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INSTALLATION AND OPERATION

SX TRANSISTOR CONTROL

Page

TRACTION

STATUS CODE

DESCRIPTION OF STATUS

CAUSE OF STATUS INDICATION

-15

Battery voltage is too low at initial key switch
closure.

This status code will be displayed when the
battery volts are less than 68.3 volts at initial key
switch on.

MEMORY RECALL

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

Circuits valid

for

Traction

Controller

SYMPTOM

Control will not operate.

POSSIBLE CAUSE

Discharged battery



Check battery voltage to confirm that it is a minimum

of 68.3 volts. Charge battery, if required.

Defective battery



Check each battery cell for proper voltage (greater

than 1.95 volts at cell). Replace or repair battery.

Incorrect control card adjustment.



Check Function 15 for proper adjustment for battery

being used. See Handset instruction sheet for
details. Adjust to proper settings.

Check “minimum” battery volts at P1 & NEG.

POWER CONNECTIONS

POS

NEG

IEL

FU1

P17

LINE

P12

AKE

+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

CORRECTIVE ACTIONS

TROUBLE-SHOOTING DIAGRAM

Circuits valid

for

Traction

Controller

SYMPTOM

Control will not operate.

POSSIBLE CAUSE

Discharged battery



Check battery voltage to confirm that it is a

minimum of 68.3 volts. Charge battery, if
required.

Battery overcharged or incorrect battery used.



Check each battery cell for proper voltage

(maximum 2.4 volts per cell). If voltage is
excessive, check battery charger for proper
output voltage.

Incorrect control card adjustment.



Check Function 15 for proper adjustment for

battery being used. See Handset instruction
sheet for details. Adjust to proper settings.

Check “maximum” battery volts at P1 & NEG.

POWER CONNECTIONS

POS

NEG

IEL

FU1

P17

LINE

P12

AKE

+72V

72 VDC

Updated Sept 2019

Содержание IC3645SR7A353T4

Страница 1: ...ber 2005 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 FEATURES OF SX FAMILY OF MOTOR CONTROLLERS 4 2 1 Performance 4 2 1 1 Oscillator Card Features 4 2 1 1 a Standard Operation 4 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: ...els between the motor base speed and maximum weak field The desirability of this feature is enhanced by the elimination of the contactor and resistor required for field weakening with a series motor With a separately excited motor overhauling speed limit or downhill speed will also be more constant By its nature the shunt motor will try to maintain a constant speed downhill This characteristic can...

Страница 5: ...et by Function 24 and the accelerator input voltage is greater than 2 9 volts It is important to note that 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 changed by field personnel without the permission of the OEM Section 2 1 4 b Speed Limits This feature provid...

Страница 6: ...ls the thermal protector will automatically reset returning the control to full power Section 2 2 5 Low Voltage Batteries under load particularly if undersized or more than 80 percent discharged will produce low voltages at the control terminals The SX control is designed for use down to 50 percent of a nominal battery voltage of 36 84 volts and 75 percent of a nominal battery voltage of 24 volts ...

Страница 7: ...l 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 are equipped with reverse battery protection such that if th...

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 P1 1 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: ...ction 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 the vehicle after the installation of the control s in the vehicle GE will not honor control failures during the warran...

Страница 13: ...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 Interconnecting wire runs should carry a level designation If wires are the same level and same type signal group those wi...

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: ...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 PLUG CURRENT LIMIT Push 5 This function allows for the adjustment of the maximum current allowed during plug braking Range 0 to 225 amps Set 0 to 255 Resolution 0 5 amps per unit Example Setting of 20 52 20 X 5 62 Amps FUNCTION 6 ARMATURE DECELERATION RATE This function allows for the...

Страница 31: ...3 FUNCTION 13 ROLLING RADIUS This function allows for defining the vehicles rolling radius in inches Range 0 to 25 5 inches Set 0 to 255 Resolution 0 1 inch per set unit Example Setting of 103 103 x 0 1 10 3 inches FUNCTION 14 NOT USED FUNCTION 15 BATTERY VOLTS In order for the battery discharge indication feature of this control to operate properly this function must be set to a value between 70 ...

Страница 32: ...he microprocessor Because absolute memory locations need to be known this function should not be used without detailed instructions from the GE application engineer To ensure optimum operation of the control this function must be left with zero stored in this register FUNCTION 26 RATIO OF FIELD TO ARMATURE AMPS This function sets the ratio between armature and field current when transitioning from...

Страница 33: ...one 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 Monitor PC or PDA None 25 26 Ratio of Field to Armature Amps 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 ...

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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