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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

(GE Models IC3645SR5W606F1 [software rev. BL3C and higher] and IC3645SP5U600F1)

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 May 2003

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

...........................................................................................6

2.1.2 Current

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

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

2.1.3.a

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

2.1.3.b

Pedal

Position

Plug

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

2.1.3.c

Auto

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

2.1.4 Auxiliary

Speed

Control ....................................................................................................6

Revised May 2003

Содержание SX Series

Страница 1: ... 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 May 2003 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...

Страница 2: ...nteractive Dash Display Modes 8 2 3 7 Circuit Board Coil Driver Modules 9 2 3 8 Truck Management Module TMM 9 2 4 Hydraulic Pump Control 9 Section 3 0 ORDERING INFORMATION ELEMENTARY AND OUTLINE DRAWINGS 10 3 1 Ordering Information for Separately Excited Controls 10 3 2 Outline SX 4 and SR 4 Package Size 11 3 3 Outline SX 3 and SR 3 Package Size 12 3 4 Traction Elementary 13 3 5 Pump Elementary 14...

Страница 3: ...shooting Instructions 20 4 6 Traction Controller Status Codes 22 39 4 7 TMM Module Status Codes 39 41 4 8 Pump Control Status Codes 42 52 Section 5 0 SX FAMILY GE HANDSET INSTRUCTIONS 53 5 1 General Features 53 5 2 Purpose Setup Functions 53 5 3 Setup Function Procedures 54 5 3 1 Setup Mode 54 5 3 2 Status Code Scrolling 54 5 3 3 SX Handset Plug Connections Outline Drawing 54 5 4 Setup Functions f...

Страница 4: ...ypical 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 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 inc...

Страница 5: ...tion 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 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 ove...

Страница 6: ...trol Because of the flyback current through 3REC the motor current is usually greater than battery current except at 100 ON time Section 2 1 3 Braking Section 2 1 3 a Regenerative Braking to Zero Speed Slow down is accomplished when reversing direction by providing a small amount of retarding torque for deceleration If the vehicle is moving and the directional lever is moved from one direction to ...

Страница 7: ...onally if the seat switch or key switch is opened the control shuts off and cannot be restarted until the directional lever is returned to neutral A time delay of approximately 2 seconds is built into the seat switch input to allow momentary opening of the seat switch if a bump is encountered Section 2 2 2 Accelerator Volts Hold Off This feature checks the voltage level at the accelerator input wh...

Страница 8: ...urs 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 Section 2 3 4 Battery Discharge Indication BDI The latest in microprocessor technology is used to provide accurate battery state of charge information and to supply passive and active warning signals to the ve...

Страница 9: ...led acceleration adjustable Battery Discharge Indicator interrupt compatible 0 100 on controlled by accelerator voltage P7 Operation of voltage regulator card This card provides the basic functions required for controlling the pump control optional contactors and PMT functions Battery positive is applied through a main control fuse to the key switch energizing the control card power supply input t...

Страница 10: ...gument 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 volts 3 36 volts 6 24 36 volts 7 72 80 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...

Страница 11: ...OUTLINE DRAWINGS ELEMENTARY DRAWINGS AND INPUTS OUTPUTS SX TRANSISTOR CONTROL Page 11 Revised May 2003 Section 3 2 Outline SX 4 and SR 4 Package Size ...

Страница 12: ...OUTLINE DRAWINGS ELEMENTARY DRAWINGS AND INPUTS OUTPUTS SX TRANSISTOR CONTROL Page 12 Revised May 2003 Section 3 3 Outline SX 3 and SR 3 Package Size ...

Страница 13: ...Y STICK CONTROLLER KEY SWITCH A2 A1 F1 F2 MOTOR CONNECTIONS CUSTOMER SUPPLIED TRACTION CONTROL PLUG PL 2 DIRECT SWITCH P18 P6 P10 P1 P7 P13 BRAKE SWITCH L P17 P2 24V FAN ENABLE FAN SEAT SWITCH P9 ACCEL SWITCH P8 P4 P5 FWD REV P20 TEMPERATURE INPUT FROM PUMP CONTROL OPEN INPUT OR VOLTAGE 3V BDI SIGNAL DISABLED P14 TEMPERATURE SENSOR INPUT FROM TRACTION MOTOR TACH SIGNAL 12V TACH P23 P22 LINE P21 2 ...

Страница 14: ...STATUS CODE 95 INPUT STATUS CODE 91 INPUT STATUS CODE 90 INPUT STATUS CODE 95 INPUT STATUS CODE 94 INPUT STATUS CODE 92 INPUT BRUSH WEAR OUTPUT OVER TEMP OUTPUT P2 P1 P3 P4 P5 P6 P8 P9 P15 P16 P11 P13 P14 P18 P12 P19 P20 P21 PUMP CONTROL TEMP SPEED 2 SPEED 1 SPEED 3 SPEED 4 P7 POWER CONNECTION SUPPLIED BY CUSTOMER PUMP CONTROL POWER CONNECTION P A1 A2 N A1 A2 A2 A1 N KEY SW BATT BATT FU2 P LINE CO...

Страница 15: ...TOR INPUT TMM1 BRUSHWEAR INDICATER OUTPUT 14 LINEAR TRACTION MOTOR TEMPERATURE TMM1 OVER TEMPERATURE OUTPUT 15 NOT USED STATUS CODE 92 INPUT 16 NOT USED STATUS CODE 90 INPUT 17 LINE CONTACTOR DRIVER AND SUPPRESSION LINE CONTACTOR DRIVER 18 FAN PUMP CONTROL TEMPERATURE 0 COLD 19 NOT USED SPEED LIMIT 2 INPUT 20 TEMPERATURE FROM PUMP CONTROL SPEED LIMIT 3 INPUT 21 PARK BRAKE NEG SL1 SPEED LIMIT 4 INP...

Страница 16: ...nce procedures recharging 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 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 w...

Страница 17: ...t apply the general 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 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 unles...

Страница 18: ... be maintained per 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 recommen...

Страница 19: ...croinches 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 should be free from nicks bumps protrusions or any other foreign object that would prevent the control from sitting flush with the vehicle mounting surface Examine the base of the control to verify that it is in good cond...

Страница 20: ...o remove the control for service careful consideration must be given to removing the old thermal compound from the control and mounting surface prior to replacement of the unit Never re use thermal compound Use a putty knife or similar straight edge to carefully remove all thermal compound residue without damaging either mounting surface Flush the surfaces with a liquid de greaser or parts cleaner...

Страница 21: ...ary 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 ...

Страница 22: ... STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 01 No brake switch or deadman switch input no voltage to P6 This status code will be displayed when P6 is less than 50 battery volts MEMORY RECALL NO CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Traction Controller SYMPTOM Control will not operate POSSIBLE CAUSE Mis adjusted or defective brake or deadman switch Check t...

Страница 23: ...K BRAKE SWITCH 2 2K 2W TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 02 Optional truck configuration with directional switch input forward directional switch is closed on initial power up This status code will be displayed when P4 is greater than 60 of battery voltage at initial key switch on MEMORY RECALL NO CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Tr...

Страница 24: ...onal truck configuration with directional switch input reverse directional switch is closed on initial power up This status code will be displayed when P5 is greater than 60 of battery voltage at initial key switch on MEMORY RECALL NO CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Traction Controller SYMPTOM Control will not operate because of Static Return to Off SRO lock out POSS...

Страница 25: ...ol wires and connections shown in Trouble Shooting Diagram BDI INTERRUPT TO JOY STICK CONTROLLER TRACTION CONTROL PLUG PL 2 P10 P1 P7 P13 P9 ACCEL SWITCH P8 P20 TEMPERATURE INPUT FROM PUMP CONTROL OPEN INPUT OR VOLTAGE 3V BDI SIGNAL DISABLED P14 TEMPERATURE SENSOR INPUT FROM TRACTION MOTOR TACH SIGNAL 12V TACH P23 P22 KEY SWITCH DIRECT SWITCH P6 BRAKE SWITCH L P17 P2 SEAT SWITCH P4 P5 FWD REV P18 ...

Страница 26: ...DISABLED P14 TEMPERATURE SENSOR INPUT FROM TRACTION MOTOR TACH SIGNAL 12V TACH P23 P22 KEY SWITCH DIRECT SWITCH P6 BRAKE SWITCH L P17 P2 SEAT SWITCH P4 P5 FWD REV P18 24V FAN ENABLE FAN P21 NEG PARK BRAKE SWITCH 2 2K 2W TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 11 Accelerator volts too low on power up This status code will be displayed when accelerator volts are less th...

Страница 27: ...T FROM PUMP CONTROL OPEN INPUT OR VOLTAGE 3V BDI SIGNAL DISABLED P14 TEMPERATURE SENSOR INPUT FROM TRACTION MOTOR TACH SIGNAL 12V TACH P23 P22 KEY SWITCH DIRECT SWITCH P6 BRAKE SWITCH L P17 P2 SEAT SWITCH P4 P5 FWD REV P18 24V FAN ENABLE FAN P21 NEG PARK BRAKE SWITCH 2 2K 2W TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 15 Battery voltage is too low or control card is mis a...

Страница 28: ...g Battery over charged or incorrect battery used Check battery for proper open circuit voltage per table at right If voltage is excessive check battery charger for proper output voltage Check maximum battery volts at P1 and NEG NEG FU5 P1 NOMINAL BATTERY VOLTAGE MAXIMUM 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 OF STATUS CAUSE OF STAT...

Страница 29: ...roller unit NO GRAPHIC FOR THIS STATUS CODE TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 27 Control s power supply is less than 10 Volts DC This status code will be displayed when the control s power supply is less than 10 volts MEMORY RECALL YES CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Traction Controller SYMPTOM Line contactor opens and closes then ...

Страница 30: ... IF FUNCTION 7 IS NOT MIS ADJUSTED THE STATUS CODE INDICATES AN APPLICATION ISSUE WHERE A MOTOR IS BEING STALLED ETC DISPLAY OF THIS STATUS CODE SHOULD NOT TRIGGER THE RETURN OF A CONTROL FOR REPAIR OR REPLACEMENT TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 41 Open thermal protector TP or transistor over temperature This status code will be displayed when the voltage at t...

Страница 31: ...3 P22 KEY SWITCH DIRECT SWITCH P6 BRAKE SWITCH L P17 P2 SEAT SWITCH P4 P5 FWD REV P18 24V FAN ENABLE FAN P21 NEG PARK BRAKE SWITCH 2 2K 2W TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 43 Motor armature offset voltage is too low This status code will be displayed when the voltage at the current sensor input is less than 2 4 volts with no current flowing in the motor circuit...

Страница 32: ...KEY SWITCH DIRECT SWITCH P6 BRAKE SWITCH L P17 P2 SEAT SWITCH P4 P5 FWD REV P18 24V FAN ENABLE FAN P21 NEG PARK BRAKE SWITCH 2 2K 2W TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 45 Armature transistor did not turn on properly This status code will be displayed when during control operation the armature transistor fails to turn on properly This will result in a PMT conditio...

Страница 33: ...CTION MOTOR TACH SIGNAL 12V TACH P23 P22 KEY SWITCH DIRECT SWITCH P6 BRAKE SWITCH L P17 P2 SEAT SWITCH P4 P5 FWD REV P18 24V FAN ENABLE FAN P21 NEG PARK BRAKE SWITCH 2 2K 2W 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 too low during the run ...

Страница 34: ...rol fuse Check control fuse for open circuit Replace fuse if necessary Defective control Replace controller unit CONTROL POWER CONNECTION POS A1 F1 NEG A2 F2 FIELD ARMATURE FU1 A2 F2 LINE FU5 FU3 KEY SWITCH P9 P1 L P17 P2 P18 24V FAN ENABLE FAN A1 P13 P7 ACCEL SWITCH P8 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 57 Controller motor current sensor input too low during run...

Страница 35: ...2 LINE FU5 FU3 KEY SWITCH P9 P1 L P17 P2 P18 24V FAN ENABLE FAN A1 P13 P7 ACCEL SWITCH P8 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 65 The line coil or fan current is too high during the run mode This status code will be displayed when the current limit in the line coil is exceeded during the run mode The line contactor will drop out and the key switch will have to be r...

Страница 36: ...L POWER CONNECTION POS A1 F1 NEG A2 F2 FIELD ARMATURE FU1 A2 F2 LINE FU5 FU3 KEY SWITCH P9 P1 L P17 P2 P18 24V FAN ENABLE FAN A1 P13 P7 ACCEL SWITCH P8 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 67 The armature current exceeds the armature transistor limit This status code will be displayed when the armature transistor exceeds its specific current limit The control is re...

Страница 37: ...Y SWITCH P9 P1 L P17 P2 P18 24V FAN ENABLE FAN A1 P13 P7 ACCEL SWITCH P8 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 71 Accelerator potentiometer out of range for single accelerator potentiometer operation This status code will be displayed when the voltage at P7 is greater than 4 13V or less than 0 196V MEMORY RECALL YES CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circui...

Страница 38: ...tery plug connection Limit Voltage Limit Batt 50V 36V 70V 48V 96V 72 80V CONTROL POWER CONNECTION POS A1 F1 NEG A2 F2 FIELD ARMATURE FU1 A2 F2 LINE FU5 FU3 KEY SWITCH P9 P1 L P17 P2 P18 24V FAN ENABLE FAN A1 P13 P7 ACCEL SWITCH P8 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 77 Motor current is detected during regenerative braking This status code will be displayed when mo...

Страница 39: ...E SWITCH L P17 P2 SEAT SWITCH P4 P5 FWD REV P18 24V FAN ENABLE FAN P21 NEG PARK BRAKE SWITCH 2 2K 2W TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 82 Traction motor is stalled This status code will be displayed when the MPH is less than the value of setting of Function 16 and the Im is greater than 370A for 3 5 seconds MEMORY RECALL YES CORRECTIVE ACTIONS TROUBLE SHOOTING D...

Страница 40: ... battery negative Defective input switch shorted Defective TMM card Defective pump card P11 SC91 NEG USER SW WHEN SR Series PUMP CONTROL IS USED TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 93 Pump motor brush wear indicator has detected worn brush This status code will be displayed when the voltage at the respective terminal of the TMM or Pump Logic Card is at battery vol...

Страница 41: ...sitive Defective input switch open Defective TMM card Defective pump card SC94 POS P5 USER SW WHEN SR Series PUMP CONTROL IS USED 4 7K 2W NEG TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 98 Traction motor temperature has exceeded maximum temperature limit This status code will be displayed when the voltage at P14 is greater than 1 15 V MEMORY RECALL YES CORRECTIVE ACTIONS ...

Страница 42: ...ey switch is first turned on and or the vehicle may run 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 selected by the user Maintenance Code Hour Meter Functions 19 and 20 are programmed with the Handset and command the display of status code 99 If desired ...

Страница 43: ...nd Battery negative Replace switch if necessary 12 19 20 21 51 SPEED 2 SPEED 1 52 53 SPEED 3 SPEED 4 7 ACCELERATOR SWITCH BATT NEG SX 2 CONTROL PLUG PL2 PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 102 SPEED 2 switch closed with the key turned off This status code will be displayed when the SPEED 2 switch closes while the key switch is turned off MEMORY RECALL NO CORRECTIVE AC...

Страница 44: ...tive Replace switch if necessary 12 19 20 21 51 SPEED 2 SPEED 1 52 53 SPEED 3 SPEED 4 7 ACCELERATOR SWITCH BATT NEG SX 2 CONTROL PLUG PL2 PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 104 SPEED 4 switch closed with the key turned off This status code will be displayed when the SPEED 4 switch closes while the key switch is turned off MEMORY RECALL NO CORRECTIVE ACTIONS TROUBLE S...

Страница 45: ...il current is low This status code will be displayed when the current draw in the pump line contactor coil circuit is less than 100 milliamps and A2 is less than 88 of battery volts MEMORY RECALL NO CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Pump Controller SYMPTOM Pump contactor will not pick up Status code may vary between code 123 and code 124 POSSIBLE CAUSE Defective pump c...

Страница 46: ...tion on the control PUMP CONTROL PLUG PL 2 P2 P1 P18 P12 P19 P20 P21 PUMP CONTROL TEMP P7 L P17 ACCEL POT INPUT SPEED 2 SPEED 1 SPEED 3 SPEED 4 POWER CONNECTION SUPPLIED BY CUSTOMER KEY SW BATT P FU4 FU2 LINE CONTACTOR ARMATURE FIELD PUMP CONTROL POWER CONNECTION A1 A2 A1 A2 A2 A1 P N N BATT PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 127 Control logic card power supply is le...

Страница 47: ...ONNECTION SUPPLIED BY CUSTOMER KEY SW BATT P FU4 FU2 LINE CONTACTOR ARMATURE FIELD PUMP CONTROL POWER CONNECTION A1 A2 A1 A2 A2 A1 P N N BATT 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 the thermal protector is greater than 2 3 volts MEMORY RECALL NO CORRECTIVE A...

Страница 48: ...CTION SUPPLIED BY CUSTOMER KEY SW BATT P FU4 FU2 LINE CONTACTOR ARMATURE FIELD PUMP CONTROL POWER CONNECTION A1 A2 A1 A2 A2 A1 P N N BATT PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 143 Pump Controller motor current sensor input is too low This status code is displayed when the voltage at the current sensor is greater than 0 1 volts with no current flowing in the motor circui...

Страница 49: ...EED 4 POWER CONNECTION SUPPLIED BY CUSTOMER KEY SW BATT P FU4 FU2 LINE CONTACTOR ARMATURE FIELD PUMP CONTROL POWER CONNECTION A1 A2 A1 A2 A2 A1 P N N BATT PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 145 Power Transistor Q1 did not turn on properly This status code is displayed when during pump control operation the transistor fails to turn on MEMORY RECALL YES CORRECTIVE ACTI...

Страница 50: ...N SUPPLIED BY CUSTOMER KEY SW BATT P FU4 FU2 LINE CONTACTOR ARMATURE FIELD PUMP CONTROL POWER CONNECTION A1 A2 A1 A2 A2 A1 P N N BATT PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 148 Look Ahead test for A2 volts greater than 88 of battery volts This status code will be displayed when the voltage at A2 is greater than 88 of battery volts MEMORY RECALL YES CORRECTIVE ACTIONS TRO...

Страница 51: ...USTOMER KEY SW BATT P FU4 FU2 LINE CONTACTOR ARMATURE FIELD PUMP CONTROL POWER CONNECTION A1 A2 A1 A2 A2 A1 P N N BATT PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 151 Capacitor volts are low before the line contactor closes Internal card function during precharge This status code will be displayed during key on when the capacitor voltage is less than 85 of battery volts at in...

Страница 52: ...ATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION 180 Voltage at capacitor 1C is less than 14 volts This status code will be displayed when the voltage at P1 is less than 14 volts This occurs typically in the run mode of operation MEMORY RECALL NO CORRECTIVE ACTIONS TROUBLE SHOOTING DIAGRAM Circuits valid for Pump Controller SYMPTOM Pump control will not operate POSSIBLE CAUSE Line contac...

Страница 53: ...OTING DIAGRAM Circuits valid for Pump Controller SYMPTOM Pump control will not operate POSSIBLE CAUSE Defective control fuse Check control fuse for open circuit replace fuse if necessary Check connection from control fuse to pump P1 for loose connections PUMP CONTROL PLUG PL 2 P2 P1 P18 P12 P19 P20 P21 PUMP CONTROL TEMP P7 L P17 ACCEL POT INPUT SPEED 2 SPEED 1 SPEED 3 SPEED 4 POWER CONNECTION SUPP...

Страница 54: ...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 control card After installing the Handset tool plug the battery in and turn the key switch on The following is the start up display sequence that will occur START UP DISPLAY SEQUENCE Key Switch On Verify Each LED Segm...

Страница 55: ...DI 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 the segment check mode at any time by holding down the ESC key until 8888 appears in the display Section 5 3 2 Status Code Scrolling The SX family of controllers furnishes a function register that contains the last 16 stor...

Страница 56: ...of the OEM FUNCTION 3 ARMATURE 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 acceleration Range 0 025 to 6 3 seconds Set 0 to 255 Resolution 0 025 seconds per set unit Example Setting of 20 0 5 seconds FUNCTION 4 SPEED REGULATION DECREASING FIELD Push 4 This funct...

Страница 57: ... 64 amps Set 51 to 255 Resolution VAL 51 x 0 314 Example Setting of 200 47 amps FUNCTION 11 MAINTENANCE AND LOST TACH SPEED LIMIT or PARK BRAKE SWITCH CLOSED Push 11 This function allows for the adjustment of the motor speed limit maximum battery volts to the motor when the tach signal is lost or a status code 81 appears on the dash display Range 100 to 0 battery volts Set 51 to 163 Resolution 0 8...

Страница 58: ... VAL x 0 1 MPH Example Setting of 10 10 x 0 1 1 0 MPH FUNCTION 17 CARD TYPE SELECTION Push CONT 2 This function allows for the selection of the card type used for your vehicle s application This function should be set at a value of 54 Setting Scale 50 54 MPH 55 59 KPH Warning These settings must be changed by authorized personnel only following instructions supplied by the vehicle manufacturer Car...

Страница 59: ...o stored in this register FUNCTION 26 RATIO Push CONT 11 This function sets the ratio between armature and field current when operating below the maximum field current and above the Field Weakening Start point The setting represents the quantity of field current changed for each 1 amp of armature current changed Volts Max Change Set Resolution 36 48 48 0 to 40 024 FUNCTION 28 STORED STATUS CODE CO...

Страница 60: ...48 0 to 40 024 This RATIO takes effect when the Mode 1 settings are called for by the interactive Dash Display FUNCTION 51 MODE 1 MPH LIMIT Push CONT 4 This function allows for the adjustment of the traction MPH limit to limit the achievable top speed of the truck VAL x 0 1 MPH This MPH LIMIT takes effect when the Mode 1 settings are called for by the interactive Dash Display FUNCTION 52 MODE 2 MI...

Страница 61: ... 51 This MPH LIMIT takes effect when the Mode 3 settings are called for by the interactive Dash Display FUNCTION 60 MODE 4 MIN FIELD Push CONT 13 Same as Function 48 This MIN FIELD takes effect when the Mode 4 settings are called for by the interactive Dash Display FUNCTION 61 MODE 4 FIELD WEAKENING START Push CONT 14 Same as Function 49 This FIELD WEAKENING START takes effect when the Mode 4 sett...

Страница 62: ...otor The field weakening start setting is adjusted by Function 24 This function sets the armature current at which minimum field current will achieved The ratio setting is adjusted by Function 26 This function sets the ratio between armature and field current when transitioning from minimum field to maximum field current Setting is the value of field current changed for each 100 amps of armature c...

Страница 63: ...T APPLICABLE This function is not applicable to this type of control and should not be adjusted FUNCTION 11 SPEED LIMIT 1 SL1 Push 11 This function allows for the adjustment of the speed limit maximum battery volts to the motor when the SL1 limit switch input signal is received by the control card SL1 limit switch is a normally open switch connected to battery negative the switch closing enables s...

Страница 64: ...TION 48 MODE 1 CONTROLLED ACCELERATION Push CONT 1 This function allows for the adjustment of the rate of time it takes for the control to accelerate to 96 applied battery voltage to the motor on hard acceleration Range 0 1 to 22 0 seconds Setting 0 to 255 Resolution 0 084 seconds per set unit Example Setting of 20 1 8 seconds C A FUNCTION 49 MODE 1 SPEED LIMIT 2 SL2 Push CONT 2 This function allo...

Страница 65: ...ION 57 MODE 3 SPEED LIMIT 2 SL2 Push CONT 10 Same as Function 49 FUNCTION 58 MODE 3 SPEED LIMIT 4 SL4 Push CONT 11 Same as Function 50 FUNCTION 59 NOT APPLICABLE This function is not applicable to this type of control and should not be adjusted FUNCTION 60 MODE 4 CONTROLLED ACCELERATION Push CONT 13 Same as Function 48 FUNCTION 61 MODE 4 SPEED LIMIT 2 SL2 Push CONT 14 Same as Function 49 FUNCTION ...

Страница 66: ...dash display should show two A s AA Re open the seat switch to begin the calibration of the fully depressed left accelerator pedal position Depress the left accelerator pedal fully and close the seat switch to calibrate the fully depressed left accelerator pedal When this is completed the dash display will return to normal operation Confirm this by opening the seat switch and the dash display will...

Страница 67: ...9 Maintenance Code HM Tens Units 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 Not applicable HS or PC For DD on power up 22 23 23 Plug Regen Transition HS or PC None 23 24 24 Field Weakening Start HS or PC None 24 25 25 Monitor HS or PC GE Temporary Storage 25 26 26 Ratio HS or PC GE Temporary Storage 26 27 27 Not applicable HS or PC ...

Страница 68: ...tatus 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 Code 10 PC Only Reset to Zero Only 69 70 BDI 10 PC Only Reset to Zero Only 70 71 Hours Tens Ones 10 PC Only Reset to Zero Only 71 72 Hours Thou Hun 10 PC Only Reset to Zero Only 72 73 38 Stored Sta...

Страница 69: ...ing Start 3 HS or PC None 106 107 58 Dash Display Ratio2 3 HS or PC None 107 108 59 Dash Display Regen Current Limit 3 HS or PC None 108 109 60 Dash Display Min Field 4 HS or PC None 109 110 61 Dash Display Field Weakening Start 4 HS or PC None 110 111 62 Dash Display Ratio2 4 HS or PC None 111 112 63 Dash Display Regen Current Limit 4 HS or PC None 112 113 Secure HM Tens Ones PC Only OEM Read Onl...

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