GE IC3645SR4W606N6 Installation And Operation Manual Download Page 13

OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS

 

SX TRANSISTOR CONTROL 

 

 

Page 

13

 

 

Section 3.4 Traction Elementary 

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October 2002

 

Summary of Contents for IC3645SR4W606N6

Page 1: ...nal information and or problem resolution please refer the matter to the OEM vehicle manufacturer through his normal field service channels Do not contact GE directly for this assistance Table of Cont...

Page 2: ...3 6 RS 232 Communication Port 9 2 3 6 a Dash Display Interaction Modes 9 2 3 7 Circuit Board Coil Driver Modules 9 2 3 8 Truck Management Module TMM 9 2 4 Hydraulic Pump Control 9 Section 3 0 ORDERING...

Page 3: ...tallation 51 5 4 Connection Diagrams 51 5 4 1 TMM7A Card Connections 51 5 4 2 TMM7A Typical Brush Wear Sensor Connections 51 5 4 3 TMM Pump Control Connections 52 5 4 4 Typical Brush Wear Sensor Conne...

Page 4: ...ce 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...

Page 5: ...More Features with Fewer Components Field weakening with a series wound motor is accomplished by placing a resistor in parallel with the field winding of the motor Bypassing some of the current flowi...

Page 6: ...C the creep speed can be adjusted by Function 2 of the Handset At creep speed the ON time can decrease to approximately 5 with the OFF time at approximately 95 At full transistor operation this condit...

Page 7: ...atures which shut down or lock out control operation if a fault conditions occurs that would cause a disruption of normal vehicle operation Section 2 1 5b Anti Rollback Look ahead This feature provide...

Page 8: ...2a Standard Status Codes Section 2 3 4 a Internal Resistance Compensation The SX traction control has over 30 Status Codes that assist the service technician and operator in trouble shooting the vehic...

Page 9: ...at the motor brushes need to be replaced before they wear to the point of causing destructive damage to the motor commutator surface Section 2 4 Hydraulic Pump Control This hydraulic motor controller...

Page 10: ...l Type SP Series Control 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 volt...

Page 11: ...OUTLINE DRAWINGS ELEMENTARY DRAWINGS AND INPUTS OUTPUTS SX TRANSISTOR CONTROL Page 11 Section 3 2 Outline SX 4 and SR 4 Package Size October 2002...

Page 12: ...OUTLINE DRAWINGS ELEMENTARY DRAWINGS AND INPUTS OUTPUTS SX TRANSISTOR CONTROL Page 12 Section 3 3 Outline SX 3 and SR 3 Package Size October 2002...

Page 13: ...1 NEG A2 F2 FIELD ARMATURE A1 A2 SP FU1 STEER PUMP ARM PUMP CONNECTION BATT NEG LINE FU4 FU3 FU5 PUMP CONNECTION POS L SP REG BRAKING POTENTIOMETER INPUT REGEN OUTPUT SIGNAL I MOTOR VOLTAGE OUT BDI IN...

Page 14: ...H WEAR OUTPUT OVER TEMP OUTPUT DASH DISPLAY 2 1 3 4 5 6 8 9 15 16 11 13 14 PY7 PY12 PY10 PY11 10 12 19 20 21 50 51 53 13C 13C 13C 13C PUMP CONTROL POWER CONNECTION P A1 A2 N A1 A2 A2 A1 N P 5A 10 12 1...

Page 15: ...RUSHWEAR INDICATER OUTPUT 14 TMM BRUSHWEAR TMM1 OVER TEMPERATURE OUTPUT 15 IMOTOR OUT STATUS CODE 92 INPUT 16 MOTOR CURRENT COMPENSATION STATUS CODE 90 INPUT 17 LINE CONTACTOR DRIVER AND SUPPRESSION L...

Page 16: ...echarging 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...

Page 17: ...ral 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 powe...

Page 18: ...own by the GE control GE recommends the addition of this lubricant to all 12 and 23 pin plugs after proper cleaning of the connectors as a preventative measure to insure fretting is not an issue befor...

Page 19: ...ter This finish is consistent with cold rolled or extruded aluminum Care should always be taken in the handling and storage of controllers The base of the control should be free from nicks bumps protr...

Page 20: ...tation on mounting plate with mounting holes aligned b Move the control slightly in all directions to eliminate voids and enhance the distribution of the thermal compound c Insert the all of the mount...

Page 21: ...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 WARNING Before troub...

Page 22: ...t or loose connection going from 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 TRACTION STATUS CODE DESCRIP...

Page 23: ...to P4 Defective control Replace the controller unit KEY SWITCH P1 P2 P3 P17 P5 REVERSE SW FORWARD SW P4 SEAT SWITCH P6 L START SW TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION...

Page 24: ...SW P7 ACCPOT P9 P1 P2 P3 P17 P5 P4 P6 NEG TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 06 Accelerator depressed with no direction selected This status code will be displayed w...

Page 25: ...ccelerator 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 P...

Page 26: ...han 60 of battery volts KEY SWITCH P1 P2 P3 P17 P5 REVERSE SW FORWARD SW P4 SEAT SWITCH P6 L START SW TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 11 Start switch closed on po...

Page 27: ...settings Check 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...

Page 28: ...ets Adjust and set card type value as instructed by OEM service manual NO GRAPHIC FOR THIS STATUS CODE TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 23 Motor field current is h...

Page 29: ...ONNECTIONS POS A1 F1 NEG A2 F2 FIELD ARMATURE FU3 KEY SWITCH P7 P1 P2 P17 P6 P3 P4 START SW FORWARD SW ACC POT LINE L REVERSE SW SEAT SW P5 P9 FU5 NEG FU1 TRACTION STATUS CODE DESCRIPTION OF STATUS CA...

Page 30: ...TATUS 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...

Page 31: ...7 P6 P3 P4 START SW FORWARD SW ACC POT L REVERSE SW SEAT SW P5 P9 FU5 NEG POWER CONNECTIONS POS A1 F1 NEG A2 F2 FIELD ARMATURE LINE FU1 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDIC...

Page 32: ...3 P4 START SW FORWARD SW ACC POT L REVERSE SW SEAT SW P5 P9 FU5 NEG POWER CONNECTIONS POS A1 F1 NEG A2 F2 FIELD ARMATURE LINE FU1 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION...

Page 33: ...NNECTIONS POS A1 F1 NEG A2 F2 FIELD ARMATURE LINE FU1 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...

Page 34: ...o the open side of the line contactor tips Verify that hydraulic pump motor contactor tips are not welded FU3 KEY SWITCH P7 P1 P2 P17 P6 P3 P4 START SW FORWARD SW ACC POT L REVERSE SW SEAT SW P5 P9 FU...

Page 35: ...1 P2 P17 P6 P3 P4 START SW FORWARD SW ACC POT L REVERSE SW SEAT SW P5 P9 FU5 NEG POWER CONNECTIONS POS A1 F1 NEG A2 F2 FIELD ARMATURE LINE FU1 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATU...

Page 36: ...Missing or damaged horn suppressor Confirm that all inductive loads accessories are suppressed FU3 KEY SWITCH P7 P1 P2 P17 P6 P3 P4 START SW FORWARD SW ACC POT L REVERSE SW SEAT SW P5 P9 FU5 NEG POWER...

Page 37: ...EG POWER CONNECTIONS POS A1 F1 NEG A2 F2 FIELD ARMATURE LINE FU1 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 76 Capacitor 1C voltage too high This status code will be display...

Page 38: ...ture motor current is greater than 450 amps for longer than 3 5 sec the armature motoring current will be turned off This status code will be displayed when the armature motor current exceeds 450 amps...

Page 39: ...ttery negative Defective input switch shorted Defective TMM module Defective pump control P16 SC90 NEG USER SW WHEN SR Series PUMP CONTROL IS USED TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF S...

Page 40: ...rted to positive Defective input switch shorted Defective TMM module Defective pump controller SC93 POS P3 USER SW WHEN SR Series PUMP CONTROL IS USED TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE...

Page 41: ...itive Defective input switch shorted Defective TMM module Defective pump controller SC94 POS P5 USER SW WHEN SR Series PUMP CONTROL IS USED TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS I...

Page 42: ...efective input switch shorted Defective TMM module Defective pump controller SC95 POS P8 USER SW WHEN SR Series PUMP CONTROL IS USED TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATI...

Page 43: ...switch is first turned on and or the vehicle may run at a reduced speed CUSTOMER SELECTED SETTING WITH THE HANDSET User defined status code is displayed when the normal hour meter reading exceeds the...

Page 44: ...ruction sheets Adjust and set card type value as instructed by OEM service manual NO GRAPHIC FOR THIS STATUS CODE PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 127 Control logic ca...

Page 45: ...TCH P1 P2 FU2 POWER CONNECTIONS POS A1 NEG A2 FIELD ARMATURE FU1 LINE October 2002 PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 141 Open thermal protector TP1 or transistor is ove...

Page 46: ...P3 P12 LINE FU6 P19 P21 TO TRACTION CARD SPEED LIMIT 1 SPEED LIMIT 2 SPEED LIMIT 3 TO TRACTION P10 BDI PY7 PY12 PY10 PY11 PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 143 Pump Con...

Page 47: ...KEY SWITCH P1 P2 P3 P12 LINE FU6 P19 P21 TO TRACTION CARD SPEED LIMIT 1 SPEED LIMIT 2 SPEED LIMIT 3 TO TRACTION P10 BDI PY7 PY12 PY10 PY11 PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICA...

Page 48: ...Y12 PY10 PY11 PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 150 Capacitor volts are low after the line contactor closes This status code will be displayed when the capacitor voltag...

Page 49: ...status code 51 Also do not connect any loads to the load side of the line contactor POWER CONNECTIONS POS A1 NEG A2 FIELD ARMATURE FU1 FU3 KEY SWITCH P1 P2 P3 P12 LINE FU6 P19 P21 TO TRACTION CARD SP...

Page 50: ...at pump control Check for dirty contactor tips POWER CONNECTIONS POS A1 NEG A2 FIELD ARMATURE FU1 FU3 KEY SWITCH P1 P2 P3 P12 LINE FU6 P19 P21 TO TRACTION CARD SPEED LIMIT 1 SPEED LIMIT 2 SPEED LIMIT...

Page 51: ...Display to warn maintenance personnel that the motor brushes need to be replaced before they wear to the point of causing destructive damage to the motor commutator surface The BWI function is compati...

Page 52: ...POSITIVE PUMP CONTROL CONNECTIONS PA 3 PA 6 PB 6 PA 1 PA 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 ARM 1 BRUSH WEAR SENSOR CONNECTIONS FOR PUMP CONTROL TYPIC...

Page 53: ...8 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 c...

Page 54: ...ult 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 E...

Page 55: ...0 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 m...

Page 56: ...termined 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 C L Push 9 This funct...

Page 57: ...0 and 31 36 volts Between 32 and 44 48 volts Between 45 and 69 72 volts Between 70 and 80 80 volts Between 81 and 183 36 48 volts Between 184 and 250 No BDI Between 251 and 255 FUNCTION 16 STALL TRIP...

Page 58: ...ustment of the Regen braking current limit The higher the current the shorter the stopping distance Setting greater than 143 disables this function AUTO REGEN C L AMPS REGEN C L VAL FNT 21 51 VAL 6 50...

Page 59: ...32 5 amps I M FWS VAL x 1 625 This FIELD WEAKENING START takes effect when the Mode 1 settings are called for by the interactive Dash Display FUNCTION 50 MODE 1 FW RATIO Push CONT 3 This function set...

Page 60: ...ash Display FUNCTION 57 MODE 3 FIELD WEAKENING START Push CONT 10 Same as Function 49 This FIELD WEAKENING START takes effect when the Mode 3 settings are called for by the interactive Dash Display FU...

Page 61: ...justed by Function 26 This function sets the ratio between armature and field current when operating I MOTOR is above FWS and less than 300 amps Setting is the value of field current changed for each...

Page 62: ...d until the total IR compensation voltage has been added Range 0 0015 to 0 383 seconds Setting 0 to 255 Resolution 0 0015 seconds per set unit Example Setting of 20 0 032 seconds For example if you ha...

Page 63: ...stored status code was the last one recorded read the number stored in Function 28 Using the Memory Map See Section 8 1 for your logic card match the stored status code pointer number the number show...

Page 64: ...DE 2 SPEED LIMIT 3 SL3 Push CONT 7 Same as Function 50 FUNCTION 55 NOT APPLICABLE This function is not applicable to this type of control and should not be adjusted FUNCTION 56 MODE 3 CONTROLLED ACCEL...

Page 65: ...00ZX From the Dash Display the operator may select any of four pre set interactive modes consisting of 4 Controlled Acceleration levels 4 Field Weakening Pick Up levels and 4 Speed Limit levels These...

Page 66: ...I 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...

Page 67: ...s HS or PC None 19 20 20 Maintenance Code 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...

Page 68: ...us Code 9 PC Only Reset to Zero Only 65 66 BDI 9 PC 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...

Page 69: ...C None 105 106 57 Dash Display FWS 3 HS or PC None 106 107 58 Dash Display Ratio2 3 HS or PC None 107 108 59 Dash Display Speed Limit 2 3 HS or PC None 108 109 60 Dash Display CA 4 HS or PC None 109 1...

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