GE SX TRANSISTOR CONTROL IC3645SP4U400N3 Installation And Operation Manual Download Page 27

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DIAGNOSTIC STATUS CODES

SX TRANSISTOR CONTROL

Page 27

January 2000

TRACTION

STATUS CODE

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

-23

Motor field current is high on start up in
the reverse direction.

This status code will be displayed when the current
draw in the motor field is too high at start up in the
reverse direction.

MEMORY RECALL

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

Circuits valid

for

Traction

Controller

SYMPTOM

Control will not operate.

POSSIBLE CAUSE

Defective control.

•

Replace controller unit.

KEY SWITCH

P17

P2 P6

P12 P8

SEAT

SW.

FOR

. S

EV.

SW.

P10

P18

PY7
PY12
PY10
PY11

FU7

ACCESSORIES

FU6

OSCILLATOR CARD

LEFT CONTROL

FU1

STEER
ANGLE

POT

LINE

POWER

CONNECTIONS

LEFT CONTROL

POS

NEG

FIE

URE

ACC POT

BDI INTERRUPT

FU4

FU2

POWER

CONNECTIONS

RIGHT CONTROL

POS

NEG

FIE

URE

FU5

BRAKE SW.

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 RECALL

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

Circuits valid

for

Traction

Controller

SYMPTOM

Control will not operate.

POSSIBLE CAUSE

Defective Control.

•

Replace controller unit.

KEY SWITCH

P17

P2 P6

P12 P8

SEAT

SW.

FOR

. S

EV.

SW.

P10

P18

PY7
PY12
PY10
PY11

FU7

ACCESSORIES

FU6

OSCILLATOR CARD

LEFT CONTROL

FU1

STEER
ANGLE

POT

LINE

POWER

CONNECTIONS

LEFT CONTROL

POS

NEG

FIE

URE

ACC POT

BDI INTERRUPT

FU4

FU2

POWER

CONNECTIONS

RIGHT CONTROL

POS

NEG

FIE

URE

FU5

BRAKE SW.

Summary of Contents for SX TRANSISTOR CONTROL IC3645SP4U400N3

Page 1: ...ion or maintenance For additional 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 Copyright by General Electric Company January 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 Featur...

Page 2: ...DI 9 2 3 4 a Internal Resistance Compensation 9 2 3 5 Handset 9 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 INFORMATION ELEMENTARY AND OUTLINE DRAWINGS 11 3 1 Ordering Information for Separately Excited Controls 11 3 2 Outline SX 3 and SR 3 ...

Page 3: ... 0 SX FAMILY GE HANDSET INSTRUCTIONS 55 6 1 General Features 55 6 2 Purpose Setup Functions 55 6 3 Setup Function Procedures 56 6 3 1 Setup Mode 56 6 3 2 Status Code Scrolling 56 6 3 3 SX Handset Plug Connections Outline Drawing 56 6 4 Setup Functions for Traction Controller 57 62 6 5 Summary of Current Limit Adjustments 62 6 6 Setup Functions for Hydraulic Pump Controller 64 66 Section 7 0 DASH D...

Page 4: ...ical 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 with the armature current If the mechanical load on the motor incre...

Page 5: ...on 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 motor speed will increase giving the effect of overdrive To change the overd...

Page 6: ...ed 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 Plug Braking Section 2 1 3 b Regenerative Braking to Zero Speed Slow down is accomplished when reversing direction by providing a small amount of retarding torque for deceleration If the veh...

Page 7: ...tended for a single motor vehicle As the steer reaches some pre selected turn angle approximately 20o the speed of the inside wheel decrease proportionally to the speed of the outside wheel This proportional decline will continue on a linear path until the steer angle reaches another pre determine angle of approximately 65o At this point the inside wheel will stop as the steer angle is increased t...

Page 8: ...d current limit the vehicle will normally be able to reach sufficient speed As the control cools the thermal protector will automatically reset returning the control to full power Section 2 2 5 Low Voltage Batteries under load particularly if undersized or more than 80 percent discharged will produce low voltages at the control terminals The SX control is designed for use down to 50 percent of a n...

Page 9: ...rating information and settings into a personal computer program Section 2 3 6 a Interactive Dash Display Modes The Interactive Custom Dash Display allows the operator to select the best vehicle performance for changing factory task conditions There are four 4 operator interaction modes that can be selected by depressing a push button on the dash display From the Dash Display the operator may sele...

Page 10: ...ction 11 using the Handset to adjust motor voltage from O to 100 The specified motor volts will be regulated however the magnitude of motor current will vary depending on the loading of the vehicle The second speed is obtained by closing SL2 P19 to control negative SL2 is adjusted using the Handset and Function 12 similar to SL1 The third speed is obtained by closing SL3 P20 to control negative SL...

Page 11: ...ment 02 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 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 A...

Page 12: ...OUTLINE DRAWINGS ELEMENTARY DRAWINGS AND INPUTS OUTPUTS SX TRANSISTOR CONTROL Page 12 January 2000 Section 3 2 Outline SX 3 and SR 3 Package Size ...

Page 13: ...BDI INTERRUPT P18 P7 P12 P6 P2 P1 P3 P4 P5 P10 P13 ELEMENTARY DRAWING FOR SEPARATELY EXCITED DUAL MOTOR PROPORTIONING CONTROLLERS WITH SOLID STATE REGENERATIVE BRAKING LINE P16 P15 PY7 PY12 PY10 PY11 P16 P15 AUTO REGENERATIVE BRAKING ENABLE PMT ENABLE OUTPUT 25 P18 STEER PUMP CONTACTOR DRIVER P11 REGEN OUTPUT SIGNAL 29 50 30 66 65 PY7 PY12 PY10 PY11 PLUG PY CONNECTIONS PLUG PY CONNECTIONS 8 6 15 7...

Page 14: ...E 95 INPUT STATUS CODE 91 INPUT STATUS CODE 90 INPUT STATUS CODE 95 INPUT STATUS CODE 94 INPUT STATUS CODE 92 INPUT BRUSH WEAR OUTPUT OVER TEMP OUTPUT 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 KEY SW FU6 LINE CONTACTOR BATT TO TRACTION PL2 10 SPEED 3 SPEED 2 SPEED 1 POWER CONNECTION S...

Page 15: ...POTENTIOMETER INPUT TMM1 BRUSHWEAR 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 LINE CONTACTOR DRIVER 18 STEER PUMP CTR DRIVER AND SUPPRESSION 1A CONTACTOR DRIVER 19 DASH DISPLAY 5 VOLT SUPPLY SPEED LIMIT 2 INPUT 20 TMM OVERTEMP SPEED LIMIT 3 INPUT 21 NOT...

Page 16: ...e 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 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 wel...

Page 17: ...apply the general 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 power levels must be grouped together In general different levels must run in separate wire bundles as defined in the different classes identified above Intermixing cannot be allowed unless ...

Page 18: ...tained per these instructions with the recommended contact cleaner and lubricant which provides a high degree of environmental and fretting protection New and re manufactured control plugs are cleaned and lubricated prior to shipment from the factory However in applications where severe vibration or high temperature cycling and excessive humidity such as freezers are present it is recommended that...

Page 19: ...he controller should then be replaced as the last option to correct the problem The same device designations have been maintained on different controls but the wire numbers may vary Refer to the elementary and wiring diagrams for your specific control The wire numbers shown on the elementary diagram will have identical numbers on the corresponding wiring diagrams for a specific vehicle but these n...

Page 20: ... 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 DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 01 No seat switch or deadman switch input no voltage to P6 This status code will be displayed when P6 is less than 50 battery volts MEMORY RECALL NO CORRECTIVE AC...

Page 21: ... 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 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 ACTIO...

Page 22: ...CCPOT P1 P2 P3 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 ...

Page 23: ...to wiring in accelerator 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 NEGATIVE P7 ACC POT KEY SWITCH 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 st...

Page 24: ... and P5 and 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 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 10 Steer angle potentiometer voltage is too high This st...

Page 25: ...switch input circuit Disconnect wire from P3 Check for short circuit from this wire to battery positive Defective control Disconnect wire from P3 Measure voltage from P3 to negative Voltage should be zero if not replace control 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 12 Steer angle potentiom...

Page 26: ... 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 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 in...

Page 27: ...LD ARMATURE ACC POT BDI INTERRUPT SP SP FU4 A1 FU2 P P POWER CONNECTIONS RIGHT CONTROL POS A1 F1 NEG F2 FIELD ARMATURE FU5 BRAKE SW A2 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 ME...

Page 28: ...S 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 POSSIBLE CAUSE Continued operation of vehicle...

Page 29: ...her control during the run mode TROUBLE SHOOTING DIAGRAM POWER CONNECTIONS LEFT CONTROL POS A1 F1 NEG A2 F2 FIELD ARMATURE FU1 POWER CONNECTIONS RIGHT CONTROL POS A1 F1 NEG A2 F2 FIELD ARMATURE FU5 KEY SWITCH L P7 P1 P17 P2 P6 P9 P3 P12 P8 P4 P5 SEAT SW START SW FORWARD SW REVERSE SW BRAKE SW P10 P21 ACC POT STEER ANGLE POT BDI INTERRUPT P18 P7 P12 P6 P2 P1 P3 P4 P5 P10 P13 LINE P16 P15 PY7 PY12 P...

Page 30: ...d PL10 of the slave auxiliary control TROUBLE SHOOTING DIAGRAM POWER CONNECTIONS LEFT CONTROL POS A1 F1 NEG A2 F2 FIELD ARMATURE FU1 POWER CONNECTIONS RIGHT CONTROL POS A1 F1 NEG A2 F2 FIELD ARMATURE FU5 KEY SWITCH L P7 P1 P17 P2 P6 P9 P3 P12 P8 P4 P5 SEAT SW START SW FORWARD SW REVERSE SW BRAKE SW P10 P21 ACC POT STEER ANGLE POT BDI INTERRUPT P18 P7 P12 P6 P2 P1 P3 P4 P5 P10 P13 LINE P16 P15 PY7 ...

Page 31: ... ARMATURE ACC POT BDI INTERRUPT SP SP FU4 A1 FU2 P P POWER CONNECTIONS RIGHT CONTROL POS A1 F1 NEG F2 FIELD ARMATURE FU5 BRAKE SW A2 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 no current flowing in the motor circuit M...

Page 32: ...P SP FU4 A1 FU2 P P POWER CONNECTIONS RIGHT CONTROL POS A1 F1 NEG F2 FIELD ARMATURE FU5 BRAKE SW A2 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 T...

Page 33: ...F1 NEG A2 F2 FIELD ARMATURE ACC POT BDI INTERRUPT SP SP FU4 A1 FU2 P P POWER CONNECTIONS RIGHT CONTROL POS A1 F1 NEG F2 FIELD ARMATURE FU5 BRAKE SW A2 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 CORRECTIV...

Page 34: ...CONTROL POS A1 F1 NEG F2 FIELD ARMATURE FU5 BRAKE SW A2 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 ...

Page 35: ...POWER CONNECTIONS RIGHT CONTROL POS A1 F1 NEG F2 FIELD ARMATURE FU5 BRAKE SW A2 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 64 The line driver input P2 17 is less than 12 of battery volts This status code will be displayed when the control detects that the line driver input P2 17 is less than 12 battery volts when the key switch is turned on MEMORY RECALL NO CORRECTIVE AC...

Page 36: ...2 F2 FIELD ARMATURE ACC POT BDI INTERRUPT SP SP FU4 A1 FU2 P P POWER CONNECTIONS RIGHT CONTROL POS A1 F1 NEG F2 FIELD ARMATURE FU5 BRAKE SW A2 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 66 The field current exceeds the current limit of the field transistor This status code will be displayed when the field transistor exceeds its specific current limit The line contactor w...

Page 37: ...r Traction Controller SYMPTOM Control will not operate POSSIBLE CAUSE Shorted motor armature A1 to A2 Power cables may be shorted to each other Measure at control terminals A1 to A2 terminals may be shorted to battery positive or negative KEY SWITCH L P7 P1 P17 P2 P6 P9 P3 P12 P8 P4 P5 SEAT SW START SW FOR SW REV SW P10 P18 PY7 PY12 PY10 PY11 SP P1 P5 P4 P2 FU7 TO ACCESSORIES FU6 P3 OSCILLATOR CAR...

Page 38: ...ntrol P10 TROUBLE SHOOTING DIAGRAM POWER CONNECTIONS LEFT CONTROL POS A1 F1 NEG A2 F2 FIELD ARMATURE FU1 POWER CONNECTIONS RIGHT CONTROL POS A1 F1 NEG A2 F2 FIELD ARMATURE FU5 KEY SWITCH L P7 P1 P17 P2 P6 P9 P3 P12 P8 P4 P5 SEAT SW START SW FORWARD SW REVERSE SW BRAKE SW P10 P21 ACC POT STEER ANGLE POT BDI INTERRUPT P18 P7 P12 P6 P2 P1 P3 P4 P5 P10 P13 LINE P16 P15 PY7 PY12 PY10 PY11 P16 P15 AUTO ...

Page 39: ...E ACC POT BDI INTERRUPT SP SP FU4 A1 FU2 P P POWER CONNECTIONS RIGHT CONTROL POS A1 F1 NEG F2 FIELD ARMATURE FU5 BRAKE SW A2 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 TRO...

Page 40: ...ACTION 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 NO CORRECTIVE ACTIONS TROUBLE SHOOTIN...

Page 41: ...ted to battery negative Defective input switch shorted Defective TMM card Defective pump card P16 SC90 NEG USER SW WHEN SR Series PUMP CONTROL IS USED TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 91 Pump motor temperature has exceeded maximum temperature limit This status code will be displayed when the voltage at the respective terminal of the TMM or Pump Logic Card is at...

Page 42: ...sitive Defective input switch shorted Defective TMM card Defective pump card SC93 POS P3 USER SW WHEN SR Series PUMP CONTROL IS USED TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 93 Steering pump motor brush wear indicator has detected worn brush This status code will be displayed when the voltage at the respective terminal of the TMM or Pump Logic Card is at battery volts ...

Page 43: ...ed to positive Defective input switch shorted Defective TMM card Defective pump card SC94 POS P5 USER SW WHEN SR Series PUMP CONTROL IS USED TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 94 Traction motor brush wear indicator had detected worn brush This status code will be displayed when the voltage at the respective terminal of the TMM or Pump Logic Card is at zero volts ...

Page 44: ...ositive Defective input switch shorted Defective TMM card Defective pump card SC95 POS P8 USER SW WHEN SR Series PUMP CONTROL IS USED TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 95 Pump motor brush wear indicator has detected worn brush This status code will be displayed when the voltage at the respective terminal of the TMM or Pump Logic Card is at battery volts MEMORY R...

Page 45: ... 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 programmed maintenance alert hours setting selected by the user Maintenance Code Hour Meter Functions 19 and 20 are programmed with the Handset and command the display of status code 99 If desired Ma...

Page 46: ... as instructed by OEM service manual Verify that the correct logic card catalog number is installed in the controller NO GRAPHIC FOR THIS STATUS CODE PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 127 Control logic card power supply is less than 10 VDC This status code is displayed when the logic card power supply is less than 10 volts MEMORY RECALL YES CORRECTIVE ACTIONS TROUBL...

Page 47: ...ds FU3 KEY SWITCH P1 P2 FU2 POWER CONNECTIONS POS A1 NEG A2 FIELD ARMATURE FU1 LINE PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 141 Open thermal protector TP1 or transistor is over temperature This status code is displayed when the voltage at the thermal protector is greater than 0 8 volts MEMORY RECALL NO CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Pump Co...

Page 48: ... 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 INDICATION 143 Pump Controller motor current sensor input is too low This status code is displayed when the voltage at the current sensor is greater than 0 1 volts with no current flowing in the motor circuit ...

Page 49: ...ATURE FU1 FU3 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 INDICATION 145 Power Transistor 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 ACTION...

Page 50: ...P10 BDI PY7 PY12 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 voltage is less than 85 of the battery voltage in the run mode MEMORY RECALL YES CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Pump Controller SYMPTOM Pump control will not ope...

Page 51: ...g will cause 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 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 157 Controller motor current sensor input v...

Page 52: ...e 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 3 TO TRACTION P10 BDI PY7 PY12 PY10 PY11 PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 181 Battery voltage is less than 14 volts This status code will be displayed when the batte...

Page 53: ...the 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 90 Neg TB3 P11 91 Neg TB4 P15 92 Neg TB5 P3 93 Pos TB6 P4 93 Pos TB8 P5 94 Pos TB10 P6 94 Pos TB11 P8 95 Pos TB12 P9 95 Pos Status codes 90 and 93 can also be programmed with the Handset to reduce the speed of the t...

Page 54: ...ctions BATTERY NEGATIVE 3 4 5 6 8 11 10 12 BATTERY 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 Section 5 5 TMM7A Outline Drawings 1 3 4 5 6 7 2 8 10 9 11 12 14 13 15 5 8 147 20 6 15 156 20 8 20 3 3 36 85 3 x 1 60 40 6 ...

Page 55: ...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 DISPLAY SEQUENCE Key Switch On Ver...

Page 56: ...o either the diagnostics mode the BDI display or 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 6 3 2 Status Code Scrolling The SX family of con...

Page 57: ...xample 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 ACCELERATION Push 3 This function allows for the adjustment of the rate of tim...

Page 58: ...ehicle 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 function allows for the adjustment of the Regen braking current limit High current correlates to shorter stopping distance Resolution Example Min Max Set Per unit value If set at 20 52A 468A 0 to 255 1 63 amps 84 6 amps REGEN BRAKE IA VAL X 1 63 52 FUNCT...

Page 59: ... Discharge Indication function In order for the 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 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 POINT WITH ON TIME Push CONT 1 This f...

Page 60: ...CTION 20 MAINTENANCE CODE THOUSANDS AND HUNDREDS HOURS SET Push CONT 5 This function allows for the adjustment of the thousands and hundreds hours of the maintenance code activation time Range 0 to 240 Set 0 to 240 Example 9999 Hours FUNCTION 21 AUTO REGEN BRAKING C L Push CONT 6 This function allows for the adjustment of the Regen braking current limit High current value correlates to shorter sto...

Page 61: ...ELD WEAKENING START Push CONT 2 This function allows for setting the armature current at which minimum field current will achieved Range 0 to 414 Amps Setting 0 to 255 Resolution 1 625 per set unit Example Setting of 20 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 ...

Page 62: ...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 FUNCTION 58 MODE 3 FW RATIO Push CONT 11 Same as Function 50 This F W RATIO takes effect when the Mode 3 settings are called for by the interactive Dash Display FUNCTION 59 MODE 3 MAX ARMATURE ON Push CONT 12 Same as Function 51 This MAX ARMATURE ON takes...

Page 63: ...djusted 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 100 amps of armature current changed The full load transition point is calculated by the control This function sets the maximum field current transition point at approximately 300A armature current T...

Page 64: ...of time adjusted 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 had selected 2 08 volts from Function 16 to be added to the motor it would take 0 18 seconds to add a total of 2 08 volts 2 08 0 375 0 032 FUNCTION 11 SPEED LIMIT 1 SL1 Push 11 This funct...

Page 65: ...termine which 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 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 the sto...

Page 66: ...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 ACCELERATION Push CONT 9 Same as function 48 FUNCTION 57 MODE 3 SPEED LIMIT 2 SL2 Push CONT 10 Same as Function 49 FUNCTION 58 MODE 3 SPEED LIMIT 3 SL3 Push CONT 11 Same as Function 50 FUNCTION 59 NOT APPL...

Page 67: ... 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 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 ...

Page 68: ...nk 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 Section 7 5 Outline Drawings 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 c...

Page 69: ...the inside 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 Speed limit 1 can be enabled at 41o and speed limit 2 can be enabled at 60o Between 66o and 71o the inside wheel will be in a free wheel mode As the steer reaches the 71o point the inside whee...

Page 70: ...r routine and then reset Function 25 to zero using the same procedure as outlined above Section 8 2 320 Degree Potentiometer Input 0 o 1 26V 1 20V 0 99V 1 94V 16 o 2 37V 3 04V 3 10V 3 31V 16 o 66 o 71 o 86 o 66 o 71 o 85 o LEFT TURN RIGHT TURN 0 00V 2 15V Over Travel Reverse Direction and Re Accelerate Proportionally Reduces The Speed of the Left Motor As Steer Angle Increases No Speed Change No S...

Page 71: ...23 Proportional Reduce 1 28 65 65 3 02 65 154 Proportional Reduce 1 88 20 96 2 42 20 123 Proportional Reduce 1 26 66 64 3 04 66 155 Creep Speed 1 87 21 95 2 43 21 124 Proportional Reduce 1 25 67 64 3 05 67 156 Zero Speed 1 85 22 95 2 45 22 125 Proportional Reduce 1 24 68 63 3 06 68 156 Zero Speed 1 84 23 94 2 46 23 125 Proportional Reduce 1 22 69 62 3 08 69 157 Zero Speed 1 83 24 93 2 47 24 126 Pr...

Page 72: ... 19 19 Maintenance Code HM Tens Units 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 Not Used HS or PC For DD on power up 22 23 23 Not Used 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 HM Minutes HS or PC GE Temporary Storage 27 28 28 F...

Page 73: ...tus 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 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 Statu...

Page 74: ...PC 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 109 110 61 Dash Display FWS 4 HS or PC None 110 111 62 Dash Display Ratio2 4 HS or PC None 111 112 63 Dash Display Speed Limit 2 4 HS or PC None 112 113 Secure HM Tens Ones PC Only OEM Read Only 113 114 S...

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GE SX TRANSISTOR CONTROL IC3645SP4U400N3, Installation And Operation Manual

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