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INSTALLATION AND OPERATION

SX TRANSISTOR CONTROL

Page

SEPARATELY EXCITED (SX) TRANSISTORIZED TRACTION MOTOR CONTROL

AND SERIES PUMP MOTOR CONTROL

INSTALLATION AND OPERATION MANUAL

(IC3645SR4W746N5 and IC3645SP4U450N10)

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.

Table of Contents

General Electric Company October 2002

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 SX FAMILY OF MOTOR CONTROLLERS.....................................................................................6

2.1

Performance ..............................................................................................................................6

2.1.1 Oscillator

Card

Features...................................................................................................6

2.1.1.a

Standard

Operation...................................................................................................6

2.1.1.b

Creep

Speed ...............................................................................................................6

2.1.1.c

Controlled Acceleration and 1A Time .....................................................................6

2.1.2 Current

Limit.......................................................................................................................6

2.1.3 Braking................................................................................................................................6

2.1.3.a

Plug

Braking...............................................................................................................6

2.1.3.b

Regenerative Braking to Zero Speed.......................................................................6

October 2002

Содержание IC3645SR4W746N5

Страница 1: ...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 direct...

Страница 2: ...charge Indication BDI 8 2 3 4 a Internal Resistance Compensation 8 2 3 5 Handset 8 2 3 6 RS 232 Communication Port 8 2 3 6 a Dash Display Interaction Modes 8 2 3 7 Circuit Board Coil Driver Modules 9...

Страница 3: ...ANAGEMENT MODULE TMM 51 5 1 General Features 51 5 2 Operation 51 5 3 Installation 51 5 4 Connection Diagrams 51 5 4 1 TMM7A Card Connections 51 5 4 2 TMM7A Typical Brush Wear Sensor Connections 51 5 4...

Страница 4: ...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 5: ...n 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...

Страница 6: ...y load currents are detected this circuit overrides the oscillator and limits the average current to a value set by Function 4 and Function 8 of the Handset The C L setting is based on the maximum the...

Страница 7: ...rectional 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 direct...

Страница 8: ...ng hours match the hours set into the maintenance alert register This feature is set with the Handset using Functions 19 and 20 The operator is alerted that maintenance on the vehicle is required Sect...

Страница 9: ...itch closure to negative Current limit and controlled acceleration adjustable Battery Discharge Indicator interrupt compatible Coil driver module designed to operate the line contactor see Section 2 3...

Страница 10: ...ent 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 vo...

Страница 11: ...OUTLINE DRAWINGS ELEMENTARY DRAWINGS AND INPUTS OUTPUTS SX TRANSISTOR CONTROL Page 11 October 2002 Section 3 2 Outline SX 4 Package Size...

Страница 12: ...OUTLINE DRAWINGS ELEMENTARY DRAWINGS AND INPUTS OUTPUTS SX TRANSISTOR CONTROL Page 12 October 2002 Section 3 3 Outline SX 3 and SR 3 Package Size...

Страница 13: ...OS A1 F1 NEG A2 F2 FIELD ARMATURE FU1 FU3 FU5 PUMP CONNECTION POS L 1A REG BRAKING POTENTIOMETER INPUT REGEN OUTPUT SIGNAL I MOTOR VOLTAGE OUT BDI INTERRUPT KEY SWITCH DIRECT SWITCH P18 P17 P2 P6 P4 P...

Страница 14: ...TATUS CODE 95 INPUT STATUS CODE 91 INPUT STATUS CODE 90 INPUT STATUS CODE 95 INPUT STATUS CODE 94 INPUT BRUSH WEAR OUTPUT OVER TEMP OUTPUT 2 1 3 4 5 6 8 9 16 11 13 14 PY7 PY12 PY10 PY11 10 12 19 20 21...

Страница 15: ...RUSHWEAR INDICATER OUTPUT 14 TMM BRUSHWEAR TMM1 OVER TEMPERATURE OUTPUT 15 IMOTOR OUT NOT APPLICABLE 16 MOTOR CURRENT COMPENSATION STATUS CODE 90 INPUT 17 LINE CONTACTOR DRIVER AND SUPPRESSION LINE CT...

Страница 16: ...echarging 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...

Страница 17: ...ral 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 powe...

Страница 18: ...own by the GE control GE 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 befor...

Страница 19: ...e roughness of 64 microinches or better This finish is consistent with cold rolled or extruded aluminum Care should always be taken in the handling and storage of controllers The base of the control s...

Страница 20: ...the control unit with desired orientation on mounting plate with mounting holes aligned b Move the control slightly in all directions to eliminate voids and enhance the distribution of the thermal co...

Страница 21: ...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 troub...

Страница 22: ...control and the Dash Display or Handset Defective Dash Display or Handset Replace Dash Display or Handset NEG FU3 KEY SWITCH P1 P2 FU5 P18 1A L P17 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF...

Страница 23: ...ntrol Replace the controller unit NEG FU3 KEY SWITCH P1 P2 FU5 P18 1A SP L P17 P6 SEAT SW P3 START SW P4 FORWARD SW P5 REVERSE SW TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION...

Страница 24: ...ORWARD SW P5 REVERSE SW P7 ACC POT P9 NEG TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 06 Accelerator depressed with no direction selected This status code will be displayed w...

Страница 25: ...ut circuit Disconnect wire from P7 and measure voltage at wire to negative Should be zero volts for potentiometer type and less than 4 2 volts for solid state type accelerator input P9 P7 ACC POT NEGA...

Страница 26: ...volts NEG FU3 KEY SWITCH P1 P2 FU5 P18 1A SP L P17 P6 SEAT SW P3 START SW P4 FORWARD SW P5 REVERSE SW TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 11 Start switch closed on po...

Страница 27: ...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...

Страница 28: ...7 P2 P6 P4 SEAT SW SP P3 FWD REV P5 ACCEL START SW P1 P7 P9 F1 F2 FIELD F1 F2 ACCEL START SW TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 24 Motor field current is high on sta...

Страница 29: ...P2 FU5 P18 1A L P17 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 28 Motor field current has remained too high during the run mode This status code will be displayed when the...

Страница 30: ...tus codes displayed in 20 hour intervals THE PRESENCE OF THIS STATUS CODE IS NOT NECESSARILY INDICATIVE OF A CONTROL ISSUE THIS STATUS CODE MAY INDICATE AN APPLICATION ISSUE DISPLAY OF THIS STATUS COD...

Страница 31: ...P18 P17 P2 P6 P4 SEAT SW SP P3 FWD REV P5 ACCEL START SW P1 P7 P9 F1 F2 FIELD F1 F2 ACCEL START SW TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 44 Armature transistor did not...

Страница 32: ...TION POS A1 NEG A2 ARMATURE FU1 LINE A2 A1 1A OSC CARD CONNECTIONS L 1A DIRECT SW P18 P17 P2 P6 P4 SEAT SW SP P3 FWD REV P5 ACCEL START SW P1 P7 P9 F1 F2 FIELD F1 F2 ACCEL START SW TRACTION STATUS COD...

Страница 33: ...6 P4 SEAT SW SP P3 FWD REV P5 ACCEL START SW P1 P7 P9 F1 F2 FIELD F1 F2 ACCEL START SW TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 51 Capacitor volts are low before the line...

Страница 34: ...P17 P2 P6 P4 SEAT SW SP P3 FWD REV P5 ACCEL START SW P1 P7 P9 F1 F2 FIELD F1 F2 ACCEL START SW TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 64 The line driver input P2 17 is...

Страница 35: ...TUS 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 it...

Страница 36: ...OL POWER CONNECTION POS A1 NEG A2 ARMATURE FU1 LINE A2 A1 1A OSC CARD CONNECTIONS L 1A DIRECT SW P18 P17 P2 P6 P4 SEAT SW SP P3 FWD REV P5 ACCEL START SW P1 P7 P9 F1 F2 FIELD F1 F2 ACCEL START SW TRAC...

Страница 37: ...tt 50V 36V 70V 48V 96V 72 80V FU3 FU5 KEY SWITCH CONTROL POWER CONNECTION POS A1 NEG A2 ARMATURE FU1 LINE A2 A1 1A OSC CARD CONNECTIONS L 1A DIRECT SW P18 P17 P2 P6 P4 SEAT SW SP P3 FWD REV P5 ACCEL S...

Страница 38: ...MORY R CALL E NO CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Traction Controller SYMPTOM The Control will not operate and can only be reset by cycling the accelerator POSSIBLE CAUSE...

Страница 39: ...us code is displayed immediately additional status codes are displayed in 20 hour intervals P16 SC90 NEG USER SW WHEN SR Series PUMP CONTROL IS USED TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF...

Страница 40: ...played immediately additional status codes are displayed in 20 hour intervals SC93 POS P3 USER SW WHEN SR Series PUMP CONTROL IS USED TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICAT...

Страница 41: ...is displayed immediately additional status codes are displayed in 20 hour intervals SC94 POS P5 USER SW WHEN SR Series PUMP CONTROL IS USED TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS I...

Страница 42: ...layed immediately additional status codes are displayed in 20 hour intervals SC95 POS P8 USER SW WHEN SR Series PUMP CONTROL IS USED TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATI...

Страница 43: ...un 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 selecte...

Страница 44: ...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 INDICATIO...

Страница 45: ...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...

Страница 46: ...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 Con...

Страница 47: ...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 INDICA...

Страница 48: ...Y12 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 voltag...

Страница 49: ...e status code 51 Also do not connect any loads to the low 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 SP...

Страница 50: ...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...

Страница 51: ...y to warn maintenance personnel that the motor brushes need to be replaced before they wear to the point of causing destructive damage to the motor commutator surface The BWI function is compatible wi...

Страница 52: ...5 6 8 11 10 12 BATTERY POSITIVE PUMP CONTROL CONNECTIONS PL2 16 PL2 11 PL2 15 PL2 3 PL2 4 PL2 5 PL2 6 PL2 8 PL2 9 PL2 13 PL2 20 1 A1 1 A1 2 A2 1 A3 1 A2 2 A3 2 TRACTION PL2 14 TRACTION PL2 20 Section...

Страница 53: ...8 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 c...

Страница 54: ...ult 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 E...

Страница 55: ...ed 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...

Страница 56: ...rtant 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 chang...

Страница 57: ...ts 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 a...

Страница 58: ...FUNCTION 25 MONITOR Push CONT 10 This function allows the monitoring of certain control functions by looking directly at the RAM of the microprocessor Because absolute memory locations need to be kno...

Страница 59: ...vided by 10 and rounded to the lowest whole number Example Setting of 45 45 10 4 5 4 VAL IFIELD VAL IMOTOR X 024 This FW RATIO takes effect when the Mode 1 settings are called for by the interactive D...

Страница 60: ...the interactive Dash Display FUNCTION 58 MODE 3 FW RATIO Push CONT 11 Same as Function 50 This FW RATIO takes effect when the Mode 3 settings are called for by the interactive Dash Display FUNCTION 5...

Страница 61: ...justed 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...

Страница 62: ...30 amps FUNCTION 3 CONTROLLED ACCELERATION 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 to the motor on hard...

Страница 63: ...e to the control and or motors FUNCTION 28 FAULT 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 statu...

Страница 64: ...Push CONT 5 Same as function 48 FUNCTION 53 MODE 2 SPEED LIMIT 2 SL2 Push CONT 6 Same as Function 49 FUNCTION 54 MODE 2 SPEED LIMIT 3 SL3 Push CONT 7 Same as Function 50 FUNCTION 55 NOT APPLICABLE Th...

Страница 65: ...00ZX From the Dash Display the operator may select 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...

Страница 66: ...I 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...

Страница 67: ...its 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 Mode Reference HS or PC For DD on power up 22 23 23 Field PWM Gain HS or PC None 23 24...

Страница 68: ...us 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...

Страница 69: ...C 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 1...

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