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GE IC3645SH7R353T1 - User Manual

GE IC3645SH7R353T1
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INSTALLATION AND OPERATION
SX TRANSISTOR CONTROL Page 1
August 2001
SEPARATELY EXCITED (SX) TRANSISTORIZED MOTOR CONTROLLERS
FOR NEIGHBORHOOD ELECTRIC VEHICLE APPLICATION
INSTALLATION AND OPERATION MANUAL
(GE MODEL IC3645SH7R353T1)
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.
General Electric Company August 2001
Section 1.0 INTRODUCTION ........................................................................................................................................................3
1.1 Motor Characteristics.............................................................................................................. 3
1.2 Solid-State Reversing............................................................................................................... 4
1.3 Flexible System Application..................................................................................................... 4
1.4 More Features with Fewer Components................................................................................ 4
Section 2.0 FEATURES OF SX FAMILY OF MOTOR CONTROLLERS ....................................................................................5
2.1 Performance.............................................................................................................................. 5
2.1.1 Oscillator Card Features.................................................................................................. 5
2.1.1.a Standard Operation................................................................................................... 5
2.1.1.b Control Acceleration ................................................................................................5
2.1.2 Current Limit...................................................................................................................... 5
2.1.3 Plug Braking...................................................................................................................... 5
2.1.4 Auxiliary Speed Control.................................................................................................... 5
2.1.4.a Field Weakening........................................................................................................ 5
2.1.4.b Speed Limits .............................................................................................................. 5
2.1.4.c Top Speed Regulation ...............................................................................................5
2.1.5 Ramp Start......................................................................................................................... 6
2.1.6 On-Board Coil Drivers and Internal Coil Suppression .................................................6
2.2 System Protective Override..................................................................................................... 6
2.2.1 Static Return to Off (SRO) ...............................................................................................6
2.2.2 Accelerator Volts Hold Off...............................................................................................6
2.2.3 Pulse Monitor Trip (PMT)................................................................................................. 6
2.2.4 Thermal Protector (TP)..................................................................................................... 6
Table of Contents

Table of Contents

Questions and Answers

  • W
    wilsontinaAug 18, 2025
    What to do if battery voltage is too high at initial key switch closure on GE Controller?
    • J
      Joseph CarrAug 18, 2025
      If the battery voltage is too high when you turn on the GE Controller, make sure the battery voltage is not more than 86 volts. Also, check the battery charger to ensure it's outputting the correct voltage.
  • B
    baileyamyAug 20, 2025
    What to do if battery voltage is too low at initial key switch closure on GE Controller?
    • E
      Edward MarshallAug 20, 2025
      If the battery voltage is too low when you initially turn on the GE Controller, check that the battery voltage is at least 68.3 volts. If needed, charge the battery.
  • A
    Andrew ColeAug 23, 2025
    What to do if the accelerator pedal is depressed with no direction selected on GE Controller?
    • R
      Robin WilsonAug 23, 2025
      If the accelerator pedal is depressed without a direction selected on your GE Controller, this can happen when the accelerator voltage at P7 is greater than 2.5V, and neither the forward (P4) nor reverse (P5) switch is activated (both are less than 50% of battery volts). The status code will disappear when you engage a directional switch or release the accelerator pedal.
  • T
    Thomas ArmstrongAug 26, 2025
    What to do if emergency brake switch is open on GE IC3645SH7R353T1 Controller?
    • D
      Douglas DrakeAug 26, 2025
      If the emergency brake switch is open on the GE Controller, it means the voltage at P13 is above 2.5 volts. You should adjust or replace the brake switch to ensure the voltage at P13 is less than 2.5VDC.
  • S
    Suzanne PearsonAug 28, 2025
    What to do if GE IC3645SH7R353T1 Controller will not operate and buzzer sounds?
    • C
      Cassandra JonesAug 28, 2025
      If the GE Controller won't operate and the buzzer sounds, it may be due to a mis-adjusted or defective emergency brake switch input. Check the start switch to ensure it closes when the accelerator pedal is pressed.
  • J
    Jason SweeneyAug 30, 2025
    What to do if accelerator voltage input is too high on power up after initial key switch closure on GE IC3645SH7R353T1?
    • D
      Donald TranAug 31, 2025
      If the accelerator voltage input is too high on power up after initial key switch closure on your GE Controller, adjust or replace the accelerator unit to ensure that the voltage at P7 is less than 0.9 volts before depressing the pedal. This issue occurs when the accelerator input voltage at P7 is greater than 0.9V after the battery plug or key switch has been opened and closed.
  • K
    Kristine GarciaSep 2, 2025
    What to do if start switch fails to close on GE IC3645SH7R353T1 Controller?
    • J
      John StewartSep 2, 2025
      If the GE Controller's start switch fails to close, it could be because the accelerator voltage at P7 is greater than 2.5V while the start switch is open. To resolve this, check the start switch to ensure it closes when the accelerator pedal is depressed.
  • T
    thomas33Sep 5, 2025
    What to do if both forward and reverse switches are closed at the same time on GE IC3645SH7R353T1 Controller?
    • B
      Brent CampbellSep 5, 2025
      If both forward and reverse switches are closed simultaneously on your GE Controller, it's because P4 and P5 are both registering voltages greater than 50% of the battery voltage. To fix this, replace or adjust the directional switches to ensure they are open when the directional switch is in the neutral position.
  • C
    Christopher ArmstrongSep 7, 2025
    What to do if capacitor volts are low before the line contactor closes on GE IC3645SH7R353T1?
    • J
      jbranchSep 7, 2025
      If the capacitor volts are low before the line contactor closes on your GE Controller, check the control fuse for an open circuit. This issue occurs during 'key on' when the capacitor volts are less than 85% of battery volts at initial key switch on.
  • J
    johnsondeborahSep 9, 2025
    What to do if motor armature offset voltage is too high on GE IC3645SH7R353T1?
    • A
      Allen RitterSep 9, 2025
      If the motor armature offset voltage is too high on your GE Controller, it means the motor amps value is greater than 138 (corresponding to 2.7 volts) with no current flowing in the motor circuit. Replace the controller unit to resolve this.

Summary

Section 1.0 INTRODUCTION

1.1 Motor Characteristics

Discusses motor controllability evolution and SX system advantages over series motors.

1.2 Solid-State Reversing

Explains transistor H-Bridges for quiet, efficient vehicle operation.

1.3 Flexible System Application

Details how independent control optimizes system efficiency.

1.4 More Features with Fewer Components

Highlights benefits like infinite field weakening and regenerative braking.

Section 2.0 FEATURES OF SX FAMILY OF TRANSISTOR MOTOR CONTROLLERS

2.1 Performance

Details performance features like oscillator card, current limit, and plug braking.

2.2 System Protective Override

Explains safety features like SRO, Accelerator Volts Hold Off, PMT, and Thermal Protector.

2.3 Diagnostics

Covers status display, codes, hourmeter, BDI, and handset diagnostics.

Section 3.0 ORDERING INFORMATION, ELEMENTARY AND OUTLINE DRAWINGS

3.1 Ordering Information for Separately Excited Controls

Provides part number structure and arguments for ordering SX controls.

3.2 Outline: SX-2 Package Size

Presents dimensional drawings and specifications for the SX-2 package.

3.3 Standard Elementary for Neighborhood Electric Vehicle Application

Shows the standard wiring diagram for NEV applications.

3.4 Standard Neighborhood Electric Vehicle Application Input;Output List

Lists pin assignments for the controller's main and 'Y' plugs.

Section 4.0 TROUBLESHOOTING AND DIAGNOSTIC STATUS CODES

4.1 General Maintenance Instructions

Provides guidelines for control maintenance, avoiding heat and ensuring proper airflow.

4.2 Cable Routing and Separation

Recommends practices for cable routing to minimize electrical noise and interference.

4.3 Recommended Lubrication of Pins and Sockets Prior to Installation

Details lubrication steps for connectors to prevent fretting and ensure reliable contact.

4.4 General Troubleshooting Instructions

Provides guidance on using status codes and general troubleshooting steps.

4.5 Traction Controller Codes

Lists and explains diagnostic status codes for traction controller faults.

Section 5.0 SX FAMILY GE HANDSET INSTRUCTIONS

5.1 General Features

Describes the GE Handset as a multi-functional tool for control setup and monitoring.

5.2 Purpose; Setup Functions

Outlines handset functions for monitoring faults, battery, and adjusting control parameters.

5.3 Setup Function Procedures

Explains how to enter setup mode and navigate functions using the Handset.

5.4 Setup Functions for Traction Controller

Details specific functions available via the Handset for controller configuration.

5.5 Summary of Current Limit Adjustments

Summarizes current limit settings and their impact on motor torque and performance.

Section 6. DASH DISPLAYS

6.1 Application

Describes how Dash Displays provide access to operation info and system diagnostics.

6.2 Standard Dash Displays

Details the GE Standard Dash Display components and information shown.

6.3 Interactive Custom Dash Displays

Explains the Custom Dash Display's interactive modes and additional features.

6.4 Start-Up Display Sequence

Illustrates the sequence of displays shown when the system powers up.

6.5 Outline Drawings

Provides outline drawings and wiring connections for dash displays.

Section 7.0 MEMORY MAP

GE IC3645SH7R353T1 Specifications

General IconGeneral
ManufacturerGE
ModelIC3645SH7R353T1
TypeController
ApplicationIndustrial Automation
Programming LanguageLadder Logic

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