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GE SX Series User Manual

GE SX Series
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INSTALLATION AND OPERATION
SX TRANSISTOR CONTROL Page 1
SEPARATELY EXCITED (SX) TRANSISTORIZED TRACTION MOTOR CONTROL
AND SERIES PUMP MOTOR CONTROL
INSTALLATION AND OPERATION MANUAL
(GE Models IC3645SR5W606F1 [software rev. BL3C and higher] and IC3645SP5U600F1)
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 May 2003
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 ...........................................................................................6
2.1.2 Current Limit.......................................................................................................................6
2.1.3 Braking................................................................................................................................6
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
Revised May 2003

Table of Contents

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GE SX Series Specifications

General IconGeneral
Programming LanguageLadder Logic, Function Block Diagram, Structured Text
Humidity5% to 95% non-condensing
Protection ClassIP20
TypeProgrammable Logic Controller
ManufacturerGE
Communication PortsRS-232, RS-485, Ethernet
Input Voltage24V DC
Operating Temperature0°C to 55°C
DimensionsVaries depending on module configuration
WeightVaries depending on module configuration
Communication ProtocolModbus
Number of Digital InputsVaries by model
Number of Digital OutputsVaries by model
Number of Analog InputsVaries by model
Number of Analog OutputsVaries by model
Power ConsumptionVaries depending on module configuration
Storage Temperature-40°C to 70°C (-40° to 158°F)

Summary

Section 1.0 INTRODUCTION

Section 2.0 FEATURES OF SX FAMILY OF MOTOR CONTROLLERS

2.2 System Protective Override

Describes safety features like SRO and thermal protection.

2.3 Diagnostics

Outlines system diagnostics and status codes.

Section 3.0 ORDERING INFORMATION, ELEMENTARY AND OUTLINE DRAWINGS

3.6 Traction and Pump Control Input / Output List

Lists all input/output connections for traction and pump control.

Section 2.2 System Protective Override

2.2.3 Pulse Monitor Trip (PMT)

Details features that shut down or lock out operation during faults.

2.2.4 Thermal Protector (TP)

Explains the internal temperature monitoring and protection.

Section 2.3 Diagnostics

2.3.1 Systems Diagnostics

Explains how the control detects and displays status.

2.3.2 Status Codes

Details standard and stored status codes.

2.3.4 Battery Discharge Indication (BDI)

Covers battery state of charge information and warnings.

2.3.5 Handset

Describes the multi-functional tool for controls.

Section 2.4 Hydraulic Pump Control

Section 3.6 Traction and Pump Control Input and Output List

Section 4.0 TROUBLESHOOTING AND DIAGNOSTIC STATUS CODES

4.1 General Maintenance Instructions

Covers maintenance, thermal considerations, and cleaning.

Section 4.2.2 Signal/Power Level Definitions

4.2.2.a Low-Level Signals (Level L)

Defines low-level signals and provides examples.

4.2.2.b High-Level Signals (Level H)

Defines high-level signals and provides examples.

Section 4.2.3 Cable Spacing Guidelines

Section 4.3 Recommended Lubrication of Pins and Sockets Prior to Installation

Section 4.4 Controller Mounting Guidelines

Section 4.4.5 Mounting the GE Control

Section 4.5 General Troubleshooting Instructions

Section 4.6 Traction Control Codes

-02 STANDARD

-02 OPTIONAL

-03 STANDARD

-03 OPTIONAL

-06

-07

-09 OPTIONAL

-11

-12

-15

-16

-23

-24

-27

-28

-41

-42

-43

-44

-45

-46

-49

-51

-57

-64

-65

-66

-67

-69

-71

-76

-77

-81

-82

Section 4.7 TMM Codes

-94

-98

-99

Section 4.8 Pump Control Codes

-103

-104

-123

-124

-127

-128

-141

-142

-143

-144

-145

-146

-148

-150

-151

-157

-180

-181

Section 5. SX FAMILY GE HANDSET INSTRUCTIONS

Section 5.3 Set-up Function Procedures

5.3.1 Setup Mode

Explains how to enter and navigate the setup mode.

Section 5.4 Setup Functions for Traction Controller

FUNCTION 7 MIN FIELD CURRENT

FUNCTION 9 REGEN BRAKING C/L

FUNCTION 10 FIELD CURRENT FOR REGEN

FUNCTION 11 MAINTENANCE AND LOST TACH SPEED LIMIT or PARK BRAKE SWITCH CLOSED

FUNCTION 12 MAX PERCENT ON

FUNCTION 14 INTERNAL RESISTANCE COMPENSATION

FUNCTION 15 BATTERY VOLTS

FUNCTION 16 STALL MPH

FUNCTION 17 CARD TYPE SELECTION

FUNCTION 21 AUTO REGEN BRAKING C/L

FUNCTION 24 FIELD WEAKENING START

FUNCTION 26 RATIO

FUNCTION 28 STORED STATUS CODE COUNT POINTER

FUNCTION 48 MODE 1 MIN FIELD

FUNCTION 49 MODE 1 FIELD WEAKENING START

FUNCTION 50 MODE 1 RATIO

FUNCTION 51 MODE 1 MPH LIMIT

FUNCTION 52 MODE 2 MIN FIELD

FUNCTION 53 MODE 2 FIELD WEAKENING START

FUNCTION 57 MODE 3 FIELD WEAKENING START

FUNCTION 58 MODE 3 RATIO

FUNCTION 59 MODE 3 MPH LIMIT

FUNCTION 60 MODE 4 MIN FIELD

FUNCTION 61 MODE 4 FIELD WEAKENING START

Section 5.5 Summary of Current Limit Adjustments

Section 5.6 Setup Functions for Hydraulic Pump Control

FUNCTION 28: FAULT COUNT POINTER

FUNCTION 48: MODE 1 CONTROLLED ACCELERATION

FUNCTION 49: MODE 1 - SPEED LIMIT 2 (SL2)

FUNCTION 50: MODE 1 - SPEED LIMIT 4 (SL4)

FUNCTION 56: MODE 3-CONTROLLED ACCELERATION

FUNCTION 57: MODE 3 - SPEED LIMIT 2 (SL2)

FUNCTION 58: MODE 3 - SPEED LIMIT 4 (SL4)

FUNCTION 60: MODE 4 - CONTROLLED ACCELERATION

FUNCTION 61: MODE 4 - SPEED LIMIT 2 (SL2)

SECTION 6.0 AUTOCALIBRATION OF ACCELERATOR POTENTIOMETERS

Section 7.0 TRACTION CONTROL MEMORY MAP

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