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INSTALLATION AND OPERATION
SX TRANSISTOR CONTROL Page 1
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
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INSTALLATION AND OPERATION SX TRANSISTOR CONTROL Page 2 Table of Contents ( Continued ) 2.1.3.d Auto Braking.............................................................................................................. 6 2.1.4 Auxiliary Speed Control.................................................................................................... 6 2.1.4.a Field Weakening...............................................................................................
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INSTALLATION AND OPERATION SX TRANSISTOR CONTROL Page 3 Table of Contents ( Continued ) 4.2.5 RF Interference.......................................................................................................................... 17 4.2.6 Suppression............................................................................................................................... 17 4.3 Recommended Lubrication of Pins and Sockets Prior to Installation.................................
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BASIC OPERATION AND FEATURES SX TRANSISTOR CONTROL Page 4 current to increase, providing the greater torque needed to Section 1. INTRODUCTION drive the increased mechanical load. If the mechanical load is decreased, the process reverses. The motor speed Section 1.1 Motor Characteristics and the back EMF increase, while the armature current and the torque developed decrease. Thus, whenever the load The level of sophistication in the controllability of traction changes, the spee
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BASIC OPERATION AND FEATURES SX TRANSISTOR CONTROL Page 5 following description provides a brief introduction to armature, the motor performance curve can be maximized examples of some of these features. through proper control application. Section 1. 2 Solid-State Reversing Section 1. 4 More Features with Fewer Components The direction of armature rotation on a shunt motor is Field weakening with a series wound motor is determined by the direction in which current flows throug
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BASIC OPERATION AND FEATURES SX TRANSISTOR CONTROL Page 6 Section 2. FEATURES OF SX FAMILY OF TRANSISTOR Section 2.1.3 Braking MOTOR CONTROLLERS Section 2.1.3.a Plug Braking Section 2.1 Performance Section 2.1.3.b Regenerative Braking to Zero Speed Section 2.1.1 Oscillator Card Features Slow down is accomplished when reversing direction by providing a Section 2.1.1.a Standard Operation small amount of retarding torque for Q2 deceleration. If the vehicle is With the
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BASIC OPERATION AND FEATURES SX TRANSISTOR CONTROL Page 7 to optimize motor and control performance, and this setting At this point, the inside wheel will stop, as the steer angle is will be determined by GE and OEM engineers at the time of increased toward the 90° point, the inside wheel will vehicle development. This setting must not be changed by reverse direction and start to accelerate proportionally in field personnel, without the permission of the OEM. speed. As the steer an
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BASIC OPERATION AND FEATURES SX TRANSISTOR CONTROL Page 8 reach sufficient speed. As the control cools, the thermal Section 2.1.7 On-Board Coil Drivers & Internal Coil protector will automatically reset, returning the control to Suppression full power. Coil drivers for the LINE and SP contactors are on-board the control card. These contactors must have Section 2.2.5 Low Voltage coils rated for the vehicle battery volts. Batteries under load, particularly if undersized or more
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BASIC OPERATION AND FEATURES SX TRANSISTOR CONTROL Page 9 Section 2.3.3 Hourmeter Readings Section 2.3.6.a Interactive Dash Display Modes This feature will display the recorded hours of use of the traction and pump control to the Dash Display each time The Interactive Custom Dash Display allows the operator to the key switch is turned off. select the best vehicle performance for changing factory (task) conditions. There are four (4) "operator interaction Section 2.3.3.a Maintena
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BASIC OPERATION AND FEATURES SX TRANSISTOR CONTROL Page 10 •= Three speeds, adjustable from O to 100% motor volts. Fixed speeds actuated by switch closure to negative. •= Current limit and controlled acceleration adjustable. •= Battery Discharge Indicator interrupt compatible. 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 applie
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OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS SX TRANSISTOR CONTROL Page 11 Section 3.0 ORDERING INFORMATION, ELEMENTARY AND OUTLINE DRAWINGS Section 3.1 Ordering Information for Separately Excited Controls Example: Part Number: IC3645 SE 4 D 33 2 C3 Argument Number: 01 02 03 04 05 06 07 Argument 01: Basic Electric Vehicle Control Number Argument 02: Control Type: SP = Series Control (Pump) SH = Separately Excited Control ( Plugging ) SR = Separat
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OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS SX TRANSISTOR CONTROL Page 12 Section 3.2 Outline: SX-3 and SR-3 Package Size January 2000
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OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS SX TRANSISTOR CONTROL Page 13 Section 3.3 Traction Elementary January 2000 BRAKE SW. 12 KEY SWITCH FU5 P1 P2 ELEMENTARY DRAWING FOR SP SEPARATELY EXCITED DUAL MOTOR L PROPORTIONING CONTROLLERS WITH P5 FU7 TO ACCESSORIES SOLID-STATE REGENERATIVE BRAKING 24 60 P4 FU6 P3 8 10 7 15 6 12-1 PLUG PY 10 12-1 CONNECTIONS PY7 PY7 OSCILLATOR CARD P15 P18 P1 P17 P2 P6 P3 P4 P5 PY12 P5 P1 P2 P6 P3 P4 PY12 P16 RIGHT CONTROL PY10 OSCILLATOR CAR
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OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS SX TRANSISTOR CONTROL Page 14 Section 3.4 Pump Elementary FU2 January 2000 10 KEY SW. 12-1 FU6 TO TRACTION 50 10 PL2-10 P 2 LINE 5A CONTACTOR 1 51 STATUS CODE 93 INPUT 3 12 4 STATUS CODE 93 INPUT STATUS CODE 94 INPUT 5 52 STATUS CODE 94 INPUT 6 19 STATUS CODE 95 INPUT 8 9 STATUS CODE 95 INPUT 15 STATUS CODE 92 INPUT 53 20 STATUS CODE 90 INPUT 16 STATUS CODE 91 INPUT 11 13 BRUSH WEAR OUTPUT 21 OVER TEMP OUTPUT 14 PY7 PY10 PY11 PY
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OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS SX TRANSISTOR CONTROL Page 15 Section 3.5. Traction and Pump Control Input and Output List CONNECTIONS TO MAIN PLUG (23 PIN) AND "Y" PLUG (12 PIN) TRACTION PUMP PIN INPUT/OUTPUT DESCRIPTION INPUT/OUTPUT DESCRIPTION 1 BATTERY VOLTS FROM BATTERY BATTERY VOLTS FROM BATTERY 2 BATTERY VOLTS FROM KEY BATTERY VOLTS FROM KEY 3 BATTERY VOLTS FROM START SWITCH STATUS CODE 93 INPUT 4 BATTERY VOLTS FROM FORWARD SWITCH STATUS CO
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DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 16 Section 4.0 TROUBLESHOOTING AND DIAGNOSTIC STATUS CODES Section 4.1 General Maintenance Instructions 160 hours of vehicle operation. Inspection is recommended to verify that the contactors are not binding and that the The transistor control, like all electrical apparatus, does tips are intact and free of contaminants. have some thermal losses. The semiconductor junctions have finite temperature limits, above which these devi
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DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 17 •= Control common tie customer must apply the general guidelines (section 4.2.3.a), outlined below. •= DC buses feeding sensitive analog or digital hardware •= All wiring connected to components associated with 4.2.3.a General Cable Spacing sensitive analog hardware with less than 5V signals (for example, potentiometers and tachometers) •= Digital tachometers and resolvers The following general practices should be used for all
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Ny Ny Ny Nye e e e LUBRICANTS DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 18 Section 4.3 Recommended Lubrication of Pins and 2. Locate the plug that contains the socket (female) Sockets Prior to Installation terminals. Maintenance needs only to be performed on the plug containing the socket (female) type terminals. Reconnecting the plugs will lubricate the pin (male) Beginning in January of 1999, GE will implement the terminals. addition of a lubricant to all connections usi
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DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 19 Section 4.4 General Troubleshooting Instructions Trouble-shooting the SX 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 the
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DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 20 Section 4.5 Traction Control Codes TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Segments do not illuminate on the No input voltage to the control card or the display unit. Dash Display and/or the Handset. NONE MEMORY RECALL CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM NO SYMPTOM Circuits valid Display screen on Dash Display and/or Handset KEY SWITCH is blank. FU3 for Traction POSSIBLE CAUS
