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.
INSTALLATION AND OPERATION SX TRANSISTOR CONTROL Page 2 Table of Contents ( Continued ) 2.1.3.d 2.1.4 2.1.4.a 2.1.4.b 2.1.4.c 2.1.5 2.1.5.a 2.1.5.b 2.1.6 2.1.7 2.2 2.2.1 2.2.2 2.2.3 2.2.4 2.2.5 2.3 2.3.1 2.3.2 2.3.2.a 2.3.2.b 2.3.3 2.3.3.a 2.3.4 2.3.4.a 2.3.5 2.3.6 2.3.6.a 2.3.7 2.3.8 2.4 Section 3.0 ORDERING INFORMATION, ELEMENTARY AND OUTLINE DRAWINGS...................................................... 11 3.1 3.2 3.3 3.4 3.5 Section 4.0 Auto Braking..................................................
INSTALLATION AND OPERATION SX TRANSISTOR CONTROL Page 3 Table of Contents ( Continued ) 4.2.5 4.2.6 4.3 4.4 4.5 4.6 4.7 Section 5.0 TRUCK MANAGEMENT MODULE (TMM)............................................................................................................ 53 5.1 5.2 5.3 5.4 5.4.1 5.4.2 5.4.3 5.5 Section 6.0 Application ............................................. ............................................................................................. 67 Standard Dash Displays ......
BASIC OPERATION AND FEATURES SX TRANSISTOR CONTROL Page 4 SPEED TORQUE ARMATURE CURRENT Figure 2 In the separately excited motor, the motor is operated as a fixed field shunt motor in the normal running range. However, when additional torque is required, for example, to climb non-level terrain, such as ramps and the like, the field current is increased to provide the higher level of torque.
BASIC OPERATION AND FEATURES SX TRANSISTOR CONTROL Page 5 following description provides a brief introduction to examples of some of these features. armature, the motor performance curve can be maximized 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 determined by the direction in which current flows through the field windings.
BASIC OPERATION AND FEATURES SX TRANSISTOR CONTROL Section 2. FEATURES OF SX FAMILY OF TRANSISTOR MOTOR CONTROLLERS Section 2.1 Performance Section 2.1.1 Oscillator Card Features Section 2.1.1.a Standard Operation With the accelerator at maximum ohms or volts, the creep speed can be adjusted by Function 2 of the Handset or a trimpot. The field control section allows the adjustment of the field weakening level in order to set the top speed of the motor.
BASIC OPERATION AND FEATURES SX TRANSISTOR CONTROL Section 2.1.4.b Speed Limits This feature provides a means to control speed by limiting motor volts utilizing three "adjustable speed limits. This motor volt limit regulates top speed of the transistor controller, but actual truck speed will vary at any set point depending on the loading of the vehicle. Each speed limit can be adjustable with the Handset using Functions 11, 12, and 13.
BASIC OPERATION AND FEATURES SX TRANSISTOR CONTROL Section 2.1.7 On-Board Coil Drivers & Internal Coil Suppression Coil drivers for the LINE and SP contactors are on-board the control card. These contactors must have coils rated for the vehicle battery volts. Section 2.2 System Protective Override Section 2.2.1 Static Return to Off (SRO) 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.
BASIC OPERATION AND FEATURES SX TRANSISTOR CONTROL Section 2.3.3 Hourmeter Readings This feature will display the recorded hours of use of the traction and pump control to the Dash Display each time the key switch is turned off. Section 2.3.3.a Maintenance Alert & Speed Limit This feature is used to display Status Code 99 and/or activate a speed limit when the vehicle operating hours match the hours set into the maintenance alert register. This feature is set with the Handset using Functions 19 and 20.
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.
OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS Page 11 SX TRANSISTOR CONTROL Section 3.0 ORDERING INFORMATION, ELEMENTARY AND OUTLINE DRAWINGS Section 3.
OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS SX TRANSISTOR CONTROL Page 12 Section 3.
- + 89 SP A2 A1 43 2 3 SP 88 TMM7 TMM7 P FU4 FU1 P4 NEG POS A1 F1 A2 F2 POWER CONNECTIONS LEFT CONTROL 5 SEAT SW. A2 A1 PY7 P2 P6 PY12 P18 P1 P17 PY10 OSCILLATOR CARD PY11 LEFT CONTROL 12-1 10 P7 13A FORWARD SW.
BATT (-) LINE CONTACTOR 5A A1 N N * A2 A2 A1 SUPPLIED BY CUSTOMER * * STATUS CODE 93 INPUT STATUS CODE 93 INPUT STATUS CODE 94 INPUT STATUS CODE 94 INPUT STATUS CODE 95 INPUT STATUS CODE 95 INPUT STATUS CODE 92 INPUT STATUS CODE 90 INPUT STATUS CODE 91 INPUT BRUSH WEAR OUTPUT OVER TEMP OUTPUT POWER CONNECTION A2 A1 PUMP CONTROL POWER CONNECTION P P 12-1 ARMATURE FIELD FU6 SX-2 CONTROL PLUG PL2 21 20 19 12 13C PLUG PY CONNECTIONS PY7 PY12 PY10 PY11 3 4 5 6 8 9 15 16 11 13 14 1
OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS Page 15 SX TRANSISTOR CONTROL Section 3.5.
DIAGNOSTIC STATUS CODES Page 16 SX TRANSISTOR CONTROL Section 4.0 TROUBLESHOOTING AND DIAGNOSTIC STATUS CODES Section 4.1 General Maintenance Instructions The transistor control, like all electrical apparatus, does have some thermal losses. The semiconductor junctions have finite temperature limits, above which these devices may be damaged.
DIAGNOSTIC STATUS CODES Page 17 SX TRANSISTOR CONTROL •= Control common tie •= DC buses feeding sensitive analog or digital hardware •= All wiring connected to components associated with sensitive analog hardware with less than 5V signals (for example, potentiometers and tachometers) •= Digital tachometers and resolvers •= Dash display cabling •= RS-232 cabling Note: Signal inputs to analog and digital blocks should be run as shielded twisted-pair (for example, inputs from tachometers, potentiometers, and
DIAGNOSTIC STATUS CODES Page 18 SX TRANSISTOR CONTROL Section 4.3 Recommended Lubrication of Pins and Sockets Prior to Installation Beginning in January of 1999, GE will implement the addition of a lubricant to all connections using pins and sockets on EV100/EV200 and Gen II products. Any connection made by GE to the A, B, X, Y, or Z plugs will have the lubricant NYE 760G added to prevent fretting of these connections during vehicle operation. 2.
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 then reading the status code.
DIAGNOSTIC STATUS CODES Page 20 SX TRANSISTOR CONTROL Section 4.5 Traction Control Codes TRACTION STATUS CODE NONE MEMORY RECALL NO Circuits valid for Traction Controller DESCRIPTION OF STATUS Segments do not illuminate on the Dash Display and/or the Handset. CAUSE OF STATUS INDICATION No input voltage to the control card or the display unit. CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM SYMPTOM Display screen on Dash Display and/or Handset is blank.
DIAGNOSTIC STATUS CODES Page 21 SX TRANSISTOR CONTROL Circuits valid for Traction Controller This status code will be displayed when P4 is greater than 60% of battery voltage at initial key switch on. CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM SYMPTOM Control will not operate because of Static Return to Off (SRO) lock out. KEY SWITCH POSSIBLE CAUSE Forward directional switch is closed on initial start up (i.e. closure of battery, key switch or seat switch).
DIAGNOSTIC STATUS CODES Page 22 SX TRANSISTOR CONTROL Circuits valid for Traction Controller CORRECTIVE ACTIONS SYMPTOM Control will not operate. TROUBLE-SHOOTING DIAGRAM KEY SWITCH POSSIBLE CAUSE Defective start switch circuit. •= Check start switch to insure closure when accelerator is depressed. •= Check for open circuit or loose connections in wiring from brake switch to start switch and from P3 to start switch. L REVERSE SW. NO This status code will be displayed when P7 is less than 2.
DIAGNOSTIC STATUS CODES Page 23 SX TRANSISTOR CONTROL TRACTION STATUS CODE -07 MEMORY RECALL NO Circuits valid for Traction Controller DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION Accelerator input voltage too high on power up after initial key switch closure. This status code will be displayed when the accelerator input voltage at P7 is higher than 4.2 volts, and a directional contactor is picked up.
DIAGNOSTIC STATUS CODES Page 24 SX TRANSISTOR CONTROL Circuits valid for Traction Controller CORRECTIVE ACTIONS SYMPTOM Control will not operate. TROUBLE-SHOOTING DIAGRAM KEY SWITCH POSSIBLE CAUSE Forward or reverse directional switch welded closed or mis-adjusted to be held closed. •= Replace or adjust directional switches to insure that they open when directional switch is returned to neutral. L REVERSE SW.
DIAGNOSTIC STATUS CODES Page 25 SX TRANSISTOR CONTROL Circuits valid for Traction Controller CORRECTIVE ACTIONS SYMPTOM Control will not operate. TROUBLE-SHOOTING DIAGRAM KEY SWITCH POSSIBLE CAUSE Start switch input mis-adjusted or defective. •= Input voltage at P3 should be less than 60% of battery volts at key switch closing. Adjust or replace accelerator unit to insure that the voltage at P3 is less than 60% of battery volts before closing the start switch. L REVERSE SW.
DIAGNOSTIC STATUS CODES Page 26 SX TRANSISTOR CONTROL TRACTION STATUS CODE -15 MEMORY RECALL NO Circuits valid for Traction Controller DESCRIPTION OF STATUS Battery voltage is too low or control card is mis-adjusted. CAUSE OF STATUS INDICATION This status code will be displayed when the battery volts are less than 1.95 volts per cell at initial key switch on. See table below. CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM SYMPTOM Control will not operate.
DIAGNOSTIC STATUS CODES Page 27 SX TRANSISTOR CONTROL CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM SYMPTOM Control will not operate. BRAKE SW. FU5 P2 KEY SWITCH FU7 POSSIBLE CAUSE Defective control. •= Replace controller unit. P5 TO ACCESSORIES P3 FU6 P1 SP L P4 PY7 PY12 P18 P17 P1 P2 P6 OSCILLATOR CARD PY10 LEFT CONTROL PY11 LINE REV. SW.
DIAGNOSTIC STATUS CODES Page 28 SX TRANSISTOR CONTROL TRACTION STATUS CODE -27 MEMORY RECALL YES Circuits valid for Traction Controller DESCRIPTION OF STATUS Control’s power supply is less than 10 Volts DC. CAUSE OF STATUS INDICATION This status code will be displayed when the control’s power supply is less than 10 volts. CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM SYMPTOM Line contactor opens and closes, then can only be closed by opening and closing the key switch.
DIAGNOSTIC STATUS CODES Page 29 SX TRANSISTOR CONTROL TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION Motor field current is too high during the run mode (Dual motor proportioning controls only) -29 MEMORY RECALL YES Circuits valid for Traction Controller This status code will be displayed when the motor current in control “A” is greater than 98A, while the motor current in control “B” is less than 26A for a 16 second interval.
DIAGNOSTIC STATUS CODES Page 30 SX TRANSISTOR CONTROL TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION PMT enable signal from auxiliary control to master at PL21 is missing during SRO check (Dual motor proportioning controls only) -30 MEMORY RECALL NO Circuits valid for Traction Controller This status code will be displayed when the voltage at PL21 of the master control is less than 5 volts. This fault is not stored.
DIAGNOSTIC STATUS CODES Page 31 SX TRANSISTOR CONTROL CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM SYMPTOM Reduced or no power to traction motor in control range. BRAKE SW. KEY SWITCH P2 FU7 POSSIBLE CAUSE Control is in thermal cut-back. •= Allow control to cool, status code should disappear. P5 TO ACCESSORIES P3 FU6 P1 SP L P4 PY7 PY12 P18 P17 P1 P2 P6 OSCILLATOR CARD PY10 LEFT CONTROL PY11 Defective control. •= Replace controller unit. REV. SW. FU5 FOR. SW.
DIAGNOSTIC STATUS CODES Page 32 SX TRANSISTOR CONTROL Circuits valid for Traction Controller CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM SYMPTOM Control will not operate. BRAKE SW. FU5 POSSIBLE CAUSE Defective control. •= Replace controller unit. P2 KEY SWITCH FU7 P5 TO ACCESSORIES P3 FU6 P1 SP L REV. SW. NO 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. FOR. SW.
DIAGNOSTIC STATUS CODES Page 33 SX TRANSISTOR CONTROL Circuits valid for Traction Controller CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM SYMPTOM Line contactor opens and closes, then can only be closed by opening and closing the key switch. BRAKE SW. FU5 P2 KEY SWITCH FU7 POSSIBLE CAUSE Defective control. •= Replace controller unit. P5 TO ACCESSORIES P3 FU6 P1 SP L P4 PY7 PY12 P18 P17 P1 P2 P6 OSCILLATOR CARD PY10 LEFT CONTROL PY11 LINE REV. SW.
DIAGNOSTIC STATUS CODES Page 34 SX TRANSISTOR CONTROL Circuits valid for Traction Controller This status code will be displayed when the current draw in the motor field is too low during the run mode. CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM SYMPTOM Control will not operate. BRAKE SW. FU5 POSSIBLE CAUSE Defective control. •= Replace controller unit. P2 KEY SWITCH FU7 P5 TO ACCESSORIES P3 FU6 P1 SP L P4 PY7 PY12 P18 P17 P1 P2 P6 OSCILLATOR CARD PY10 LEFT CONTROL PY11 LINE REV. SW.
DIAGNOSTIC STATUS CODES Page 35 SX TRANSISTOR CONTROL Circuits valid for Traction Controller CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM SYMPTOM Control will not operate. BRAKE SW. FU5 POSSIBLE CAUSE Defective control. •= Replace controller unit. P2 KEY SWITCH FU7 P5 TO ACCESSORIES P3 FU6 P1 SP L P4 PY7 PY12 P18 P17 P1 P2 P6 OSCILLATOR CARD PY10 LEFT CONTROL PY11 LINE REV. SW. YES This status code will be displayed when the voltage input from the current sensor is too low during running.
DIAGNOSTIC STATUS CODES Page 36 SX TRANSISTOR CONTROL Circuits valid for Traction Controller CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM SYMPTOM Control will not operate. BRAKE SW. FU5 POSSIBLE CAUSE P2 KEY SWITCH FU7 - Shorted line contactor coil - Short between wires connected to line coil (wires #10 and 24) P5 TO ACCESSORIES P3 FU6 P1 SP L P4 PY7 PY12 P18 P17 P1 P2 P6 OSCILLATOR CARD PY10 LEFT CONTROL PY11 If line coil resistance is correct: Defective control. •= Replace controller unit.
DIAGNOSTIC STATUS CODES Page 37 SX TRANSISTOR CONTROL TROUBLE-SHOOTING DIAGRAM SYMPTOM Control will not operate. POSSIBLE CAUSE •= Shorted motor armature A1 to A2 •= Power cables may be shorted to each other (Measure at control terminals) •= A1 to A2 terminals may be shorted to battery positive or negative P2 KEY SWITCH FU7 FU6 P5 TO ACCESSORIES P3 P1 SP L P4 PY7 PY12 P18 P17 P1 P2 P6 OSCILLATOR CARD PY10 LEFT CONTROL PY11 LINE REV. SW. BRAKE SW. FU5 FOR. SW.
DIAGNOSTIC STATUS CODES Page 38 SX TRANSISTOR CONTROL TRACTION STATUS CODE DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION The PMT enable signal from the auxiliary (slave) control to the master control drops below 5V. -68 MEMORY RECALL YES Circuits valid for Traction Controller This status code will be displayed when the voltage at the master PL21 drops below 5V. CORRECTIVE ACTIONS POSSIBLE CAUSE Auxiliary control shut down. •= Check auxiliary control for stored faults.
DIAGNOSTIC STATUS CODES Page 39 SX TRANSISTOR CONTROL Circuits valid for Traction Controller CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM SYMPTOM Control will not operate. BRAKE SW.
DIAGNOSTIC STATUS CODES Page 40 SX TRANSISTOR CONTROL Circuits valid for Traction Controller CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM SYMPTOM Line contactor opens and closes, then opens and can only close by opening and closing the key switch. BRAKE SW. FU5 P2 KEY SWITCH FU7 FU6 POSSIBLE CAUSE Defective control. •=Replace controller unit P5 TO ACCESSORIES P3 P1 SP L P4 PY7 PY12 P18 P17 P1 P2 P6 OSCILLATOR CARD PY10 LEFT CONTROL PY11 LINE REV. SW.
DIAGNOSTIC STATUS CODES Page 41 SX TRANSISTOR CONTROL Section 4.6 TMM Status Codes TRACTION STATUS CODE -90 MEMORY RECALL YES Circuits valid for Traction Motor Temperature DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION Traction motor temperature has exceeded maximum temperature limit. This status code will be displayed when the voltage at the respective terminal of the TMM or Pump Logic Card is at zero volts. CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM SYMPTOM Status code flashes “on and off”.
DIAGNOSTIC STATUS CODES Page 42 SX TRANSISTOR CONTROL TRACTION STATUS CODE -93 MEMORY RECALL YES Circuits valid for Steer Pump Motor Brush Wear Indicator DESCRIPTION OF STATUS Steering pump motor brush wear indicator has detected worn brush. CORRECTIVE ACTIONS CAUSE OF STATUS INDICATION This status code will be displayed when the voltage at the respective terminal of the TMM or Pump Logic Card is at battery volts. TROUBLE-SHOOTING DIAGRAM SYMPTOM Status code flashes “on and off”.
DIAGNOSTIC STATUS CODES Page 43 SX TRANSISTOR CONTROL TRACTION STATUS CODE -94 MEMORY RECALL YES Circuits valid for Traction Motor Brush Wear Indicator DESCRIPTION OF STATUS Traction motor brush wear indicator has detected worn brush. CAUSE OF STATUS INDICATION This status code will be displayed when the voltage at the respective terminal of the TMM or Pump Logic Card is at battery volts. CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM SYMPTOM Status code flashes “on and off”.
DIAGNOSTIC STATUS CODES Page 44 SX TRANSISTOR CONTROL TRACTION STATUS CODE -95 MEMORY RECALL YES Circuits valid for Pump Motor Brush Wear Indicator DESCRIPTION OF STATUS Pump motor brush wear indicator has detected worn brush. CAUSE OF STATUS INDICATION This status code will be displayed when the voltage at the respective terminal of the TMM or Pump Logic Card is at battery volts. CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM SYMPTOM Status code flashes “on and off”.
DIAGNOSTIC STATUS CODES Page 45 SX TRANSISTOR CONTROL TRACTION STATUS CODE -99 MEMORY RECALL YES Circuits valid for Traction Controller DESCRIPTION OF STATUS Maintenance alert and speed limit. CORRECTIVE ACTIONS SYMPTOM Status code is displayed for 4 seconds when the key switch is first turned on, and/or the vehicle may run at a reduced speed.
DIAGNOSTIC STATUS CODES Page 46 TRANSISTOR PUMP CONTROL Section 4.7 Pump Control Codes PUMP STATUS CODE -117 MEMORY RECALL NO Circuits valid for Pump Controller DESCRIPTION OF STATUS “Card Type” selection is invalid. CORRECTIVE ACTIONS SYMPTOM Control will not operate. POSSIBLE CAUSE Invalid card type selection. •=Review function 17 in the Handset Instruction sheets. Adjust and set card type value as instructed by OEM service manual.
DIAGNOSTIC STATUS CODES Page 47 TRANSISTOR PUMP CONTROL PUMP STATUS CODE -128 MEMORY RECALL YES Circuits valid for Pump Controller DESCRIPTION OF STATUS Armature current is too high during the lift mode. CAUSE OF STATUS INDICATION Status code displayed when the current in the armature circuit is sustained above 300A for 70 sec. CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM KEY SWITCH FU3 SYMPTOM Control will not operate.
DIAGNOSTIC STATUS CODES Page 48 TRANSISTOR PUMP CONTROL MEMORY RECALL NO Pump Controller “motor current sensor” input is missing. CAUSE OF STATUS INDICATION 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 circuit. CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM FU3 SYMPTOM No power to pump motor in control range. POSSIBLE CAUSE Control is defective. •=Replace controller unit.
DIAGNOSTIC STATUS CODES Page 49 TRANSISTOR PUMP CONTROL YES CORRECTIVE ACTIONS Circuits valid for Pump Controller SYMPTOM With no pump contactor, control may run continuously. This status code is displayed when, during pump control operation, the transistor fails to turn off. This will result in a PMT condition. TROUBLE-SHOOTING DIAGRAM FU3 KEY SWITCH FU6 TO TRACTION P10 - BDI PY7 P1 P2 P3 PY12 P21 P19 P12 PY10 PY11 POSSIBLE CAUSE Control is defective. •=Replace controller unit.
DIAGNOSTIC STATUS CODES Page 50 TRANSISTOR PUMP CONTROL DESCRIPTION OF STATUS “Look Ahead” test for T2 volts less than 12% of battery volts. YES Circuits valid for Pump Controller CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM FU3 SYMPTOM Pump control will not operate. KEY SWITCH FU6 TO TRACTION P10 - BDI PY7 P1 P2 POSSIBLE CAUSE Check for short circuit from the motor armature to the frame of the vehicle. LINE P3 PY12 P21 P19 P12 PY10 PY11 FU1 Control is defective. •=Replace controller unit.
DIAGNOSTIC STATUS CODES Page 51 TRANSISTOR PUMP CONTROL PUMP DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Circuits valid for Pump Controller CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM SYMPTOM Pump control will not operate. FU3 KEY SWITCH FU6 TO TRACTION P10 - BDI PY7 POSSIBLE CAUSE Defective control fuse. •=Check control fuse for open circuit, replace fuse, if necessary. P1 P2 LINE P3 PY12 P21 P19 P12 PY10 PY11 FU1 Defective control. •=Replace controller unit.
DIAGNOSTIC STATUS CODES Page 52 TRANSISTOR PUMP CONTROL CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM SYMPTOM Pump control will not operate. KEY SWITCH FU6 PY7 LINE + NO Circuits valid for Pump Controller DESCRIPTION OF STATUS A2 TO TRACTION CARD CAUSE OF STATUS INDICATION This status code will be displayed when the battery voltage measured at P1 is less than 14 volts. CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM SYMPTOM Pump control will not operate.
INSTALLATION AND OPERATION MANUAL Page 53 SX TRANSISTOR CONTROL Section 5. TRUCK MANAGEMENT MODULE (TMM) Section 5.1 General Features The Truck Management Module is a multi-functional accessory card (IC3645TMM7A), or an integral function of the SR Pump control when used with the SX Family of Traction controls.
INSTALLATION AND OPERATION MANUAL Page 54 SX TRANSISTOR CONTROL Section 5.4.3 TMM Pump Control Connections PUMP CONTROL CONNECTIONS PA 5 PZ 10 PZ 11 A3-2 PA 4 A3-1 PA 2 A2-2 PA 1 A2-1 3 PB 6 A1-2 1 BATTERY NEGATIVE PA 6 A1-1 PA 3 5 6 8 10 11 12 PY 10 PA 3 4 BATTERY POSITIVE TO PY10 TRACTION Section 5.5 TMM7A Outline Drawings 2 3 7 4 9 5 6 8 10 14 11 12 13 15 3.36 (85.3) 1 5.8 (147 .2 6.15 0) 156. 20 1.60 (40.6) x .8 (20.
ADJUSTABLE FEATURES Page 55 SX TRANSISTOR CONTROLS Section 6. SX FAMILY GE HANDSET INSTRUCTIONS Section 6.1 General Features 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 and a keyboard for data entry. Note: The Handset is the same for all GE controls, however, the cable will change between some control types. Section 6.
ADJUSTABLE FEATURES Page 56 SX TRANSISTOR CONTROLS Section 6.3 Set-up Function Procedures With the Handset connected, hold down the CONT key and turn on the key switch. This will place you in the set-up mode, ready to monitor or adjust control function settings. NOTE: The term “Push” means to depress key for approximately one second. status codes will be overwritten each time a new status code occurs. This stored status code register can be cleared from memory by using the Handset.
ADJUSTABLE FEATURES Page 57 SX TRANSISTOR CONTROLS LX g accelerator ohm input between 6.0K and 4.0K ohms is provided. HANDSET + EVC Range Set Resolution Example Important Note: This function is used to optimize motor and control performance, and this setting will be determined by GE and OEM engineers at the time of vehicle development. This setting must not be changed by field personnel without the permission of the OEM.
ADJUSTABLE FEATURES Page 58 SX TRANSISTOR CONTROLS FUNCTION 6 FW RATIO (Push 6) FUNCTION 9 REGEN BRAKING C/L (Push 9) This function sets the ratio between armature and field current when operating below the Field Weakening Start point. The setting represents the quantity of field current changed for each 1 amp of armature current changed. This function allows for the adjustment of the Regen braking current limit. High current correlates to shorter stopping distance.
ADJUSTABLE FEATURES Page 59 SX TRANSISTOR CONTROLS FUNCTION 13 SPEED LIMIT 3 ( Push 13 ) The SL3 set speed limit is activated by the Truck Management Module 90, 91 and 92. See Section 5 for Truck Management Module details. FUNCTION 14 INTERNAL RESISTANCE COMPENSATION ( Push 14 ) This function is used when the Battery Discharge Indicator is present. Adjustment of this function will improve the accuracy of the BDI.
ADJUSTABLE FEATURES Page 60 SX TRANSISTOR CONTROLS FUNCTION 18 STEER PUMP TIME DELAY ( Push CONT 3 ) This function allows for the selection of steer pump contactor pick up input, either seat switch or directional switch closing, and adjustment of the time delay for the contactor drop out. •= Pick up steer pump contactor on seat switch closure and time delay drop out of steer pump contactor on seat switch opening: Range Setting Resolution 1.5 to 65 seconds Between 0 and 128 0.
ADJUSTABLE FEATURES Page 61 SX TRANSISTOR CONTROLS The ratio value (VAL) is the set value divided by 10 and rounded to the whole number. FUNCTION 49 Example: Setting of 45 = 45/10 = 4.5 = 4 VAL This function allows for setting the armature current at which minimum field current will achieved . IFIELD = VAL ( IMOTOR x 0.029 ) FUNCTION 28 STORED STATUS CODE COUNT POINTER ( Push CONT 13) This register contains the location of the last stored status code recorded of the 16 stored status codes.
ADJUSTABLE FEATURES Page 62 SX TRANSISTOR CONTROLS FUNCTION 52 MODE 2 ARMATURE CONTROLLED ACCELERATION ( Push CONT 5) Same as Function 48. This C/A takes effect when the Mode 2 settings are called for by the interactive Dash Display. FUNCTION 53 MODE 2 FIELD WEAKENING START ( Push CONT 6) Same as Function 49. This FIELD WEAKENING START takes effect when the Mode 2 settings are called for by the interactive Dash Display.
ADJUSTABLE FEATURES Page 63 SX TRANSISTOR CONTROLS 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 field current is fixed at 37.5 amps MAXIMUM The " ratio" setting is adjusted by Function 26. This function sets the ratio between armature is and field current when operating,MOTOR I above FWS and less than 300 amps.
ADJUSTABLE FEATURES Page 64 TRANSISTOR PUMP CONTROLS Section 6.6 Setup Functions for Hydraulic Pump Control FUNCTION 1: NOT APPLICABLE This function is not applicable to this type of control and should not be adjusted. FUNCTION 2: INTERNAL RESISTANCE COMPENSATION START (Push 2) This function allows for the adjustment of the current level at which the internal resistance compensation feature (Function 16) will take effect. Range Setting Resolution 0 to 1325 amps 52 to 255 6.
ADJUSTABLE FEATURES TRANSISTOR PUMP CONTROLS Page 65 of 0.375 volts each whereas, a setting of 4 will be added in 15 steps of 0.375 volts each. SETTING 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 FUNCTION 17: SPEED / TORQUE COMPENSATION TABLE VOLTAGE DROP SETTING 11.44 17 7.60 18 5.72 19 4.57 20 3.81 21 3.27 22 2.86 23 2.54 24 2.28 25 2.08 26 1.90 27 1.76 28 1.63 29 1.52 30 1.43 31 VOLTAGE DROP 1.34 1.27 1.20 1.14 1.09 1.04 0.99 0.95 0.91 0.88 0.85 0.82 0.79 0.76 0.
ADJUSTABLE FEATURES TRANSISTOR PUMP CONTROLS switch input signal is received by the control card. SL3 limit switch is a normally open switch connected to battery negative, the switch closing enables speed limit. Range Setting Resolution 0% to 100% battery volts 0 to 255 0.375 volts per set unit Example: Setting of 50=18.75 volts FUNCTION 52: Page 66 FUNCTION 61: MODE 4 - SPEED LIMIT 2 (SL2) (Push CONT 14) Same as Function 49.
INSTALLATION AND OPERATION MANUAL IT/IP TRANSISTOR CONTROL Page 67 Section 7. DASH DISPLAYS From the Dash Display, the operator may select any of four pre-set interactive modes consisting of (4) Controlled Acceleration levels, (4) Field Weakening Pick Up levels and (4) Speed Limit levels. Section 7.
INSTALLATION AND OPERATION MANUAL IT/IP TRANSISTOR CONTROL Section 7.4 Start-Up Display Sequence Page 68 Section 7.5 Outline Drawings START-UP DISPLAY SEQUENCE g GE Electric Vehicle Motors & Controls Key Switch On Verify Each LED Segment 8888 + - 0.41 (10.4) If Maintenance Code Is Not Active Display Code "-99" For Four Seconds and Activate Speed Limit (if selected) BDI Display or Blank Display (no BDI used) 3.20 (81.3) 2.45 (62.2) CONNECTOR OMITTED IF NOT REQUIRED 0.19 (4.
TURN ANGLE POTENTIOMETER INSTALLATION SX TRANSISTOR CONTROL Page 69 Section 8.0 TURN ANGLE POTENTIOMETER INSTALLATION Section 8.1 GENERAL: The potentiometer used for the turn angle must be a 320 degree rotation device that is attached to the steer wheel in a manner to cause a 1:1 rotation ratio between the two devices. Any ohm value potentiometer can be used, but it is suggested that it be at least 2K ohms or above, to keep the wattage of the potentiometer to a minimum.
TURN ANGLE POTENTIOMETER INSTALLATION SX TRANSISTOR CONTROL Page 70 Adjust the potentiometer until the Handset reads 110. Lock down the potentiometer shaft and turn the vehicle all the way to the left turn stop, the reading should be 37 or less. Turn the wheel to the right turn stop, the reading should be 183 or greater. After adjusting the potentiometer, be sure to ESC out of the monitor routine and then reset Function 25 to zero using the same procedure as outlined above. Section 8.
TURN ANGLE POTENTIOMETER INSTALLATION SX TRANSISTOR CONTROL Page 71 Section 8.3 Turn Angle Input Volts vs. Steer Wheel Degrees vs. Handset Readings 320 Degree Potentiometer 320 Degree Potentiometer Left Right Left Right Volts Deg HS Volts Deg HS Actions Volts Deg HS Volts Deg HS Actions 2.15 Ctr 110 2.15 Ctr 110 No Change 1.53 46 78 2.77 46 141 Proportional Reduce 2.14 1 109 2.16 1 110 No Change 1.52 47 77 2.78 47 142 Proportional Reduce 2.12 2 108 2.18 2 111 No Change 1.51 48 77 2.
RS-232 MEMORY MAP TABLES SX TRANSISTOR CONTROL Page 72 Section 9.0 MEMORY MAPS Section 9.1 Traction Control E2 Func No. 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 HS No.
RS-232 MEMORY MAP TABLES SX TRANSISTOR CONTROL E2 Func No. 43 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 44 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 ; 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 HS No. (26) (28) (30) (32) (34) (36) (38) (40) .
RS-232 MEMORY MAP TABLES SX TRANSISTOR CONTROL E2 90 91 92 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 Func No. HS No.