 10: ...of voltage regulator card This card provides the basic functions required for controlling the pump control optional contactors and PMT functions Battery positive is applied through a main control fuse...

Page 11: ...Number 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...

Page 12: ...OUTLINE DRAWINGS ELEMENTARY DRAWINGS AND INPUTS OUTPUTS SX TRANSISTOR CONTROL Page 12 October 1998 Section 3 2 Outline SX 2 Package Size...

Page 13: ...OUTLINE DRAWINGS ELEMENTARY DRAWINGS AND INPUTS OUTPUTS SX TRANSISTOR CONTROL Page 13 October 1998 Section 3 3 Outline SR 2 Package Size...

Page 14: ...ORWARD SW REVERSE SW BRAKE SW P10 P21 P13 ACC POT STEER ANGLE POT BDI INTERRUPT P14 P15 12V FOR TACH SIGNAL TACH INPUT SIGNAL STEER PUMP FIELD STEER PUMP ARM P11 P18 1A OR SP DVR PLUG RGN OUTPUT P7 P1...

Page 15: ...P9 95 INPUT P8 95 INPUT LINE FU6 P19 P20 P21 P4 P3 93 INPUT 93 INPUT TO TRACTION CARD SPEED LIMIT 1 SPEED LIMIT 2 SPEED LIMIT 3 SPEED LIMIT 4 TO TRACTION P10 BDI PY7 PY12 PY10 PY11 SERIAL RECEIVE SERI...

Page 16: ...OUTPUT 14 TACHOMETER INPUT SIGNAL TRUCK MANAGEMENT OVERTEMP OUTPUT 15 TACHOMETER 12 VOLTS SUPPLY OVERTEMP TMM FAULT 90 16 MOTOR CURRENT COMPENSATION OVERTEMP TMM FAULT 92 17 LINE CONTACTOR DRIVER AND...

Page 17: ...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 Inspectio...

Page 18: ...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 mus...

Page 19: ...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...

Page 20: ...ircuit or loose 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 TRACTION STATUS CODE DESCRIP...

Page 21: ...ve control Replace the controller unit KEY SWITCH P1 P2 P3 BRAKE SWITCH P17 P5 REVERSE SW FORWARD SW P4 SEAT SWITCH P6 L START SW TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION...

Page 22: ...switch potentiometer for proper operation and ohmic value KEY SWITCH BRAKE SWITCH REVERSE SW FORWARD SW SEAT SWITCH L START SW P8 P7 ACCPOT P9 P1 P2 P3 P17 P5 P4 P6 TRACTION STATUS CODE DESCRIPTION O...

Page 23: ...r input circuit Disconnect wire from P7 and measure voltage at wire to negative Should be zero volts for potentiometer type and less than 3 7 volts for solid state type accelerator input P9 P7 P8 ACC...

Page 24: ...nd check wire for short circuit to positive side of directional switch Defective Control Disconnect wires and measure voltage at P4 and P5 Voltage should be less than 60 of battery volts KEY SWITCH P1...

Page 25: ...t wire from P3 Check for short circuit from this wire to battery positive Resistance should be greater than 4 7K ohms Defective control Disconnect wire from P3 Measure voltage from P3 to negative Volt...

Page 26: ...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...

Page 27: ...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 INDICAT...

Page 28: ...e 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 28 Motor field current is too high...

Page 29: ...IBLE CAUSE Control is in thermal cut back Allow control to cool status code should disappear Defective control Replace controller unit NO GRAPHIC FOR THIS STATUS CODE TRACTION STATUS CODE DESCRIPTION...

Page 30: ...when during control operation the armature transistor fails to turn off This will result in a PMT condition MEMORY RECALL YES CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Traction C...

Page 31: ...LEFT CONTROL MASTER TO PUMP CONTROL POSITIVE TO PUMP CONTROL POSITIVE LINE PY11 PY12 SERIAL RECEIVE SERIAL TRANSMIT BRAKE POT FU3 KEY SWITCH BRAKE SW TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE O...

Page 32: ...r 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 cl...

Page 33: ...de will be displayed when the voltage at master PL21 drops below 5V MEMORY RECALL YES CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Traction Controller SYMPTOM Control will not operat...

Page 34: ...AL STEER PUMP FIELD STEER PUMP ARM P11 P18 1A OR SP DVR PLUG RGN OUTPUT LEFT CONTROL MASTER TO PUMP CONTROL POSITIVE TO PUMP CONTROL POSITIVE LINE PY11 PY12 SERIAL RECEIVE SERIAL TRANSMIT BRAKE POT FU...

Page 35: ...card 1 3 4 5 2 7 9 6 8 10 11 12 13 14 15 P16 NEG USER SW SC90 WHEN TMM7A CARD IS USED NEG USER SW WHEN SR Series PUMP CONTROL IS USED TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICAT...

Page 36: ...card 1 3 4 5 2 7 9 6 8 10 11 12 13 14 15 P15 NEG SC92 WHEN TMM7A CARD IS USED NEG USER SW WHEN SR Series PUMP CONTROL IS USED USER SW TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICA...

Page 37: ...card 1 3 4 5 2 7 9 6 8 10 11 12 13 14 15 POS SC93A WHEN TMM7A CARD IS USED POS USER SW P4 USER SW WHEN SR Series PUMP CONTROL IS USED TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICAT...

Page 38: ...card 1 3 4 5 2 7 9 6 8 10 11 12 13 14 15 SC94A WHEN TMM7A CARD IS USED POS P6 USER SW WHEN SR Series PUMP CONTROL IS USED POS USER SW TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICAT...

Page 39: ...0 PY11 SERIAL RECEIVE SERIAL TRANSMIT 5V FROM TRACTION PY10 P17 P18 ACC POT POWER CONNECTIONS POS A1 NEG FIELD ARMATURE FU1 FU5 KEY SWITCH FU6 L 1A A2 1A PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE O...

Page 40: ...EIVE SERIAL TRANSMIT 5V FROM TRACTION PY10 P17 P18 ACC POT POWER CONNECTIONS POS A1 NEG FIELD ARMATURE FU1 FU5 KEY SWITCH FU6 L 1A A2 1A PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATI...

Page 41: ...AM Circuits valid for Pump Controller SYMPTOM Pump contactor will not pick up Status code may alternate between code 123 and code 124 Complete check for code 123 if the problem is not found perform ch...

Page 42: ...20 P21 P4 P3 93 INPUT 93 INPUT TO TRACTION CARD SPEED LIMIT 1 SPEED LIMIT 2 SPEED LIMIT 3 SPEED LIMIT 4 TO TRACTION P10 BDI PY7 PY12 PY10 PY11 SERIAL RECEIVE SERIAL TRANSMIT 5V FROM TRACTION PY10 P17...

Page 43: ...VER TEMP OUTPUT PY8 P15 92 INPUT P12 P9 95 INPUT P8 95 INPUT LINE P19 P20 P21 P4 P3 93 INPUT 93 INPUT TO TRACTION CARD SPEED LIMIT 1 SPEED LIMIT 2 SPEED LIMIT 3 SPEED LIMIT 4 TO TRACTION P10 BDI PY7 P...

Page 44: ...TOM No power to pump motor in control range POSSIBLE CAUSE Defective controller unit Replace control NO GRAPHIC FOR THIS STATUS CODE PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 1...

Page 45: ...or Q1 did not turn on properly This status code is displayed when during pump control operation the transistor fails to turn on MEMORY RECALL YES CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits v...

Page 46: ...S CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 151 Capacitor volts are low before the line contactor closes Internal card function during precharge This status code will be displayed during k...

Page 47: ...A2 1A PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 180 Voltage at capacitor 1C is less than 14 volts This status code will be displayed when the voltage between B and B buss bar...

Page 48: ...Check connection from P17 to Line coil for loose connection Check connection from battery to Line coil for loose connection Check power connection from battery to contactor L Check for blown fuse ele...

Page 49: ...e status code displayed for each input when that point is closed to battery negative or positive as indicated TMM7A Pump Card Control Status Terminal Terminal Code Connect To TB1 P16 92 Neg TB3 P11 91...

Page 50: ...A 2 PA 4 PA 5 PZ 10 PZ 11 PY 10 PA 3 1 A1 1 A1 2 A2 1 A3 1 A2 2 A3 2 TO PY10 TRACTION Section 5 4 4 Typical Brush Wear Sensor Connections For Pump Control ARM 1 BRUSH WEAR SENSOR CONNECTIONS FOR PUMP...

Page 51: ...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 locati...

Page 52: ...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 t...

Page 53: ...25 5 seconds Set 1 to 255 Resolution 0 1 seconds per set unit Example Setting of 20 2 0 seconds C A and 1A Time 2 2 seconds FUNCTION 4 ARMATURE CURRENT LIMIT Push 4 This function allows for the adjust...

Page 54: ...mission of the OEM FUNCTION 9 REGEN BRAKING CURRENT LIMIT Push 9 This function allows for the adjustment of the regen braking current limit Resolution Example Min Max Set Per unit value If set at 20 3...

Page 55: ...sition plug range Pedal position will reduce the plugging current to the current value set by this function as the accelerator is returned to the creep speed position Maximum plug current is obtained...

Page 56: ...should not be adjusted FUNCTION 23 ERROR COMPENSATION Push CONT 8 This function is used to reduce the ripple in the field current due to the interaction between the motor field design and the digital...

Page 57: ...ess than 200 ohms Range 0 1 to 22 0 seconds Set 0 to 255 Resolution 0 084 seconds per set unit Example Setting of 20 1 78 seconds C A and 1 98 seconds 1A time This C A AND 1A TIME takes effect when th...

Page 58: ...led for by the Interactive Dash Display FUNCTION 55 MODE 2 RATIO Push CONT 8 Same as Function 51 This RATIO takes effect when the Mode 2 settings are called for by the Interactive Dash Display FUNCTIO...

Page 59: ...his MINIMUM FIELD CURRENT takes effect when the Mode 4 settings are called for by the Interactive Dash Display FUNCTION 63 MODE 4 RATIO Push CONT 16 Same as Function 51 This RATIO takes effect when th...

Page 60: ...usted by Function 24 This function sets the armature current at which minimum field current will achieved The ratio setting isadjusted by Function 26 This function sets the ratio between armature and...

Page 61: ...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 perfo...

Page 62: ...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...

Page 63: ...e motor will reduce its speed proportionally from top speed at 16o to creep speed at 66o There will also be also available two vehicle speed limit enable points during the transition from 16o to 66o S...

Page 64: ...on 25 to zero using the same procedure as outlined above Section 8 2 270 Degree Potentiometer Input 0 o 1 10V 1 02V 0 78V 1 90V 16 o 2 40V 3 20V 3 28V 3 52V 16 o 66 o 71 o 86 o 66 o 71 o 85 o 1 19V SL...

Page 65: ...Proportional Reduce 1 11 65 57 3 19 65 162 Proportional Reduce 1 83 20 93 2 47 20 126 Proportional Reduce 1 10 66 56 3 20 66 163 Creep Speed 1 82 21 93 2 48 21 127 Proportional Reduce 1 08 67 55 3 22...

Page 66: ...Tens Units HS or PC None 19 20 20 HM Thou Hun HS or PC None 20 21 21 Auto Regen HS or PC None 21 22 22 Mode Reference HS or PC For DD on power up 22 23 23 Field PWM Gain HS or PC None 23 24 24 FW Sta...

Page 67: ...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...

Page 68: ...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...

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