GE IC3645SR4T405E1 Installation And Operation Manual Download Page 31

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DIAGNOSTIC STATUS CODES

IT TRANSISTOR CONTROL

Page

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
draw in the motor field is too low during the run mode.

MEMORY RECALL

YES

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

Circuits valid

for

Traction

Controller

SYMPTOM

Control will only operate for a second
or two before shutting down.

POSSIBLE CAUSE

If the fault code is intermittent, verify
that the accelerator pot is adjusted
correctly.

Check for open motor field coils or
loose or intermittent field connections,
or open F1 or F2 connections.

FU5

KEY SWITCH

SEAT

T SW

RWA

RD S

EVER

SE SW

BRAKE SW.

P17

P2 P6

P10

P21

ACC POT

BUZZER

P18

P15

PLUG PY

CONNECTIONS

OSCILLATOR CARD

+5V

NEG

PY11

PY12

P14 P20

TACH

P12

P22

P23

-232

FU1

POWER

CONNECTIONS

POS

NEG

ATU

FU6

LINE

TRACTION

STATUS CODE

DESCRIPTION OF STATUS

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 voltage is less than 85% of
battery volts at initial key switch on.

MEMORY RECALL

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

Circuits valid

for

Traction

Controller

SYMPTOM

Line contactor does not close when
capacitor does not precharge.

POSSIBLE CAUSE

Defective control fuse.

•

Check control fuse for open circuit.
Replace fuse, if necessary.

Loose connector at P1.

•

Verify connection at P1.

Verify that hydraulic pump motor
contactor tips are not welded.
Verify that no external load has been
added to the open side of line
contactor tips.

Note: Repeated “charging/discharging”
the capacitors during troubleshooting
will cause status code 51.

FU5

KEY SWITCH

SEAT

T SW

RWA

RD S

EVER

SE SW

BRAKE SW.

P17

P2 P6

P10

P21

ACC POT

BUZZER

P18

P15

PLUG PY

CONNECTIONS

OSCILLATOR CARD

+5V

NEG

PY11

PY12

P14 P20

TACH

P12

P22

P23

-232

FU1

POWER

CONNECTIONS

POS

NEG

ATU

FU6

LINE

November 2005

Summary of Contents for IC3645SR4T405E1

Page 1: ...he matter to the OEM vehicle manufacturer through his normal field service channels Do not contact GE directly for this assistance General Electric Company November 2005 Table of Contents 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 IT FAMILY OF MOTOR CONTROLLER...

Page 2: ... 10 3 2 Outline IT400 Package Size 11 3 3 Traction Elementary 12 3 4 Traction Control Input Output List 13 Section 4 0 TROUBLESHOOTING AND DIAGNOSTIC STATUS CODES 14 4 1 General Maintenance Instructions 14 4 2 Cable Routing and Separation 14 4 2 1 Application Responsibility 14 4 2 2 Signal Power Level Definitions 14 4 2 2 a Low Level Signals Level L 15 4 2 2 b High Level Signals Level H 15 4 2 2 c...

Page 3: ...8 5 3 2 Status Code Scrolling 38 5 3 3 IT Handset Plug Connections Outline Drawing 38 5 4 Setup Functions for Traction Controller 39 44 5 5 Summary of Current Limit Adjustments 45 Section 6 0 DASH DISPLAYS 46 6 1 Application 46 6 2 Standard Dash Displays 46 6 3 Interactive Dash Displays 46 6 4 Start up Display Sequence 47 6 5 Outline Drawings 47 Section 7 0 MEMORY MAPS 48 7 1 Traction Control 48 5...

Page 4: ...NT ARMATURECURRENT Figure1 SPEED TORQUE As shown in from the typical 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 wit...

Page 5: ...ure control circuit typically operates at 12KHZ to 15KHZ a frequency range normally above human hearing This high frequency coupled with the elimination of directional contactors provides very quiet vehicle operation The field control circuits typically operate at 2 KHZ The line contactor is normally the only contactor required for the shunt motor traction circuit This contactor is used for both p...

Page 6: ...o 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 by providing a small amo...

Page 7: ...signed to require the driver to return the directional lever to the neutral position anytime he leaves the vehicle and returns Additionally if the seat switch or key switch is opened the control shuts off and cannot be restarted until the directional lever is returned to neutral A time delay of approximately 2 seconds is built into the seat switch input to allow momentary opening of the seat switc...

Page 8: ...ng the Handset into the y plug of the logic card Features and functions With the status code number follow the procedures outlined in DIAGNOSTIC STATUS CODES to determine the problem and a solution Monitor existing system status codes for both traction and pump controls Monitor intermittent random status codes Note The Status Code Instruction Sheets do not claim to cover all possible causes of a d...

Page 9: ...vehicle performance for changing tasks or conditions Section 2 3 7 Circuit Board Coil Driver Modules Coil drivers are internal to the control card and are the power devices that operate the Line contactor and brake coils On command from the control card these drivers initiate opening and closing the coils All driver modules are equipped with reverse battery protection such that if the battery is c...

Page 10: ...l Pump SH Separately Excited Control Plugging SR Separately Excited Control Regen to Zero Argument 03 Operating Voltage 1 120 volts 4 48 volts 2 24 volts 5 36 48 volts 3 36 volts 6 24 36 volts 7 72 80 volts Argument 04 Package Size D 6 86 X 6 67 R 6 86 X 8 15 T 9 63 X 7 05 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 11: ...OUTLINE DRAWINGS ELEMENTARY DRAWINGS AND INPUTS OUTPUTS IT TRANSISTOR CONTROL Page 11 November 2005 ...

Page 12: ...EY SWITCH L P1 P17 P2 P6 P9 P3 P7 P8 P4 P5 SEAT SW CHARGER START SW FORWARD SW REVERSE SW BRAKE SW P10 P21 ACC POT BUZZER P18 ELEMENTARY DRAWING FOR SEPARATELY EXCITED MOTOR CONTROLLER WITH SOLID STATE REGENERATIVE BRAKING LINE P15 PLUG PY CONNECTIONS B P1 P5 P4 P2 FU7 TO ACCESSORIES FU6 P3 OSCILLATOR CARD A2 A1 5V NEG PY11 PY12 P14 P20 TACH P12 SW1 SW2 P22 P23 RS 232 November 2005 ...

Page 13: ...ER 11 PLUG RGN OUTPUT SIGNAL 12V 1 0V REGEN 12 SW1 BV 13 NOT USED 14 TACH INPUT 15 TACH 12V 16 NOT USED 17 LINE CONTACTOR DRIVER AND SUPPRESSION 18 BRAKE CTR DRIVER AND SUPPRESSION 19 NOT USED 20 TACH NEGATIVE 21 SW2 22 SERIAL RECEIVE DASH DISPLAY 23 SERIAL TRANSMIT DASH DISPLAY MOTOR PROPORTIONING Y PLUG PIN INPUT OUTPUT DESCRIPTION 1 CLOCK OUT 2 DATA OUT 3 ENABLE OUT 4 NEGATIVE 5 5V SUPPLY 6 CON...

Page 14: ...nufacturer before hipotting Use a lead acid battery with the voltage and ampere hour rating specified for the vehicle Follow normal battery maintenance 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 rec...

Page 15: ...e wire bundles as defined in the different classes identified above Intermixing cannot be allowed unless noted by exception 4 2 2 b High Level Signals Level H Interconnecting wire runs should carry a level designation High level signals are designated as level H These signals consist of If wires are the same level and same type signal group those wires from one location to any other location toget...

Page 16: ... operation 1 Disconnect plug from controller or mating plug 2 Locate the plug that contains the socket female terminals Maintenance needs only to be performed on the plug containing the socket female type terminals Reconnecting the plugs will lubricate the pin male terminals Fretting occurs during microscopic movement at the contact points of the connection This movement exposes the base metal of ...

Page 17: ...plication of thermal compound as detailed in the following paragraphs must be completed during the installation of GE controls There are many techniques for applying thermal compound and we have outlined one approach below that has shown to apply a consistent thickness of material Section 4 4 1 Necessary Tools GE recommends the use of the following components or equivalent substitutions during the...

Page 18: ...ll add to the overall thermal resistance of the interface Section 4 4 5 Mounting the GE Control a Place the control unit with desired orientation on mounting plate with mounting holes aligned To avoid these air pockets and improve thermal conductivity thermal compound must be applied between the GE control base plate and the vehicle mounting surface The function of this compound is to conform to s...

Page 19: ...ntrol for service careful consideration must be given to removing the old thermal compound from the control and mounting surface prior to replacement of the unit Never re use thermal compound Use a putty knife or similar straight edge to carefully remove all thermal compound residue without damaging either mounting surface Flush the surfaces with a liquid de greaser or parts cleaner and allow them...

Page 20: ...om the control and the Dash Display or Handset Defective Dash Display or Handset Replace Dash Display or Handset NEG FU3 KEY SWITCH P1 P2 FU5 November 2005 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 01 No seat switch or charger switch input no voltage to P6 This status code will be displayed when P6 is less than 50 battery volts MEMORY RECALL NO CORRECTIVE ACTIONS TROUBL...

Page 21: ...ontrol Replace the controller unit KEY SWITCH P1 P2 P3 P17 P5 REVERSE SW FORWARD SW P4 SEAT CHARGER SWITCH P6 L START SW TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 03 Reverse directional switch is closed on initial power up This status code will be displayed when P5 is greater than 60 of battery voltage at initial key switch on MEMORY RECALL NO CORRECTIVE ACTIONS TROUBLE...

Page 22: ...3 P17 P5 P4 P6 NEG KEY SWITCH TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 06 Accelerator depressed with no direction selected This status code will be displayed when P4 and P5 are less than 60 of battery volts and P7 is less than 2 5 volts MEMORY RECALL NO CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Traction Controller SYMPTOM Control will not operate P...

Page 23: ...ator 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 P7 ACC POT P9 P8 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 08 Accelerator input voltage too low on power up after initial key switch closure This status code will be displayed when t...

Page 24: ...ts KEY SWITCH P1 P2 P3 P17 P5 REVERSE SW FORWARD SW P4 SEAT CHARGER SWITCH P6 L START SW TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 11 Start switch closed on power up after initial key switch closure This status code will be displayed when P3 is greater than 60 of battery voltage when the key switch is closed MEMORY RECALL NO CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM C...

Page 25: ...k minimum battery volts at P1 and NEG NEG FU5 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 swit...

Page 26: ... RS 232 FU1 POWER CONNECTIONS POS A1 F1 NEG A2 F2 FIELD ARMATURE A2 A1 FU6 LINE 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 offset voltage is too high at start up in the forward direction MEMORY RECALL NO CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits vali...

Page 27: ...FU5 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 28 Motor field current is too high during the run mode This status code will be displayed when the current draw in the motor field is sustained above a preset limit for longer than 70 seconds MEMORY RECALL YES CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Traction Controller SYMPTOM Control will not operate ...

Page 28: ...ICATIVE OF A CONTROL ISSUE THIS STATUS CODE MAY INDICATE AN APPLICATION ISSUE DISPLAY OF THIS STATUS CODE SHOULD NOT TRIGGER THE RETURN OF A CONTROL FOR REPAIR OR REPLACEMENT TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 42 Motor armature offset voltage is too high This status code will be displayed when the voltage at the current sensor input is greater than 2 6 volts with...

Page 29: ... RS 232 FU1 POWER CONNECTIONS POS A1 F1 NEG A2 F2 FIELD ARMATURE A2 A1 FU6 LINE TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 44 Armature transistor did not turn off properly This status code will be displayed 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 DIAG...

Page 30: ...TOR CARD 5V NEG PY11 PY12 P14 P20 TACH P12 P22 P23 RS 232 FU1 POWER CONNECTIONS POS A1 F1 NEG A2 F2 FIELD ARMATURE A2 A1 FU6 LINE TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 46 Look Ahead test for A2 volts less than 12 of battery volts This status code will be displayed when the voltage at A2 is less than 12 of battery volts MEMORY RECALL NO CORRECTIVE ACTIONS TROUBLE SHO...

Page 31: ...A2 A1 FU6 LINE TRACTION STATUS CODE DESCRIPTION OF STATUS 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 voltage 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 contacto...

Page 32: ...32 FU1 POWER CONNECTIONS POS A1 F1 NEG A2 F2 FIELD ARMATURE A2 A1 FU6 LINE TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 63 The voltage at P18 brake input less than 12 of battery volts This status code will be displayed when the control detects the voltage at the brake coil driver P18 is less than 12 of the battery voltage MEMORY RECALL YES CORRECTIVE ACTIONS TROUBLE SHOOTI...

Page 33: ...CTIONS POS A1 F1 NEG A2 F2 FIELD ARMATURE A2 A1 FU6 LINE TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 65 The line coil current is too high during the run mode This status code will be displayed when the current 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 MEMORY RECA...

Page 34: ...SE SW BRAKE SW B SW1 SW2 P1 P17 P2 P6 P9 P3 P7 P8 P4 P5 P10 P21 ACC POT BUZZER P18 P15 PLUG PY CONNECTIONS OSCILLATOR CARD 5V NEG PY11 PY12 P14 P20 TACH P12 P22 P23 RS 232 FU1 POWER CONNECTIONS POS A1 F1 NEG A2 F2 FIELD ARMATURE A2 A1 FU6 LINE TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 67 The armature current exceeds the armature transistor limit This status code will be...

Page 35: ... NEG A2 F2 FIELD ARMATURE A2 A1 FU6 LINE TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 76 Capacitor 1C voltage too high This status code will be displayed when the voltage on the capacitor goes above limit voltage during the regenerative braking cycle MEMORY RECALL YES CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Traction Controller SYMPTOM Line contactor ...

Page 36: ...TION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 82 When armature motor current is greater than 400 amps for more than 3 5 sec the armature motor current will be turned off This status code will be displayed when the armature motor current exceeds 400 amps for 3 5 sec and the accelerator pedal is calling for maximum performance MEMORY RECALL YES CORRECTIVE ACTIONS TROUBLE SHOOTING...

Page 37: ...Indication Battery 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 following is the start up display sequence that will occur START UP DISP...

Page 38: ... 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 and IT families of controllers furnish a function register that contains the last 16 st...

Page 39: ...rovided Range 2 to 15 on time Set 0 to 255 Resolution 0 05 per set unit Example Setting of 20 3 on time Important Note This 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 3 ARMATURE CONTROLLED ACCEL...

Page 40: ...out the permission of the OEM FUNCTION 9 REGEN BRAKING C L Push 9 This function allows for the adjustment of the Regen braking current limit Higher current correlates to shorter stopping distance Resolution Example Min Max Set Per unit value If set at 20 32A 291A 0 to 255 1 0156 amps 53 amps REGEN BRAKE IA VAL X 1 0156 32 FUNCTION 10 REGEN FIELD CURRENT LIMIT Push 10 This function allows for the a...

Page 41: ...9 01 20 5 04 57 20 01 14 6 03 81 21 01 09 7 03 27 22 01 04 8 02 86 23 00 99 9 02 54 24 00 95 10 02 28 25 00 91 11 02 08 26 00 88 12 01 90 27 00 85 13 01 76 28 00 82 14 01 63 29 00 79 15 01 52 30 00 76 16 01 43 31 00 74 FUNCTION 15 BATTERY VOLTS Push l5 This function allows for the adjustment of voltage range for controls equipped with the Battery Discharge Indication function In order for the BDI ...

Page 42: ...the accelerator pedal up and the start switch closed Setting 0 to 128 Resolution 6 5 per set unit Current 128 SETTING VALUE x 6 5 FUNCTION 21 PEDAL DOWN BRAKE REGEN RATE Push CONT 6 This function allows for the adjustment of the rate at which speed is reduced during regenerative braking under speed regulation Range 0 1 to 25 5 seconds Set 0 to 255 Resolution 0 086 seconds per set unit Example Sett...

Page 43: ...r 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 status code register the register always starts at status code 1 and scrolls to status code 16 Instructions for scrolling the register are in section 5 3 2 of this instruction booklet FUNCTION 48...

Page 44: ... FUNCTION 55 MODE 2 FORWARD SPEED LIMIT Push CONT 8 Same as Function 51 This TOP SPEED REGULATION POINT takes effect when the vehicle is in Mode 2 SW1 B volts SW2 0 FUNCTION 56 MODE 3 ARMATURE CONTROLLED ACCELERATION Push CONT 9 Same as Function 48 This C A takes effect when the vehicle is in Mode 3 SW1 0 volts SW2 B FUNCTION 57 MODE 3 PEDAL DOWN REGEN CURRENT LIMIT Push CONT 10 Same as Function 4...

Page 45: ...unction 24 This function sets the armature current at which minimum field current will be achieved The ratio setting is adjusted by Function 26 This function sets the ratio between armature and field current when operating IMOTOR is above FWS and less than 300 amps Setting is the value of field current changed for each 100 amps of armature current changed The full load transition point is calculat...

Page 46: ...ctive modes consisting of 4 Controlled Acceleration levels 4 Field Weakening Pick Up levels and 4 Speed Limit levels g GE Electric Vehicle Motors Controls BATTERY PUSH PUSH EVT100ZX 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...

Page 47: ... 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 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 co...

Page 48: ...r PDA None 18 19 Brake Coil Line Contactor Coil Hold Voltage PC or PDA None 19 20 Armature Braking Current PC or PDA None 20 21 Pedal Down or Brake Regen Rate PC or PDA None 21 22 Overspeed Decrease Rate for Field Armature Current PC or PDA None 22 23 Field Gain PC or PDA None 23 24 Field Weakening Start PC or PDA None 24 25 Monitor PC or PDA None 25 26 Base Ratio PC or PDA None 26 27 MINUTES PC o...

Page 49: ...ou Hun 8 PC or PDA Reset to Zero Only 64 65 Stored Status Code 9 PC or PDA Reset to Zero Only 65 66 BDI 9 PC or PDA Reset to Zero Only 66 67 Hours Tens Ones 9 PC or PDA Reset to Zero Only 67 68 Hours Thou Hun 9 PC or PDA Reset to Zero Only 68 69 Stored Status Code 10 PC or PDA Reset to Zero Only 69 70 BDI 10 PC or PDA Reset to Zero Only 70 71 Hours Tens Ones 10 PC or PDA Reset to Zero Only 71 72 H...

Page 50: ...PEDAL DOWN RATE 3 PC or PDA None 106 107 MIN FIELD RATE 3 PC or PDA None 107 108 SPEED LIMIT 3 PC or PDA None 108 109 CA 4 PC or PDA None 109 110 RGN PEDAL DOWN RATE 4 PC or PDA None 110 111 MIN FIELD RATE 4 PC or PDA None 111 112 SPEED LIMIT 4 PC or PDA None 112 113 Secure HM Tens Ones PC or PDA OEM Read Only 113 114 Secure HM Thou Hun PC or PDA OEM Read Only 114 115 Secure Aux HM Tens Ones PC or...

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