GE IC3645SR7T405T5 Installation And Operation Manual Download Page 24

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DIAGNOSTIC STATUS CODES

IT TRANSISTOR CONTROL

Page

April 2012

TRACTION

STATUS CODE

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

-16

Battery voltage is too high at initial key
switch closure.

This status code will be displayed when the
battery volts are greater than 86 volts at initial
key switch on.

MEMORY RECALL

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

Circuits valid

for

Traction

Controller

SYMPTOM

Control will not operate.

POSSIBLE CAUSE

Discharged battery



Check battery voltage to confirm that it is a

minimum of 68.3 volts. Charge battery, if
required.

Battery overcharged or incorrect battery used.



Check each battery cell for proper voltage

(maximum 2.4 volts per cell). If voltage is
excessive, check battery charger for proper
output voltage.

Incorrect control card adjustment.



Check Function 15 for proper adjustment for

battery being used. See Handset instruction
sheet for details. Adjust to proper settings.

Check “maximum” battery volts at P1 & NEG.

POWER CONNECTIONS

POS

NEG

FU1

P17

LINE

P12

AKE

+72V

72 VDC

72V

NEG

TRACTION

STATUS CODE

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

-21

Accelerator voltage is too high.

This status code will be displayed when the
accelerator voltage at P7 is greater than 4.5
volts.

MEMORY RECALL

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

Circuits valid

for

Traction

Controller

SYMPTOM

Control will not operate.

POSSIBLE CAUSE

Accelerator input is mis-adjusted or
defective.



Input voltage at P7 should be less than
4.5 volts after initial key switch closure.



Open wire exists between
potentiometer negative and P8.



Open wire exists between P7 and
potentiometer wiper.

P17

RF SW

D SW

REV

E SW

ACC POT

TACHOMETER

P15 P14 P16

P10

P12

REGEN

E S

P21

ER T

+72V

P22

P23

P20

RS232

72V

NEG

PUT

T SW

72V

NEG

P13

PUT

AKE

72V

NEG

Summary of Contents for IC3645SR7T405T5

Page 1: ...tter to the OEM vehicle manufacturer through his normal field service channels Do not contact FSIP directly for this assistance Flight Systems Industrial Products April 2012 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 CONTRO...

Page 2: ...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 Med...

Page 3: ... Setup Mode 36 5 3 2 Status Code Scrolling 36 5 3 3 IT Handset Plug Connections Outline Drawing 36 5 4 Setup Functions for Traction Controller 37 40 5 5 Summary of Current Limit Adjustments 41 Section 6 0 DASH DISPLAYS 42 6 1 Application 42 6 2 Standard Dash Displays 42 6 3 Interactive Dash Displays 42 6 4 Start up Display Sequence 43 6 5 Outline Drawings 43 Section 7 0 MEMORY MAPS 44 7 1 Traction...

Page 4: ...TING CURRENT ARMATURE CURRENT Figure 1 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 ...

Page 5: ...e motor performance curve can be maximized through proper control application Section 1 4 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 flowing in the field into the resistor causes the field current to be less or weakened With the field weakened the m...

Page 6: ...ge 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 by providing...

Page 7: ... control is designed 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 ...

Page 8: ...s of use of the traction and pump control to the Dash Display each time the key switch is turned off Section 2 3 4 Battery Discharge Indication BDI The latest in microprocessor technology is used to provide accurate battery state of charge information and to supply passive and active warning signals to the vehicle operator Features and functions Displays 100 to 0 percent charge Display blinks with...

Page 9: ...ance 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 connected incorr...

Page 10: ...Control 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 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...

Page 11: ...OUTLINE DRAWINGS ELEMENTARY DRAWINGS AND INPUTS OUTPUTS IT TRANSISTOR CONTROL Page 11 April 2012 Section 3 2 Outline IT400 Package ...

Page 12: ...S ELEMENTARY DRAWINGS AND INPUTS OUTPUTS IT IP TRANSISTOR CONTROL Page 12 OUTLINE DRAWINGS ELEMENTARY DRAWINGS AND INPUTS OUTPUTS IT IP TRANSISTOR CONTROL Page 12 April 2012 April 2012 Section 3 3 Traction Elementary ...

Page 13: ...GN OUTPUT SIGNAL 12V 1 0V REGEN 12 BATTERY NEG REGEN BRAKE SW 13 BATTERY NEG PARK BRAKE SW 14 TACH INPUT 15 TACH 12V 16 TACH NEG 17 LINE CONTACTOR DRIVER AND SUPPRESSION 18 NOT USED 19 NOT USED 20 SENTRY NEG 21 MOTOR TEMP SW 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 SUPP...

Page 14: ...trol manufacturer 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 FSIP contactors contained in the traction and pump systems is recommended to occur during every 1000 hours of vehicle operation Inspecti...

Page 15: ...pecific examples of level HP signals used in drive equipment cabling Motor armature loops DC outputs 10 A and above Motor field loops 10 A and above 4 2 3 Cable Spacing Guidelines Recommended spacing or clearance between cables or wires is dependent on the level of the wiring inside them For correct level separation when installing cable the customer must apply the general guidelines section 4 2 3...

Page 16: ...shutdown by the FSIP control FSIP 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 before FSIP control replacement Also for long term reliable control operation the plug terminals must be maintained per these instructions with the recommended contact cleaner and lubricant which ...

Page 17: ...g the installation of FSIP 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 FSIP recommends the use of the following components or equivalent substitutions during the control installation process a Thermal compound Dow Corning 340 maintained per the manuf...

Page 18: ...e plate and the vehicle mounting surface The function of this compound is to conform to surface discrepancies filling gaps and optimizing the metal to metal contact of the control and the vehicle a Prepare the two mounting surfaces control and vehicle as indicated above b Using a triangular notched trowel of 3 32 09 01 apply the grease to the vehicle mounting surface c Use straight non crossing st...

Page 19: ...With the status code number follow the procedures outlined in the status code instruction sheets to determine the problem Important Note Due to the interaction of the logic card with all vehicle functions almost any status code or control fault could be caused by the logic card After all other status code procedures have been followed and no problem is found the controller should then be replaced ...

Page 20: ...W ACC POT TACHOMETER P15 P14 P16 P10 BUZZER RED GREEN BLACK P12 REGEN BRAKE SW P21 MOTOR OVER TEMP 72V 72V 72V 72V 72V 72V 72V P22 P23 P20 RS232 72V NEG P3 NEG INPUT START SW 72V NEG P13 NEG INPUT BRAKE SW 72V NEG TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 05 Start switch fails to close This status code will be displayed when the accelerator voltage at P7 is 1 4V with th...

Page 21: ... ACC POT TACHOMETER P15 P14 P16 P10 BUZZER RED GREEN BLACK P12 REGEN BRAKE SW P21 MOTOR OVER TEMP 72V 72V 72V 72V 72V 72V 72V P22 P23 P20 RS232 72V NEG P3 NEG INPUT START SW 72V NEG P13 NEG INPUT BRAKE SW 72V NEG TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 08 Accelerator voltage input is too high on power up after initial key switch closure This status code will be displa...

Page 22: ... 72V 72V 72V 72V 72V 72V P22 P23 P20 RS232 72V NEG P3 NEG INPUT START SW 72V NEG P13 NEG INPUT BRAKE SW 72V NEG 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 less than 2 5 volts when the key switch is closed MEMORY RECALL NO CORRECTIVE ACTIONS TROUBLE SHOOTING D...

Page 23: ... CAUSE OF STATUS INDICATION 15 Battery voltage is too low at initial key switch closure This status code will be displayed when the battery volts are less than 68 3 volts at initial key switch on MEMORY RECALL NO CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Traction Controller SYMPTOM Control will not operate POSSIBLE CAUSE Discharged battery Check battery voltage to confirm that...

Page 24: ...n sheet for details Adjust to proper settings Check maximum battery volts at P1 NEG POWERCONNECTIONS POS A1 F1 NEG A2 F2 FIELD ARMATURE FU1 L P 1 P17 P2 LINE NEG INPUT START SW P12 REGEN BRAKE SW 72V 72V 72 VDC 72V NEG TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 21 Accelerator voltage is too high This status code will be displayed when the accelerator voltage at P7 is gre...

Page 25: ... 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 too high when the key switch is turned on This status code will be displayed when the current draw in the motor field is too high on start up MEMORY RECALL NO CORRECTIVE ...

Page 26: ... Replace controller unit POWERCONNECTIONS POS A1 F1 NEG A2 F2 FIELD ARMATURE FU1 L P1 P17 P2 LINE NEG INPUT START SW P12 REGEN BRAKE SW 72V 72V 72 VDC 72V NEG TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 41 Shorted thermal protector TP or transistor over temperature This status code will be displayed when the voltage at the thermal protector is too low MEMORY RECALL YES CO...

Page 27: ...trol operation and it will display a value for the motor amps that is greater than 133 corresponding to 2 6V triggering 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 value of motor amps is less than 123 corresponding to 2 4 volts with no current flowing in the motor circ...

Page 28: ...ns and closes then can only be closed by opening and closing the key switch POSSIBLE CAUSE Defective control Replace controller unit NO GRAPHIC FOR THIS STATUS CODE 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 Th...

Page 29: ... frame of the vehicle Defective control Replace controller unit POWER CONNECTIONS TO CONTROL POS A1 F1 NEG A2 F2 FIELD ARMATURE A1 A2 A1 A2 F2 F1 BATT FU1 LINE 400A FU3 10A 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 less than 1 3 amps and a...

Page 30: ...Turn key off and wait 1 minute then try again Defective control Replace controller unit POWER CONNECTIONS TO CONTROL POS A1 F1 NEG A2 F2 FIELD ARMATURE A1 A2 A1 A2 F2 F1 BATT FU1 LINE 400A FU3 10A TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 57 Controller motor current sensor input is too low during running This status code will be displayed when the voltage input from the...

Page 31: ... 72V 72V 72V P22 P23 P20 RS232 72V NEG P3 NEG INPUT START SW 72V NEG P13 NEG INPUT BRAKE SW 72V NEG 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 b...

Page 32: ... unit L P9 P7 P8 P1 P17 P2 P6 P4 P5 TURF SW FORWARD SW REVERSE SW ACC POT TACHOMETER P15 P14 P16 P10 BUZZER RED GREEN BLACK P12 REGEN BRAKE SW P21 MOTOR OVER TEMP 72V 72V 72V 72V 72V 72V 72V P22 P23 P20 RS232 72V NEG P3 NEG INPUT START SW 72V NEG P13 NEG INPUT BRAKE SW 72V NEG TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 76 Capacitor 1C voltage too high during pedal up reg...

Page 33: ...STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 81 No tachometer signal is detected This status code will be displayed when no tachometer signal is detected MEMORY RECALL YES CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Traction Controller SYMPTOM Vehicle s speed will limited to about half of the normal speed POSSIBLE CAUSE Defective tachometer Replace tachometer uni...

Page 34: ...TROUBLE SHOOTING DIAGRAM Circuits valid for Traction Controller SYMPTOM The Control will not operate and can only be reset by cycling the key switch POSSIBLE CAUSE Continued operation of vehicle in high motor current condition Operating control at stall motor current for more than 3 5 seconds Defective motor tachometer Function 16 is incorrectly adjusted for control on time Adjust function per OEM...

Page 35: ...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 36: ... 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 37: ...1 to 25 5 seconds Set 0 to 255 Resolution 0 086 seconds per set unit Example Setting of 20 1 72 seconds FUNCTION 4 ARMATURE CURRENT LIMIT Push 4 This function allows for the adjustment of the armature current limit of the control The rating of the control will determine the range of adjustment for this function Please refer to the specification sheets and current limit curves for the control used ...

Page 38: ...d 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 11 TURF SPEED LIMIT Push 11 This function allows for the adjustment of the top speed of the vehicle maximum battery volts to the motor when it is being operated in the forward direction Ra...

Page 39: ... Push CONT 2 This function allows for the adjustment of the pedal up field gain This value is determined by GE application engineering and should be set using the OEM setting specifications for this vehicle FUNCTION 18 LINE CONTACTOR COIL VOLTAGE Push CONT 4 this function sets the voltage level at which the line contactor and brake coils are held Range 0 to 96 volts Setting 0 to 255 Resolution 0 3...

Page 40: ...kening Start point the field current will increase by 0 129 amps Setting 0 to 255 Resolution 1 625 per set unit I MOTOR FWS VAL x 1 625 FUNCTION 28 STORED STATUS CODE COUNT POINTER Example Setting of 20 32 5 amps Push CONT 13 This register contains the location of the last stored status code recorded of the 16 stored status codes These stored status codes have caused a PMT controller shutdown and ...

Page 41: ...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 42: ...pre set interactive modes consisting of 4 Controlled Acceleration levels 4 Field Weakening Pick Up levels 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 Custom Dash Display incorporates all the featu...

Page 43: ...elected 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 conn...

Page 44: ...e Contactor Coil Voltage PC or PDA None 18 19 Pedal Down Regen Decel Rate PC or PDA None 19 20 Pedal Up Regen Decel Rate PC or PDA None 20 21 MPH Overspeed PC or PDA None 21 22 Overspeed Brake Rate PC or PDA None 22 23 NA 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 or PDA None 27 28 Stored Status Code Count...

Page 45: ...3 64 Hours Thou 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...

Page 46: ...05 106 Spare PC or PDA None 106 107 Spare PC or PDA None 107 108 Spare PC or PDA None 108 109 Spare PC or PDA None 109 110 Spare PC or PDA None 110 111 Spare PC or PDA None 111 112 Spare 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 PDA OEM Read Only 115 116 Secure Aux HM Thou Hun PC or PD...

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