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INSTALLATION AND OPERATION

SX TRANSISTOR CONTROL

Page

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 current
draw in the motor field is less than 1.3 amps and
armature current is greater than 100 amps for more
than 1.27 seconds during the run mode.

MEMORY RECALL

YES

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

Circuits valid

for

Traction

Controller

SYMPTOM

Control will not operate.

POSSIBLE CAUSE

Motor field is open circuit



Replace motor

Loose between control and motor field



Check connections

Defective 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

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

Circuits valid

for

Traction

Controller

SYMPTOM

Line contactor does not close when
capacitor does not pre-charge.

POSSIBLE CAUSE

Defective control fuse.



Check control fuse for open circuit
condition. Replace fuse, if
necessary.



Turn key off and wait 1 minute,
then try again.

Defective control.



Replace controller unit.

POWER CONNECTIONS

TO CONTROL

POS

NEG

IEL

BAT

FU1 *

LINE *

400A

FU3 *

10A

Updated Sept 2019

Содержание IC3645SR7A353T3

Страница 1: ...ne 2003 INTRODUCTION Section 1 0 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 FEATURES OF SX FAMILY OF MOTOR CONTROLLERS Section 2 0 4 2 1 Performance 4 2 1 1 Oscillator Card Features 4 2 1 1 a Standard Operation 5 2 1 1 b Control Acceleration 5 2 1 2 Current Limit 5 2 1 3 Regenerative Braking to Base Speed 5 ...

Страница 2: ...le 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 Power Signals Level HP 1...

Страница 3: ...peed 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 EMF which depend...

Страница 4: ...e 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 levels between the motor base speed and maximum ...

Страница 5: ...will increase until it reaches a preset value 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 Section 2 1 ...

Страница 6: ...t 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 maintain the transistors within their t...

Страница 7: ...nication Port This serial communication port can be used with Interactive Custom Dash Displays to allow changes to vehicle operating parameters by the operator 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...

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: ...for Neighborhood Electric Vehicle Application POWER CONNECTIONS POS A1 F1 NEG A2 F2 FIELD ARMATURE FU1 FUSE KEY SWITCH L P9 P7 P8 P1 P 11 7 P2 P6 P4 P5 TURF 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: ...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 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 welding be performed on th...

Страница 13: ...ines 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 noted by exception Inter...

Страница 14: ... 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 plug ...

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: ... P22 P23 P20 RS232 72V NEG 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: ...V 72V 72V P22 P23 P20 RS232 72V NEG 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: ...esistance 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 P3 NEG INPUT START SW P12 REGEN BRAKE SW P21 MOTOR OVER TEMP 72V 72V 72V 72V 72V 72V 72V P22 P23 P20...

Страница 19: ...D ARMATURE FU1 L P1 P17 P2 LINE NEG INPUT START SW P12 REGEN BRAKE SW 72V 72V 72 VDC 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: ...egative 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 P3 NEG INPUT START SW P12 REGEN BRAKE SW P21 MOTOR OVER TEMP 72V 72V 72V 72V 72V 72V 72V P22 P23 P20 RS232 72V NEG TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 23 Motor field current is too ...

Страница 21: ...is 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 Vol...

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: ...E 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 ...

Страница 27: ... P12 REGEN BRAKE SW P21 MOTOR OVER TEMP 72V 72V 72V 72V 72V 72V 72V P22 P23 P20 RS232 72V NEG 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: ... Replace 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 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: ...nt of the armature current limit of the control during motoring Range 0 to 350 amps Set 0 to 255 Resolution 1 38 amps per unit Example Setting of 255 255x1 38 350 amps FUNCTION 5 NOT USED FUNCTION 6 NOT USED FUNCTION 7 NOT USED FUNCTION 8 MAX FIELD CURRENT This function allows for the adjustment of the maximum field current in order to obtain the maximum torque of the motor Range 0 to 30 amps Set ...

Страница 31: ...This value is determined by GE application engineering and should be set using the OEM setting specifications for this vehicle FUNCTION 19 PEDAL DOWN OR BRAKE REGEN RATE This function adjusts the rate at which speed is reduced during regenerative when a direction change is made or the brake switch is closed in neutral Setting 1 to 255 Setting of 1 Most aggressive braking Setting of 255 Least aggre...

Страница 32: ...of the last stored status code recorded of the 16 stored status codes These stored status codes have caused a PMT controller shutdown and or disruption of normal vehicle operation FUNCTION 29 HOUR METER TENS AND UNITS HOURS SET This function allows for the adjustment of the tens and units hours of the hour meter Range 0 to 99 Set 0 to 99 Example 9999 Hours FUNCTION 30 HOUR METER THOUSANDS AND HUND...

Страница 33: ...n Point PC or PDA None 21 22 NOT USED PC or PDA None 22 23 Error Compensation PC or PDA None 23 24 NOT USED 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 Hundreds PC or PDA None 30 31 Aux HM Tens One...

Страница 34: ...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 35: ...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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