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INSTALLATION AND OPERATION

SX TRANSISTOR CONTROL

Page

15

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.

Updated Sept 2019

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Содержание IC3645SR7A353E1

Страница 1: ...r 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 2004 Table of Contents 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 Sept 2019 Updated 2 2 1 Static Return to O...

Страница 2: ...ighborhood Electric Vehicle Application Input Output List 11 Section 4 0 TROUBLESHOOTING 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...

Страница 3: ...ves 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 increases the motor slows...

Страница 4: ...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 adjustments of overdrive level...

Страница 5: ...lue set by Function 10 and transistor Q2 on time will increase until it reaches 100 on time Once both of the above conditions have been met and regen current limit can no longer be maintained the braking function is canceled Part of the energy produced by the motor during regen is returned to the battery and part is dumped in the motor as heat ARM Q1 Q2 Figure 5 Section 2 1 4 Auxiliary Speed Contr...

Страница 6: ...s Codes Section 2 2 2 Accelerator Volts Hold Off Section 2 3 1a Standard Status Codes This feature checks the voltage level at the accelerator input whenever the key switch is activated If at start up the voltage is greater than 0 9 volts the control will not operate This feature assures that the control is calling for low speed operation at start up The SX control has a wide variety of Status Cod...

Страница 7: ...erator Or it can be used by service personnel to dump control operating information and settings into a personal computer program Section 2 3 4 Circuit Board Coil Driver Modules A Coil driver is internal to the control card and is the power device that operate the Line contactor coil On command from the control card these drivers initiate opening and closing the contactor coils All driver modules ...

Страница 8: ... 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 Argument 06 Field C...

Страница 9: ...OUTLINE DRAWINGS ELEMENTARY DRAWINGS AND INPUTS OUTPUTS SX TRANSISTOR CONTROL Page 9 Section 3 2 Outline Package Size Updated Sept 2019 ...

Страница 10: ...Neighborhood Electric Vehicle Application POWER CONNECTIONS POS A1 F1 NEG A2 F2 FIELD ARMATURE FU1 FUSE KEY SWITCH L P9 P7 P8 P1 P17 P2 P6 P3 P4 P5 TURF SW START SW FORWARD SW REVERSE SW ACC POT P12 TACHOMETER P15 P14 P16 P10 BUZZER REGEN BRAKE LINE RED GREEN BLACK 400A P3 START SWITCH P21 MOTOR OVER TEMP Updated Sept 2019 ...

Страница 11: ...H 6 BATTERY VOLTS POS FROM TURF SPEED LIMIT SWITCH 7 ACCELERATOR INPUT VOLTAGE SIGNAL 8 ACCELERATOR NEGATIVE 9 ACCELERATOR POT 5 VOLTS SUPPLY 3 WIRE POT 10 BACK UP ALARM 11 N A 12 BATTERY NEG FROM REGEN SWITCH 13 N A 14 TACHOMETER INPUT SIGNAL 15 TACHOMETER 12 VOLT OUTPUT 16 NEGATIVE FOR TACH 17 LINE CONTACTOR COIL DRIVER 18 N A 19 N A 20 NEGATIVE DP9 21 BATTERY VOLTS POS FROM MOTOR THERMAL SWITCH...

Страница 12: ...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 1000 hours of vehicle operation Inspection is Sept 2019 Updated in drive equipment cabling The following are specific examples of level L signals used DC busses less than 15 V and 250 mA 4 20 mA current loops Digi...

Страница 13: ...y electrical surges controlled by an output This suppression minimizes noise example a snubber is required on all inductive devices Unless specifically noted otherwise suppression for Section 4 2 6 Suppression controlled devices be taken in routing power cables in the vicinity of radio To prevent radio frequency RF interference care should 4 2 5 RF Interference HP wires Do not loop level L signal ...

Страница 14: ...ptoms of intermittent mis operation or shutdown 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 before GE control replacement Also for long term reliable control operation the plug terminals must be maintained per these instructions with the recommended con...

Страница 15: ...me 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...

Страница 16: ... P3 NEG INPUT START SW 72V 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 1 4V 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 Tract...

Страница 17: ...2 72V NEG P3 NEG INPUT START SW 72V TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 09 Both the forward and reverse switches or the turf and reverse switches are closed at the same time This status code will be displayed when P4 and P5 or P6 and P5 are greater than 50 of battery volts MEMORY RECALL NO CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Traction Con...

Страница 18: ...istance should be greater than 20K ohms Defective control Disconnect wire from P3 Measure voltage from P3 to negative Voltage should be 2 5 to 5 0 volts If not replace the control L P9 P7 P8 P1 P17 P2 P6 P4 P5 TURF SW FORWARD SW REVERSE SW ACC POT TACHOMETER P15 P14 P16 P10 BUZZER RED GREEN BLACK P12 REGEN BRAKE SW P21 MOTOR OVER TEMP 72V 72V 72V 72V 72V 72V 72V P22 P23 P20 RS232 72V NEG P3 NEG IN...

Страница 19: ...MATURE FU1 L P1 P17 P2 LINE NEG INPUT START SW P12 REGEN BRAKE SW 72V 72V 72 VDC 72V 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 Circuits valid...

Страница 20: ...ative and P8 Open wire exists between P7 and potentiometer wiper L P9 P7 P8 P1 P17 P2 P6 P4 P5 TURF SW FORWARD SW REVERSE SW ACC POT TACHOMETER P15 P14 P16 P10 BUZZER RED GREEN BLACK P12 REGEN BRAKE SW P21 MOTOR OVER TEMP 72V 72V 72V 72V 72V 72V 72V P22 P23 P20 RS232 72V NEG P3 NEG INPUT START SW 72V TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 23 Motor field current is to...

Страница 21: ... too low This status code will be displayed when the internal power supply of the control dips below 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 closed by opening and closing the key switch POSSIBLE CAUSE Discharged battery Check battery to insure proper state of charge Volta...

Страница 22: ...ol 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 greater than 1...

Страница 23: ...oftware can be used to monitor control operation and it will display a value for the motor amps that is less than 123 corresponding to 2 4V 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 turn off This w...

Страница 24: ...ATUS 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 selected MEMORY RECALL YES CORRECTIVE ACTIONS TROUBLE SHOOTING DIAG...

Страница 25: ...ive control Replace 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 ...

Страница 26: ...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 ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Traction Controller SYMPTOM Co...

Страница 27: ...TOR OVER TEMP 72V 72V 72V 72V 72V 72V 72V P22 P23 P20 RS232 72V NEG P3 NEG INPUT START SW 72V 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 current limit The line contactor will drop out and the key switch will have to be recycled t...

Страница 28: ...lace controller unit POWER CONNECTIONS POS A1 F1 NEG A2 F2 FIELD ARMATURE FU1 L P1 P17 P2 LINE NEG INPUT START SW P12 REGEN BRAKE SW 72V 72V 72 VDC 72V TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 77 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 T...

Страница 29: ...RIPTION OF STATUS CAUSE OF STATUS INDICATION 82 If the armature current greater than 280 amps for longer than 3 5 seconds in control mode the armature motoring current will be turned off This status code will be displayed when the armature current exceeds 280 amps for 3 5 sec and the accelerator pedal is calling for maximum performance in the control mode MEMORY RECALL NO CORRECTIVE ACTIONS TROUBL...

Страница 30: ... 2 X Pi X RR 5280 X 12 X GR X PPR X 005 Setting 3600 X 2 X 3 14159265 X 9 5280 X 12 X 8 91 X 4 X 005 Setting 203575 11290 Setting 18 CREEP SPEED FUNCTION 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 2 to 15 on time Range 0 to 255 Set 0 047 per set unit Resolution Setting of 205 ...

Страница 31: ...ing regenerative braking 32 to 350 amps Range 1 to 255 Set 1 38 amps per set unit Resolution Setting of 221 221x1 38 Example 212 amps FUNCTION 10 REGEN FIELD CURRENT LIMIT This function allows for the adjustment of the maximum field current limit during regenerative braking 0 to 30 amps Range 51 to 255 Set 0 147 amps per set unit Resolution Setting of 180 180 51 x0 147 Example 19 0 amps CAUTION Do...

Страница 32: ...is function allows for defining the vehicles gear ratio in X to 1 format 0 to 25 5 units Range 0 to 255 Set 0 1 per set unit Resolution Setting of 103 103 x 0 1 Example 10 3 to 1 gear ratio FUNCTION 17 FIELD GAIN This function allows for the adjustment of the pedal field gain This value is determined by GE application engineering and should be set using the OEM setting specifications for this vehi...

Страница 33: ...ARMATURE AMPS This function sets the ratio between armature and field current when transitioning from minimum field to maximum field current The setting represents the quantity of field current changed for each 1 amp of armature current changed Example Resolution Max Set If set at 100 Per unit value Change 0 072 amps 0 00072 amps 0 to 255 18 FUNCTION 27 HOUR METER MINUTES This function adjusts the...

Страница 34: ...Regulation Point PC or PDA None 21 22 NOT USED PC or PDA None 22 23 Error Compensation PC or PDA None 23 24 Field Weakening Start or Motor Knee Point PC or PDA None 24 25 NOT USED PC or PDA None 25 26 NOT USED PC or PDA None 26 27 Hour Meter Minutes PC or PDA None 27 28 Stored Status Code Count Pointer PC or PDA None 28 29 Hour Meter Tens and Units PC or PDA None 29 30 Hour Meter Thousands and Hun...

Страница 35: ...Only 66 67 Hours Tens Ones 9 PC or PDA Reset to Zero Only 67 68 Hours Thou Hun 9 PC or PDA Reset to Zero Only 68 69 Stored Status Code 10 PC or PDA Reset to Zero Only 69 70 BDI 10 PC or PDA Reset to Zero Only 70 71 Hours Tens Ones 10 PC or PDA Reset to Zero Only 71 72 Hours Thou Hun 10 PC or PDA Reset to Zero Only 72 73 Stored Status Code 11 PC or PDA Reset to Zero Only 73 74 BDI 11 PC or PDA Rese...

Страница 36: ...able PC or PDA None 108 109 Not applicable PC or PDA None 109 110 Not applicable PC or PDA None 110 111 Not applicable PC or PDA None 111 112 Not applicable PC or PDA None 112 113 Secure HM Tens Ones PC or PDA OEM Read Only 113 114 Secure HM Thou Hun PC or PDA OEM Read Only 114 115 Secure Aux HM Tens Ones PC or PDA OEM Read Only 115 116 Secure Aux HM Thou Hun PC or PDA OEM Read Only 116 117 Field ...

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