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DIAGNOSTIC STATUS CODES

SX TRANSISTOR CONTROL

Page

15

July 2001

Section 4.4 General Troubleshooting Instructions

Trouble-shooting the ZX family of controls should be quick
and easy when following the instructions outlined in the
following status code instruction sheets.

If mis-operation of the vehicle occurs, a status code will be
displayed on the Dash Display (for vehicles equipped with a
Dash Display) or made available by plugging a Handset into
the plug "Y" location, and then reading the status code.

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 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 numbers
may be different from the numbers referenced in this
publication.

WARNING: Before trouble-shooting, jack up the drive

wheels, disconnect the battery and discharge the

capacitors. Reconnect the battery as needed for specific

checks. Capacitors should be discharged by connecting a

200 ohm 2 watt resistor between the positive and negative

terminals on the control panel.

Check resistance on R x 1000 scale from frame to power
and control terminals. A resistance of less than 20,000
ohms can cause misleading symptoms. Resistance less
than 1000 ohms should be corrected first.

Before proceeding, visually check for loose wiring,
mis-aligned linkage to the accelerator switch, signs of
overheating of components, etc.

Tools and test equipment required are: clip leads, volt-ohm
meter (20,000 ohms per volt) and basic hand tools.

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Содержание IC3645SH7R354D1

Страница 1: ...itional 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 July 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 FEA...

Страница 2: ...ING AND DIAGNOSTIC STATUS CODES 12 4 1 General Maintenance Instructions 12 4 2 Cable Routing and Separation 12 4 2 1 Application 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 Sp...

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 E...

Страница 4: ...ld 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 adjust...

Страница 5: ...ncreasing 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 this braking mode Section 2 1 4 Auxiliary Speed Control Section 2 1 4 ...

Страница 6: ...ovement 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 maintain the transistors within their temperature limits As the control cools the thermal protector will automatically reset returning the control ...

Страница 7: ...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 traction controls Monitor intermittent random status codes Monitor battery state of charge if available Monitor hour meter reading on traction controls Monitor or adjust the control functions Section 2 3 6 RS 232 Communication Port This s...

Страница 8: ...umber 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 Argum...

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

Страница 10: ...ATURE FU1 LINE A1 A2 A1 A2 F2 F1 BATT 400A FU3 L TURF SPEED LIMIT SWITCH 10A CHARGER SWITCH KEY SWITCH START SWITCH DIRECTIONAL SWITCH FORWARD REVERSE N C MOTOR THERMOSTAT BUZZER AUX ACCEL POT ACCEL POT P1 P2 P3 P4 P5 P21 P11 P10 P15 TACHOMETER P14 12V P16 P7 P9 P13 P8 P6 RED GREEN BLACK ELEMENTARY DRAWING FOR TYPICAL SEPARATELY EXCITED TRACTION MOTOR CONTROLLER FOR NEV APPLICATIONS MOTOR CONNECTI...

Страница 11: ...EED LIMIT SWITCH 7 ACCELERATOR INPUT VOLTAGE SIGNAL 8 BATTERY NEGATIVE FOR CONTROL ACCESSORIES 9 ACCELERATOR POT 5 VOLTS SUPPLY 3 WIRE POT 10 BACK UP ALARM 11 LINE CONTACTOR COIL DRIVER 12 N A 13 AUXILIARY ACCELERATOR POT 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 NORMALLY CLOSED MOTOR THERMOSTAT 22 SERIAL RECEIVE 23 SERIAL TRA...

Страница 12: ... 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 weld...

Страница 13: ...ply 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 no...

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 pl...

Страница 15: ...oblem 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 WA...

Страница 16: ...e Y plug and the Dash Display or Handset Defective Dash Display or Handset Replace Dash Display or Handset FU3 KEY SWITCH P1 P2 NEG CHARGER SWITCH 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 5V with the start switch open P3 7 2V MEMORY RECALL NO CORRECTIVE ACTIONS TRO...

Страница 17: ...TOR THERMOSTAT BUZZER AUX ACCEL POT ACCEL POT P1 P2 P3 P4 P5 P21 P11 P10 P15 TACHOMETER P14 12V P16 P7 P9 P13 P8 P6 RED GREEN BLACK PLUG 23 PIN 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 displayed when the accelerator input voltage at P7 1 24V and either the bat...

Страница 18: ... POT P1 P2 P3 P4 P5 P21 P11 P10 P15 TACHOMETER P14 12V P16 P7 P9 P13 P8 P6 RED GREEN BLACK PLUG 23 PIN 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 7 2V when the key switch is closed MEMORY RECALL NO CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circ...

Страница 19: ... to proper settings Check minimum battery volts at P1 NEG FU3 KEY SWITCH P1 P2 NEG CHARGER SWITCH 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 NO CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM C...

Страница 20: ...ire exists between P7 and potentiometer negative L TURF SPEED LIMIT SWITCH KEY SWITCH START SWITCH DIRECTIONAL SWITCH FORWARD REVERSE N C MOTOR THERMOSTAT BUZZER AUX ACCEL POT ACCEL POT P1 P2 P3 P4 P5 P21 P11 P10 P15 TACHOMETER P14 12V P16 P7 P9 P13 P8 P6 RED GREEN BLACK PLUG 23 PIN TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 23 Motor field current is too high when the st...

Страница 21: ...ive control Replace controller unit NO GRAPHIC FOR THIS STATUS CODE TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 27 12V buss is too low This status code will be displayed when the voltage at P1 is less than 9 35V MEMORY RECALL YES CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Traction Controller SYMPTOM Line contactor opens and closes and then can only be ...

Страница 22: ...failed control GE Sentry for Windows software can be used to monitor control operation and it will display a value for the thermal protector that is greater than 84 corresponding to 1 65V triggering this status code 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 value of motor amps is gr...

Страница 23: ...or Windows software can be used to monitor control operation and it will display a value for the motor amps that is less than 117 corresponding to 2 3V triggering this status code 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 tur...

Страница 24: ...e controller unit NO GRAPHIC FOR THIS STATUS CODE TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 46 Look Ahead test for A2 volts is less than 12 5 of battery volts This status code will be displayed when the voltage at A2 is less than 12 5 of battery volts and Im is greater than 52 amps when the control is in the neutral state with no start switch or direction selected MEMOR...

Страница 25: ...place controller unit NO GRAPHIC FOR THIS STATUS CODE 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 volts is less than 85 of battery volts at initial key switch on MEMORY RECALL NO CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Trac...

Страница 26: ...rol Replace controller unit Line contactor tips bounce or are not fully picked up NO GRAPHIC FOR THIS STATUS CODE TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 75 Capacitor 1C voltage too high during motoring This status code will be displayed when the voltage at 1C exceeds 96 volts during motoring MEMORY RECALL YES CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid...

Страница 27: ...ELD ARMATURE A1 A2 A1 A2 F2 F1 BATT FU1 LINE 400A FU3 10A TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 90 Motor thermostat is open during control operation This status code will be displayed when the voltage at P21 5 66V for at least 30 seconds MEMORY RECALL YES CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Traction Controller SYMPTOM Maximum motor armatur...

Страница 28: ...attery 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 start up display s...

Страница 29: ...r 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 con...

Страница 30: ...imize 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 ACCELERATION RATE FORWARD Push 3 This function allows for the adjustment of the rate of time it takes for the control to accelerate to 100 applied battery voltage ...

Страница 31: ...ormance 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 9 REGEN ARMATURE CURRENT LIMIT Push 9 This function allows for the adjustment of the maximum armature current limit during regenerative braking Range 32 to 240 amps Set 1 to 255 Resolution 0 8157 amps p...

Страница 32: ... appropriate setting using the calculated VDrop as a reference INTERNAL RESISTANCE COMPENSATION TABLE Setting VDrop Setting VDrop 2 11 44 17 1 34 3 7 60 18 1 27 4 5 72 19 1 20 5 4 57 20 1 14 6 3 81 21 1 09 7 3 27 22 1 04 8 2 86 23 0 99 9 2 54 24 0 95 10 2 28 25 0 91 11 2 08 26 0 88 12 1 90 27 0 85 13 1 76 28 0 82 14 1 63 29 0 79 15 1 52 30 0 76 16 1 43 31 0 74 FUNCTION 15 BATTERY VOLTS Push l5 In ...

Страница 33: ...field current due to the interaction between motor field design and the digital field current regulation circuit The value for this function should be set to 32 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 not be changed by field personnel without the pe...

Страница 34: ...corded read the number stored in Function 28 Using the Memory Map 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 through the stored status code register the register always starts at statu...

Страница 35: ...t 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 36: ...ring Regen HS or PC None 19 20 20 MPH Overspeed Limit HS or PC None 20 21 21 Rate Field Changes in Overspeed HS or PC None 21 22 22 Pulse Counts HS or PC For DD on power up 22 23 23 Error Compensation HS or PC None 23 24 24 Field Weakening Start 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 N...

Страница 37: ... 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 PC...

Страница 38: ...06 107 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 114 115 Secure Aux HM Tens Ones PC Only OEM Read Only 115 116 ...

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