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INSTALLATION AND OPERATION

SX TRANSISTOR CONTROL

Page 1

August 2001

SEPARATELY EXCITED (SX) TRANSISTORIZED MOTOR CONTROLLERS

FOR NEIGHBORHOOD ELECTRIC VEHICLE APPLICATION

INSTALLATION AND OPERATION MANUAL

(GE MODEL IC3645SH7R353T1)

Note: The information contained herein is intended to assist OEM's, Dealers and Users of electric vehicles in the application,

installation and service of GE solid-state controllers. This manual does not purport to cover all variations in OEM vehicle types.

Nor does it provide for every possible contingency to be met involving vehicle installation, operation 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.

General Electric Company August 2001

Section 1.0

INTRODUCTION ........................................................................................................................................................3

1.1

Motor

Characteristics .............................................................................................................. 3

1.2

Solid-State

Reversing............................................................................................................... 4

1.3

Flexible System Application..................................................................................................... 4

1.4

More Features with Fewer Components ................................................................................ 4

Section 2.0

FEATURES OF SX FAMILY OF MOTOR CONTROLLERS ....................................................................................5

2.1

Performance.............................................................................................................................. 5

2.1.1 Oscillator

Card

Features .................................................................................................. 5

2.1.1.a

Standard

Operation................................................................................................... 5

2.1.1.b

Control

Acceleration

................................................................................................ 5

2.1.2 Current

Limit ...................................................................................................................... 5

2.1.3 Plug

Braking ...................................................................................................................... 5

2.1.4 Auxiliary

Speed

Control.................................................................................................... 5

2.1.4.a

Field Weakening........................................................................................................ 5

2.1.4.b

Speed Limits .............................................................................................................. 5

2.1.4.c

Top

Speed

Regulation

...............................................................................................5

2.1.5 Ramp

Start ......................................................................................................................... 6

2.1.6

On-Board Coil Drivers and Internal Coil Suppression ................................................. 6

2.2

System Protective Override ..................................................................................................... 6

2.2.1

Static Return to Off (SRO) ............................................................................................... 6

2.2.2

Accelerator Volts Hold Off............................................................................................... 6

2.2.3

Pulse Monitor Trip (PMT)................................................................................................. 6

2.2.4

Thermal Protector (TP)..................................................................................................... 6

Table of Contents

Содержание IC3645SH7R353T1

Страница 1: ... vehicle manufacturer through his normal field service channels Do not contact GE directly for this assistance General Electric Company August 2001 Section 1 0 INTRODUCTION 3 1 1 Motor Characteristics 3 1 2 Solid State Reversing 4 1 3 Flexible System Application 4 1 4 More Features with Fewer Components 4 Section 2 0 FEATURES OF SX FAMILY OF MOTOR CONTROLLERS 5 2 1 Performance 5 2 1 1 Oscillator C...

Страница 2: ... Responsibility 12 4 2 2 Signal Power Level Definitions 12 4 2 2 a Low Level Signals Level L 12 4 2 2 b High Level Signals Level H 13 4 2 2 c Medium Power Signals Level MP 13 4 2 2 d High Power Signals Level HP 13 4 2 3 Cable Spacing Guidelines 13 4 2 3 a General Cable Spacing 13 4 2 4 Cabling for Vehicle Retrofits 13 4 2 5 RF Interference 13 4 2 6 Suppression 13 4 3 Recommended Lubrication of Pin...

Страница 3: ... 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 increases the motor slows down reducing the back ...

Страница 4: ...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 overdrive speed it is necessary to change the resistor value In a separately excited motor independent control of the field current provides for infinite adj...

Страница 5: ...current limit as set by Function 16 Armature current is regulated by increasing the field current as the vehicle slows down Once the field current reaches a preset value set by Function 10 and armature plug current can no longer be maintained the braking function is canceled and the control reverts back to motoring All energy produced by the motor during plugging is dumped as heat in the motor in ...

Страница 6: ...tor to close at start up or will drop it out during running if either the armature or field FET s are defective so as to cause uncontrolled truck movement Section 2 2 4 Thermal Protector TP This temperature sensitive device is internal to the power transistor Q1 module If the transistor s temperature begins to exceed the design limits the thermal protector will lower the maximum current limit and ...

Страница 7: ...the BDI Section 2 3 5 Handset This is a multi functional tool used with the LX ZX and SX Series GE solid state controls The Handset consists of a Light Emitting Diode LED display and a keyboard for data entry Features and functions Monitor existing system status codes for both traction and pump controls Monitor intermittent random status codes Monitor battery state of charge if available Monitor h...

Страница 8: ...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 volts 7 72 80 volts 4 48 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 Amps etc Argu...

Страница 9: ...OUTLINE DRAWINGS ELEMENTARY DRAWINGS AND INPUTS OUTPUTS SX TRANSISTOR CONTROL Page 9 August 2001 Section 3 2 Outline SX 2 Package Size ...

Страница 10: ...2 F2 FIELD ARMATURE FU1 LINE A1 A2 A1 A2 F2 F1 400A FU3 L TURF SPEED LIMIT SWITCH 10A CHARGER SWITCH KEY SWITCH START SWITCH DIRECTIONAL SWITCH FORWARD REVERSE BUZZER ACCEL POT P1 P2 P3 P4 P5 P11 P10 P15 TACHOMETER P14 P16 P7 P9 P13 P8 P6 RED GREEN BLACK ELEMENTARY DRAWING FOR TYPICAL SEPARATELY EXCITED TRACTION MOTOR CONTROLLER FOR NEV APPLICATIONS PLUG 23 PIN MOTOR CONNECTIONS CUSTOMER SUPPLIED ...

Страница 11: ...ATTERY VOLTS FROMTURFSPEED LIMIT SWITCH 7 ACCELERATOR INPUT VOLTAGE SIGNAL 8 ACCELERATOR NEGATIVE 9 ACCELERATOR POT 5 VOLTS SUPPLY 3 WIRE POT 10 BACK UP ALARM 11 LINE CONTACTOR COIL DRIVER 12 N A 13 PARK BRAKE SWITCH INPUT 14 TACHOMETER INPUT SIGNAL 15 TACHOMETER 12 VOLT OUTPUT 16 NEGATIVE FOR TACH 17 N A 18 N A 19 N A 20 N A 21 N A 22 SERIAL RECEIVE 23 SERIAL TRANSMIT PIN Y PLUG INPUT OUTPUT DESC...

Страница 12: ...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...

Страница 13: ...pply 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 n...

Страница 14: ... 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 the p...

Страница 15: ...roblem 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 numbers may be different from the numbers referenced in this publication W...

Страница 16: ...ash Display or Handset FU3 KEY SWITCH P1 P2 NEG CHARGER SWITCH TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 04 Emergency brake switch is open This status code will be displayed when P13 is greater than 2 5 volts MEMORY RECALL NO CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Traction Controller SYMPTOM Control will not operate buzzer will sound POSSIBLE CAU...

Страница 17: ...WITCH TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 06 The accelerator pedal is depressed with no direction selected This status code will be displayed when the accelerator voltage at P7 2 5V and no direction is selected P4 and P5 are both less than 50 of battery volts MEMORY RECALL NO CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Traction Controller SYMPTO...

Страница 18: ...BUZZER ACCEL POT P1 P2 P3 P4 P5 P11 P10 P15 TACHOMETER P14 P16 P7 P9 P13 P8 P6 RED GREEN BLACK PLUG 23 PIN EMERGENCY BRAKE SWITCH TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 09 Both the forward and reverse switches are closed at the same time This status code will be displayed when P4 and P5 are greater than 50 of battery volts MEMORY RECALL NO CORRECTIVE ACTIONS TROUBLE ...

Страница 19: ... from P3 to negative Voltage should be zero If not replace the control L TURF SPEED LIMIT SWITCH CHARGER SWITCH KEY SWITCH START SWITCH DIRECTIONAL SWITCH FORWARD REVERSE BUZZER ACCEL POT P1 P2 P3 P4 P5 P11 P10 P15 TACHOMETER P14 P16 P7 P9 P13 P8 P6 RED GREEN BLACK PLUG 23 PIN EMERGENCY BRAKE SWITCH TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 15 Battery voltage is too low...

Страница 20: ...for proper adjustment for battery being used See Handset instruction sheet for details Adjust to proper settings Check maximum battery volts at P1 NEG FU3 KEY SWITCH P1 P2 NEG CHARGER SWITCH 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 R...

Страница 21: ...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 on when the start switch is closed and the forward direction is selected This status code will be displayed when the current draw in the motor field is too high o...

Страница 22: ...roller unit FU3 KEY SWITCH P1 P2 NEG CHARGER SWITCH TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 41 Open thermal protector TP or transistor over temperature This status code will be displayed when the voltage at the thermal protector is too high MEMORY RECALL YES CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Traction Controller SYMPTOM Reduced or no power ...

Страница 23: ...ntrol operation and it will display a value for the motor amps that is greater than 138 corresponding to 2 7V 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 117 corresponding to 2 3 volts with no current flowing in the motor cir...

Страница 24: ...sed 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 This will result in a PMT condition ...

Страница 25: ...E Check for short circuit from the motor armature to the 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 cur...

Страница 26: ...n circuit condition Replace fuse if necessary 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...

Страница 27: ...voltage at 1C exceeds 96 volts during the regenerative braking cycle MEMORY RECALL YES CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Traction Controller SYMPTOM Line contactor opens and closes then opens and can only close by opening and closing the key switch POSSIBLE CAUSE Defective control Replace controller unit POWER CONNECTIONS TO CONTROL POS A1 F1 NEG A2 F2 FIELD ARMATURE A...

Страница 28: ...mpensation for Battery State of Charge 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 chart at the right details the st...

Страница 29: ...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 5 3 2 Status Code Scrolling The SX family of controllers furnishes a function register that co...

Страница 30: ...ting 18 FUNCTION 2 CREEP SPEED Push 2 This function allows for the adjustment of the creep speed of the vehicle when the accelerator potentiometer is at its minimum value and the start switch is closed Range 2 to 15 on time Set 0 to 255 Resolution 0 047 per set unit Example Setting of 205 205x0 047 2 11 on time Important Note The function is used to optimize motor and control performance and this ...

Страница 31: ...btain the maximum torque of the motor Range 0 to 30 amps Set 51 to 255 Resolution 0 147 amps per set unit Example Setting of 251 251 51 x0 147 29 4 amps CAUTION Do not set this function to a value less than 51 Important Note The 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...

Страница 32: ...termine this setting the voltage drop of the battery under load must first be calculated by the following method 1 Record open circuit voltage Vo by measuring the voltage at the control positive and negative power terminals 2 Load the traction motor to 100 amps in 1A and record the voltage VL at the control positive and negative power terminals 3 Calculate voltage drop VDrop as follows VDrop VO VL...

Страница 33: ...ng must not be changed by field personnel without the permission of the OEM FUNCTION 21 ARMATURE CURRENT RAMP DURING REGEN Push CONT 6 This function adjusts the rate at which armature current ramps 8 amps steps to full value during regenerative braking when a direction change is made Range 001 to 0 255 seconds Setting 0 to 255 Resolution 0 8 seconds per set unit Example Setting of 12 0 012 seconds...

Страница 34: ...hour meter This function is typically not set by an OEM it is usually only read from the register Range 0 to 60 minutes Resolution 0 5 minutes per set unit Setting 0 to 120 Example Setting of 60 60 x 0 5 30 minutes FUNCTION 28 STORED STATUS CODE COUNT POINTER Push CONT 13 This register contains the location of the last stored status code recorded of the 16 stored status codes These stored status c...

Страница 35: ... miles or kilometers on the odometer Range 0 to 99 Set 0 to 99 Example 999999 9 Miles or Kilometers FUNCTION 50 ODOMETER THOUSANDS AND HUNREDS OF MILES OR KILOMETERS SET Push CONT 3 This function allows for the adjustment of the thousands and hundreds of miles or kilometers on the odometer Range 0 to 99 Set 0 to 99 Example 999999 9 Miles or Kilometers FUNCTION 51 ODOMETER HUNDRED THOUSANDS AND TEN...

Страница 36: ...rt setting is adjusted by Function 24 This function sets the armature current at which minimum field current will achieved The ratio setting is adjusted by Function 26 This function sets the ratio between armature and field current when transitioning from minimum field to maximum field current Setting is the value of field current changed for each 100 amps of armature current changed The full load...

Страница 37: ...elect any of four pre set interactive modes consisting of 4 Controlled Acceleration levels 4 Auto Regen 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 ...

Страница 38: ...iagnostics Override With Fault Key Switch Off Display Odometer Thousands Hundreds Tens Units For Four Seconds Display Odometer Hundred Thousands Ten Thousands For Four Seconds Section 6 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 connections to Y plugs of Traction Pump controls 2 45 62 2 ...

Страница 39: ... or PC None 20 21 21 Armature Current Ramp During Regen HS or PC None 21 22 22 Odometer Calibration HS or PC For DD on power up 22 23 23 Error Compensation HS or PC None 23 24 24 Field Weakening Start or Motor Knee Point HS or PC None 24 25 25 Monitor HS or PC GE Temporary Storage 25 26 26 Ratio of Field to Armature Amps HS or PC None 26 27 27 Hour Meter Minutes HS or PC None 27 28 28 Stored Statu...

Страница 40: ...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 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 Status Code 11 PC Only Reset to Zero Only 73 74 BDI 11 P...

Страница 41: ...licable HS or PC None 105 106 57 Not applicable HS or PC None 106 107 58 Not applicable HS or PC None 107 108 59 Not applicable HS or PC None 108 109 60 Not applicable HS or PC None 109 110 61 Not applicable HS or PC None 110 111 62 Not applicable HS or PC None 111 112 63 Not applicable HS or PC None 112 113 Secure HM Tens Ones PC Only OEM Read Only 113 114 Secure HM Thou Hun PC Only OEM Read Only...

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