GE IC3645SR7A353T3 Installation And Operation Manual
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GE IC3645SR7A353T3 Installation And Operation Manual

Separately excited (sx) transistorized motor controllers for neighborhood electric vehicle applications
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INSTALLATION AND OPERATION
SX TRANSISTOR CONTROL
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
1.1
1.2
1.3
1.4
Section 2.0
2.1
2.1.1
2.1.2
2.1.3
2.1.4
2.1.5
2.1.6
2.2
2.2.1
SEPARATELY EXCITED (SX) TRANSISTORIZED MOTOR
FOR NEIGHBORHOOD ELECTRIC VEHICLE APPLICATIONS
INSTALLATION AND OPERATION MANUAL
General Electric Company June 2003

Table of Contents

.................................................................................................................. 3
Motor Characteristics ........................................................................................ 3
Solid-State Reversing ........................................................................................ 4
Flexible System Application ............................................................................... 4
More Features with Fewer Components ........................................................... 4
Performance ...................................................................................................... 4
Oscillator Card Features ............................................................................. 4
Standard Operation..................................................................................... 5
Control Acceleration ............................................................................ 5
Current Limit ............................................................................................... 5
Regenerative Braking to Base Speed ......................................................... 5
Auxiliary Speed Control ............................................................................... 5
Field Weakening ......................................................................................... 5
Speed Limits .............................................................................................. 5
Top Speed Regulation ................................................................................5
Ramp Start .................................................................................................. 6
On-Board Coil Drivers and Internal Coil Suppression ................................ 6
System Protective Override ............................................................................... 6
Static Return to Off (SRO) ......................................................................... 6
CONTROLLERS
GE MODEL IC3645SR7A353T3
............................................... 4
Page 1
Updated Sept 2019

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Summary of Contents for GE IC3645SR7A353T3

  • Page 1: Table Of Contents

    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 INSTALLATION AND OPERATION SX TRANSISTOR CONTROL Page 2 Table of Contents ( Continued ) 2.2.2 Accelerator Volts Hold Off................6 2.2.3 Pulse Monitor Trip (PMT) ................6 2.2.4 Thermal Protector (TP)................6 2.2.5 Low Voltage ....................6 Diagnostics......................6 2.3.1 Status Codes..........

  • Page 3: Introduction

    Development is being done in a multi-generational format that allows the market to take advantage of today’s technology, while looking forward to new advances on the horizon. GE has introduced a SPEED 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 4: Solid-State Reversing

    For GE, the future is now, as we make available a losure, and de -energize on time out of idle vehicle.

  • Page 5: Standard Operation

    This feature requires a system tachometer. The greater than battery current, except at 100% ON time. standard GE system tach is built into the motor and provides four pulses per armature revolution. Once Section 2.1.3 Regenerative Braking to Zero Speed...

  • Page 6: Ramp Start

    BASIC OPERATION AND FEATURES SX TRANSISTOR CONTROL Page 6 automatically transitions back to the normal running if either the armature or field FET's are defective, mode. so as to cause uncontrolled truck movement. Section 2.2.4 Thermal Protector (TP) Section 2.1.5 Ramp Start This temperature sensitive device is internal to the This feature provides maximum control torque to power transistor (Q1) module.

  • Page 7: Odometer Readings

    BASIC OPERATION AND FEATURES SX TRANSISTOR CONTROL Page 7 and/or disrupted normal vehicle operation. (PMT type command from the control card, these drivers initiate faults are reset by cycling the key switch). These opening and closing the contactor coils. All driver status codes, along with the corresponding BDI and modules are equipped with reverse battery protection, hourmeter readings, can be accessed with the...

  • Page 8: Ordering Information, Elementary And Outline Drawings

    OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS SX TRANSISTOR CONTROL Page 8 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: Separately Excited Control ( Plugging )

  • Page 9: Outline: Sx-2 Package Size

    OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS SX TRANSISTOR CONTROL Page 9 Section 3.2 Outline: Package Size Updated Sept 2019...

  • Page 10: Standard Elementary For Neighborhood Electric Vehicle Application

    OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS SX TRANSISTOR CONTROL Page 10 Section 3.3 Standard Elementary for Neighborhood Electric Vehicle Application FUSE Updated Sept 2019...

  • Page 11: Standard Neighborhood Electric Vehicle Application Input/Output List

    OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS SX TRANSISTOR CONTROL Page 11 Section 3.4 Neighborhood Electric Vehicle Application Input/Output List PIN MAIN PLUG INPUT/OUTPUT DESCRIPTION BATTERY VOLTS POS FROM KEY BATTERY VOLTS POS FROM KEY BATTERY NEG FROM ACCELERATOR START SWITCH BATTERY VOLTS POS FROM FORWARD SWITCH BATTERY VOLTS POS FROM REVERSE SWITCH BATTERY VOLTS POS FROM TURF SPEED LIMIT SWITCH...

  • Page 12: Troubleshooting And Diagnostic Status Codes

    For these reasons, normal GE does not recommend that any type of welding be maintenance should guard against any action which will performed on the vehicle after the installation of the expose the components to excessive heat and/or those control(s) in the vehicle.

  • Page 13: High Level Signals (Level H)

    INSTALLATION AND OPERATION SX TRANSISTOR CONTROL Page 13   DC buses feeding sensitive analog or digital All cables and wires of like signal levels and power hardware levels must be grouped together.   All wiring connected to components associated with In general, different levels must run in separate wire sensitive analog hardware with less than 5V signals bundles, as defined in the different classes,...

  • Page 14: Recommended Lubrication Of Pins And Sockets Prior To Installation

    EV100/EV200 and Gen II products. Any connection made by GE to the A, B, X, Y, or Z plugs, includes the lubricant NYE 760G to prevent fretting of these connections during vehicle operation.

  • Page 15: General Troubleshooting Instructions

    INSTALLATION AND OPERATION SX TRANSISTOR CONTROL Page 15 Section 4.4 General Troubleshooting Instructions Trouble-shooting the ZX 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 16: Traction Controller Status Codes

    INSTALLATION AND OPERATION SX TRANSISTOR CONTROL Page 16 Section 4.5 Traction Control Codes TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Start switch fails to close. This status code will be displayed when the accelerator voltage at P7 is >1.4V, with the start switch open (P3 >...
  • Page 17 INSTALLATION AND OPERATION SX TRANSISTOR CONTROL Page 17 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Accelerator voltage input is too high on This status code will be displayed when the power up after initial key switch accelerator input voltage at P7 >0.9V when the closure.
  • Page 18 INSTALLATION AND OPERATION SX TRANSISTOR CONTROL Page 18 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Start switch closed on power up after initial This status code will be displayed when P3 is key switch closure. less than 2.5 volts when the key switch is closed.
  • Page 19 INSTALLATION AND OPERATION SX TRANSISTOR CONTROL Page 19 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Battery voltage is too low at initial key switch This status code will be displayed when the closure. battery volts are less than 68.3 volts at initial key switch on.
  • Page 20 INSTALLATION AND OPERATION SX TRANSISTOR CONTROL Page 20 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Accelerator voltage is too high. This status code will be displayed when the accelerator voltage at P7 is greater than 4.5 volts. MEMORY RECALL CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM...
  • Page 21 INSTALLATION AND OPERATION SX TRANSISTOR CONTROL Page 21 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Motor field current is too high when the This status code will be displayed when the current key switch is turned on. draw in the motor field is too high on start up.
  • Page 22 (Values of less than 1.5 V at the thermal protector are typically indicative of a failed control.) 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...
  • Page 23 Traction Defective control. Controller  Replace controller unit. GE Sentry for Windows software 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.
  • Page 24 INSTALLATION AND OPERATION SX TRANSISTOR CONTROL Page 24 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Armature transistor did not turn on This status code will be displayed when, during properly. control operation, the armature transistor fails to turn on properly.
  • Page 25 INSTALLATION AND OPERATION SX TRANSISTOR CONTROL Page 25 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 run mode. draw in the motor field is less than 1.3 amps and armature current is greater than 100 amps for more than 1.27 seconds during the run mode.
  • Page 26 INSTALLATION AND OPERATION SX TRANSISTOR CONTROL Page 26 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Controller “motor current sensor” input This status code will be displayed when the voltage is too low during running. input from the current sensor is too low (less than 1.0V, 416 amps) during running.
  • Page 27 INSTALLATION AND OPERATION SX TRANSISTOR CONTROL Page 27 TRACTION DESCRIPTION OF CAUSE OF STATUS INDICATION STATUS CODE STATUS The line coil current is too high This status code will be displayed when the current limit in the during the run mode line coil is exceeded during the run mode.
  • Page 28 INSTALLATION AND OPERATION SX TRANSISTOR CONTROL Page 28 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Capacitor (1C) voltage too high during This status code will be displayed when the voltage at pedal up regen braking. 1C exceeds 96 volts during the regenerative braking cycle.
  • Page 29 INSTALLATION AND OPERATION SX TRANSISTOR CONTROL Page 29 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE No tachometer signal is detected. This status code will be displayed when no tachometer signal is detected. MEMORY RECALL CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM SYMPTOM +72V +72V...

  • Page 30: Set Up Functions Fortraction Controller

    NOT USED Controller FUNCTION 8 MAX FIELD CURRENT With GE intelliGEnce for Palm OS or GE Sentry for Windows, the user can access any E Prom setting, quickly perform various maintenance, This function allows for the adjustment of the maximum...
  • Page 31 Important Note: The function is used to optimize motor and = 10.3 to 1 gear ratio control performance and this setting will be determined by GE and OEM engineers at the time of vehicle FUNCTION 17 FIELD GAIN development. This setting must not be changed by field personnel without the permission of the OEM.
  • Page 32 ADJUSTABLE FEATURES SX TRANSISTOR CONTROLS Page 32 This function allows for the adjustment of the tens and FUNCTION 27 HOUR METER MINUTES units hours of the hour meter. This function adjusts the number of 30 second intervals Range 0 to 99 registering in the hour meter.

  • Page 33: Memory Map

    RS-232 MEMORY MAP TABLES SX TRANSISTOR CONTROL Page 33 Section 7.0 MEMORY MAP Func Traction Control Access By Restrictions Function NOT USED PC or PDA None Creep Speed PC or PDA None Armature Acceleration Rate PC or PDA None Max Armature Current Limit PC or PDA None NOT USED...
  • Page 34 RS-232 MEMORY MAP TABLES SX TRANSISTOR CONTROL Page 34 Func Traction Control Access By Restrictions Function BDI 4 PC or PDA Reset to Zero Only Hours (Tens/Ones) 4 PC or PDA Reset to Zero Only Hours (Thou/Hun) 4 PC or PDA Reset to Zero Only Stored Status Code #5 PC or PDA...
  • Page 35 Field Offset PC or PDA OEM Read Only Armature Offset PC or PDA OEM Read Only Reserved PC or PDA GE Future Use OEM Use PC or PDA None OEM Use PC or PDA None OEM Use PC or PDA...

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