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GE IC3645SR4W606MC2 Installation And Operation Manual

Separately excited (sx) transistorized traction motor control and series pump motor control
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INSTALLATION AND OPERATION
SX TRANSISTOR CONTROL
SEPARATELY EXCITED (SX) TRANSISTORIZED TRACTION MOTOR CONTROL
(GE Models IC3645SR4W606MC2, IC3645SR4W606MC3, IC3645SR7W455MC3, IC3645SR4W746MC2,
IC3645SR4W746MC3, IC3645SP4U500MC2, IC3645SP4U500MC3, IC3645SP4U600MC2, IC3645SP4U600MC3,
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.
Section 1.0
INTRODUCTION .................................................................................................................................................... 4
1.1
1.2
1.3
1.4
Section 2.0
FEATURES OF SX FAMILY OF MOTOR CONTROLLERS .................................................................................. 6
2.1
2.1.1
2.1.1.a
2.1.1.b
2.1.1.c
2.1.2
2.1.3
AND SERIES PUMP MOTOR CONTROL
INSTALLATION AND OPERATION MANUAL
IC3645SP4U600MC4, IC3645SP7U450MC3 and IC3645SR4W10010M1)
General Electric Company September 2004
Motor Characteristics ................................................................................................................. 4
Solid-State Reversing .................................................................................................................. 5
Flexible System Application........................................................................................................ 5
More Features with Fewer Components .................................................................................. 5
Performance.................................................................................................................................. 6
Oscillator Card Features.............................................................................................................. 6
Standard Operation ..................................................................................................... 6
Creep Speed.................................................................................................................. 6
Control Acceleration ................................................................................................... 6
Current Limit .................................................................................................................................. 6
Braking 6
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Summary of Contents for GE IC3645SR4W606MC2

  • Page 1 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.

  • Page 2: Table Of Contents

    INSTALLATION AND OPERATION SX TRANSISTOR CONTROL Page 2 Table of Contents ( Continued ) 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 2.1.4.a Field Weakening ........................6 2.1.4.b Speed Limits .........................
  • Page 3 TMM Pump Control Connections ..................... 58 5.4.4 Typical Brush Wear Sensor Connections For Pump Control............58 TMM7A Outline Drawings........................58 Section 6.0 SX FAMILY - GE HANDSET INSTRUCTIONS ....................59 General Features ..........................59 Purpose/Setup Functions ........................59 Setup Function Procedures ....................... 59 6.3.1 Setup Mode ..........
  • Page 4 SPEED new advances on the horizon. GE has introduced a second generation system using separately excited DC shunt wound motors. The separately excited DC motor system offers many of the features that are generally found on the advanced AC systems.
  • Page 5 The line contactor is normally the only contactor required for the shunt motor traction circuit. This contactor is used For GE, the future is now as we make available a new for both pre-charge of the line capacitors and for...

  • Page 6: Regenerative Braking To Zero Speed

    Because of the flyback current through Q2, the motor will be determined by GE and OEM engineers at the time of current is usually greater than battery current, except at vehicle development. This setting must not be changed by 100% ON time.

  • Page 7: Speed Limits

    BASIC OPERATION AND FEATURES SX TRANSISTOR CONTROL Page 7 Section 2.1.4.b Speed Limits This inherent feature of the control is designed to require the driver to return the directional lever to the neutral position anytime he leaves the vehicle and returns. This feature provides a means to control speed by limiting motor volts utilizing three "adjustable speed limits.

  • Page 8: Diagnostics

    This is a multi-functional tool used with the LX, ZX, and SX vehicles so equipped, or be available by plugging the Series GE solid state controls. The Handset consists of a Handset into the “y” plug of the logic card.

  • Page 9: Interactive Dash Display Modes

    The Truck Management Module is a multifunction control negative. SL2 is adjusted using the Handset and accessory card, or an integral function of the GE Pump Function 12, similar to SL1. controls when used with the SX Traction control. The...

  • Page 10: Ordering Information, Elementary And Outline Drawings

    OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS SX TRANSISTOR CONTROL Page 10 Section 3.0 ORDERING INFORMATION, ELEMENTARY AND OUTLINE DRAWINGS Section 3.1 Ordering Information for Separately Excited Controls Example: Part Number: IC3645 Argument Number: Argument 01: Basic Electric Vehicle Control Number Argument 02: Control Type: Series Control (Pump)

  • Page 11: Outline: Sx-4 And Sr-4 Package Size

    OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS Page 11 SX TRANSISTOR CONTROL Section 3.2 Outline: SX-4 Package Size September 2004...

  • Page 12: Outline: Sx-3 And Sr-3 Package Size

    OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS Page 12 SX TRANSISTOR CONTROL Section 3.3 Outline: SX-3 and SR-3 Package Size September 2004...

  • Page 13: Traction Elementary For Use With A Pump Control (No 1A Contactor)

    OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS SX TRANSISTOR CONTROL Page 13 Section 3.4 Traction Elementary for Use with a Pump Control (no 1A Contactor) September 2004...

  • Page 14: Traction Elementary For Use With A Pump Control (Including1A Contactor)

    OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS SX TRANSISTOR CONTROL Page 14 Section 3.5 Traction Elementary for Use with a Pump Control (including 1A Contactor) September 2004...

  • Page 15: Traction Elementary For Use With A Pump Contactor And Tmm Card (No1A Contactor)

    OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS SX TRANSISTOR CONTROL Page 15 Section 3.6 Traction Elementary for Use with a Pump Contactor and TMM Card (no 1A Contactor) FU4 * FU2 * September 2004...

  • Page 16: Traction Elementary For Use With A Pump Contactor And Tmm Card (Incl. 1A Contactor)

    OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS SX TRANSISTOR CONTROL Page 16 Section 3.7 Traction Elementary for Use with a Pump Contactor and TMM Card (Including 1A Contactor) FU4 * FU2 * September 2004...

  • Page 17: Pump Control Elementary (No 1A Contactor)

    OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS SX TRANSISTOR CONTROL Page 17 Section 3.8 Pump Control Elementary (no 1A Contactor) September 2004...

  • Page 18: Pump Control Elementary (Including 1A Contactor)

    OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS SX TRANSISTOR CONTROL Page 18 Section 3.9 Pump Control Elementary (including 1A Contactor) September 2004...

  • Page 19: Traction And Pump Control Input / Output List

    OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS SX TRANSISTOR CONTROL Page 19 Section 3.10 Traction and Pump Control Input and Output List CONNECTIONS TO MAIN PLUG (23 PIN) AND "Y" PLUG (12 PIN) TRACTION PUMP INPUT/OUTPUT DESCRIPTION INPUT/OUTPUT DESCRIPTION BATTERY VOLTS FROM BATTERY BATTERY VOLTS FROM BATTERY BATTERY VOLTS FROM KEY BATTERY VOLTS FROM KEY...

  • Page 20: Troubleshooting And Diagnostic Status Codes

    The semiconductor junctions have finite temperature limits, above which these devices GE does not recommend that any type of welding be may be damaged. For these reasons, normal maintenance performed on the vehicle after the installation of the should guard against any action which will expose the control(s) in the vehicle.

  • Page 21: High Level Signals (Level H)

    DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 21 • 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) The following general practices should be used for all...

  • Page 22: Recommended Lubrication Of Pins And Sockets Prior To Installation

    EV100/EV200 and Gen II products. Any Clean each terminal using Chemtronics contact connection made by GE to the A, B, X, Y, or Z plugs will cleaner “Pow-R-WasH CZ “ as shown in Figure 1. have the lubricant NYE 760G added to prevent fretting of these connections during vehicle operation.

  • Page 23: General Troubleshooting Instructions

    DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 23 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"...

  • Page 24: Traction Controller Status Codes

    DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 24 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 NONE Dash Display and/or the Handset.
  • Page 25 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 25 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Forward directional switch is closed on This status code will be displayed when P4 is greater initial power up. than 60% of battery voltage at initial key switch on. MEMORY RECALL CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM...
  • Page 26 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 26 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Start switch fails to close. Cycle the This status code will be displayed when P7 is calling key switch off and on to clear the code. for greater than 40% speed and P3 is less than 60% of battery volts.
  • Page 27 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 27 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Accelerator input speed too low on This status code will be displayed when the power up after initial key switch accelerator input voltage at P7 is 0.7 volts less than closure.
  • Page 28 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 28 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Both the forward and reverse This status code will be displayed when P4 and P5 directional switches are closed at the are greater than 60% of battery volts at the same same time.
  • Page 29 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 29 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Battery voltage is too low or control This status code will be displayed when the battery card is mis-adjusted. volts are less than 1.95 volts per cell at initial key switch on.
  • Page 30 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 30 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE The accelerator voltage is too high. This status code will be displayed when the voltage at Cycle the key switch off and on to clear P7 is greater than 4.5 volts.
  • Page 31 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 31 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Motor field current is high on start up in This status code will be displayed when the current the forward direction. draw in the motor field is too high at start up in the forward direction.
  • Page 32 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 32 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Motor field current is too high during This status code will be displayed when the current in the run mode. the motor field is sustained above a preset limit for longer than 70 seconds.
  • Page 33 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 33 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Motor armature offset voltage is too This status code will be displayed when the voltage at high. the current sensor input is greater than 2.6 volts with no current flowing in the motor circuit.
  • Page 34 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 34 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Armature transistor did not turn off This status code will be displayed when, during properly. control operation, the armature transistor fails to turn off.
  • Page 35 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 35 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE “Look Ahead” test for A2 volts less This status code will be displayed when the voltage at than 12% of battery volts. A2 is less than 12% of battery volts.
  • Page 36 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 36 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Motor field current is too low during the This status code will be displayed when the current neutral or run modes. The key must draw in the motor field is too low during the neutral or be cycled off and on to clear the code.
  • Page 37 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 37 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Controller “motor current sensor” This status code will be displayed when the voltage input too low during running. input from the current sensor is too low during running. MEMORY RECALL CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM...
  • Page 38 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 38 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE The line coil current is too high during This status code will be displayed when the current the run mode 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 recycled to reset the control.
  • Page 39 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 39 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE The armature current exceeds the This status code will be displayed when the armature armature transistor limit. transistor exceeds its specific current limit. The control is reset by recycling the key switch.
  • Page 40 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 40 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Capacitor (1C) voltage too high. This status code will be displayed when the voltage on the capacitor goes above limit voltage* during the regenerative braking cycle. MEMORY RECALL CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM...
  • Page 41 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 41 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE If the armature motor current is greater This status code will be displayed when the armature than a preset value for longer than 3.5 motor current exceeds a preset value for 3.5 sec and sec the armature motoring current will the accelerator pedal is calling for maximum...
  • Page 42 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 42 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Motor armature current is too high, and This status code will be displayed when the motor the control trip time is less than 1 armature current is >1600 amps in 1A mode, or millisecond.
  • Page 43 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 43 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Hydraulic lever is activated before the This status code will be displayed when the voltage at pump is enabled. P14 is greater than 3 volts at pump enable (10ms). MEMORY RECALL CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM...

  • Page 44: Tmm Module Status Codes

    DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 44 Section 5.4 TMM Codes TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Traction motor temperature has This status code will be displayed when the voltage at exceeded maximum temperature limit. the respective terminal of the TMM or Pump Logic Card is at zero volts.
  • Page 45 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 45 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Steering pump motor brush wear This status code will be displayed when the voltage at indicator has detected worn brush. the respective terminal of the TMM or Pump Logic Card is at battery volts.
  • Page 46 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 46 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Traction motor brush wear indicator This status code will be displayed when the voltage at has detected worn brush. the respective terminal of the TMM or Pump Logic Card is at battery volts.
  • Page 47 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 47 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Pump motor brush wear indicator has This status code will be displayed when the voltage at detected worn brush. the respective terminal of the TMM or Pump Logic Card is at battery volts.
  • Page 48 DIAGNOSTIC STATUS CODES SX TRANSISTOR CONTROL Page 48 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Maintenance alert and speed limit. This status code will be displayed when the “normal” hour meter exceeds the “maintenance alert hours” setting for the vehicle. MEMORY RECALL CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM...

  • Page 49: Pump Control Status Codes

    DIAGNOSTIC STATUS CODES TRANSISTOR PUMP CONTROL Page 49 Section 4.6 Pump Control Codes PUMP DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE “Card Type” selection is invalid. This status code will be displayed when the card type -117 selection value is set to an invalid number. MEMORY RECALL CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM...
  • Page 50 DIAGNOSTIC STATUS CODES TRANSISTOR PUMP CONTROL Page 50 PUMP DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Armature current is too high during the Status code displayed when the current in the -128 lift mode. armature circuit is sustained above 400A for 70 sec. MEMORY RECALL CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM...
  • Page 51 DIAGNOSTIC STATUS CODES TRANSISTOR PUMP CONTROL Page 51 PUMP DESCRIPTION OF CAUSE OF STATUS INDICATION STATUS CODE STATUS Pump Controller “motor current This status code is displayed when the voltage at the -142 sensor” input is missing. current sensor is greater than 1.6 volts with no current flowing in the motor circuit.
  • Page 52 DIAGNOSTIC STATUS CODES TRANSISTOR PUMP CONTROL Page 52 PUMP DESCRIPTION OF CAUSE OF STATUS INDICATION STATUS CODE STATUS Power Transistor (Q1) did not This status code is displayed when, during pump control -144 turn off properly. operation, the transistor fails to turn off. MEMORY RECALL CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM...
  • Page 53 DIAGNOSTIC STATUS CODES TRANSISTOR PUMP CONTROL Page 53 PUMP DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE “Look Ahead” test for T2 volts less than This status code will be displayed when the voltage -146 12% of battery volts. at T2 is less than 12% of battery volts.
  • Page 54 DIAGNOSTIC STATUS CODES TRANSISTOR PUMP CONTROL Page 54 PUMP DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Capacitor volts are low before the line This status code will be displayed during “key on” when -151 contactor closes. (Internal card the capacitor volts is less than 85% of battery volts at function during pre-charge) initial key switch on.
  • Page 55 DIAGNOSTIC STATUS CODES TRANSISTOR PUMP CONTROL Page 55 PUMP DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Voltage at capacitor (1C) is less than This status code will be displayed when the voltage at -180 14 volts. P1 is less than 14 volts. This occurs typically in the run mode of operation.
  • Page 56 DIAGNOSTIC STATUS CODES TRANSISTOR PUMP CONTROL Page 56 PUMP DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Input switch closed before pump enable This status code will be displayed when pin 12, 19, 20 -189 signal is received. or 21 is pulled to negative before pin 10 is greater than 5.0 volts.

  • Page 57: Truck Management Module (Tmm)

    INSTALLATION AND OPERATION MANUAL Page 57 SX TRANSISTOR CONTROL Section 5. TRUCK MANAGEMENT MODULE (TMM) IMPORTANT NOTE: Status Codes 93, 94 and 95 are only checked when a neutral signal is present (i.e., open start Section 5.1 General Features switch or open F/R switch). The status code is displayed and the speed limit enabled when the control is returned The Truck Management Module is a multi-functional to the run mode.

  • Page 58: Tmm Pump Control Connections

    INSTALLATION AND OPERATION MANUAL Page 58 SX TRANSISTOR CONTROL Section 5.4.3 TMM Pump Control Connections Section 5.4.4 Typical Brush Wear Sensor Connections For Pump Control PUMP CONTROL CONNECTIONS BRUSH WEAR SENSOR CONNECTIONS FOR PUMP CONTROL (TYPICAL) PL2- PL2- PL2- PL2- PL2- PL2- PL2-11...

  • Page 59: Sx Family - Ge Handset Instructions

    INSTRUCTIONS Section 6.1 General Features Key Switch On The GE Handset is a multi-functional tool to be used with the LX, ZX, and SX Series GE solid-state controls. The Handset consists of a Light Emitting Diode (LED) display Verify Each LED Segment and a keyboard for data entry.

  • Page 60: Setup Function Procedures

    NOTE: The term “Push” means to depress key for ACCESSING STORED STATUS CODES approximately one second. WITH GE HANDSET Section 6.3.1 Setup Mode Key Switch Off SET-UP MODE Push ESC and CONT...

  • Page 61: Setup Functions For Traction Controller

    ADJUSTABLE FEATURES SX TRANSISTOR CONTROLS Page FUNCTION 3 ARMATURE CONTROLLED ACCELERATION HANDSET (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 0 to 255...
  • Page 62 Important Note: This function is used to optimize motor Resolution Example and control performance and this setting will be determined by GE and OEM engineers at the time of Rating Per unit value If set at 71 vehicle development. This setting must not be changed by...
  • Page 63 Important Note: This function is used to optimize motor 02.54 00.95 and control performance, and this setting will be 02.28 00.91 determined by GE and OEM engineers at the time of 02.08 00.88 vehicle development. This setting must not be changed by 01.90 00.85 field personnel without the permission of the OEM.
  • Page 64 Note: If the seat switch opens, the steer pump contactor determined by GE and OEM engineers at the time of will open immediately. vehicle development. This setting must not be changed by field personnel without the permission of the OEM.
  • Page 65 [the number shown in (bold italics) detailed instructions from the GE application engineer. in the HS (Handset) number column] on the memory map, This function should only be adjusted by the vehicle OEM.
  • Page 66 ADJUSTABLE FEATURES SX TRANSISTOR CONTROLS Page Example Setting of 80 = 75% of battery volts Range 1.0 to 25.5 seconds 10 to 255 SPEED LIMIT = 100% - ((VAL-46) x 0.75%) Resolution 0.10 seconds per set unit Example: Setting of 20 = 2.0 seconds This SPEED LIMIT 2 takes effect when the Mode 1 settings are called for by the interactive Dash Display.
  • Page 67 ADJUSTABLE FEATURES SX TRANSISTOR CONTROLS Page FUNCTION 57 MODE 3 REGEN CURRENT LIMIT ( Push CONT ESC ) ( Push CONT 10) Same as Function 51. Same as Function 49. This REGEN CURRENT LIMIT takes effect when the Mode 3 This SPEED LIMIT 2 takes effect when the Mode 4 settings are called for by the interactive Dash Display.

  • Page 68: Summary Of Current Limit Adjustments

    ADJUSTABLE FEATURES SX TRANSISTOR CONTROLS Page Section 6.5 Summary of Current Limit Adjustments The "maximum field current" setting is adjusted by Function 8. This function, along with the "armature current limit", Function 4, sets the maximum torque of the motor. MAXIMUM The "...

  • Page 69: Setup Functions For Hydraulic Pump Controller

    ADJUSTABLE FEATURES TRANSISTOR PUMP CONTROLS Page 69 Section 6.6 Setup Functions for Hydraulic Pump Control Range 0.0015 to 0.383 seconds FUNCTION 1 NOT APPLICABLE Setting 0 to 255 Resolution 0.0015 seconds per set unit This function is not applicable to this type of control and Example: Setting of 20 = 0.032 seconds should not be adjusted.
  • Page 70 ADJUSTABLE FEATURES TRANSISTOR PUMP CONTROLS Page 70 This function is not applicable to this type of control and Warning: These setting must be changed by authorized should not be adjusted. personnel only, following instructions supplied by the manufacturer. Card type selection must be made within the capabilities of the TRANSISTOR control panel used FUNCTION 16 SPEED / TORQUE COMPENSATION...
  • Page 71 ADJUSTABLE FEATURES TRANSISTOR PUMP CONTROLS Page 71 This function allows for the adjustment of the speed limit FUNCTION 54 MODE 2 – TILT SPEED LIMIT (SL3) (maximum battery volts to the motor) when the SL2 limit (Push CONT 7) switch input signal is received by the control card. SL2 limit switch is a normally open switch connected to battery Same as Function 50.

  • Page 72: Dash Displays

    Plug "Y" of each control. Shielded cable is required to eliminate signal interference. Part Number IC3645LXTDD The GE Standard Dash Display is a four segment Light T=Traction Only Emitting Diode (LED) instrument that displays the GE LX, ZX, P=Traction & Pump and SX Status Codes, Hourmeter Readings, Battery Discharge Indication, and Maintenance Required Code.

  • Page 73: Start-Up Display Sequence

    INSTALLATION AND OPERATION MANUAL SX TRANSISTOR CONTROL Page 73 Section 7.4 Start-Up Display Sequence Section 7.5 Outline Drawings START-UP DISPLAY SEQUENCE GE Electric Vehicle Motors & Controls Key Switch On Verify Each LED Segment 8 8 8 8 0.41 (10.4) 3.20 (81.3)

  • Page 74: Auto Calibration Of Acclerator Potentiometer

    RS-232 MEMORY MAP TABLES SX TRANSISTOR CONTROL Page 74 SECTION 7.0 AUTOCALIBRATION OF ACCELERATOR POTENTIOMETERS When calibrating the accelerator pot, program Function 6 with a handset to a value between 15 and 20, and then exit programming mode. Cycle the key switch on and off to store the function setting, and leave the handset plugged in.

  • Page 75: Memory Maps

    Regen Cancel Current HS or PC None FW Start HS or PC None Monitor HS or PC GE Temporary Storage Ratio HS or PC GE Temporary Storage Steer Pump Minutes HS or PC GE Temporary Storage Fault Count Pointer HS or PC...
  • Page 76 RS-232 MEMORY MAP TABLES SX TRANSISTOR CONTROL Page 76 Func No. Traction Control Access By Restrictions Function Hours (Thou/Hun) 3 PC Only Reset to Zero Only BDI 4 PC Only Reset to Zero Only Hours (Tens/Ones) 4 PC Only Reset to Zero Only Hours (Thou/Hun) 4 PC Only Reset to Zero Only...
  • Page 77 OEM Read Only Secure Aux HM (Tens/Ones) PC Only OEM Read Only Secure Aux HM (Thou/Hun) PC Only OEM Read Only Reserved PC Only GE Future Use Reserved PC Only GE Future Use Reserved PC Only GE Future Use Reserved PC Only...

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