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INSTALLATION AND OPERATION
IT/IP TRANSISTOR CONTROL
SEPARATELY EXCITED TRANSISTORIZED TRACTION 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 FSIP 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 FSIP directly for this
assistance.
Section 1.0
INTRODUCTION .................................................................................................................. 4
1.1
1.2
1.3
1.4
Section 2.0
FEATURES OF IT FAMILY OF MOTOR CONTROLLERS................................................. 6
2.1
2.1.1
2.1.1.a
2.1.1.b
2.1.1.c
2.1.2
2.1.3
2.1.3.a
2.1.3.b
2.1.3.c
2.1.4
2.1.4.a
2.1.4.b
2.1.5
INSTALLATION AND OPERATION MANUAL
IC3645SR7T405T5
Table of Contents
Flight Systems Industrial Products April 2012
Motor Characteristics ........................................................................................ 4
Solid-State Reversing ....................................................................................... 5
Flexible System Application .............................................................................. 5
More Features with Fewer Components........................................................... 5
Performance...................................................................................................... 6
Oscillator Card Features............................................................................. 6
Standard Operation.............................................................................. 6
Creep Speed ........................................................................................ 6
Control Acceleration ............................................................................ 6
Current Limit ............................................................................................... 6
Braking........................................................................................................ 6
Regenerative Braking to Zero Speed................................................... 6
Pedal Position Plug Braking................................................................. 6
Auto Braking......................................................................................... 6
Auxiliary Speed Control .............................................................................. 6
Field Weakening .................................................................................. 6
Speed Limits ........................................................................................ 7
Ramp Operation ......................................................................................... 7
Table of Contents ( Continued )
Page 1
April 2012
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Table of Contents
Troubleshooting
Related Manuals for GE IC3645SR7T405T5
Summary of Contents for GE IC3645SR7T405T5
- Page 1 SEPARATELY EXCITED TRANSISTORIZED TRACTION CONTROL INSTALLATION AND OPERATION MANUAL IC3645SR7T405T5 Note: The information contained herein is intended to assist OEM's, Dealers and Users of electric vehicles in the application, installation and service of FSIP solid-state controllers. This manual does not purport to cover all variations in OEM vehicle types.
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Page 2: Table Of Contents
INSTALLATION AND OPERATION IT/IP TRANSISTOR CONTROL Page 2 2.1.5.a Ramp Start ................... 7 2.1.5.b Anti-Rollback ..................7 2.1.6 On-Board Coil Drivers and Internal Coil Suppression ....... 7 System Protective Override ................7 2.2.1 Static Return to Off (SRO) ................. 7 2.2.2 Accelerator Volts Hold Off ................ - Page 3 INSTALLATION AND OPERATION IT/IP TRANSISTOR CONTROL Page 3 Section 5.0 IT FAMILY - GE HANDSET INSTRUCTIONS ..............35 General Features ....................35 Purpose/Setup Functions ..................35 Setup Function Procedures ..................36 5.3.1 Setup Mode ...................... 36 5.3.2 Status Code Scrolling..................
- Page 4 BASIC OPERATION AND FEATURES IT400 TRANSISTOR CONTROL Page 4 motor slows down, reducing the back EMF (which Section 1. INTRODUCTION depends on the speed, as well as the constant field strength). The reduced back EMF allows the Section 1.1 Motor Characteristics armature current to increase, providing the greater torque needed to drive the increased mechanical The level of sophistication in the controllability of...
- Page 5 BASIC OPERATION AND FEATURES IT400 TRANSISTOR CONTROL Page 5 Aside from the constant horsepower characteristics Because the shunt motor controller has the ability to described above, there are many other features that control both the armature and field circuits provide increased performance and lower cost. The independently, the system can normally be adjusted following description provides a brief introduction to for maximum system efficiencies at certain operating...
- Page 6 BASIC OPERATION AND FEATURES IT400 TRANSISTOR CONTROL Page 6 motor current is usually greater than battery current, Section 2. FEATURES OF IT FAMILY OF except at 100% ON time. TRANSISTOR MOTOR CONTROLLERS Section 2.1 Performance Section 2.1.3 Braking Section 2.1.1 Oscillator Card Features Section 2.1.3.a Regenerative Braking to Zero Speed Section 2.1.1.a Standard Operation...
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Page 7: Ramp Start
BASIC OPERATION AND FEATURES IT400 TRANSISTOR CONTROL Page 7 current is less than the value set by Function 24 and is opened, the control shuts off and cannot be the accelerator input voltage is less than 1 volt. It is restarted until the directional lever is returned to important to note that this function is used to optimize neutral. -
Page 8: Diagnostics
BASIC OPERATION AND FEATURES IT400 TRANSISTOR CONTROL Page 8 however, the resulting PMT should open the Line contactor, in the event of a failure. The latest in microprocessor technology is used to provide accurate battery state of charge information Section 2.3 Diagnostics and to supply passive and active warning signals to the vehicle operator. -
Page 9: Circuit Board Coil Driver Modules
BASIC OPERATION AND FEATURES IT400 TRANSISTOR CONTROL Page 9 These interactive modes are "pre-set" using the Handset (Functions 48-62) or a personal computer (Functions 97-112). This feature allows the operator to select the best vehicle performance for changing tasks or conditions. Section 2.3.7 Circuit Board Coil Driver Modules Coil drivers are internal to the control card, and are the power devices that operate the Line contactor... -
Page 10: Ordering Information, Elementary And Outline Drawings
OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS IT TRANSISTOR CONTROL Page 10 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: Series Control (Pump) -
Page 11: Outline: It400 Package Size
OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS IT TRANSISTOR CONTROL Page 11 Section 3.2 Outline: IT400 Package April 2012... -
Page 12: Traction Elementary
OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS IT/IP TRANSISTOR CONTROL IT/IP TRANSISTOR CONTROL Page 12 Page 12 Section 3.3 Traction Elementary April 2012 April 2012... -
Page 13: Traction Control Input / Output List
OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS IT/IP TRANSISTOR CONTROL Page 13 ection 3.4. Traction Control Input and Output List INPUT/OUTPUT DESC RIPTION BATTERY VOLTS FROM BATTERY BATTERY VOLTS FROM KEY BATTERY NEG FROM START SWITCH BATTERY VOLTS FROM FORWARD SWITCH BATTERY VOLTS FROM REVERSE SWITCH BATTERY VOLTS FROM TURF SWITCH ACCELERATOR INPUT VOLTAGE SIGNAL... -
Page 14: Troubleshooting And Diagnostic Status Codes
DIAGNOSTIC STATUS CODES IT TRANSISTOR CONTROL Page 14 Section 4.0 TROUBLESHOOTING AND DIAGNOSTIC STATUS CODES Section 4.1 General Maintenance Instructions battery maintenance procedures, recharging before 80 percent discharged with periodic equalizing The transistor control, like all electrical apparatus, charges. does have some thermal losses. The semiconductor junctions have finite temperature limits, above which Visual inspection of FSIP contactors contained in the these devices may be damaged. -
Page 15: Low Level Signals (Level L)
DIAGNOSTIC STATUS CODES IT TRANSISTOR CONTROL Page 15 4.2.2.d High Power Signals (Level HP) 4.2.2.a Low-Level Signals (Level L) Power wiring is designated as level HP. This consists Low-level signals are designated as level L. These of DC buses and motor wiring with currents greater than 10 A. -
Page 16: 4.2.5 Rf Interference
DIAGNOSTIC STATUS CODES IT TRANSISTOR CONTROL Page 16 New and re-manufactured control plugs are cleaned 4.2.5 RF Interference and lubricated prior to shipment from the factory. However, in applications where severe vibration or To prevent radio frequency (RF) interference, care high temperature cycling and excessive humidity ( should be taken in routing power cables in the vicinity such as freezers ) are present, it is recommended... -
Page 17: Controller Mounting Guidelines
DIAGNOSTIC STATUS CODES IT TRANSISTOR CONTROL Page 17 controller warranty for units returned solely due to the presence of these status codes. Careful surface preparation, including adequate application of thermal compound, as detailed in the following paragraphs, must be completed during the installation of FSIP controls. -
Page 18: Application Of Thermal Compound
DIAGNOSTIC STATUS CODES IT TRANSISTOR CONTROL Page 18 equivalent to the flatness of the control surface (0.005” per linear inch). Use a straight edge or dial indicator to verify the mounting surface. The biggest hindrance to heat transfer is the presence of rust, scale, weld splatter or paint on the vehicle mounting surface. -
Page 19: Maintenance
DIAGNOSTIC STATUS CODES IT TRANSISTOR CONTROL Page 19 With the status code number, follow the procedures outlined in the status code instruction sheets to determine the problem. Important Note: Due to the interaction of the logic card with all vehicle functions, almost any status code or control fault could be caused by the logic card. -
Page 20: Traction Controller Status Codes
DIAGNOSTIC STATUS CODES IT TRANSISTOR CONTROL Page 20 Section 4.6 Traction Control Codes TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Emergency brake switch is open. This status code will be displayed when P13 is greater than 2.5 volts. MEMORY RECALL CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM... - Page 21 DIAGNOSTIC STATUS CODES IT TRANSISTOR CONTROL Page 21 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE The accelerator pedal is depressed with This status code will be displayed when the no direction selected. accelerator voltage, at P7>1.4V, and no direction is selected (P4 and P5 are both less than 50% of battery volts) MEMORY RECALL...
- Page 22 DIAGNOSTIC STATUS CODES IT TRANSISTOR CONTROL Page 22 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Both the forward and reverse switches or This status code will be displayed when P4 and the turf and reverse switches are closed at P5 or P6 and P5 are greater than 50% of battery the same time.
- Page 23 DIAGNOSTIC STATUS CODES IT TRANSISTOR CONTROL Page 23 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Rolling Radius or Gear Ratio or Top Speed This status code will be displayed when the parameters are out of limits for the motor. Rolling Radius or Gear Ratio or Top Speed perimeters are out of limits for the motor.
- Page 24 DIAGNOSTIC STATUS CODES IT TRANSISTOR CONTROL Page 24 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Battery voltage is too high at initial key This status code will be displayed when the switch closure. battery volts are greater than 86 volts at initial key switch on.
- Page 25 DIAGNOSTIC STATUS CODES IT TRANSISTOR CONTROL Page 25 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 26 (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 status code.
- Page 27 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 greater than 133, (corresponding to 2.6V), triggering this status code.
- Page 28 DIAGNOSTIC STATUS CODES IT TRANSISTOR CONTROL Page 28 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Armature transistor did not turn off This status code will be displayed when, during properly. control operation, the armature transistor fails to turn off.
- Page 29 DIAGNOSTIC STATUS CODES IT TRANSISTOR CONTROL Page 29 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE “Look Ahead” test for A2 volts is less This status code will be displayed when the voltage at than 12.5% of battery volts. A2 is less than 12.5% of battery volts and I greater than 52 amps, when the control is in the neutral state, with no start switch selected.
- Page 30 DIAGNOSTIC STATUS CODES IT TRANSISTOR CONTROL Page 30 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE Capacitor volts are low before the line This status code will be displayed during “key on” contactor closes. when the capacitor volts is less than 85% of battery volts at initial key switch on.
- Page 31 DIAGNOSTIC STATUS CODES IT TRANSISTOR CONTROL Page 31 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE The line driver input (P2-17) is less This status code will be displayed when the control than 12% of battery volts detects that the line driver input (P2-17) is less than 12% battery volts when the key switch is turned on.
- Page 32 DIAGNOSTIC STATUS CODES IT TRANSISTOR CONTROL Page 32 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE The field current exceeds the current limit This status code will be displayed when the field of the field transistor. transistor exceeds its current limit. The line contactor will drop out and the key switch will have to be recycled to restart the control.
- Page 33 DIAGNOSTIC STATUS CODES IT TRANSISTOR CONTROL Page 33 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 motoring. 1C exceeds 96 volts during motoring. MEMORY RECALL CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM...
- Page 34 DIAGNOSTIC STATUS CODES IT TRANSISTOR CONTROL Page 34 TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION STATUS CODE If the armature current greater than 280 amps for This status code will be displayed when the armature current longer than 3.5 seconds in control mode, the exceeds 280 amps for 3.5 sec and the accelerator pedal is calling armature motoring current will be turned off.
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Page 35: Family - Ge Handset Instructions
INSTRUCTIONS Section 5.1 General Features Key Switch On The GE Handset is a multi-functional tool to be used with the LX, ZX, SX and IT Series GE solid-state controls. The Handset consists of a Light Emitting Diode (LED) display Verify Each LED Segment and a keyboard for data entry. -
Page 36: Setup Function Procedures
This will place you in the set- up mode, ready to monitor or adjust control function ACCESSING STORED STATUS CODES settings. WITH GE HANDSET NOTE: The term “Push” means to depress key for approximately one second. Key Switch Off Section 5.3.1 Setup Mode... -
Page 37: Setup Functions For Traction Controller
FUNCTION 7 MIN FIELD CURRENT be determined by GE and OEM engineers at the time ( Push 7 ) of vehicle development. This setting must not be changed by field personnel without the permission of This function allows the adjustment of the field weakening the OEM. - Page 38 Important Note: This function is used to optimize the OEM. motor and control performance, and this setting will be determined by GE and OEM engineers at the time FUNCTION 11 TURF SPEED LIMIT of vehicle development. This setting must not be...
- Page 39 ( Push CONT 2 ) Drop This function allows for the adjustment of the pedal up field gain. This value is determined by GE application INTERNAL RESISTANCE COMPENSATION engineering and should be set using the OEM setting TABLE specifications for this vehicle.
- Page 40 RAM of the scrolling the register are in section 5.3.2 of this microprocessor. Because absolute memory locations instruction booklet. need to be known, this function should not be used without detailed instructions from the GE application engineer. October 2007...
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Page 41: Summary Of Current Limit Adjustments
The value for this function will be defined by the GE application engineer. The " minimum field current" setting is adjusted by Function 7. -
Page 42: Dash Displays
A push-button associated with the four segment GE Electric Vehicle LED that displays Status Codes can be used to Motors & Controls scroll the last 16 “Stored Status Codes” that shut down vehicle operation with a PMT fault. -
Page 43: Start-Up Display Sequence
INSTALLATION AND OPERATION MANUAL IT TRANSISTOR CONTROL Page 43 Section 6.4 Start-Up Display Sequence Section 6.5 Outline Drawings START-UP DISPLAY SEQUENCE GE Electric Vehicle Motors & Controls Key Switch On Verify Each LED Segment 8 8 8 8 0.41 (10.4) 3.20 (81.3) -
Page 44: Memory Maps
RS-232 MEMORY MAP TABLES IT TRANSISTOR CONTROL Page 44 Section 7.0 MEMORY MAP Func Traction Control Function Access By Restrictions 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 Armature Braking Rate... -
Page 45: Traction Control
RS-232 MEMORY MAP TABLES IT TRANSISTOR CONTROL Page 45 Func Traction Control Function Access By Restrictions Hours (Thou/Hun) 2 PC or PDA Reset to Zero Only Stored Status Code #4 PC or PDA Reset to Zero Only BDI 4 PC or PDA Reset to Zero Only Hours (Tens/Ones) 4 PC or PDA... - Page 46 RS-232 MEMORY MAP TABLES IT TRANSISTOR CONTROL Page 46 Func Traction Control Function Access By Restrictions BDI 15 PC or PDA Reset to Zero Only Hours (Tens/Ones) 15 PC or PDA Reset to Zero Only Hours (Thou/Hun) 15 PC or PDA Reset to Zero Only Stored Status Code #16 PC or PDA...