Ge SX TRANSISTOR CONTROL IC3645SR4U404N2 User Manual

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INSTALLATION AND OPERATION
SX TRANSISTOR CONTROL Page 1
January 2000
SEPARATELY EXCITED (SX) TRANSISTORIZED DUAL MOTOR TRACTION CONTROL
AND SERIES PUMP CONTROL
INSTALLATION AND OPERATION MANUAL
(IC3645SR4U404N2 and IC3645SP4U400N3)
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.
Copyright by General Electric Company January 2000
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 Plug Braking.............................................................................................................. 6
2.1.3.b Regenerative Braking to Zero Speed...................................................................... 6
2.1.3.c Pedal Position Plug Braking.................................................................................... 6
Table of Contents
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Summary of Contents

Page 1 - Page 1

INSTALLATION AND OPERATION SX TRANSISTOR CONTROL Page 1 January 2000 SEPARATELY EXCITED (SX) TRANSISTORIZED DUAL MOTOR TRACTION CONTROL AND SERIE

Page 2 - Page 2

BASIC OPERATION AND FEATURES SX TRANSISTOR CONTROL Page 10 January 2000 •= Three speeds, adjustable from O to 100% motor volts. Fixed speeds actua

Page 3 - Page 3

OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS SX TRANSISTOR CONTROL Page 11 January 2000 Section 3.0 ORDERING INFORMATION, ELEMENTARY

Page 4 - Section 1. INTRODUCTION

OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS SX TRANSISTOR CONTROL Page 12 January 2000 Section 3.2 Outline: SX-3 and SR-3 Package S

Page 5

OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS SX TRANSISTOR CONTROL Page 13 January 2000 Section 3.3 Traction Elementary POWERCONNECT

Page 6 - Figure 5

OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS SX TRANSISTOR CONTROL Page 14 January 2000 Section 3.4 Pump Elementary ARMATURE*FIELDF

Page 7

OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS SX TRANSISTOR CONTROL Page 15 January 2000 Section 3.5. Traction and Pump Control Inpu

Page 8 - •= Look again

DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 16 January 2000 Section 4.0 TROUBLESHOOTING AND DIAGNOSTIC STATUS CODES Section 4.1 Gener

Page 9

DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 17 January 2000 •= Control common tie •= DC buses feeding sensitive analog or digital hard

Page 10 - January 2000

DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 18 January 2000 Section 4.3 Recommended Lubrication of Pins and Sockets Prior to Installa

Page 11

DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 19 January 2000 Section 4.4 General Troubleshooting Instructions Trouble-shooting the SX

Page 12

INSTALLATION AND OPERATION SX TRANSISTOR CONTROL Page 2 January 2000 2.1.3.d Auto Braking...

Page 13 - SEPARATELY EXCITED DUAL MOTOR

DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 20 January 2000 Section 4.5 Traction Control Codes TRACTION STATUS CODE DESCRIPTION OF ST

Page 14 - Section 3.4 Pump Elementary

DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 21 January 2000 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION -0

Page 15

DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 22 January 2000 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION -0

Page 16 - January 2000

DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 23 January 2000 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION -0

Page 17

DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 24 January 2000 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION -0

Page 18

DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 25 January 2000 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION -1

Page 19

DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 26 January 2000 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION -1

Page 20 - CAUSE OF STATUS INDICATION

DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 27 January 2000 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION -2

Page 21 - DIAGNOSTIC STATUS CODES

DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 28 January 2000 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION -2

Page 22

DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 29 January 2000 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

Page 23

INSTALLATION AND OPERATION SX TRANSISTOR CONTROL Page 3 January 2000 4.2.5 RF Interference...

Page 24

DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 30 January 2000 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

Page 25

DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 31 January 2000 -41 Open thermal protector (TP) or transistor over temperature. This sta

Page 26

DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 32 January 2000 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION -4

Page 27

DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 33 January 2000 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION -4

Page 28

DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 34 January 2000 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION -4

Page 29

DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 35 January 2000 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION -5

Page 30

DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 36 January 2000 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION -65

Page 31

DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 37 January 2000 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION -6

Page 32

DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 38 January 2000 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION -6

Page 33

DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 39 January 2000 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION -6

Page 34

BASIC OPERATION AND FEATURES SX TRANSISTOR CONTROL Page 4 January 2000 Section 1. INTRODUCTION Section 1.1 Motor Characteristics The level of so

Page 35

DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 40 January 2000 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION -7

Page 36

DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 41 January 2000 Section 4.6 TMM Status Codes TRACTION STATUS CODE DESCRIPTION OF STATUS

Page 37

DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 42 January 2000 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION -9

Page 38

DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 43 January 2000 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION -9

Page 39

DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 44 January 2000 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION -9

Page 40

DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 45 January 2000 TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION -9

Page 41

DIAGNOSTIC STATUS CODES TRANSISTOR PUMP CONTROL Page 46 January 2000 Section 4.7 Pump Control Codes PUMP STATUS CODE DESCRIPTION OF STATUS C

Page 42

DIAGNOSTIC STATUS CODES TRANSISTOR PUMP CONTROL Page 47 January 2000 PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION -128

Page 43

DIAGNOSTIC STATUS CODES TRANSISTOR PUMP CONTROL Page 48 January 2000 PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION -142

Page 44

DIAGNOSTIC STATUS CODES TRANSISTOR PUMP CONTROL Page 49 January 2000 PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION -144

Page 45

BASIC OPERATION AND FEATURES SX TRANSISTOR CONTROL Page 5 January 2000 following description provides a brief introduction to examples of some of

Page 46 - STATUS CODE

DIAGNOSTIC STATUS CODES TRANSISTOR PUMP CONTROL Page 50 January 2000 PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION -146

Page 47

DIAGNOSTIC STATUS CODES TRANSISTOR PUMP CONTROL Page 51 January 2000 PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION -151

Page 48

DIAGNOSTIC STATUS CODES TRANSISTOR PUMP CONTROL Page 52 January 2000 PUMP STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION -180

Page 49

INSTALLATION AND OPERATION MANUAL SX TRANSISTOR CONTROL Page 53 January 2000 Section 5. TRUCK MANAGEMENT MODULE (TMM) Section 5.1 General Fe

Page 50

INSTALLATION AND OPERATION MANUAL SX TRANSISTOR CONTROL Page 54 January 2000 Section 5.4.3 TMM Pump Control Connections BATTERYNEGATIVE3456811

Page 51

ADJUSTABLE FEATURES SX TRANSISTOR CONTROLS Page 55 January 2000 Section 6. SX FAMILY GE HANDSET INSTRUCTIONS Section 6.1 General Features The

Page 52

ADJUSTABLE FEATURES SX TRANSISTOR CONTROLS Page 56 January 2000 Section 6.3 Set-up Function Procedures With the Handset connected, hold down t

Page 53

ADJUSTABLE FEATURES SX TRANSISTOR CONTROLS Page 57 January 2000 ESCESCESCESCLXHANDSETgEVCCONTCONTCONTCONTSTORESTORESTORESTORE15+ +91326101437111

Page 54

ADJUSTABLE FEATURES SX TRANSISTOR CONTROLS Page 58 January 2000 FUNCTION 6 FW RATIO (Push 6) This function sets the ratio between armature a

Page 55 - INSTRUCTIONS

ADJUSTABLE FEATURES SX TRANSISTOR CONTROLS Page 59 January 2000 FUNCTION 13 SPEED LIMIT 3 ( Push 13 ) The SL3 set speed limit is activated

Page 56 - SET-UP MODE

BASIC OPERATION AND FEATURES SX TRANSISTOR CONTROL Page 6 January 2000 Section 2. FEATURES OF SX FAMILY OF TRANSISTOR MOTOR CONTROLLERS Section 2

Page 57 - CONTCONT

ADJUSTABLE FEATURES SX TRANSISTOR CONTROLS Page 60 January 2000 vehicle manufacturer. Card type selection must be made within the capabilities o

Page 58 - Page 58

ADJUSTABLE FEATURES SX TRANSISTOR CONTROLS Page 61 January 2000 The ratio value (VAL) is the set value divided by 10 and rounded to the whole nu

Page 59 - Page 59

ADJUSTABLE FEATURES SX TRANSISTOR CONTROLS Page 62 January 2000 FUNCTION 52 MODE 2 ARMATURE CONTROLLED ACCELERATION ( Push CONT 5) Same a

Page 60 - Page 60

ADJUSTABLE FEATURES SX TRANSISTOR CONTROLS Page 63 January 2000 Section 6.5 Summary of Current Limit Adjustments ZEROMAXIMUMZEROMAXIMUMFIELD CUR

Page 61 - Page 61

ADJUSTABLE FEATURES TRANSISTOR PUMP CONTROLS Page 64 January 2000 Section 6.6 Setup Functions for Hydraulic Pump Control FUNCTION 1: NOT APP

Page 62 - Page 62

ADJUSTABLE FEATURES TRANSISTOR PUMP CONTROLS Page 65 August 1999 of 0.375 volts each whereas, a setting of 4 will be added in 15 steps of 0.37

Page 63 - ARMATURE CURRENT

ADJUSTABLE FEATURES TRANSISTOR PUMP CONTROLS Page 66 August 1999 switch input signal is received by the control card. SL3 limit switch is a n

Page 64

INSTALLATION AND OPERATION MANUAL IT/IP TRANSISTOR CONTROL Page 67 January 2001 Section 7. DASH DISPLAYS Section 7.1 Application The SX famil

Page 65 - August 1999

INSTALLATION AND OPERATION MANUAL IT/IP TRANSISTOR CONTROL Page 68 January 2001 Section 7.4 Start-Up Display Sequence START-UP DISPLAY SEQUENCE

Page 66

TURN ANGLE POTENTIOMETER INSTALLATION SX TRANSISTOR CONTROL Page 69 January 2000 Section 8.0 TURN ANGLE POTENTIOMETER INSTALLATION Section 8.1 G

Page 67 - IC3645LXTDD T 3

BASIC OPERATION AND FEATURES SX TRANSISTOR CONTROL Page 7 January 2000 to optimize motor and control performance, and this setting will be determi

Page 68 - TRACTION

TURN ANGLE POTENTIOMETER INSTALLATION SX TRANSISTOR CONTROL Page 70 January 2000 Adjust the potentiometer until the Handset reads 110. Lock down

Page 69 - Page 69

TURN ANGLE POTENTIOMETER INSTALLATION SX TRANSISTOR CONTROL Page 71 January 2000 Section 8.3 Turn Angle Input Volts vs. Steer Wheel Degrees vs. H

Page 70 - Figure 2

RS-232 MEMORY MAP TABLES SX TRANSISTOR CONTROL Page 72 January 2000 Section 9.0 MEMORY MAPS Section 9.1 Traction Control E2 Func No. HS No.

Page 71 - Page 71

RS-232 MEMORY MAP TABLES SX TRANSISTOR CONTROL Page 73 January 2000 E2 Func No. HS No. Traction Control Function Access By Restrictions 43 4

Page 72

RS-232 MEMORY MAP TABLES SX TRANSISTOR CONTROL Page 74 January 2000 E2 Func No. HS No. Traction Control Function Access By Restrictions 90 9

Page 73

BASIC OPERATION AND FEATURES SX TRANSISTOR CONTROL Page 8 January 2000 Section 2.1.7 On-Board Coil Drivers & Internal Coil Suppression Coil d

Page 74

BASIC OPERATION AND FEATURES SX TRANSISTOR CONTROL Page 9 January 2000 Section 2.3.3 Hourmeter Readings This feature will display the recorded ho

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