GE IC3645SR4W606N6 User Manual

INSTALLATION AND OPERATION
SX TRANSISTOR CONTROL Page 1
SEPARATELY EXCITED (SX) TRANSISTORIZED TRACTION MOTOR CONTROL
AND SERIES PUMP MOTOR CONTROL
INSTALLATION AND OPERATION MANUAL
(IC3645SR4W606N6, IC3645SR7W455N8, IC3645SP4U450N10 and IC3645SP7U350N9)
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.
Table of Contents
General Electric Company October 2002
Section 1.0 INTRODUCTION.........................................................................................................................................................4
1.1 Motor Characteristics...............................................................................................................4
1.2 Solid-State Reversing................................................................................................................5
1.3 Flexible System Application .....................................................................................................5
1.4 More Features with Fewer Components.................................................................................5
Section 2.0 FEATURES OF SX FAMILY OF MOTOR CONTROLLERS.....................................................................................6
2.1 Performance ..............................................................................................................................6
2.1.1 Oscillator Card Features...................................................................................................6
2.1.1.a Standard Operation...................................................................................................6
2.1.1.b Creep Speed ...............................................................................................................6
2.1.1.c Controlled Acceleration and 1A Time .....................................................................6
2.1.2 Current Limit.......................................................................................................................6
2.1.3 Braking................................................................................................................................6
2.1.3.a Plug Braking...............................................................................................................6
2.1.3.b Regenerative Braking to Zero Speed.......................................................................6
2.1.3.c Pedal Position Plug Braking.....................................................................................6
2.1.3.d Auto Braking ..............................................................................................................6
2.1.3.e Brake Pedal Regenerative Braking..........................................................................6
October 2002

GE IC3645SR4W606N6 Specifications

General

Brand	GE
Model	IC3645SR4W606N6
Category	Control Unit
Language	English

Summary

Section 1.0 INTRODUCTION

1.1 Motor Characteristics

Explains motor types and performance curves for traction systems.

1.2 Solid-State Reversing

Details using H-Bridge for directional control, reducing component count.

1.3 Flexible System Application

Discusses independent armature/field control for system efficiency.

1.4 More Features with Fewer Components

Highlights advantages like field weakening and regenerative braking.

Section 2.0 FEATURES OF SX FAMILY OF MOTOR CONTROLLERS

2.1 Performance

Describes operational features like creep speed, acceleration, and current limits.

2.2 System Protective Override

Covers safety features including SRO, voltage monitoring, and thermal protection.

2.3 Diagnostics

Explains status codes, system diagnostics, and Handset interaction for fault finding.

2.4 Hydraulic Pump Control

Details the features and operation of the hydraulic pump controller.

Section 3.0 ORDERING INFORMATION, ELEMENTARY AND OUTLINE DRAWINGS

3.1 Ordering Information for Separately Excited Controls

Specifies the part number structure and configuration options.

3.2 Outline: SX-4 and SR-4 Package Size

Provides physical dimensions and mounting details for SX-4/SR-4.

3.3 Outline: SX-3 and SR-3 Package Size

Provides physical dimensions and mounting details for SX-3/SR-3.

3.4 Traction Elementary

Presents the electrical schematic diagram for traction control circuits.

3.5 Pump Elementary

Presents the electrical schematic diagram for pump control circuits.

3.6 Traction and Pump Control Input and Output List

Details pin assignments and signal descriptions for connectors.

Section 4.0 TROUBLESHOOTING AND DIAGNOSTIC STATUS CODES

4.1 General Maintenance Instructions

Outlines basic maintenance, cleaning, and battery care procedures.

4.2 Cable Routing and Separation

Provides guidelines for cable installation to minimize electrical noise.

4.3 Recommended Lubrication of Pins and Sockets Prior to Installation

Details cleaning and lubrication for connector reliability.

4.4 Controller Mounting Guidelines

Explains surface preparation for optimal heat transfer and mounting.

4.5 General Troubleshooting Instructions

Provides an overview of the process for diagnosing issues.

4.6 Traction Control Codes

Lists and explains status codes for traction control troubleshooting.

4.7 TMM Module Status Codes

Lists and explains status codes for the Truck Management Module.

4.8 Pump Control Codes

Lists and explains status codes for pump control troubleshooting.

Section 5.0 TRUCK MANAGEMENT MODULE (TMM)

5.1 General Features

Describes the TMM's role in monitoring and reporting system status.

5.2 Operation

Explains how the TMM processes inputs and generates status codes.

5.3 Installation

Provides guidelines for physically installing the TMM accessory card.

5.4 Connection Diagrams

Illustrates the wiring schematics for TMM card and sensors.

5.5 TMM7A Outline Drawings

Presents the physical dimensions and mounting details for the TMM7A card.

Section 6.0 SX FAMILY - GE HANDSET INSTRUCTIONS

6.1 General Features

Introduces the GE Handset as a tool for system configuration and monitoring.

6.2 Purpose / Setup Functions

Lists the key functions performable with the Handset.

6.3 Setup Function Procedures

Details the steps for using the Handset to access and adjust settings.

6.4 Setup Functions for Traction Controller

Explains adjustable parameters and their ranges for traction control.

6.5 Summary of Current Limit Adjustments

Provides a graphical summary of current limit settings and their effects.

6.6 Setup Functions for Hydraulic Pump Control

Details adjustable parameters for hydraulic pump control settings.

Section 7.0 DASH DISPLAYS

7.1 Application

Explains the function of Dash Displays for operator information and diagnostics.

7.2 Standard Dash Displays

Describes the features and indicators of the standard dash display unit.

7.3 Interactive Custom Dash Displays

Highlights advanced features of custom dash displays for performance selection.

7.4 Start-Up Display Sequence

Outlines the sequence of displays shown when the system powers on.

7.5 Outline Drawings

Presents the physical dimensions and wiring connections for the dash display.

Section 8.0 MEMORY MAP

8.1 Traction Control

Lists the memory map for traction control functions, access, and restrictions.