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INSTALLATION AND OPERATION

SX TRANSISTOR CONTROL

Page

1

January 1999

SEPARATELY EXCITED (SX) TRANSISTORIZED DUAL MOTOR CONTROLLERS

AND SERIES PUMP MOTOR CONTROL

INSTALLATION AND OPERATION MANUAL

(IC3645SR4U454Z2 IC3645SR4U454Z3, IC3645SR4U454Z4,

IC3645SR3U454Z2, IC3645SR3U454Z3, IC3645SR3U454Z4 ,

and IC3645SP4U450Z1)

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.

Copyright by General Electric Company January 1999

Section 1.0

INTRODUCTION .......................................................................................................... 5

1.1

Motor Characteristics.................................................................................. 5

1.2

Solid-State Reversing.................................................................................. 6

1.3

Flexible System Application ........................................................................ 6

1.4

More Features with Fewer Components ........................................................ 6

Section 2.0

FEATURES OF SX FAMILY OF MOTOR CONTROLLERS .............................................. 7

2.1

Performance............................................................................................... 7

2.1.1

Oscillator Card Features........................................................................ 7

2.1.1.a

Standard Operation......................................................................... 7

2.1.1.b

Proportional Operation for Dual Motor Vehicles .................................. 7

2.1.1.c

Creep Speed .................................................................................. 7

2.1.1.d

Controlled Acceleration and 1A Time ................................................ 7

2.1.2

Current Limit ........................................................................................ 8

2.1.3

Braking................................................................................................ 8

Table of Contents

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Содержание IC3645SR4U454Z2

Страница 1: ...ontingency 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 no...

Страница 2: ...2 Status Codes 10 2 3 2 a Standard Codes 10 2 3 2 b Stored Codes 10 2 3 3 Hourmeter Readings 10 2 3 3 a Maintenance Alert and Speed Limit 10 2 3 4 Battery Discharge Indication BDI 10 2 3 4 a Internal...

Страница 3: ...4 Connection Diagrams 56 5 4 1 TMM7A Card Connections 56 5 4 2 TMM7A Typical Brush Wear Sensor Connections 56 5 4 3 TMM Pump Control Connections 57 5 4 4 Typical Brush Wear Sensor Connections For Pum...

Страница 4: ...INSTALLATION AND OPERATION SX TRANSISTOR CONTROL Page 4 January 1999 Section 9 0 MEMORY MAPS 72 9 1 Typical Memory Map for Single Motor and DM Proportioning Control 72 74 Table of Contents Continued...

Страница 5: ...cal 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 therefor...

Страница 6: ...ed 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 f...

Страница 7: ...heel A potentiometer is attached to the steer wheel in order to communicate the steer angle to the controllers During vehicle manufacture software selection identifies each control for its application...

Страница 8: ...be maintained the braking function is canceled The fields will then reverse and the control reverts back to motoring Part of the energy produced by the motor during regen is returned to the battery a...

Страница 9: ...s are on board the control card These contactors must have coils rated for the vehicle battery volts Section 2 2 System Protective Override Section 2 2 1 Static Return to Off SRO This inherent feature...

Страница 10: ...the logic card With the status code number follow the procedures outlined in DIAGNOSTIC STATUS CODES to determine the problem and a solution Note The Status Code Instruction Sheets do not purport to...

Страница 11: ...henever a normally open switch or sensor wire provides a signal to the Module The TMM Module can be used to display a separate status code indicating over temperature of traction motors hydraulic moto...

Страница 12: ...current limit The controlled acceleration circuit is adjustable and operates the same as the traction circuit Adjustment range is from 0 1 to 5 5 seconds The variable resistor input will override the...

Страница 13: ...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...

Страница 14: ...OUTLINE DRAWINGS ELEMENTARY DRAWINGS AND INPUTS OUTPUTS SX TRANSISTOR CONTROL Page 14 January 1999 Section 3 2 Outline SR 3 Package Size...

Страница 15: ...OUTLINE DRAWINGS ELEMENTARY DRAWINGS AND INPUTS OUTPUTS SX TRANSISTOR CONTROL Page 15 January 1999 Section 3 3 Outline SX 3 Package Size...

Страница 16: ...21 P13 ACC POT STEER ANGLE POT SERIAL RECEIVE SERIAL TRANSMIT BDI INTERRUPT STEER PUMP FIELD STEER PUMP ARM P11 P18 SP DVR PLUG RGN OUTPUT P7 P12 P6 P2 P1 P3 P4 P5 LEFT CONTROL MASTER RIGHT CONTROL SL...

Страница 17: ...FIELD ARMATURE FU1 FU5 KEY SWITCH P1 P2 P10 P6 P5 P16 94 INPUT 94 INPUT 90 INPUT P13 P11 91 INPUT BRUSHWEAR OUTPUT P14 P14 OVER TEMP OUTPUT P20 P15 92 INPUT ELEMENTARY DRAWING FOR PUMP MOTOR CONTROLLE...

Страница 18: ...T USED TMM1 BRUSHWEAR INDICATER OUTPUT 14 N O BRAKE SW TMM1 OVER TEMPERATURE OUTPUT 15 IMOTOR OUT STATUS CODE 92 INPUT 16 MOTOR CURRENT COMPENSATION STATUS CODE 90 INPUT 17 LINE CONTACTOR DRIVER AND S...

Страница 19: ...cent 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 Inspe...

Страница 20: ...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 dif...

Страница 21: ...d 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 tha...

Страница 22: ...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 spec...

Страница 23: ...it or loose connection going from the Y plug and the Dash Display or Handset Defective Dash Display or Handset Replace Dash Display or Handset NEG FU3 KEY SWITCH P1 P2 TRACTION STATUS CODE DESCRIPTION...

Страница 24: ...ve control Replace the controller unit KEY SWITCH P1 P2 P3 BRAKE SWITCH P17 P5 REVERSE SW FORWARD SW P4 SEAT SWITCH P6 L START SW TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION...

Страница 25: ...switch potentiometer for proper operation and ohmic value KEY SWITCH BRAKE SWITCH REVERSE SW FORWARD SW SEAT SWITCH L START SW P8 P7 ACCPOT P9 P1 P2 P3 P17 P5 P4 P6 TRACTION STATUS CODE DESCRIPTION O...

Страница 26: ...r input circuit Disconnect wire from P7 and measure voltage at wire to negative Should be zero volts for potentiometer type and less than 3 7 volts for solid state type accelerator input P9 P7 P8 ACC...

Страница 27: ...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 P...

Страница 28: ...ct wire from P3 Check for short circuit from this wire to battery positive Resistance should be greater than 4 7K ohms Defective control Disconnect wire from P3 Measure voltage from P3 to negative Vol...

Страница 29: ...settings Check minimum battery volts at P1 and NEG NEG FU3 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...

Страница 30: ...set card type value as instructed by OEM service manual NO GRAPHIC FOR THIS STATUS CODE TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 23 Motor field current is high on start up...

Страница 31: ...Y SWITCH P8 P7 P1 P2 P17 P6 P3 P4 START SW FORWARD SW BRAKE SW ACC POT LINE L REVERSE SW SEAT SW P5 FU1 PLUG PL2 P9 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 27 Power suppl...

Страница 32: ...E OF STATUS INDICATION 29 Motor armature current is too high during the run mode Dual Motor Proportioning Controls Only This status code will be displayed when the motor current in control A is greate...

Страница 33: ...ry control P7 P8 P1 P17 P2 P6 P9 P3 P12 P8 P4 P5 P23 P22 P10 P21 P13 ACC POT STEER ANGLE POT SERIAL RECEIVE SERIAL TRANSMIT BDI INTERRUPT P14 BRAKE SW P11 P18 1A OR SP DVR PLUG RGN OUTPUT P7 P12 P6 P2...

Страница 34: ...on 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 INDIC...

Страница 35: ...G RGN OUTPUT LEFT CONTROL MASTER TO PUMP CONTROL POSITIVE TO PUMP CONTROL POSITIVE LINE SPEED LIMIT SWITCH FU3 KEY SWITCH BRAKE SW TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION...

Страница 36: ...CONNECTIONS RIGHT CONTROL POS A1 F1 NEG A2 F2 FIELD ARMATURE L P1 P17 P2 P6 P3 P4 P5 SEAT SW START SW FORWARD SW REVERSE SW P23 P22 P10 P13 SERIAL RECEIVE SERIAL TRANSMIT BDI INTERRUPT P14 P15 I MOTO...

Страница 37: ...FIELD ARMATURE FU4 A1 A2 S1 S2 SP FU1 POWER CONNECTIONS RIGHT CONTROL POS A1 F1 NEG A2 F2 FIELD ARMATURE L P1 P17 P2 P6 P3 P4 P5 SEAT SW START SW FORWARD SW REVERSE SW P23 P22 P10 P13 SERIAL RECEIVE...

Страница 38: ...rol is reset by recycling the key switch MEMORY RECALL YES CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Traction Controller SYMPTOM Control will not operate POSSIBLE CAUSE Defective...

Страница 39: ...SERIAL RECEIVE SERIAL TRANSMIT BDI INTERRUPT P14 P15 I MOTOR OUTPUT BRAKESW STEER PUMP FIELD STEER PUMP ARM P11 P18 1A OR SP DVR PLUG RGN OUTPUT LEFT CONTROL MASTER TO PUMP CONTROL POSITIVE TO PUMP CO...

Страница 40: ...BDI INTERRUPT P14 P15 I MOTOR OUTPUT BRAKESW STEER PUMP FIELD STEER PUMP ARM P11 P18 1A OR SP DVR PLUG RGN OUTPUT LEFT CONTROL MASTER TO PUMP CONTROL POSITIVE TO PUMP CONTROL POSITIVE LINE SPEED LIMI...

Страница 41: ...PUMP FIELD STEER PUMP ARM P11 P18 1A OR SP DVR PLUG RGN OUTPUT LEFT CONTROL MASTER TO PUMP CONTROL POSITIVE TO PUMP CONTROL POSITIVE LINE SPEED LIMIT SWITCH FU3 KEY SWITCH BRAKE SW TRACTION STATUS COD...

Страница 42: ...ASTER TO PUMP CONTROL POSITIVE TO PUMP CONTROL POSITIVE LINE SPEED LIMIT SWITCH FU3 KEY SWITCH BRAKE SW Section 4 5 TMM Codes TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 90 U...

Страница 43: ...card 1 3 4 5 2 7 9 6 8 10 11 12 13 14 15 P17 SC91 WHEN TMM7A CARD IS USED NEG USER SW WHEN SR Series PUMP CONTROL IS USED NEG USER SW TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICAT...

Страница 44: ...card 1 3 4 5 2 7 9 6 8 10 11 12 13 14 15 POS SC93 WHEN TMM7A CARD IS USED POS USER SW P3 USER SW WHEN SR Series PUMP CONTROL IS USED TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATI...

Страница 45: ...card 1 3 4 5 2 7 9 6 8 10 11 12 13 14 15 SC94 WHEN TMM7A CARD IS USED POS P5 USER SW WHEN SR Series PUMP CONTROL IS USED POS USER SW TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATI...

Страница 46: ...card 1 3 4 5 2 7 9 6 8 10 11 12 13 14 15 SC95 WHEN TMM7A CARD IS USED POS P8 USER SW WHEN SR Series PUMP CONTROL IS USED POS USER SW TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATI...

Страница 47: ...SPEED LIMIT 1 SPEED LIMIT 2 SPEED LIMIT 3 SPEED LIMIT 4 TO TRACTION P10 BDI POWER CONNECTIONS POS A1 NEG A2 FIELD ARMATURE LINE FU1 PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 1...

Страница 48: ...BRUSHWEAR OUTPUT P14 P14 OVER TEMP OUTPUT P20 P15 92 INPUT P12 P9 95 INPUT P8 95 INPUT FU6 P19 P20 P21 P4 P3 93 INPUT 93 INPUT TO TRACTION CARD SPEED LIMIT 1 SPEED LIMIT 2 SPEED LIMIT 3 SPEED LIMIT 4...

Страница 49: ...uld be between 10 and 14 ohms POWER CONNECTIONS POS A1 NEG A2 FIELD ARMATURE FU1 LINE FU5 KEY SWITCH P1 P2 FU6 P 1A P17 P18 PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 124 T2 vol...

Страница 50: ...LIMIT 2 SPEED LIMIT 3 SPEED LIMIT 4 TO TRACTION P10 BDI POWER CONNECTIONS POS A1 NEG A2 FIELD ARMATURE LINE FU1 PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 128 Armature current...

Страница 51: ...back Allow control to cool status code should disappear If control cools to ambient temperature and the fault remains when the control is restarted replace the control NO GRAPHIC FOR THIS STATUS CODE...

Страница 52: ...M No power to pump motor in control range POSSIBLE CAUSE Control is defective Replace controller unit NO GRAPHIC FOR THIS STATUS CODE PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION...

Страница 53: ...RD SPEED LIMIT 1 SPEED LIMIT 2 SPEED LIMIT 3 SPEED LIMIT 4 TO TRACTION P10 BDI POWER CONNECTIONS POS A1 NEG A2 FIELD ARMATURE LINE FU1 PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION...

Страница 54: ...94 INPUT 90 INPUT P13 P11 91 INPUT BRUSHWEAR OUTPUT P14 P14 OVER TEMP OUTPUT P20 P15 92 INPUT P12 P9 95 INPUT P8 95 INPUT FU6 P19 P20 P21 P4 P3 93 INPUT 93 INPUT TO TRACTION CARD SPEED LIMIT 1 SPEED L...

Страница 55: ...20 P21 P4 P3 93 INPUT 93 INPUT TO TRACTION CARD SPEED LIMIT 1 SPEED LIMIT 2 SPEED LIMIT 3 SPEED LIMIT 4 TO TRACTION P10 BDI POWER CONNECTIONS POS A1 NEG A2 FIELD ARMATURE LINE FU1 PUMP STATUS CODE DES...

Страница 56: ...e 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...

Страница 57: ...A 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 4 4 Typical Brush Wear Sensor Connections For Pump Control ARM 1 BRUSH WEAR SENSOR CONNECTIONS FOR PUMP...

Страница 58: ...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 locati...

Страница 59: ...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 t...

Страница 60: ...vehicle development This setting must not be changed by field personnel without the permission of the OEM FUNCTION 3 ARMATURE CONTROLLED ACCELERATION AND 1A TIME Push 3 This function allows for the a...

Страница 61: ...ent of the maximum field current to be used during the regen braking mode Resolution Example Min Max Set Per unit value If set at 71 0 40 51 to 255 0 185 amps 3 7 amps Important Note The function is u...

Страница 62: ...ct on plugging distance Note Vehicles equipped with regenerative braking will vary the regen current with pedal position However minimum regen current is fixed at 50 amps The pedal position will vary...

Страница 63: ...tting 0 to 255 Resolution 815 per set unit Example Setting of 20 20 815 52 68 3 FUNCTION 24 FIELD WEAKENING START Push CONT 9 This function allows for setting the armature current at which minimum fie...

Страница 64: ...E CONTROLLED ACCELERATION AND 1A TIME Push CONT 5 Same as Function 48 This C A AND 1A TIME takes effect when the Mode 2 settings are called for by the Interactive Dash Display FUNCTION 53 MODE 2 REGEN...

Страница 65: ...y the Interactive Dash Display FUNCTION 60 MODE 4 ARMATURE CONTROLLED ACCELERATION AND 1A TIME Push CONT 13 Same as Function 48 This C A AND 1A TIME takes effect when the Mode 4 settings are called fo...

Страница 66: ...nction 4 The function along with the maximum field current Function 8 sets the maximum torque of the motor The field weakening start setting is adjusted by Function 24 This function sets the armature...

Страница 67: ...ny 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 Func...

Страница 68: ...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...

Страница 69: ...wo 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...

Страница 70: ...o 1 19V SL2 1 50V SL1 2 80V SL1 3 11V SL2 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...

Страница 71: ...1 83 20 93 2 47 20 126 Proportional Reduce 1 10 66 56 3 20 66 163 Creep Speed 1 82 21 93 2 48 21 127 Proportional Reduce 1 08 67 55 3 22 67 164 Zero Speed 1 80 22 92 2 50 22 128 Proportional Reduce 1...

Страница 72: ...Tens Units HS or PC None 19 20 20 HM Thou Hun HS or PC None 20 21 21 Auto Regen HS or PC None 21 22 22 Mode Reference HS or PC For DD on power up 22 23 23 Field PWM Gain HS or PC None 23 24 24 FW Sta...

Страница 73: ...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...

Страница 74: ...PC None 106 107 58 Dash Display Min Fld 3 HS or PC None 107 108 59 Dash Display If Im Ratio 3 SL 3 HS or PC None 108 109 60 Dash Display CA 4 HS or PC None 109 110 61 Dash Display FWS 4 Ratio2 4 HS or...

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