DeLonghi | EV100 | Specifications | DeLonghi EV100 Specifications

DeLonghi EV100 Specifications
GEH-5714
GE Electric Vehicle
Systems
INSTRUCTIONS
EV100 LX/LXT SCR
CONTROLS
The information contained herein is intended to assist truck users and dealers in the servicing of SCR controls furnished
by the General Electric Company. It does not purport to cover all variations in equipment nor to provide for every possible
contingency to be met with installation, operation or maintenance.
Should further information be desired or should particular problems arise which are not covered sufficiently for the
purchaser's purpose, the matter should be referred to the truck manufacturer through his normal service channels, not directly
to the General Electric Company.
September 1993
1
EV100LX SCR CONTROL ORDERING INFORMATION
EXAMPLE-------------------------- IC3645EV
ARGUMENT NO.
01
ARGUMENT NO. 01 -
100
02
T1
03
TT
04
1
05
BASIC CATALOG NUMBER
ARGUMENT NO. 02 - POWER BASE RATING
100
200
-
EV100 POWER BASE ( APPLICATIONS LESS THAN 150 FLLR )
EV200 POWER BASE ( APPLICATIONS LESS THAN 200 FLLR )
ARGUMENT NO. 03 - APPLICATION AND 1 REC OPTIONS
T1
T2
P1
P2
-
STANDARD CURRENT LIMIT TRACTION
HIGH PERFORMANCE CURRENT LIMIT TRACTION
STANDARD CURRENT LIMIT PUMP
HIGH PERFORMANCE CURRENT LIMIT PUMP
ARGUMENT NO. 04 - LOGIC CARD OPTIONS
MX - TRACTION DUAL MOTOR WITHOUT BDI
MT - TRACTION DUAL MOTOR WITH BDI
PX - PUMP CONTROL WITH TMM
TX - TRACTION WITHOUT BDI
TT - TRACTION WITH BDI
ARGUMENT NO. 05 - REVISION CODE
1
2
-
ACTIVE
EV100LX COMPONENT LOCATIONS
3
EV100LX OUTLINE DRAWING
4
9
EV100LX WITH SPEED LIMIT AND FW
5
9
EV100LX WITH REGEN AND FW
6
9
EV100LX DUAL MOTOR CONTROL
7
9
EV100LX PUMP CONTROL
8
EV100LX PART NUMBER IDENTIFICATION
NO.
4
11
11
12
14
15
16
18
19
20
21
22
24
26
26
26
26
26
28
29
30
34
37
38
39
40
43
48
49
50
52
53
54
55
56
57
58
59
60
61
62
63
64
67
69
70
73
PART-NUMBER
158C3100EEP1
171B3939G1
171B3939G2
273A2523P9
171B3949G1
259A3290P1
273A2523P8
44A717068-001
44A717067-001
44A723544-001
44A723543-001
158C3234G1
259A9053P2
IC3645LXCD1TX
IC3645LXCD1TT
IC3645LXCD1MX
IC3645LXCD1MT
IC3645LXCD1PX
171B3933G1
44A727009-G01
171B3940G1
44A718897-001
148B5620DPP1
148B5620DPP2
148B5620DPP4
148B5620DPP3
WH7138R36G1
L201P17B33
L400P10B33
L401P27B33
44A723274-001
44A723274-002
L14P17020B33
L10P14010B33
L400P7B33
L401P25B33
44A723274-401
L10P11044B33
44A723274-204
L400P5B33
L401P23B33
L10P11008B33
L10P11016B33
L14P15016B33
L400P8B33
171B3954G1
N402P39B6
DESCRIPTION
QUANTITY
BASE DETAIL ...........................................................01
1REC ASSEMBLY LOW POWER ...........................01
1REC ASSEMBLY HIGH POWER ..........................01
THRM COND INSULATION ...................................01
3 AND 4 REC. ASM. .................................................01
INSULATING BUSHING ..........................................03
THRM COND INSULATION ...................................01
SCR, 2REC .................................................................01
SCR, 5REC .................................................................01
CAP. “WARNING” LABEL ......................................01
EV-100 LOGO LABEL ..............................................01
REACTOR ASSEMBLY ............................................01
CAP MT FILM 150MF 25 .........................................01
TRACTION WITHOUT BDI .....................................01
TRACTION WITH BDI .............................................01
DUAL MTR TRACTION WITHOUT BDI ...............01
DUAL MTR TRACTION WITH BDI .......................01
PUMP CONTROL ......................................................01
SPIDER AND WIRE ASM. .......................................01
THERMISTOR ASM .................................................01
SNUBBER ASM. ........................................................04
CAPACITOR MTG. STRAP .....................................02
BUS BAR ....................................................................01
BUS BAR ....................................................................01
BUS BAR ....................................................................01
BUS BAR ....................................................................01
WIRE HARNESS .......................................................01
NUT, M8X1.25MM ....................................................02
M8 FLAT WASHER ..................................................05
M8 LOCK WASHER .................................................05
M5X50MM T/R SCREW ...........................................04
M5X26MM T/R SCREW ...........................................07
M8X1.25X20MM SCREW ........................................03
M5X0.8X10MM SCREW ..........................................05
M5 NAR. FLAT WASHER ........................................05
M5 SPRING LOCKWASHER ...................................05
M3.5X12MM T/R SCREW ........................................04
M3.5X0.6X44MM SCREW .......................................01
M3.5X23MM T/R SCREW ........................................08
M3.5 NAR FLAT WASHER ......................................06
M3.5 LOCK WASHER ..............................................06
M3.5X0.6X8MM SCREW .........................................06
METRIC PAN HD SCREW .......................................02
M6X1.0X16MM SCREW ..........................................01
M6 FLAT WASHER ..................................................01
SHUNT-WIRE ASM ..................................................01
WASHER FLAT ST ...................................................03
9
EV100LX PART NUMBER IDENTIFICATION
10
11
TRACTION
STANDARD
Accel Pot Input
Start Switch Input
Seat Switch Input
Key Switch Input
Forward Switch Input
Reverse Switch Input
Plug Signal
BDI Interrupt
Aux Hourmeter Input
Not Used
Not Used
Not Used
FW Coil Driver
Not Used
SP Coil Driver
F Coil Driver
R Coil Driver
1A Coil Driver
Dash Display 4 Input
Dash Display 3 Input
Dash Display 1 Input
Dash Display 2 Input
Dash Display 5 Input
Not Used
Im
TMMA-9 / Pump-PY12
TMMA-7 / Pump-PY11
TMMA-2 / Pump-PY10
Not Used
Not Used
Not Used
Not Used
INPUT
TB1
TB2
TB3
TB4
TB5
TB6
PA1
PA2
PA3
PA4
PA5
PA6
PB1
PB2
PB3
PB4
PB5
PB6
PY1
PY2
PY3
PY4
PY5
PY6
PY7
PY8
PY9
PY10
PY11
PY12
PY13
PY14
Dash Display 4 Input
Dash Display 3 Input
Dash Display 1 Input
Dash Display 2 Input
Dash Display 5 Input
Not Used
Im
TMMA-9 / Pump-PY12
TMMA-7 / Pump-PY11
TMMA-2 / Pump-PY10
Not Used
Not Used
Not Used
Not Used
FW Coil Driver
Not Used
SP Coil Driver
F Coil Driver
R Coil Driver
1A Coil Driver
Plug Signal
BDI Interrupt
Aux Hourmeter Input
SL2
SL3
SL1
TRACTION
SL/FW
Accel Pot Input
Start Switch Input
Seat Switch Input
Key Switch Input
Forward Switch Input
Reverse Switch Input
Dash Display 4 Input
Dash Display 3 Input
Dash Display 1 Input
Dash Display 2 Input
Dash Display 5 Input
Not Used
Im
TMMA-9 / Pump-PY12
TMMA-7 / Pump-PY11
TMMA-2 / Pump-PY10
Not Used
Not Used
Not Used
Not Used
FW Coil Driver
Regen Coil Driver
SP Coil Driver
F Coil Driver
R Coil Driver
1A Coil Driver
Plug Signal
BDI Interrupt
Aux Hourmeter Input
Sensor 2 Yellow Wire
Sensor 2 Green wire
Mtr A2 Input
TRACTION
REGEN/FW
Accel Pot Input
Start Switch Input
Seat Switch Input
Key Switch Input
Forward Switch Input
Reverse Switch Input
Dash Display 4 Input
Dash Display 3 Input
Dash Display 1 Input
Dash Display 2 Input
Dash Display 5 Input
Not Used
Not Used
TMMA-9 / Pump-PY12
TMMA-7 / Pump-PY11
TMMA-2 / Pump-PY10
Not Used
Not Used
Not Used
Not Used
F Rht Mtr Coil Driver
F Lft Mtr Coil Driver
R Rht Mtr Coil Driver
R Lft Mtr Coil Driver
1A coil Driver
D Coil Driver
PS Coil Driver
BDI Interrupt
Aux Hourmeter Input
In-Board Mtr Rev Sw
Right Mtr Dropout Sw
Left Mtr Dropout Sw
TRACTION
DUAL MTR
Accel Pot Input
Start Switch Input
Seat Switch Input
Key Switch Input
Forward Switch Input
Reverse Switch Input
TERMINAL CONNECTIONS FOR LX/LXT
LOGIC CARDS
Dash Display 4 Input
Dash Display 3 Input
Dash Display 1 Input
Dash Display 2 Input
Not Used
Not Used
Not Used
Not Used
Not Used
Traction PY10
Traction PY9
Traction PY8
Not Used
Not Used
Status Code 95 Input
Status Code 95 Input
BDI Enable Signal Input
Pump (PMT) Coil Driver
1A Coil Driver
Status Code 92 Input
Status Code 93 Input
Status Code 93 Input
Status Code 90 Input
Status Code 94 Input
Status Code 94 Input
Status Code 91 Input
PUMP
Accel Pot Input
SL1
SL2
Key Switch Input
SL3
SL4
EV100LX Logic Card Specifications
IC3645LXCD1T
IC3645LXCD1M
IC3645LXCD1P
On-Board Diagnostics
Standard Displayed to
Handset or Dash Display
Standard Displayed to
Handset or Dash Display
Standard Displayed to
Handset or Dash Display
Hourmeter
Standard Displayed to
Handset or Dash Display
Standard Displayed to
Handset or Dash Display
Standard Displayed to
Handset or Dash Display
Stored Status Codes
Standard
Standard
Standard
Card Type Selection
Standard Enable/Disable
Features
Standard Enable/Disable
Features
Standard Enable/Disable
Features
Creep Speed
Adjustable
2% to 15% On Time
Adjustable
2% to 15% On Time
Not Applicable
Current Limit
Adjustable
See C/L Curves
Standard/High
Performance
Adjustable
See C/L Curves
Standard/High
Performance
Adjustable
See C/L Curves
Standard/High
Performance
Plugging
Adjustable
200 to 930 Amps
Adjustable
200 to 930 Amps
Not Applicable
Pedal Position Plug
Adjustable
100 to 930 amps
Can be Disabled
Adjustable
100 to 930 amps
Can be Disabled
Not Applicable
Standard
Standard
Not Applicable
Standard with 1A Ctr
Standard with 1A Ctr
Standard with 1A Ctr
Adjustable
.1 to 22 seconds
Adjustable
.1 to 22 seconds
Adjustable
.1 to 5.5 seconds
Follows CA by .2 seconds
with Accel Volts is < .5V
or Accel Ohms is < 200
Follows CA by .2 seconds
with Accel Volts is < .5V
or Accel Ohms is < 200
Follows CA by .2 seconds
with Accel Volts is < .5V
or Accel Ohms is < 200
1A Thermal Hold-Off
Standard at 90oC
cutback at 20% TON
Standard at 90oC
cutback at 20% TON
Standard at 90oC
cutback at 20% TON
1A Plugging Hold-Off
Standard
Standard
Not Applicable
Delay to First Pulse
Standard
Standard
Standard
Standard
Look Ahead and Reset two
count
Standard
Look Ahead and Reset two
count
Standard
Look Ahead and Reset two
count
Thermal Protection
Standard
90oC Cutback
Standard
90oC Cutback
Standard
90oC Cutback
Static Return to Off
Standard
2 Second Delay
Standard
2 Second Delay
Not Applicable
Control Features
Ramp Start
Full Power Transition
Controlled Acceleration
1A Timed Pick-Up
PMT (Fault Shut Down)
12
Control Features
IC3645LXCD1T
IC3645LXCD1M
IC3645LXCD1P
24-80 VDC
24-80 VDC
24-80 VDC
5000-0 Ohms
3.5-0 VDC
5000-0 Ohms
3.5-0 VDC
5000-0 Ohms
3.5-0 VDC
Standard
50% at 36-80 VDC
75% at 24 VDC
Standard
50% at 36-80 VDC
75% at 24 VDC
Standard
50% at 36-80 VDC
75% at 24 VDC
Standard
Standard
Standard
Ambient Temperature
-30 to +50oC
-30 to +50oC
-30 to +50oC
Approximate Weight
5.5 Kg
5.5 Kg
5.5 Kg
On-Board
On-Board
On-Board
On-Board
Not Applicable
On-Board
On-Board
On-Board
Not Applicable
Not Applicable
On-Board
On-Board
On-Board
On-Board
Not Applicable
Not Applicable
Not Applicable
Not Applicable
Shorted Driver Protection
Standard
Standard
Standard
Shorted 3 REC Protection
Standard
Standard
Standard
F/R and Speed Input
Switch Loading
Logic Current
Logic Current
Logic Current
1A switch
Not Required
Not Required
Not Required
Adjustable
450 to 1260 Amps
Adjustable
450 to 1260 Amps
Not Applicable
Dual Mtr Steering Logic
Not Available
Standard
Not Available
Dual Mtr Inside Wheel
Reversal
Not Available
Standard
Not Available
Regenerative Braking
Adjustable
Regen C/L - 75A to 630A
Regen Start - 15% to 96%
Not Applicable
Not Applicable
Adjustable
Pick-up - 52A - 466A
Drop-out - 65A to 895A
Not Applicable
Not Applicable
Speed Limit
Three Ranges
Creep to Full Speed
Standard
Adjustable
Input by Limit Switch
Standard
Adjustable
Two Speed Limits
Standard
Adjustable
Input by Limit Switch
Steer pump Time Delay
Seat - .5 to 63 sec
Neutral - .5 to 63 sec
Seat - .5 to 63 sec
Neutral - .5 to 63 sec
Not Applicable
Voltage Range
Accelerator Input
Low Battery Operation
Reverse Battery Protection
Coil Drivers
F/R or Line
1A
FW
Regen
D
PS
1A Current dropout
Field Weakening
13
IC3645LXCD1T
IC3645LXCD1M
IC3645LXCD1P
Accelerator Volts Lockout
Accel volts > 2.5V
Standard
Standard
Standard
Battery Volts Check
Standard
Standard
Standard
Battery Discharge Indication
Optional
Optional
Optional
Full Load Level Running
Mtr Current at 50% 1A
duty
150 Amps Plus
150 Amps Plus
150 Amps Plus
Continuous Duty Mtr
Current with 0.3oC/Watt
Heatsink at 40oC Ambient
103 Amps Plus
103 Amps Plus
103 Amps Plus
330/950 Amps
330/650 Amps
330/950 Amps
330/650 Amps
Not Applicable
Min-Max @ 30% TON
405/640 Amps (STD)
405/640 Amps (STD)
405/640 Amps (STD)
Min-Max @ 50% TON
320/565 Amps (STD)
320/565 Amps (STD)
320/565 Amps (STD)
Min-Max @ 70% TON
230/495 Amps (STD)
230/495 Amps (STD)
230/495 Amps (STD)
Min-Max @ 30% TON
475/690 Amps (H/P)
475/690 Amps (H/P)
475/690 Amps (H/P)
Min-Max @ 50% TON
455/685 Amps (H/P)
455/685 Amps (H/P)
455/685 Amps (H/P)
Min-Max @ 70% TON
435/680 Amps (H/P)
435/680 Amps (H/P)
435/680 Amps (H/P)
Control Features
Plug Current Limit
Min-Max @ 1 Sec
Min-Max @ 3 Sec
Average Motor C/L with
Typical Mtr Inductance
EV100LX Traction and Pump H/P Curve
14
EV100LX Traction and Pump STD Curve
BASICS OF CIRCUIT OPERATION
The control circuit is energized by closing the key switch, seat switch, and moving the forward or reverse lever to either position, and then depressing the accelerator closing the start switch.
This applies power to the control card turning on the PMT driver , which will close the selected
directional contactor and complete the circuits to the drive motor. (See elementary drawings.)
The control card then supplies a gate pulse to 2REC turning it on to a conducting state,
allowing current to flow from the battery through lC, lX, 2REC, motor field, motor armature, sensor,
and back to the battery. After lC charges, 2REC shuts off due to lack of holding current. The control card checks that lC is charged and unlocks the gate to lREC and 5REC.
The control card then supplies a gate pulse to lREC turning it on to a conducting state, allowing current to flow from the battery through lREC, motor field, motor armature, sensor, and back to
the battery. 5REC turns on and allows current to flow T4-T3, lC, lREC, 5REC to T4-T3. This
current charges the bottom of lC positive with respect to the battery positive bus. This charging cycle
occurs in less than l millisecond (.00l sec.) and 5REC shuts off. This charge is now stored on the
capacitor until it is time to turn off lREC.
Current continues to flow in lREC until the control card fires 2REC. When 2REC conducts,
capacitor lC discharges around the circuit composed of lC, 1X, 2REC, and lREC. This discharge
current opposes the battery current through lREC so that the resultant current is zero. With reverse
voltage across lREC, lREC is turned off. Current continues to flow in the 2REC, lC, motor and
battery loop until the capacitor (card terminal l4) is fully charged negative. This charge exceeds
battery voltage by an amount which is a function of peak motor current, and 2REC turns off. Figure l
illustrates the pulsing of current from the battery.
Figure l
Figure 2
During the off time, the energy stored in the motor, by virtue of the motors inductance, will
cause current to circulate through the motor around the loop formed by 3REC. Thus, providing MD=J
15
is called “flyback current”. Figure 2 shows the nature of the motor current which is composed of
both battery current and the inductive flyback current. It should be noted that the average motor
current measured will be greater than the average battery current. The SCR control, in effect, converts battery current at battery volts into a higher motor current and a lower motor volts.
The time for the next ON and OFF cycle to start is determined by the time that the control
card takes to oscillate. This frequency of oscillation is controlled by the potentiometer in the accelerator and automatic circuitry in the card. Slow speed is obtained by having maximum ohms in the
potentiometer. As the resistance in the potentiometer decreases, the speed of the motor increases.
The SCR circuit is capable of delivering approximately 95% speed. For full speed operation, the lA
contactor is closed to apply full battery voltage across the motor.
CONTROL FEATURES
OSCILLATOR - the oscillator section of the card has two adjustable features and one fixed feature.
With the accelerator potentiometer at maximum ohms, the creep speed can be adjusted by the
handset unit. Top speed is fixed by card and is
obtained with the accelerator potentiometer at
minimum ohms. The % ON time has a range of
approximately 5 to 95 percent. The center
operating condition of the oscillator is at 50
percent ON time with a nominal l.8 milliseconds
ON time and l.8 millisecond OFF time. This
corresponds to a maximum operating frequency
of about 300 hertz. At creep the ON time will
decrease to approximately 0.8 milliseconds while
OFF time will become in the order of 20 milliseconds. At full SCR operation, this condition
will be reversed (short OFF time, long ON time).
This variation of ON and OFF time of the
oscillator produces the optimum frequencies
Figure 3
through the SCR range. The frequency curve of
the oscillator is shown in Figure 3.
The rate at which the oscillator may increase its percent ON time is limited by “Controlled
Acceleration”. The minimum time required to go from creep speed to 80-85% on time point may be
varied by the “C/A” trimpot on the card, adjustable from approximately 0.1 seconds to 22.0 seconds.
CURRENT LIMIT - This circuit monitors motor current by utilizing a sensor in series with the
armature. The information detected across the sensor is fed back to the card so current may be
limited to a pre-set value. If heavy load currents are detected, this circuit overrides the oscillator and
limits the average current to a value set by function 4 of the handset. The C/L setting is based on the
maximum thermal rating of lREC and the peak voltage on the capacitor. Because of the flyback
current through 3REC, the motor current usually runs 2 to 3 times battery current. See current limit
curves for available current and adjustment range.
16
PLUGGING - Slow down is accomplished when reversing by providing a small amount of retarding
torque for deceleration. If the vehicle is moving and the directional lever is moved from one direction
to the other, the motor field is reversed. The plug signal is initiated by the fact that the directional
switch has moved from one direction to the other. The motor armature, driven by the inertia of the
vehicle, acts as generator. This generated current passes through 4REC and the sensor. The oscillator circuit regulates at a plug current limit level as set by the Handset this controls the pulse rate of
lREC to regulate the generated motor current and bring the truck to a smooth stop and reversal. With
the accelerator potentiometer at minimum resistance, function 5 will enable adjustment of plugging
current from max to min. current level for plug current limit.
PEDAL POSITION PLUG - This feature will allow for plugging distance based on pedal position.
Pedal position will reduce the plugging current to the current value set by this function as the accelerator is returned to the creep speed position. Maximum plug current is obtained with the accelerator
in the top speed position. This feature is adjustable by using function 16 on the handset.
RAMP START - This feature provides full SCR torque to restart a vehicle on an incline. The
memory for this function is the directional switch. When stopping on an incline, the directional
switch must be left in its original or neutral position to allow the control to assure full power when
restarted. The accelerator potentiometer input will modulate ramp start current.
FULL POWER TRANSITION - this built-in feature provides smooth transition from SCR to lA
bypass. This is accomplished by the SCR continuing to pulse until the lA contactor power tips close.
CONTROL ACCELERATION AND 1A TIME - This feature allows for adjustment of the rate of
time it takes for the control to accelerate to 96% applied battery voltage to the motor on hard acceleration. The 1A contactor will automatically close .2 seconds after the controlled acceleration stops
and the accelerator input is less than .5 volts or less than 50 ohms. C/A is adjusted by function 3 from
.1 to 22 seconds.
1A CURRENT DROP OUT - This adjustable feature can be set to open the 1A contactor if the
traction motor is subject to excessive currents. The dropout is adjustable with function 6 of the
handset. Once the control has dropped out the 1A contactor due to excess current, the directional or
accelerator switch must be returned to neutral to unlock the dropout circuit to allow the control to
pick up the 1A contactor again. Using this feature will reduce the 1A contactor tip life, thus it should
be used only where needed to protect the motor.
STATIC RETURN TO OFF - This built-in feature of the control is set up to make the driver return
the directional lever to neutral anytime he leaves the vehicle and returns. If the seat switch or key
switch is opened, the control will shut off and cannot be restarted until directional lever is returned to
neutral. A time delay of approximately .75 seconds is built into the seat switch input to allow momentary opening of the seat switch if a bump is encountered.
ACCELERATOR VOLTS HOLD-OFF This feature checks the voltage level at the accelerator
input when ever the key switch or seat switch is activated. If the voltage is less than 2.5 volts the
control will not start. This is to assure that the control is calling for low speed operation at start-up.
17
COIL DRIVER MODULES - these drivers are internal to the control card. They are the power
devices that operate F, R, lA, D, FW, RB, and PS contactor coils. These drivers open or close these
coils on command from the control card. All modules are equipped with reverse battery protection in
that if the battery is connected incorrectly, none of the contactors controlled can be closed electrically.
lA THERMAL HOLD OFF - this feature prevents the lA contactor from closing when the truck is
in severe thermal cutback to avoid torque jumps. When the control goes into severe cutback, the
must pulse to time will inhibit the lA timer.
MUST PULSE TO TIME - this feature prevents the lA timer from timing if the oscillation pulse rate
has not reached a particular level of operation.
PULSE MONITOR TRIP ( PMT ) - This feature contains three features which shuts down or locks
out control operation if fault conditions exist that would allow uncontrolled ( run away ) speed of the
vehicle:
Look ahead
Look again
Automatic look again and reset
The PMT circuit will not allow the control to start under the following conditions:
1. If 1REC is shorted or if 1A contactor is welded, the control will not allow the F or R
contactor to close.
2. Will not allow the control to operate if F and R internal coil drivers are shorted or if
3REC diode is shorted.
The PMT circuit will shut down operation of the control ( opening of the F or R contactor ) under the
following conditions:
If 1REC fails to commutate ( shut off ), or if 1A power tips remain closed when they should be open.
After opening the F or R contactor the PMT circuit will check for a fault and if none is found will
reclose the directional contactor. If the fault still exist, the directional contactor will open and remain
open.
If 1A closes before a second commutation failure, the look again counter will automatically reset.
This eliminates the inconvenience of resetting the PMT with the key switch if the trip is due to random noise.
When the PMT circuit prevents F or R contactors from closing, the PMT circuit can be reset only by
opening the key switch.
THERMAL PROTECTOR - (TP) - this temperature sensitive device is mounted on the lREC heat
sink. If the lREC temperature begins to exceed the design limits, the thermal protector will lower the
18
maximum current limit and not allow lREC to exceed its temperature limits. Even at a reduced
current limit, the vehicle will normally be able to reach sufficient speed for full lA operation, thereby
allowing the panel to cool. As the panel cools, the thermal protector will automatically return the
control to full power.
LOW VOLTAGE- batteries under load, particularly if undersized or more than 80 percent discharged, will produce low voltages at the SCR control terminals. The EV-l00 control is designed for
use down to 50 percent of a nominal battery volts of 36-84 V, and 75 percent of a nominal battery
volts of 24 V. Lower battery volts may cause the control to not operate correctly; however the PMT
should open the F or R contactor in the event of a commutation failure.
FIELD WEAKENING - if the vehicle is supplied with a field weakening circuit, the “FW PU” and
“FW DO” (function 7 and 8) can be adjusted from the handset unit. Field weakening is a method of
attaining higher running speed for the vehicle in level operation. The normal settings for this feature
are: pickup of FW contactor from l25 to l50 percent of normal full-load running current (lA), and
dropout of FW contactor from 275 to 300 percent current. The dropout puts the motor back to the
lA range to climb ramps and inclines.
REGENERATIVE BRAKING if the vehicle is moving and the directional lever is moved from one
direction to the other, this initiates a plugging signal by reversing the motor field. During the standard motoring mode and the plugging mode, the RB contactor remains picked up. In the plugging
mode, the motor armature acts as generator. Once the generated current reaches a particular current
level, the plugging mode transitions to regenerative braking mode.
Transitioning to regenerative braking mode, opens the RB contactor, disconnecting the motor armature from battery negative and inserting 7REC and REGEN SENSOR-2 in the regen circuit. During
the lREC on time, the field and armature current is increased. During the 1REC off time, the energy
stored in the field and armature generates the regenerative current, which passes through 7REC, #2
sensor, battery, 3REC/4REC and back to motor field and armature.
The control will remain in regenerative mode as long as the regen current can maintain regenerative
current limit. When the regenerative current cannot be maintained and drops below the level set by
the regenerative current limit trimpot (RB C/L), the regenerative braking mode transitions back to
plugging mode. During the transition back to plugging mode, the RB contactor will reclose enabling
the control to function in plugging mode, regulating plugging currents to bring the vehicle to a
smooth stop and reversal. The accelerator potentiometer input will modulate plugging as well as
regenerative braking current. The major advantage of regen is longer motor life due to reduced motor
heating. This feature has two adjustable functions, regen current limit (function 9) and regen start
(function 10).
DUAL MOTOR OPERATION - This function is used to connect the motor armatures of a dual
motor vehicle system in parallel during a “ plug “ if both motors are in operation at the time of the
plug cycle. This prevents the fields from building flux in the opposite directions and prohibits the
motors from acting as a series generator thereby causing uncontrollable plugging torques. This circuit
require the addition of an armature shorting contactor ( D contactor ) and an additional 4REC diode (
4REC-B). The D contactor only closes when both motors are energized during a plugging cycle.
19
DUAL MOTOR IN-BOARD WHEEL REVERSAL - This feature allows for the control of the inboard traction motor while in a sharper turning condition. The in-board motor is controlled by inputs
from limit switches located on the rear steering wheel which connect card input points to negative.
Logic for turn switch operation is shown below:
LEFT TURN
- L1 and L2 open
- L1 closed and L2 open
- L1 and L2 closed
- motor energized.
- motor disabled.
- motor reversed from normal direction.
RIGHT TURN
- R1 and R2 open
- R1 closed and R2 open
- R1 and R2 closed
- motor energized.
- motor disabled.
- motor reversed from normal direction.
DUAL MOTOR SHARP TURN SPEED LIMIT - This handset adjustable feature allows for the
limiting of top speed when either the R1 and R2 or the L1 and L2 switches are both closed.
TOP SPEED ( MOTOR VOLTS ) LIMIT - This feature provides a means to limit motor volts to
three adjustable limits by limit switch opening between input points on the control card and negative.
The lower motor volt limit always takes priority when more than one switch input is closed. This
motor volt limit effects top speed of the SCR, but actual truck speed will vary at any set point depending on the loading of the vehicle. Each speed limit is adjustable by the handset, function 11, 12,
and 13, for speed limits 1, 2, and 3.
STEER PUMP CONTACTOR TIME DELAY - This feature provides two options for SP time
delay option 1 provides a .5 to 63 second time delayed drop out of the steer pump contactor when the
Forward or Reverse directional switch is opened. This is overridden by a 1.5 second time delayed
drop-out whenever the seat switch is opened. Option 2 provides a .5 to 63 second time delayed drop
out of the SP contactor when the seat switch is opened.
CONSTANT CURRENT COIL DRIVERS AND INTERNAL COIL SUPPRESSION - This
feature allows the use of 24 volt contactor coils on through the entire voltage range of the EV100 (
24 volts to 84 volts ) for the F,R,1A,SP,RG,D,and FW contactors.
This feature also allows the above contactors to operate cooler due to less current being applied to
the coil after pick-up.
HOUR METER READINGS - This feature will display the recorded hours of use of the traction
control and pump control to the dash display each time the key switch is turned off.
INTERNAL RESISTANCE COMPENSATION - This feature is used when the Battery Discharge
Indicator is present. Adjustment of this function will improve the accuracy of the BDI.
TRUCK MANAGEMENT MODULE (TMM1) - is a multi-function accessory card that provides
the OEM the ability to provide status codes or operator warning codes that will be displayed on the
dash display whenever a normally open switch or sensor wire provides a negative signal to the card.
Typically the TMM1A can be used to display over temperature of motors, hydraulic systems or any
other switch that closes at the desired temperature. The TMM1A can also be used to monitor and
display motor brush wear warnings when the motor brushes require replacement.
20
TRUCK MANAGEMENT MODULE (TMM2) - is a multi-function accessory card that provides a
horn alarm circuit which blows the horn when the truck is left unattended without the park brake
being set, and also provides a dash board located controlled acceleration adjustment for use by the
operator.
STORED STATUS CODE - This feature furnishes a function register functional that contains the
last fault that shut down vehicle operation (PMT type fault that is reset by cycling the key switch).
This status code will be over written each time a new status code occurs and can be cleared from
memory by adjusting the value to zero.
ON-BOARD DIAGNOSTICS - The logic card detects the systems current operating status which
can be displayed to either the Dash Display or the Handset. There are currently over 75 status codes
that are available with systems using Traction and Pump SCR controls and Truck Management
Module (TMM). Along with the status code display from the TMM, the logic card is capable of
reducing the current to the control to alert the operator of a critical fault condition.
BATTERY DISCHARGE INDICATION - This feature uses the latest in microprocessor technology to provide accurate battery state of charge information and supplies passive and active warning
signals to the vehicle operator.
Features and functions:
Displays 100 to 0 percent charge
Display blinks with 20% charge
Disables pump circuit with 10% charge
Auto ranging for 36/48 volt operation
Adjustable for use on 24 to 80 volts
HANDSET - This is a multi-functional tool to be used with the EV100 LX and LXT SCR controls.
The Handset consist of a Light Emitting Diode (LED) display and a keyboard for data entry.
Features and functions:
• Monitor existing system status code for both traction and pump SCR systems
• Monitor intermittent random status code
• Monitor battery state of charge on LXT systems
• Monitor hourmeter reading on traction and pump SCR systems
• Monitor or adjust the control functions.
21
HYDRAULIC SCR CONTROL ( EV100P ) - This hydraulic controller consist of the following
features:
Three speeds adjustable from “0” volts to full motor volts.
Fixed speeds actuated by switch closure to negative.
1A bypass contactor ( if required )
Variable resistor input (5K-0 ohms).
PMT functions available with use of line contactor.
Current limit and controlled acceleration adjustable.
Battery Discharge Indicator interrupt compatible.
On-board TMM1A functions
Operation of voltage regulator card:
This card provides the basic functions required for controlling the EV100 hydraulic control and
optional contactors and PMT functions. Battery positive is applied through a main control fuse to the
key switch, energizing the control card power supply input to TB4.
When the line contactor is used, PMT operation is the same as outlined for the EV100 traction
controllers.
The four speed ( motor volts ) reference points TB2, TB3, TB5, and TB6 are selected by connecting
these points independently to battery negative.
The first speed is obtained by closing speed point 1, TB2, to SCR control negative. Speed point 1 is
adjustable by function 11 to adjust motor voltage from 0 to full motor volts. The specified motor
volts will be regulated, however, the magnitude of motor current will vary depending on the loading
of the vehicle.
The second speed is obtained by closing speed point 2, TB3, to SCR control negative. Speed point 2
is adjustable by function 12 to adjust motor voltage form 0 to full motor volts.
The third speed is obtained by closing speed point 3, TB5, to SCR control negative. Speed point 3 is
adjustable by function 13 to adjust motor voltage form 0 to full motor volts.
The fourth speed is obtained by closing speed point 4, TB6, to SCR control negative. Speed point 4 is
non-adjustable and provides full control motor volts. Speed input 4 must be activated to enable the
optional 1A contactor.
If more than one speed input is activated, the selected speed with the highest motor volts will override the low motor volt speed.
The 1A contactor is activated by closing the speed input switch connected to TB6 and SCR negative.
This starts the time delay circuit of the 1A contactor. This time is trimpot adjustable from 1 to 4
seconds. A clockwise rotation of the trimpot will increase the time delay.
22
The current limit circuit is adjustable and operates the same as the traction SCR current limit. See
current limit curves for limits and range.
The controlled acceleration circuit is adjustable and operates the same as the traction SCR circuit.
Adjustment range is from .45 to 4.0 seconds.
The variable resistor input will override the fixed motor volt limits set by the three adjustable speed
inputs. It will vary motor volts above the set limits up to full motor volts, as resistance is decreased.
The Battery Discharge Indicator ( BDI ) interrupt will disable the hydraulic controller if the connection between PB3 and PB6 is opened. If a BDI circuit is not used, a jumper must be placed between
PB3 and PB6 to allow the hydraulic control to operate.
The following are the input/output terminals for the pump control.
TB1
TB2
TB3
TB4
TB5
TB6
-
Accelerator Input
SL1 Input
SL2 Input
Key Switch Input
SL3 Input
SL4 Input
PA1
PA2
PA3
PA4
PA5
PA6
-
93 Status Code Input
93 Status Code Input
90 Status Code Input
94 Status Code Input
94 Status Code Input
91 Status Code Input
PB1
PB2
PB3
PB4
PB5
PB6
-
95 Status Code Input
95 Status Code Input
BDI Enable Signal
PMT Driver
1A Driver
92 Status Code Input
PY10
PY11
PY12
-
Input to Traction PY10
Input to Traction PY9
Input to Traction PY8
23
GENERAL MAINTENANCE INSTRUCTIONS
The SCR control, like all electrical apparatus, does have some thermal losses. The semiconductor
junctions have finite temperature limits above which these devices may be damaged. For these reasons, normal maintenance should guard against any action which will expose the components to
excessive heat, such as steam cleaning; or which will reduce heat dissipating ability of the control,
such as restricting air flow.
The following DO’S and DON’TS should be observed:
Any controls that will be used in ambients of 100 F (40 C) or over should be brought to the
attention of the truck manufacturer.
All external components having inductive coils must be filtered. Refer to vehicle manufacturer for specifications.
The control should not be steam cleaned. In dusty areas, use low-pressure air to blow off the
control. In oily or greasy areas, a mild solution of detergent or denatured alcohol can be used
to wash off the control and then blow completely dry with low-pressure air. The control can
also be cleaned with Freon TF degreaser.
For the SCR panel to be most effective, it must be mounted against the frame of the truck.
The truck frame, acting as an additional heat sink, will give improved truck performance by
keeping the SCR control package cooler. The use of a heat-transfer grease (Dow Corning
340) is recommended.
Terminal boards and other exposed SCR control parts should be kept free of dirt and paint
that might change the effective resistance between points.
CAUTION: The truck should not be plugged when the truck is jacked up and the drive
wheels are in a free wheeling position. The higher motor speeds can create excessive
voltages that can be harmful to the control.
Do not hipot (or megger) the control. Unless the terminals of each semiconductor and card
are connected together, the control may be damaged. Refer to control manufacturer before
hipotting.
Use a lead-acid battery with the voltage and ampere hour rating specified for the vehicle.
Follow normal battery maintenance procedures, recharging before 80 percent discharged and
with periodic equalizing charges.
24
TROUBLE-SHOOTING INSTRUCTIONS
Trouble-shooting the EV100/200 LX/LXT control should be quick and easy by following the instruction 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 vehicle
equipped with a Dash Display or by plugging a Handset into logic card's plug "Y" location and then
reading the status code.
With the status code number, follow the procedures outlined in the status code instruction sheets to
determine the problem.
Checking and replacement of components are also outlined in sections of this instruction book. Please
refer to these section as needed.
Important Note: Due to the interaction of the logic card with all vehicle functions, almost any status
code or control fail could be caused by the logic card. After all other status code procedures have
been followed and no problem is found the logic card should then be replaced as the last option to
correct problem.
The same device designations have been maintained on different controls but the wire numbers may
vary. Refer to the elementary and wiring diagrams for your specific control. The wire numbers
shown on the elementary diagram will have identical numbers on the corresponding wiring diagrams
for a specific truck, but these numbers may be different from the numbers referenced in this publication.
WARNING: Before trouble-shooting, jack up wheels, disconnect the battery and
discharge capacitor 1C. Reconnect the battery as needed for the specific check.
If capacitor 1C terminals are not accessible, discharge capacitor by connecting from SCR POS terminal to 2 REC anode. Check resistance on Rx1000 scale from frame to SCR power and control
terminals. A resistance of less than 20,000 ohms can cause misleading symptoms. Resistance less
than 1000 ohms should be corrected first.
Before proceeding, visually check for loose wiring, maladjusted linkage to the accelerator switch,
signs of overheating of components, etc.
Tools and test equipment required are: (a) 6-volt lamp, 6-volt battery, two A14 diodes (1 Amp
400V), clip leads, volt-ohm meter (20,000 ohms per volt) and general hand tools.
25
Reactor/Choke
Disconnect all leads to the reactor.
Remove the two mounting bolts and lift out.
Set new reactor on SCR base and start screws back into base. Be sure to use the original
screws and washers. run screws in to base “finger tight”.
Check that the bottom of the reactor is flat against the base.
Alternately tighten the two screws by 1/4 turn until firm.
Replace all connections removed in step 1.
26
GEH-5722
GE Electric Vehicle
Systems
INSTRUCTIONS
STATUS CODES
The information contained herein is intended to assist truck users and dealers in the servicing of Solid-State controls
furnished by the General Electric Company. It does not purport to cover all variations in equipment nor to provide for every
possible contingency to be met with installation, operation or maintenance.
Should further information be desired or should particular problems arise which are not covered sufficiently for the
purchaser's purpose, the matter should be referred to the vehicle manufacturer through his normal service channels, not
directly to the General Electric Company.
September 1993
27
STATUS
DESCRIPTION
CODE
BLANK
DISPLAY
Segments do not illuminate on Dash Display or Handset
MEMORY
RECALL
No
C O N T R O L Traction
TYPE
and Pump
SYMPTOM
Display screen on Dash Display or Handset is blank.
POSSIBLE CAUSE
Positive or negative control voltage is missing.
• Insure that the key switch is closed and voltage is
present between PZ7 and PZ3 control negative , and
that voltage is present between TB4 and PZ3 control
negative.
Open circuit between logic card plug "Y" and Dash Display
or Handset.
• Check for a loose connection or open wire between
logic card plug "Y" and Dash Display or Handset.
Defective Dash Display or Handset
• Replace Dash Display or Handset.
STATUS
STATUS INDICATION CRITERIA
This indicates a lack of input voltage to the logic card
and/or display unit.
DESCRIPTION
CODE
-01
Figure 1
No seat/deadman switch input.
MEMORY
RECALL
CONTROL
TYPE
No
Traction
SYMPTOM
Forward or reverse contactor will not pick up.
POSSIBLE CAUSE
Mis-adjusted or defective seat switch.
• Check seat switch to insure proper closure.
Open circuit between battery positive TB3.
• Check for loose connections or broken wire
between seat switch and TB3 and between key
switch and positive side of the seat switch and seat
switch to TB4.
•
On vehicles without seat switch, check for loose
connections or broken wire from TB4 to TB3.
Figure 1
STATUS INDICATION CRITERIA
This status code will be displayed when TB3 is less
than 50% battery volts.
28
STATUS
CODE
-02
DESCRIPTION
Forward directional switch is closed on initial power up.
MEMORY
RECALL
CONTROL
TYPE
No
Traction
SYMPTOM
Forward contactor will not close because of Static Return to
Off (SRO) lock out.
POSSIBLE CAUSE
Forward directional switch is closed on initial start up (i.e.
closure of battery, key switch or seat/deadman switch).
• Return directional switch lever to neutral and then
return lever to forward position.
Forward directional switch is welded closed or mis-adjusted
to be held closed.
• Replace or adjust directional switch to insure that it
opens when the directional switch is returned to
neutral.
Short circuit between TB2 and TB5.
• Disconnect the wire from TB5 and check for a short
circuit between TB2 and the wire.
Figure 1
STATUS INDICATION CRITERIA
This status code will be displayed when TB5 is greater
than 60% of battery volts on initial start up.
Defective logic card.
• Disconnect wire at TB5; Measure voltage at TB5,
should be less than 60% of battery volts.
STATUS
CODE
-03
DESCRIPTION
Reverse directional switch is closed on initial power up.
MEMORY
RECALL
CONTROL
TYPE
No
Traction
SYMPTOM
Reverse contactor will not close because of Static Return to
Off (SRO) lock out.
POSSIBLE CAUSE
Reverse directional switch is closed on initial start up (i.e.
closure of battery, key switch or seat/deadman switch).
• Return directional switch lever to neutral and then
return lever to reverse position.
Reverse directional switch is welded closed or mis-adjusted
to be held closed.
• Replace or adjust directional switch to insure that it
opens when the directional switch is returned to
neutral.
Short circuit between TB2 and TB6.
• Disconnect the wire from TB6 and check for a short
circuit between TB2 and the wire.
Figure 1
STATUS INDICATION CRITERIA
This status code will be displayed when TB6 is greater
than 60% of battery volts on initial start up.
Defective logic card.
• Disconnect wire at TB6; Measure voltage at TB6,
should be less than 60% of battery volts.
29
STATUS
DESCRIPTION
CODE
-04
Start switch input low after initial start up
MEMORY
RECALL
CONTROL
TYPE
No
Traction
SYMPTOM
Forward or reverse contactor will not pick-up.
POSSIBLE CAUSE
Forward or reverse directional switch closed on initial start
up.
• Depress accelerator to close start switch. Status code
will change to 03 if reverse directional switch or to
02 if forward directional switch is closed. If either of
these codes appear, return directional switch to
neutral and then select the desired direction.
Excessive leakage from TB2 to battery negative.
• Check voltage at TB2 with key and seat switches
closed and directional switch in neutral. Voltage
should be greater than 60% of battery voltage.
•
If less than 60% battery voltage. Remove wire and
measure ohmic value from wire to SCR negative.
Value should be less than 22k ohms.
STATUS
STATUS INDICATION CRITERIA
This status code is displayed when TB2 voltage is less
than 60% of battery volts at initial start-up (seat switch
closure).
DESCRIPTION
CODE
-05
Figure 1
Start switch or brake switch fails to close.
MEMORY
RECALL
CONTROL
TYPE
No
Traction
SYMPTOM
Forward or reverse contactor will not pick up.
POSSIBLE CAUSE
Defective brake switch circuit.
• Check brake switch to insure closure with brake
pedal released.
• Check for open circuit or loose connections in
wiring from brake switch to seat switch and TB3,
and from brake switch to start switch.
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
TB2 to start switch.
Figure 1
STATUS INDICATION CRITERIA
This status code is when TB1 is less than 2.5 volts and
TB2 is less than 60% battery volts.
30
STATUS
DESCRIPTION
CODE
-06
Accelerator depressed with no direction selected.
MEMORY
RECALL
CONTROL
TYPE
No
Traction
SYMPTOM
Forward or reverse contactor will not pick up.
POSSIBLE CAUSE
Accelerator pedal is depressed before closing forward or
reverse directional switch.
• Status code will disappear when directional switch
is
closed or when accelerator pedal is
released.
Defective directional switch
• Check forward or reverse switch to insure closure
when direction is selected.
Open circuit between directional switch(s) and battery
positive or between directional switch(s) and TB5 or TB6.
• Check all control wires and connections shown in
Figure 1.
STATUS
STATUS INDICATION CRITERIA
This status code will be displayed when TB5 and TB6
are less than 60% of the battery volts, and TB1 is less
than 2.5 volts.
DESCRIPTION
CODE
-07
Figure 1
Accelerator input voltage too high.
MEMORY
RECALL
CONTROL
TYPE
No
Traction
SYMPTOM
Forward or reverse contactor picks up but control will not operate
when accelerator pedal is depressed or status code -07 is displayed
then disappears when the vehicle starts to accelerate.
POSSIBLE CAUSE
Accelerator input mis-adjusted or defective.
•
Input voltage at TB1 should be less than 3.7 volts. Adjust or replace accelerator unit to insure that the
voltage at TB1 will vary from 3.5 volts to less than .5
volts when the pedal is depressed.
Open circuit between battery negative and TB1 in accelerator input
circuit.
•
Check for broken wires or loose connections or open
potentiometer / voltage supply in the circuit shown in
Figure 1.
Short circuit from battery positive to wiring in accelerator input
circuit.
•
Figure 1
STATUS
INDICATION
CRITERIA
This status code is displayed when the acceleraDisconnect wire from TB1 and measure voltage at wire to tor input voltage at TB1 is higher than 3.7 volts,
negative. Should be zero volts for potentiometer type and
and a directional contactor is picked up.
less than 3.7 volts for solid state type accelerator input.
31
STATUS
-08
MEMORY
RECALL
DESCRIPTION
CODE
Accelerator input voltage too low on power up after
initial key switch closure.
CONTROL
TYPE
No
Traction
SYMPTOM
Forward or reverse contactor does not pick up.
POSSIBLE CAUSE
Accelerator input mis-adjusted or defective.
• Input voltage at TB1 should be more than 3.0 volts.
Adjust or replace accelerator unit to insure that the
voltage at TB1 is more than 3.0 volts before depressing pedal.
Short circuit between battery negative and TB1 in accelerator input circuit.
• Disconnect wire from TB1. Check for short circuit
from wire to battery negative. Resistance should be
greater than 4.7K ohms.
Figure 1
STATUS INDICATION CRITERIA
This status code will be displayed when the accelerator
input voltage at TB1 is less than 3.0 volts, and any of
Disconnect wire from TB1. Measure voltage from
the following connections are opened and closed,
TB1 to negative. Voltage should be greater than 4.5
battery plug or seat switch or key switch.
volts, if not, replace card.
Defective Card
•
STATUS
DESCRIPTION
CODE
-09
Both forward and reverse directional switches are closed
at the same time.
MEMORY
RECALL
CONTROL
TYPE
No
Traction
SYMPTOM
Forward or reverse contactor will not pick up.
POSSIBLE CAUSE
Forward or reverse directional switch welded closed or misadjusted to be held closed.
• Replace or adjust directional switches to insure that
they open when directional switch is returned to
neutral.
Short circuit between battery positive and TB5 and/or TB6.
• Disconnect wires from TB5 and TB6 and check wires
for short circuit to positive side of directional switch.
Defective card
• Disconnect wires and measure voltage at TB5 and
TB6 . Voltage should be less than 60% of battery
volts.
32
Figure 1
STATUS INDICATION CRITERIA
This status code will be displayed when TB5 and TB6
are greater than 60% of battery volts at the same time.
STATUS
DESCRIPTION
CODE
-15
Battery volts too low.
MEMORY
RECALL
CONTROL
TYPE
No
Traction
SYMPTOM
Forward or reverse contactor will not pick up.
POSSIBLE CAUSE
Discharged battery
• Check battery for proper open circuit voltage as
outlined in figure 1 and charge battery if required.
Defective battery
• Check each battery cell for proper voltage (greater
than 1.95 volts at cell). Replace or repair battery.
Incorrect control card adjustment.
• Check function 15 for proper adjustment for
battery
being used. See handset instruction
sheet for details. Adjust to proper settings.
Figure 1
STATUS INDICATION CRITERIA
This status code is displayed when the battery volts are
less than 1.95 volts per cell at initial start up. (See table
in figure 1).
STATUS
DESCRIPTION
CODE
-16
Battery volts too high.
MEMORY
RECALL
CONTROL
TYPE
No
Traction
SYMPTOM
Forward and reverse contactor will not pick up.
POSSIBLE CAUSE
Incorrect control card adjustment
• Check function 15 for proper adjustment for battery
being used. See handset instructions for details.
Adjust to proper setting.
Battery over charged or incorrect battery used.
• Check battery for proper open circuit voltage per
table in figure 1. If voltage excessive-check battery
charger for proper output voltage.
Figure 1
STATUS INDICATION CRITERIA
This status code is displayed when the battery volts
are greater than 2.40 volts per cell at initial start up.
(See table in figure 1.)
33
STATUS
DESCRIPTION
CODE
-17
Invalid card type selection.
MEMORY
RECALL
CONTROL
TYPE
No
Traction
SYMPTOM
Forward or reverse contactors will not close.
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.
Figure 1
STATUS INDICATION CRITERIA
This status code is displayed when the card type
selection value is set to an invalid number.
STATUS
CODE
-23
DESCRIPTION
Forward and reverse contactor coil current low.
MEMORY
RECALL
CONTROL
TYPE
No
Traction
SYMPTOM
Forward or reverse contactor will not pick up. Status code
may alternate between code 23 and code 24. Complete
check for code 23, if the problem is not found, perform
check for code 24.
POSSIBLE CAUSE
Defective F and R contactor coil circuit.
• Check for open circuit or loose connection between
PB4 and positive side of F contactor coil and
between PB5 and positive side of R contactor coil.
•
Remove plug B. Check ohmic value from PB4 to
positive side of F coil. Value should be 10-14
ohms. Make same check for R coil.
Defective 1A, RB, SP,or FW contactor coil.
• Remove plug B. Check ohmic value from positive
side of each coil to its respective plug connection.
Value should be 10-14 ohms.
34
Figure 1
STATUS INDICATION CRITERIA
This status code is displayed when the current draw in
the forward or reverse contactor coil circuit is less than
100 ma.
STATUS
DESCRIPTION
CODE
-24
T2 voltage low. (Less than 12% battery volts.)
MEMORY
RECALL
CONTROL
TYPE
No
Traction
SYMPTOM
SCR control does not operate. Status code may alternate between
code 23 and code 24. Complete checks for 24, if the problem is not
found, perform code 23 check.
POSSIBLE CAUSE
Defective F or R contactor.
•
F or R power tips fail to close because:
1) Welded normally closed power tips.
2) Binding contactor tip assembly.
3) Defective F or R contactor coil.
( See status code 23)
Defective RB contactor.
•
Check RB contactor power tips for closure and proper pick
up.
•
Check for open circuit or loose connections between
positive side of RB contactor coil and PB2.
Open motor circuit
•
Check for open circuit or loose connection in motor circuit
from the A1 connection to the A2 connection on the SCR
control panel.
Figure 1
STATUS INDICATION CRITERIA
This status code is displayed when T2 volts is greater
than 12% of battery volts and the F and R driver is
energized.
Defective 1A,RB,SP or FW contactor
•
Perform checks as outlined in status 23.
STATUS
DESCRIPTION
CODE
-25
1A contactor does not drop out or drops out slowly.
MEMORY
RECALL
CONTROL
TYPE
Yes
Traction
SYMPTOM
Short tip life on F and R or 1A contactor. Status code 46
displayed and no fault found.
POSSIBLE CAUSE
Note: This status code can only be found by using the
handset and looking at function 1. This status code is
furnished as a troubleshooting aid for status code 46.
Defective 1A contactor
• Check 1A contactor for binding or slow operation
when dropping out.
Figure 1
STATUS INDICATION CRITERIA
This status code is displayed when 1A contactor drop
out time exceeds .060 seconds.
35
STATUS
-26
MEMORY
RECALL
DESCRIPTION
CODE
Shorted coil driver for SP or FW contactor.
CONTROL
TYPE
No
Traction
SYMPTOM
SP or FW contactor picks up immediately when key switch
is closed.
POSSIBLE CAUSE
Defective coil driver internal to logic card.
• Replace logic card.
Figure 1
STATUS INDICATION CRITERIA
This status code is displayed when there is a shorted
RB,SP or FW coil driver.
STATUS
CODE
-41
DESCRIPTION
Open thermal protector (TP) or control over temperature.
MEMORY
RECALL
CONTROL
TYPE
No
Traction
SYMPTOM
Reduced or no power to traction motor in SCR range.
POSSIBLE CAUSE
Open thermal protector circuit.
• Check for loose connection or broken wire between:
Black wire-Thermal proctor and PZ1.
Gray wire-Thermal proctor and PZ5.
Defective thermal protector.
• Disconnect wires from PZ1 and PZ5. At room
temperature (25oC or 75oF) measure resistance
between black and gray wire. Replace TP if ohmic
value is greater than 300 ohms.
SCR is in thermal cut-back.
• Allow control to cool, status code should disappear.
36
Figure 1
STATUS INDICATION CRITERIA
This status code is displayed when the voltage
between PZ1 and PZ5 is greater than 1.8 volts.
STATUS
DESCRIPTION
CODE
-42
Control motor current sensor input missing.
MEMORY
RECALL
CONTROL
TYPE
No
Traction
SYMPTOM
No power to traction motor in SCR range.
POSSIBLE CAUSE
Open sensor wire circuit to PZ4.
• Check for loose connection or broken wire (green
wire) from current sensor to PZ4 on the logic card.
Figure 1
STATUS INDICATION CRITERIA
This status code is displayed when voltage between
PY7 and negative is greater than 1.6 volts with no
current flowing in the motor circuit.
STATUS
CODE
-43
DESCRIPTION
Control motor current sensor input missing.
MEMORY
RECALL
CONTROL
TYPE
No
Traction
SYMPTOM
Stall currents in SCR range higher than normal and
uncontrollable with C/L adjustment.
POSSIBLE CAUSE
Open sensor wire circuit to PZ3.
• Check for loose connections or broken wire (yellow
wire) from current sensor to PZ3 on logic card.
Figure 1
STATUS INDICATION CRITERIA
This status code is displayed when voltage between
PY7 and negative is less than .84 volts with no
current flowing in motor circuit.
37
STATUS
DESCRIPTION
CODE
-44
1REC did not turn off properly.
MEMORY
RECALL
CONTROL
TYPE
Yes
Traction
SYMPTOM
Forward or reverse contactors open and close, then can
only be closed by opening and closing the key switch.
POSSIBLE CAUSE
Defective 5 REC circuit.
• Check for shorted 5 REC.
• Check for shorted 5 REC snubber (25 REC).
Defective 2 REC circuit.
• Check for shorted 2 REC.
• Check for shorted 2 REC snubber (22 REC).
Open choke (1X).
• Check for open circuit between T5 and T3. Ohm
meter should read zero ohms.
1 REC defective.
• Turn off time for 1 REC out of specification. No
field
test is possible. Replace 1 REC
after above checks, show no problem found.
STATUS
DESCRIPTION
CODE
-45
Figure 1
STATUS INDICATION CRITERIA
This status code is displayed when, during SCR
operation, 1 REC fails to turn off.
1 REC did not turn on properly.
MEMORY
RECALL
CONTROL
TYPE
Yes
Traction
SYMPTOM
Forward or reverse contactor will open and close, then open
and then can only be closed by opening and closing the
key switch.
POSSIBLE CAUSE
Defective 2 REC circuit.
• Check for shorted 2 REC.
• Check for shorted 2 REC snubber (22 REC).
Defective 1 REC circuit.
• Check for open circuit or loose connections between
1REC and PZ8. (white/blue wire)
• Check for open circuit or loose connection between
1REC (3 REC snubber) and PZ9. (blue wire)
Defective 1 REC.
• Intermittent or open 1 REC gate. Field test may or
may not show defect. Replace 1 REC after above
checks, show no problem found.
38
Figure 1
STATUS INDICATION CRITERIA
This status code is displayed when 1 REC fails to gate
on.
STATUS
DESCRIPTION
CODE
-46
Look ahead test for T2 volts. ( Greater than 85% of
battery volts)
MEMORY
RECALL
CONTROL
TYPE
No
Traction
SYMPTOM
Forward or reverse contactor will not pick up.
POSSIBLE CAUSE
Defective 1 REC.
• Check for shorted 1 REC.
• Check for defective 1 REC insulator (co-therm)
that may short 1 REC heat sink to base plate.
Defective 1A contactor.
• Check for welded 1A contactor power tips.
Figure 1
STATUS INDICATION CRITERIA
This status code is displayed when the voltage at T2 is
greater than 85% of battery volts.
STATUS
DESCRIPTION
CODE
-47
2REC does not turn properly
MEMORY
RECALL
CONTROL
TYPE
No
Traction
SYMPTOM
Forward or reverse contactor will open and close, then
open and then can only be closed by opening and closing
the key switch.
POSSIBLE CAUSE
Defective 2 REC circuit.
• Check that 2 REC will gate on.
• Check for open circuit or loose connection
between 2 REC gate and PZ10. (white/red wire)
• Check for open circuit or loose connection 1 REC
and 1C through the 2 REC circuit.
F or R contactor or power tips bouncing open.
• Check that power tips on F and R contactor power
tips do not bounce open during operation (ie:
travel over speed bumps or dock plates).
Figure 1
STATUS INDICATION CRITERIA
This status code is displayed when the 2 REC fails to
turn on.
39
STATUS
DESCRIPTION
CODE
-48
Look ahead test for T2 volts. (Less than 12% of battery
volts)
MEMORY
RECALL
CONTROL
TYPE
No
Traction
SYMPTOM
Forward or reverse contactor will not pick up.
POSSIBLE CAUSE
Defective forward or reverse contactor.
• Check for welded forward or reverse contactor
power tips.
• Check for sluggish operation of forward or reverse
contactor.
Defective 3 REC circuit.
• Check for shorted 3 REC.
Figure 1
• Check for shorted 3 REC snubber (23 REC).
STATUS
CODE
-49
STATUS INDICATION CRITERIA
This status code is displayed when the voltage at T2
is less than 12% of battery volts.
DESCRIPTION
5 REC does not turn on properly
MEMORY
RECALL
CONTROL
TYPE
No
Traction
SYMPTOM
Forward or reverse contactor will open and close, then
open and then can only be closed by opening and closing
the key switch.
POSSIBLE CAUSE
Defective 5 REC circuit
• Check for shorted 5 REC.
•
Check for shorted 5 REC snubber ( 25 REC ).
•
Check that 5 REC will gate on.
•
Check for open circuit or loose connection
between 5 REC gate and PZ12 ( white/violet wire
).
Shorted 2 REC circuit.
• Check 2 REC and 2 REC snubber ( 22 REC ) for
short circuit.
Defective capacitor circuit.
• Check for open capacitor.
40
•
Check for loose connections at capacitor terminals.
Figure 1
STATUS INDICATION CRITERIA
This status code is displayed when the 5 REC circuit
fails to turn on.
STATUS
CODE
-50
MEMORY
RECALL
DESCRIPTION
Capacitor volts low .
CONTROL
TYPE
No
Traction
SYMPTOM
Forward or reverse contactor picks up. Control does not
operate.
POSSIBLE CAUSE
Defective 2 REC circuit.
• Open circuit or loose connection between spider
assembly and 5 REC (BUS A).
• Open circuit or loose connection between 5 REC
and
2 REC.
• Open circuit or loose connection between 2 REC
and PZ11 (red wire) and between 2 REC gate and
PZ10
(white/red wire).
• Check 2 REC to insure that it will gate on.
STATUS
DESCRIPTION
CODE
-51
Figure 1
STATUS INDICATION CRITERIA
This status code is displayed when 2 REC circuit fails
to turn on at initial start up.
Excessive capacitor voltage when motor current is high.
MEMORY
RECALL
CONTROL
TYPE
No
Traction
SYMPTOM
Forward or reverse contactors open and close, then can
only be closed by opening and closing the key switch.
POSSIBLE CAUSE
Excessive source inductance.
• Tag lines without filters are being used.
• Battery cables are too long.
High peak current in motor.
• Check for shorted field winding.
• Check for shorted armature winding.
Figure 1
STATUS INDICATION CRITERIA
This status code is displayed when capacitor volts
exceed 225 volts and motor current is greater than 300
amps.
41
STATUS
DESCRIPTION
CODE
-52
Excessive capacitor voltage when motor current is low.
MEMORY
RECALL
CONTROL
TYPE
Yes
Traction
SYMPTOM
Forward or reverse contactors open and close, then can
only be closed by opening and closing the key switch.
POSSIBLE CAUSE
Excessive source inductance.
• Tag lines without filters are being used.
• Battery cables are too long.
Defective 4 REC circuit.
• Check for shorted 4 REC.
• Check for open circuit or loose connection in 4
REC
circuit.
Defective 3 REC circuit.
• Check for open circuit or loose connection in 3
REC
circuit.
STATUS
STATUS INDICATION CRITERIA
This status code is displayed when capacitor volts
exceed 225 volts and motor current is less than 200
amps.
DESCRIPTION
CODE
-53
Figure 1
1 REC fails to turn off during plug cycle.
MEMORY
RECALL
CONTROL
TYPE
Yes
Traction
SYMPTOM
Forward or reverse contactor opens and closes, then opens and can
only close by opening and closing the key switch.
POSSIBLE CAUSE
1 REC turn off failure not related to plugging.
• Stall vehicle in both directions and note any status codes
displayed that may more closely define the failure mode.
Troubleshoot per new status code.
1 REC turn off related to plugging.
• Check 4 REC circuit for open 4 REC, loose or open
bus connections.
cable/
• Check current sensor for loose or open connection in power
circuit. Check yellow and green wire from sensor to logic
card for open and loose connection.
Defective motor circuit.
• Check motor circuit for open or loose connections.
• Check motor brushes for proper seating.
F or R contactor power bouncing open.
• Insure that F and R contactor does not bounce open during
vehicle operation (ie: traveling over speed bumps and dock
plates).
42
Figure 1
STATUS INDICATION CRITERIA
This status code is displayed when any failure of 1
REC to turn off during plug cycle.
STATUS
CODE
-54
DESCRIPTION
Shorted F, R or 1A contactor coil driver.
MEMORY
RECALL
CONTROL
TYPE
No
Traction
SYMPTOM
Control will not operate.
POSSIBLE CAUSE
Defective logic card.
• Replace logic card.
Figure 1
STATUS INDICATION CRITERIA
This status code is displayed when either the forward,
reverse or 1A contactor coil driver is shorted internal to
the logic card.
STATUS
CODE
-57
DESCRIPTION
Current sensor input voltage polarity check.
MEMORY
RECALL
CONTROL
TYPE
No
Traction
SYMPTOM
Forward or reverse contactors open and close, then can
only be closed by opening and closing the key switch.
POSSIBLE CAUSE
Reversed yellow and green current senors wires
• Insure that the: -green wire connects to PZ4 with
no open circuits.
-yellow wire connects to PZ3 with
no open circuits or loose
connections.
Reversed power cable connection.
• Insure that the battery negative cable connects to
SCR NEG and the motor A2 cable connects to SCR
A2.
Figure 1
STATUS INDICATION CRITERIA
This status code is displayed when the voltage input
to PZ4 and PZ3 is the wrong polarity.
43
STATUS
DESCRIPTION
CODE
-70
Regen current sensor input missing ( yellow wire ).
MEMORY
RECALL
CONTROL
TYPE
Yes
Traction
SYMPTOM
Control does not operate.
POSSIBLE CAUSE
Defective regen sensor input circuit.
• Check yellow sensor wire for open circuit or loose
connection between sensor (welded connection) and
PA4.
Figure 1
STATUS INDICATION CRITERIA
This status code is displayed when input signal at PA4
is missing.
STATUS
DESCRIPTION
CODE
-71
Regen current sensor input missing ( green wire ).
MEMORY
RECALL
CONTROL
TYPE
Yes
Traction
SYMPTOM
Control does not operate.
POSSIBLE CAUSE
Defective regen sensor input circuit.
• Check green sensor wire for open circuit or loose
connection between sensor (welded connection) and
PA5.
Figure 1
STATUS INDICATION CRITERIA
This status code is displayed when input signal at PA5
is missing.
44
STATUS
-72
MEMORY
RECALL
DESCRIPTION
CODE
Regen contactor does not pick up.
CONTROL
TYPE
Yes
Traction
SYMPTOM
Regen control does not operate.
POSSIBLE CAUSE
Open connection in the PA6 circuit.
• Check for open circuit or loose connection between
PA6 and the A2 connection of the RB contactor.
• Check for open circuit or loose connection between
7 REC and the A2 connection of the RB contactor.
Figure 1
STATUS INDICATION CRITERIA
This status code is displayed when logic card is in run
mode and 2.5 volts or greater is present at PA6.
STATUS
CODE
-73
DESCRIPTION
Regen contactor does not drop out or drops out slowly.
MEMORY
RECALL
CONTROL
TYPE
Yes
Traction
SYMPTOM
Forward or reverse contactor opens and closes, then opens
and can only close by opening and closing the key
switch.
POSSIBLE CAUSE
Defective RB contactor.
• Check RB contactor for smoothness of operation
and excessive wear on moving parts.
Intermittent PA6 input.
• Check for loose connections in PA6 circuit from
PA6 to RB contactor A2 connection.
Figure 1
STATUS INDICATION CRITERIA
This status code is displayed when the RB contactor
power tips fail to open after 100 milliseconds after
power is removed from the RB contactor coil.
45
STATUS
CODE
-74
DESCRIPTION
Regen contactor picks up too slow.
MEMORY
RECALL
CONTROL
TYPE
Yes
Traction
SYMPTOM
Forward or reverse contactor opens and closes, then opens
and can only close by opening and closing the key switch.
POSSIBLE CAUSE
Defective RB contactor.
• Check RB contactor for smoothness of operation
and excessive wear on moving parts.
Intermittent PA6 input.
• Check for loose connections in PA6 circuit from
PA6 to RB contactor A2 connection.
Defective RB contactor coil circuit.
• Check RB contactor coil for proper ohmic value. It
should be 10-14 ohms.
• Check coil connection from PB2 to RB coil (-) for
loose connections.
• Check coil connections from battery positive to RB
coil (+) for loose connections.
STATUS
CODE
-75
Figure 1
STATUS INDICATION CRITERIA
This status code is displayed when the RB contactor
power tips do not close within 100 milliseconds after
power is applied to the RB contactor coil.
DESCRIPTION
1 REC fails to turn off during Regen.
MEMORY
RECALL
CONTROL
TYPE
Yes
Traction
SYMPTOM
Forward or reverse contactor opens and closes, then opens and can
only close by opening and closing the key switch.
POSSIBLE CAUSE
1 REC turn off failure not related to regen.
• Stall vehicle in both directions and note any status codes
displayed that may more closely define the failure mode.
Trouble shoot per new status code.
1 REC turn off related to regen.
• Check for loose connections on all regen power circuits from
battery positive to RB contactor A2 connection.
• Check for loose connection on the following regen input
circuits.
• Yellow wire from sensor 2 to PA4.
• Green wire from sensor 2 to PA5.
• Wire 17 from RB contactor to PA6.
Defective motor circuit.
• Check motor circuit for open or loose connections.
• Check motor brushes for proper seating.
F or R contactor power bouncing open.
• Insure that F and R contactor does not bounce open during
vehicle operation (ie: traveling over speed bumps and dock
plates).
46
Figure 1
STATUS INDICATION CRITERIA
This status code is displayed when any failure of 1
REC to turn off during regen cycle.
STATUS
-76
MEMORY
RECALL
DESCRIPTION
CODE
Capacitor overvoltage during Regen.
CONTROL
TYPE
Yes
Traction
SYMPTOM
Forward or reverse contactor opens and closes, then opens
and can only close by opening and closing the key switch
POSSIBLE CAUSE
Intermittent connection in battery power circuit.
• Check battery power circuit, both positive and
negative for loose connections.
• Check power fuse, battery connectors, line
contactors, and etc., for possible opening during
regen cycle.
Excessive source inductance.
• Check for unfiltered tag lines.
Figure 1
STATUS INDICATION CRITERIA
This status code is displayed when capacitor voltage is
greater than 225 volts during the regen cycle.
• Check for long battery cables.
STATUS
DESCRIPTION
CODE
-90
User defined status code - see OEM instructions manual.
MEMORY
RECALL
No
CONTROL
TYPE
TMM
SYMPTOM
Status code flashes on and off.
POSSIBLE CAUSE
User defined status code is displayed by switch closure or
motor brush sensor closure to negative.
• See OEM instruction manual for corrective action
required.
Other Causes:
• Terminal 1 shorted to negative.
•
Defective input switch (shorted).
•
Defective TMM card.
NOTE: When SCR pump control is used with internal
TMM function, input terminal is PA3 on pump logic
card.
Figure 1
STATUS INDICATION CRITERIA
This status code is displayed when the voltage at
terminal 1 of TMM is at zero volts.
47
STATUS
DESCRIPTION
CODE
-91
User defined status code - see OEM instructions manual.
MEMORY
RECALL
No
CONTROL
TYPE
TMM
SYMPTOM
Status code flashes on and off.
POSSIBLE CAUSE
User defined status code is displayed by switch closure or
motor brush sensor closure to negative.
• See OEM instruction manual for corrective action
required.
Other Causes:
• Terminal 3 shorted to negative.
•
Defective input switch (shorted).
•
Defective TMM card.
NOTE: When SCR pump control is used with internal
TMM function, input terminal is PA6 on pump logic
card.
STATUS
STATUS INDICATION CRITERIA
This status code is displayed when the voltage at
terminal 3 of TMM is at zero volts.
DESCRIPTION
CODE
-92
Figure 1
User defined status code - see OEM instructions manual.
MEMORY
RECALL
No
CONTROL
TYPE
TMM
SYMPTOM
Status code flashes on and off.
POSSIBLE CAUSE
User defined status code is displayed by switch closure or
motor brush sensor closure to negative.
• See OEM instruction manual for corrective action
required.
Other Causes:
• Terminal 4 shorted to negative.
•
Defective input switch (shorted).
•
Defective TMM card.
NOTE: When SCR pump control is used with internal
TMM function, input terminal is PB6 on pump logic
card.
48
Figure 1
STATUS INDICATION CRITERIA
This status code is displayed when the voltage at
terminal 4 of TMM is at zero volts.
STATUS
DESCRIPTION
CODE
-93
User defined status code - see OEM instructions manual.
MEMORY
RECALL
No
CONTROL
TYPE
TMM
SYMPTOM
Status code flashes on and off.
POSSIBLE CAUSE
User defined status code is displayed by switch closure or
motor brush sensor closure to negative.
• See OEM instruction manual for corrective action
required.
Other Causes:
• Terminal 5 and 6 shorted to negative.
•
Defective input switch (shorted).
•
Defective TMM card.
Figure 1
NOTE: When SCR pump control is used with internal
TMM function, input terminal is PA1 and PA2 on pump
logic card.
STATUS
DESCRIPTION
CODE
-94
STATUS INDICATION CRITERIA
This status code is displayed when the voltage at
terminal 5 and 6 of TMM is at zero volts.
User defined status code - see OEM instructions manual.
MEMORY
RECALL
No
CONTROL
TYPE
TMM
SYMPTOM
Status code flashes on and off.
POSSIBLE CAUSE
User defined status code is displayed by switch closure or
motor brush sensor closure to negative.
• See OEM instruction manual for corrective action
required.
Other Causes:
• Terminal 8 and 10 shorted to negative.
•
Defective input switch (shorted).
•
Defective TMM1 card.
Figure 1
NOTE: When SCR pump control is used with internal
TMM function, input terminal is PA4 and PA5 on pump
logic card.
STATUS INDICATION CRITERIA
This status code is displayed when the voltage at
terminal 8 and 10 of TMM is at zero volts.
49
STATUS
DESCRIPTION
CODE
-95
User defined status code - see OEM instructions manual.
MEMORY
RECALL
No
CONTROL
TYPE
TMM
SYMPTOM
Status code flashes on and off.
POSSIBLE CAUSE
User defined status code is displayed by switch closure or
motor brush sensor closure to negative.
• See OEM instruction manual for corrective action
required.
Other Causes:
• Terminal 11 and 12 shorted to negative.
•
Defective input switch (shorted).
•
Defective TMM card.
NOTE: When SCR pump control is used with internal
TMM function, input terminal is PB1 and PB2 on pump
logic card.
50
Figure 1
STATUS INDICATION CRITERIA
This status code is displayed when the voltage at
terminal 11 and 12 of TMM is at zero volts.
STATUS
DESCRIPTION
CODE
-117
Invalid card type selection.
MEMORY
RECALL
No
CONTROL
TYPE
Pump
SYMPTOM
Pump contactor will not close.
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.
Figure 1
STATUS INDICATION CRITERIA
This status code is displayed when the card type
selection value is set to an invalid number.
STATUS
CODE
-123
DESCRIPTION
Forward and reverse contactor coil current low.
MEMORY
RECALL
No
CONTROL
TYPE
Pump
SYMPTOM
Pump contactor will not pick up. Status code may alternate between code 23 and code 24. Complete check for
code 23, if the problem is not found, perform check for
code 24.
POSSIBLE CAUSE
Defective Pump contactor coil circuit.
• Check for open circuit or loose connection between
PB4 and positive side of Pump contactor coil.
•
Remove plug A. Check ohmic value from PB4 to
positive side of F coil. Value should be 10-14
ohms.
Defective 1A contactor coil.
• Remove plug A. Check ohmic value from positive
side of coil to its plug connection. Value should be
10-14 ohms.
Figure 1
STATUS INDICATION CRITERIA
This status code is displayed when the current draw in
the pump contactor coil circuit is less than 100 ma.
51
STATUS
DESCRIPTION
CODE
-124
T2 voltage low. (Greater than 12% battery volts.)
MEMORY
RECALL
No
CONTROL
TYPE
Pump
SYMPTOM
Control does not operate. Status code may alternate
between code 23 and code 24. Complete checks for 24, if
the problem is not found, perform code 23 check.
POSSIBLE CAUSE
Defective Pump contactor.
• Pump power tips fail to close because:
1) Welded normally closed power tips.
2) Binding contactor tip assembly.
3) Defective Pump contactor coil.
( See status code 123)
Open motor circuit
• Check for open circuit or loose connection in motor
circuit from the A1 connection to the A2 connection
on the control panel.
Defective 1A contactor.
• Perform checks as outlined in status 123.
STATUS
STATUS INDICATION CRITERIA
This status code is displayed when T2 volts is greater
than 12% of battery volts and the pump driver is
energized.
DESCRIPTION
CODE
-125
Figure 1
1A contactor does not drop out or drops out slowly.
MEMORY
RECALL
No
CONTROL
TYPE
Pump
SYMPTOM
Short tip life on Pump or 1A contactor. Status code 46
displayed and no fault found.
POSSIBLE CAUSE
Note: This status code can only be found by using the
handset and looking at function 1. This status code is
furnished as a troubleshooting aid for status code 146.
Defective 1A contactor
• Check 1A contactor for binding or slow operation
when dropping out.
Figure 1
STATUS INDICATION CRITERIA
This status code is displayed when 1A contactor drop
out time exceeds .060 seconds.
52
STATUS
DESCRIPTION
CODE
-141
Open thermal protector (TP) or control over temperature.
MEMORY
RECALL
No
CONTROL
TYPE
Pump
SYMPTOM
Reduced or no power to pump motor in SCR range.
POSSIBLE CAUSE
Open thermal protector circuit.
• Check for loose connection or broken wire between:
Black wire-Thermal proctor and PZ1.
Gray wire-Thermal proctor and PZ5.
Defective thermal protector.
• Disconnect wires from PZ1 and PZ5. At room
temperature (25oC or 75oF) measure resistance
between black and gray wire. Replace TP if ohmic
value is greater than 300 ohms.
SCR is in thermal cut-back.
• Allow control to cool, status code should disappear.
STATUS
STATUS INDICATION CRITERIA
This status code is displayed when the voltage
between PZ1 and PZ5 is greater than 1.8 volts.
DESCRIPTION
CODE
-142
Figure 1
Control motor current sensor input missing.
MEMORY
RECALL
No
CONTROL
TYPE
Pump
SYMPTOM
No power to pump motor in SCR range.
POSSIBLE CAUSE
Open sensor wire circuit to PZ4.
• Check for loose connection or broken wire (green
wire) from current sensor to PZ4 on the logic card.
Figure 1
STATUS INDICATION CRITERIA
This status code is displayed when voltage between
PY7 and negative is greater than 1.6 volts with no
current flowing in the motor circuit.
53
STATUS
DESCRIPTION
CODE
-143
Control motor current sensor input missing.
MEMORY
RECALL
CONTROL
TYPE
No
Traction
SYMPTOM
Stall currents in SCR range higher than normal and
uncontrollable with C/L adjustment.
POSSIBLE CAUSE
Open sensor wire circuit to PZ3.
• Check for loose connections or broken wire (yellow
wire) from current sensor to PZ3 on logic card.
Figure 1
STATUS INDICATION CRITERIA
This status code is displayed when voltage between
PY7 and negative is less than .84 volts with no
current flowing in motor circuit.
STATUS
DESCRIPTION
CODE
-144
1REC did not turn off properly.
MEMORY
RECALL
Yes
CONTROL
TYPE
Pump
SYMPTOM
Forward or reverse contactors open and close, then can
only be closed by opening and closing the key switch.
POSSIBLE CAUSE
Defective 5 REC circuit.
• Check for shorted 5 REC.
• Check for shorted 5 REC snubber (25 REC).
Defective 2 REC circuit.
• Check for shorted 2 REC.
• Check for shorted 2 REC snubber (22 REC).
Open choke (1X).
• Check for open circuit between T5 and T3. Ohm
meter should read zero ohms.
1 REC defective.
• Turn off time for 1 REC out of specification. No
field
test is possible. Replace 1 REC
after above checks, show no problem found.
54
Figure 1
STATUS INDICATION CRITERIA
This status code is displayed when, during SCR
operation, 1 REC fails to turn off.
STATUS
DESCRIPTION
CODE
-145
1 REC did not turn on properly.
MEMORY
RECALL
Yes
CONTROL
TYPE
Pump
SYMPTOM
Forward or reverse contactor will open and close, then open
and then can only be closed by opening and closing the
key switch.
POSSIBLE CAUSE
Defective 2 REC circuit.
• Check for shorted 2 REC.
• Check for shorted 2 REC snubber (22 REC).
Defective 1 REC circuit.
• Check for open circuit or loose connections between
1REC and PZ8. (white/blue wire)
• Check for open circuit or loose connection between
1REC (3 REC snubber) and PZ9. (blue wire)
Defective 1 REC.
• Intermittent or open 1 REC gate. Field test may or
may not show defect. Replace 1 REC after above
checks, show no problem found.
STATUS
STATUS INDICATION CRITERIA
This status code is displayed when 1 REC fails to gate
on.
DESCRIPTION
CODE
-146
Figure 1
Look ahead test for T2 volts. ( Greater than 85% of
battery volts)
MEMORY
RECALL
No
CONTROL
TYPE
Pump
SYMPTOM
Pump contactor will not pick up.
POSSIBLE CAUSE
Defective 1 REC.
• Check for shorted 1 REC.
• Check for defective 1 REC insulator (co-therm)
that may short 1 REC heat sink to base plate.
Defective 1A contactor.
• Check for welded 1A contactor power tips.
Figure 1
STATUS INDICATION CRITERIA
This status code is displayed when the voltage at T2 is
greater than 85% of battery volts.
55
STATUS
DESCRIPTION
CODE
-147
2REC does not turn properly
MEMORY
RECALL
No
CONTROL
TYPE
Pump
SYMPTOM
Pump contactor will open and close, then open and then
can only be closed by opening and closing the key
switch.
POSSIBLE CAUSE
Defective 2 REC circuit.
• Check that 2 REC will gate on.
• Check for open circuit or loose connection
between 2 REC gate and PZ10. (white/red wire)
• Check for open circuit or loose connection 1 REC
and 1C through the 2 REC circuit.
F or R contactor or power tips bouncing open.
• Check that power tips on F and R contactor power
tips do not bounce open during operation (ie:
travel over speed bumps or dock plates).
STATUS
STATUS INDICATION CRITERIA
This status code is displayed when the 2 REC fails to
turn on.
DESCRIPTION
CODE
-148
Figure 1
Look ahead test for T2 volts. (Less than 12% of battery
volts)
MEMORY
RECALL
No
CONTROL
TYPE
Pump
SYMPTOM
Pump contactor will not pick up.
POSSIBLE CAUSE
Defective forward or reverse contactor.
• Check for welded forward or reverse contactor
power tips.
• Check for sluggish operation of forward or reverse
contactor.
Defective 3 REC circuit.
• Check for shorted 3 REC.
• Check for shorted 3 REC snubber (23 REC).
56
Figure 1
STATUS INDICATION CRITERIA
This status code is displayed when the voltage at T2
is less than 12% of battery volts.
STATUS
CODE
-149
DESCRIPTION
5 REC does not turn on properly
MEMORY
RECALL
No
CONTROL
TYPE
Pump
SYMPTOM
Pump contactor will open and close, then open and then
can only be closed by opening and closing the key
switch.
POSSIBLE CAUSE
Defective 5 REC circuit
• Check for shorted 5 REC.
•
Check for shorted 5 REC snubber ( 25 REC ).
•
Check that 5 REC will gate on.
•
Check for open circuit or loose connection
between 5 REC gate and PZ12 ( white/violet wire
).
Shorted 2 REC circuit.
• Check 2 REC and 2 REC snubber ( 22 REC ) for
short circuit.
Figure 1
STATUS INDICATION CRITERIA
This status code is displayed when the 5 REC circuit
fails to turn on.
Defective capacitor circuit.
• Check for open capacitor.
•
Check for loose connections at capacitor terminals.
STATUS
CODE
-150
DESCRIPTION
Capacitor volts low .
MEMORY
RECALL
No
CONTROL
TYPE
Pump
SYMPTOM
Pump contactor picks up. Control does not operate.
POSSIBLE CAUSE
Defective 2 REC circuit.
• Open circuit or loose connection between spider
assembly and 5 REC (BUS A).
• Open circuit or loose connection between 5 REC
and
2 REC.
• Open circuit or loose connection between 2 REC
and PZ11 (red wire) and between 2 REC gate and
PZ10
(white/red wire).
• Check 2 REC to insure that it will gate on.
Figure 1
STATUS INDICATION CRITERIA
This status code is displayed when 2 REC circuit fails
to turn on at initial start up.
57
STATUS
DESCRIPTION
CODE
-151
Excessive capacitor voltage when motor current is high.
MEMORY
RECALL
No
CONTROL
TYPE
Pump
SYMPTOM
Pump contactors open and close, then can only be closed
by opening and closing the key switch.
POSSIBLE CAUSE
Excessive source inductance.
• Tag lines without filters are being used.
• Battery cables are too long.
High peak current in motor.
• Check for shorted field winding.
• Check for shorted armature winding.
Figure 1
STATUS INDICATION CRITERIA
This status code is displayed when capacitor volts
exceed 225 volts and motor current is greater than 300
amps.
STATUS
DESCRIPTION
CODE
-152
Excessive capacitor voltage when motor current is low.
MEMORY
RECALL
Yes
CONTROL
TYPE
Pump
SYMPTOM
Pump contactors open and close, then can only be closed
by opening and closing the key switch.
POSSIBLE CAUSE
Excessive source inductance.
• Tag lines without filters are being used.
• Battery cables are too long.
Defective 4 REC circuit.
• Check for shorted 4 REC.
• Check for open circuit or loose connection in 4
REC
circuit.
Defective 3 REC circuit.
• Check for open circuit or loose connection in 3
REC
circuit.
58
Figure 1
STATUS INDICATION CRITERIA
This status code is displayed when capacitor volts
exceed 225 volts and motor current is less than 200
amps.
STATUS
CODE
-154
DESCRIPTION
Shorted F, R or 1A contactor coil driver.
MEMORY
RECALL
No
CONTROL
TYPE
Pump
SYMPTOM
Control will not operate.
POSSIBLE CAUSE
Defective logic card.
• Replace logic card.
Figure 1
STATUS INDICATION CRITERIA
This status code is displayed when either the forward,
reverse or 1A contactor coil driver is shorted internal to
the logic card.
STATUS
CODE
-157
DESCRIPTION
Current sensor input voltage polarity check.
MEMORY
RECALL
No
CONTROL
TYPE
Pump
SYMPTOM
Pump contactors open and close, then can only be closed
by opening and closing the key switch.
POSSIBLE CAUSE
Reversed yellow and green current senors wires
• Insure that the: -green wire connects to PZ4 with
no open circuits.
-yellow wire connects to PZ3 with
no open circuits or loose
connections.
Reversed power cable connection.
• Insure that the battery negative cable connects to
SCR NEG and the motor A2 cable connects to SCR
A2.
Figure 1
STATUS INDICATION CRITERIA
This status code is displayed when the voltage input
to PZ4 and PZ3 is the wrong polarity.
59
60
TABLE 4 CHECKING COMPONENTS
Main Logic Card
All trouble-shooting is written to check all outside devices and eliminate them as the source of the
symptoms. The conclusion being then that the card is faulty.
1. Instructions for Removal of Control Card.
Remove control wires on the screw terminals 1 through 6 as required.
Unplug A, B, and Z plugs by pressing down on tab with wide blade screwdriver
and rotating 90 degrees.
Remove the two mounting screws and lift card box free.
NOTE: Do not attempt to remove circuit broad from card box.
Reverse procedures to install new control card.
Mounting
Screw
A and B Plugs
Terminals 1 - 6
Y Plug
Z Plug
61
Capacitor 1C
Disconnect the battery and discharge the capacitor. Measure ohms through the capacitor using the R x
10,000 scale. Meter should read zero and then swing slowly to above 100,000 ohms. Replace the
capacitor if above reading is not obtained.
Contactors F, R, 1A,SP,FW,D,REGEN and P
150 ampere contactors instruction sheets.
300 ampere contactors instruction sheets.
NOTE:
Control is arranged so that the F and R contactors do not break current. Check to see that the
1A contactor drops out before the F or R contactor.
Most contactor coils are polarity sensitive. The left-hand terminal must be connected to
positive.
Potentiometer in Accelerator
To check operation of the potentiometer, disconnect the battery and disconnect the wire at
control card TB1. Connect a VOM to the wire that was removed from TB1 and to negative. Place the VOM on the R x 100 scale. With the accelerator in the creep speed position,
the ohms reading should be 4800 to 6000 ohms. With the accelerator in the top speed
position, the ohm reading should be 50 ohms or less. With the wire disconnected as above,
check for resistance of 1 megohm or higher from pot wire to the truck frame.
SCR’s (1REC, 2REC,5REC)
These are silicon controlled rectifiers. Before checking, disconnect the battery and discharge capacitor 1C. Disconnect gate leads of SCR’s at the SCR terminal.
To check an SCR, it is necessary to have a 6 volt battery and 2 A-14 diodes.
Connect the positive lead to the anode, connect the negative lead to the cathode as shown
below.
62
(1). The lamp should not light. If the lamp does light, the SCR is shorted and must be
replaced.
(2). If check (1) was satisfactory, test the SCR for its ability to be turned on by the gate.
Connect positive through two diodes to the gate terminal. If the gate is operative, the lamp
will come on and remain on when the gate is removed. Some SCR’s will operate correctly
even if the lamp does not remain on, particularly with a weak battery.
(3). If the lamp cannot be lit under step (2) the SCR is open and must be replaced.
NOTE:
If you do not have a test light to check the SCR’s as described above, they may be checked
for shorts and opens by use of the VOM.
Measure resistance from anode to cathode (R x 100 scale). If SCR is shorted (zero
ohms), it must be replaced.
Measure resistance from the gate terminal to the cathode and then from the cathode to
the gate terminal (R x100 scale). If resistance reads either zero ohms (short) or infinity
ohms (open), replace the SCR. When reassembling SCR’s, refer to TABLE 5.
Rectifiers (3REC, 4REC, Diode Blocks)
When checking diodes, disconnect battery and discharge capacitor 1C. When replacing
rectifiers, refer to TABLE 5. For 3REC and 4REC, disconnect one lead or flexible connection.
3REC and 4REC are diode with about 7 to 12 ohms in the conducting direction (anode to
cathode) measure on the R x 100 scale, and 10,000 ohms or higher, in the non-conducting
direction (cathode to anode) measured on the R x 10,000 scale.
Thermal Protector (TP)
Remove both the GRAY and BLACK wires from the “Z” plug that connects to the control
card. Read the resistance between these two wires with the VOM set on the R x 100 scale.
VOM should read 100 to 200 ohms if the 1REC heatsink is at room temperature (25C or
75F). Set the VOM to the highest ohm scale and read from each wires end to the 1REC
heatsink, reading should be infinity.
63
Filter Block(23FIL,etc.)
To check, disconnect all wires from the filter block on remove from panel. With VOM on
the R x 10,000, touch the leads to the filter terminals to charge the filter. After a few seconds, reverse the meter leads and touch the filter terminal. The VOM needle will deflect and
return to infinity. If this capacitor action is not observed, replace the filter block.
Filter Block(23FIL,etc.)
Filter block test 4K is only to detect an open or shorted filter. If the control has symptoms as
in 1E, interchange 22REC and 25REC and try again. If the problem is corrected, the old
25REC is marginal and should be replaced. If the problem is not corrected, replace both
filters.
1X Choke and Reactor T3-T4
Refer to panel wiring diagram to locate windings. With VOM on R x 1 scale, measure
choke or reactor winding, reading should be less than 1 ohm.
64
REPLACEMENT OF EV-100 COMPONENTS
When replacing stud semiconductors such as 3REC and 4REC it is not necessary to torque these
devices to a specific value.
The use of a heat-transfer grease (such as GE Versilube G-350-M or equivalent) is recommended.
When replacing module semiconductors such as 1REC, 2REC or 5REC
Remove all module connections. (As required)
Remove module by backing out the two screws at the device sides.
Clean the insulator surface with a clean rag and isopropyl alcohol.
Inspect the insulator surface for tears or cracks. If defective, replace. Wipe a light layer of
machine oil on the base and smooth the insulator into position.
NOTE: Insulator not required for 2REC and 5REC.
Coat insulator with a light coat of heat-transfer grease similar to GE-350.
Set new module on insulator and start screws back into base. Be sure to use the original
screws and washers. run screws in to base “finger tight”.
Check that the bottom of the module is flat against the insulator or base.
Alternately tighten the two screws by 1/4 turn until firm.
Replace all connections removed in step 1.
Capacitor
Remove nuts from capacitor connections and remove wires.
Remove hold down brackets and lift out.
Reverse procedure to replace capacitor.
22REC, 23REC and 25REC
Remove mounting screws and lift out.
NOTE: When replacing these devices, use the original hardware in the same holes, as the
inserts are used for electrical connections.
65
Reactor/Choke
Disconnect all leads to the reactor.
Remove the two mounting bolts and lift out.
Set new reactor on SCR base and start screws back into base. Be sure to use the original
screws and washers. run screws in to base “finger tight”.
Check that the bottom of the reactor is flat against the base.
Alternately tighten the two screws by 1/4 turn until firm.
Replace all connections removed in step 1.
66
GEH-5716
GE Electric Vehicle
Systems
GENERAL
The Handset is a multi-functional tool to be used with the
EV100/200 LX and LXT SCR controls. The Handset consist
of a Light Emitting Diode (LED) display and a keyboard for
data entry.
INSTRUCTIONS
EV100 HANDSET
location " Y " on the control card. After installing the handset
tool, plug in the battery and turn on the key switch. The
following is the start-up display sequence that will occur:
START-UP DISPLAY SEQUENCE
PURPOSE:
The purpose of the Handset is to allow authorized personnel
to perform the following functions:
• Monitor existing system fault codes for both traction
and pump SCR systems
• Monitor intermittent random status code
• Monitor battery state of charge on LXT systems
• Monitor hourmeter reading on traction and pump
SCR systems
• Monitor or adjust the following control functions:
• Creep speed
• Controlled Acceleration and 1A time
• Current Limit
• Steer pump time delay and define signal input
( seat switch or directional switch )
• Plugging distance (Current)
• Pedal position plug range or disable
• 1A drop out current or disable
• Field Weakening drop out
• Field Weakening pick up
• Regen braking current limit
• Regen braking drop out
• Speed limit points ( SL1,SL2, and SL3)
• Truck Management fault speed limit
• Internal resistance compensation for battery
state of charge indication
• Battery voltage ( 36/48 volts is auto ranging )
• Selection of card operation type:
• Standard traction card selection:
• Standard traction with Field Weakening
• Standard traction with speed limits
• Standard traction with Regen/Field Weakening
• High or low current limit for all of the above.
OPERATION:
Warning : Before connecting or disconnecting the handset tool, jack up the drive wheels of the vehicle, turn off
the key switch, unplug the battery and discharge the
capacitors.
At the SCR control traction card, unplug the " Y plug " if the
dash display is in use and plug in the handset to the plug
September 1993
Key Switch on
Verify Display Segments for
one second
8888
BDI Display
or
Blank Display
( No BDI used )
Diagnostics
override
with fault
Run Mode
BDI Display
or
Blank Display
( No BDI used )
Diagnostics
override
with fault
Key Switch Off
Display traction
hourmeter for
four seconds
Display pump
hourmeter for
four seconds
or
Blank
( If no Pump SCR used )
NOTE: The vehicle can be operated with the handset
connected, however, the adjustment knob must be set
fully clockwise to insure the control operates at top
speed.
FUNCTION SET-UP PROCEDURES:
Warning: Before making any adjustments to the control
you must consult the operating and maintenance instructions supplied by the vehicle manufacturer. Failure to
follow proper set up instructions could result in
misoperation or damage to the control system.
DESCRIPTION AND LOCATION
A PLUG
B PLUG
Y PLUG
Z PLUG
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.
SET UP MODE
Action
Hold down CONT,
turn on key
Push function
number
After one second
time delay
Push CONT
Change value with
adjustment knob
Push STORE
Push ESC
Display shows
Remarks
8888
Segment check
displayed
U 005
Selected
function number
is displayed
085
1234567890
1234567890
1234567890
085
1234567890
1234567890
1234567890
1234567890
125
1234567890
Stored value for
the function is
displayed
Displayed value
will blink
Value changes
while blinking
125
New value
stored and
blinking stops
8888
Segment check
displayed
At this point another function can be monitored/changed
by pushing another function number, or the vehicle can be
placed in the run mode by holding the ESC key down for
one second or longer. The display will return to either the
diagnostics mode or the BDI display or a blank display (
if BDI is not used and there are no fault codes). The
vehicle can now be operated with the handset connected
or the handset can be disconnected before operation.
NOTE: You can return to the segment check mode at any
time, by holding down the ESC key until 8888 appears in
the display.
68
EV100 LX/LXT
DESCRIPTION OF FUNCTION NUMBERS FOR:
Control Cards IC3645EVLXCD1TT AND
IC3645EVLXCD1TX
FUNCTION 1
STORED FAULT CODE
( Push 1)
This function register contains the last fault that shut down
vehicle operation ( PMT type fault that is reset by cycling the
key switch ) . This fault code will be over written each time
a new fault occurs and can be cleared from memory by
adjusting the value to zero.
FUNCTION 2
CREEP SPEED
( Push 2 )
This function allows for the adjustment of the creep speed of
the vehicle. A constant creep speed frequency will be maintained when an accelerator input voltage between 3.7 and 3.5
volts or an accelerator ohmic input between 6K and 4.7K
ohms is provided.
Range
Set
Resolution
2% to 15% on time
0 to 255
.03% per set unit
Example:
Setting of 20 = 2.6% on time
FUNCTION 3
CONTROLLED ACCELERATION
AND 1A TIME
( Push 3 )
This function allows for the adjustment of the rate of time it
takes for the control to accelerate to 96% applied battery
voltage to the motor on hard acceleration. The 1A contactor
will automatically close .2 seconds after the controlled
acceleration stops and the accelerator input is less than .5
volts or less than 50 ohms.
Range
Set
Resolution
.1 to 22.0 seconds
0 to 255
.084 seconds per set unit
Example:
Setting of 20 = 1.8 seconds C/A
and 2.0 1A time.
FUNCTION 4
CURRENT LIMIT
( Push 4 )
This function allows for the adjustment of the current limit
of the control. The rating of the control will determine the
range of adjustment for this function. Please refer to the
operating instructions for the control used in your vehicle.
Range
Set
See control C/L curves
0 to 255
Example:
0 = min. current, 255 = max. current
FUNCTION 5
PLUGGING DISTANCE (CURRENT)
( Push 5 )
This function allows for the adjustment of the plugging
distance of the vehicle. The larger the current setting, the
shorter the stopping distance.
Range
Set
Resolution
Example:
200 to 1000 amps (EV100)
300 to 1500 amps (EV200)
0 to 255
3.14 amps per set unit (EV100)
4.7 amps per set unit (EV200)
Setting of 20 = 263 amps (EV100)
Warning: Plug settings must be in accordance with
control operating instructions. An excessively high setting could cause damage to control system or traction
motor.
FUNCTION 6
1A DROP OUT CURRENT
( Push 6 )
This function allows for the adjustment of the 1A contactor
drop out current. The 1A contactor will be dropped out and
the vehicle motor torque will be limited to SCR current limit
when the set drop out current is reached.
Range
Set
Resolution
450 to 1260 amps (EV100)
675 to 1890 amps (EV200)
0 to 250
3.24 amps per set unit (EV100)
4.86 amps per set unit (EV200)
Settings above 250 set units will disable 1A drop out function
( 1A will not drop out).
Example
Setting of 20 = 515 amps (EV100)
FUNCTION 7
FIELD WEAKENING PICK UP
( Push 7 )
This function allows the adjustment of field weakening
contactor pick up current. This setting allows the FW
contactor to pick up when the vehicle has returned to about
150% of its full load level running current after acceleration.
Range
Set
Resolution
Example
52 to 466 amps (EV100)
78 to 699 amps (EV200)
0 to 255
1.6 amps per set unit
2.4 amps per set unit
Setting of 20 = 84 amps
69
FUNCTION 8
FIELD WEAKENING DROP OUT
( Push 8 )
This function allows for the adjustment of the field weakening contactor drop out current. This setting allows the FW
contactor to drop out when the vehicle requires greater than
300% of the full load level running current for greater
torque.
Range
Set
Resolution
Example
FUNCTION 9
65 to 895 amps (EV100)
98 to 1343 amps (EV200)
0 to 255
3.25 amps per set unit (EV100)
4.88 amps per set unit (EV200)
Setting of 20 = 130 amps
REGEN BRAKING C/L
( Push 9 )
This function allows for the adjustment of the Regen braking
current limit. The higher the current the shorter the stopping
distance.
Range
Set
Resolution
75 to 630 amps
0 to 255
2.2 amps per set unit
Example:
Setting of 20 = 119 amps
FUNCTION 10 REGEN START
( Push 10 )
This function allows for the adjustment of the percent on
time at which the control will start to regen. Adjustment of
this function allows the OEM to set the regen start speed of
the vehicle to eliminate regen attempts when motor regen
current is low.
Range
Set
Resolution
0 to 95% on time
0 to 255
.37% per set unit
Example:
Setting of 20 = 7.4% on time
FUNCTION 11 SPEED LIMIT 1 (SL1)
( Push 11 )
This function allows for the adjustment of the speed limit (
maximum battery volts to the motor ) when the SL1 limit
switch input signal is received by the control card. SL1 limit
switch is a normally closed switch connected to battery
negative, the switch opening enables speed limit.
Range
Set
96% to 0% battery volts
0 to 180
Setting of 0 set units will disable speed limit function and
70
allow top speed with no limit switch connected.
FUNCTION 12 SPEED LIMIT 2 (SL2)
( Push 12 )
Same as Function 11 except using SL2 limit switch for input.
FUNCTION 13 SPEED LIMIT 3 (SL3)
( Push 13 )
Same as Function 11 except using SL3 limit switch for input.
The SL3 set speed limit is also activated by the Truck
Management Module fault codes 90 and 93. See instructions
for IC3645TMM1A Truck Management Module for 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. In order to made this setting the voltage
drop of the battery under load must first be determined by
following the steps listed below.
1. Load the traction motor to 100 amps in 1A and
record the voltage (VO) at the SCR positive and
negative power terminal.
2. Load the traction motor to 200 amps in 1A and
record the voltage (VL) at the SCR positive and
negative power terminal.
3. Calculate voltage drop (VD) as follows:
VD = VO - VL
4. Use the table below to determine the setting using
the calculated VD as a reference.
Setting
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
EV100
VD
11.44
07.60
05.72
04.57
03.81
03.27
02.86
02.54
02.28
02.08
01.90
01.76
01.63
01.52
01.43
EV200
VD
07.63
05.07
03.81
03.05
02.54
02.18
01.91
01.69
01.52
01.39
01.27
01.17
01.08
01.01
00.95
Setting
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
EV100
VD
01.34
01.27
01.20
01.14
01.09
01.04
00.99
00.95
00.91
00.88
00.85
00.82
00.79
00.76
00.74
EV200
VD
00.89
00.85
00.80
00.76
00.73
00.69
00.66
00.63
00.61
00.59
00.57
00.55
00.53
00.51
00.49
FUNCTION 15 BATTERY VOLTS
( Push 15 )
This function allows for the adjustment of voltage range for
controls equipped with the Battery Discharge Indication
function. In order for the BDI to operate properly, the setting
as shown in the table must be entered .
Battery volts
Set units
24 volts
36 volts
48 volts
72 volts
80 volts
36/48 volts
No BDI
Between 0 and 31
Between 32 and 44
Between 45 and 69
Between 70 and 80
Between 81 and 183
Between 184 and 250
Between 251 and 255
The following functions have function numbers larger
than the numbers on the Handset keyboard. To access
these functions, push the CONT key and the number shown
in the following instructions at the same time.
FUNCTION 16 PEDAL POSITION PLUG
( Push CONT and 1 )
This function will allow the adjustment of the pedal position
plug range. Pedal position will reduce the plugging current
to the current value set by this function as the accelerator is
returned to the creep speed position. Maximum plug current
is obtained with the accelerator in the top speed position.
Range
Set
Resolution
Example
100 to 930 amps (EV100)
150 to 1425 amps (EV200)
0 to 255
3.2 amps per set unit (EV100)
5.0 amps per set unit (EV200)
Setting of 20 = 164 amps
To disable the pedal position plug function, adjust the
current value to the same current value as the plug distance
current.
Example: If plug distance current Function 5 is set at 500
amps, then set pedal plug current at 500 amps. With this
setting pedal position will have no effect on plugging
distance.
FUNCTION 17 CARD TYPE SELECTION
( Push CONT and 2 )
This function allows for the selection of the card type used for
your vehicle's application. The table below shows the setting
to select card application type depending on which control
card is used.
EV100
Function
STD C/L
High C/L
STD C/L
(Auto plug)
High C/L
Standard
with FW
Speed
Limit
0 to 4
5 to 9
20 to 24
25 to 29
40 to 44
45 to 49
10 to 14
30 to 34
50 to 54
(Auto plug)
15 to 19
35 to 39
55 to 59
EV200
Function
Standard
with FW
Speed
Limit
STD C/L
STD C/L
(Auto plug)
64 to 68
84 to 88
104 to 108
74 to 78
94 to 98
114 to 118
Regen/FW
Settings for these function should be made in between the
values shown.
Warning: These settings must be changed by authorized
personnel only, following instructions supplied by the
manufacturer. Card type selection must be made within
the capabilities of the SCR control panel used and the
supporting electro-mechanical devices. Failure to comply with proper application standards could result in
misoperation or damage to the control and/or motors.
FUNCTION 18 STEER PUMP TIME DELAY
( Push CONT and 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 on seat switch closure and time delay drop out on
seat switch opening.
Range
Setting
Resolution
1.5 to 65 seconds
Between 0 and 128
.5 seconds per set unit
Example:
Setting of 20 = 10.5 seconds
Pick up on directional switch closure and drop out time
delay on directional switch opening.
Range
Setting
Resolution
.5 to 63 seconds
129 to 255
.5 seconds per set unit
Example:
Setting of 149 = 10.5 seconds
Drop out will be 1.5 seconds after the seat switch opens.
Regen/FW
71
DESCRIPTION OF FUNCTION NUMBERS FOR:
Control Cards IC3645EVLXCD1MT AND
IC3645EVLXCD1MX
FUNCTION 1
STORED FAULT CODE
( Push 1)
This function register contains the last fault that shut down
vehicle operation ( PMT type fault that is reset by cycling the
key switch ) . This fault code will be over written each time
a new fault occurs and can be cleared from memory by
adjusting the value to zero.
FUNCTION 2
CREEP SPEED
( Push 2 )
This function allows for the adjustment of the creep speed of
the vehicle. A constant creep speed frequency will be maintained when an accelerator input voltage between 3.7 and 3.5
volts or an accelerator ohmic input between 6K and 4.7K
ohms is provided.
Range
Set
Resolution
2% to 15% on time
0 to 255
.03% per set unit
Example:
Setting of 20 = 2.6% on time
FUNCTION 3
CONTROLLED ACCELERATION
AND 1A TIME
( Push 3 )
This function allows for the adjustment of the rate of time it
takes for the control to accelerate to 96% applied battery
voltage to the motor on hard acceleration. The 1A contactor
will automatically close .2 seconds after the controlled
acceleration stops and the accelerator input is less than .5
volts or less than 50 ohms.
Range
Set
Resolution
.1 to 22.0 seconds
0 to 255
.084 seconds per set unit
Example:
Setting of 20 = 1.8 seconds C/A
and 2.0 1A time.
FUNCTION 4
CURRENT LIMIT
( Push 4 )
This function allows for the adjustment of the current limit
of the control. The rating of the control will determine the
range of adjustment for this function. Please refer to the
operating instructions for the control used in your vehicle.
Range
Set
72
See control C/L curves
0 to 255
Example:
0 = min. current, 255 = max. current
FUNCTION 5
PLUGGING DISTANCE (CURRENT)
( Push 5 )
This function allows for the adjustment of the plugging
distance of the vehicle. The larger the current setting, the
shorter the stopping distance.
Range
Set
Resolution
Example:
200 to 1000 amps (EV100)
300 to 1500 amps (EV200)
0 to 255
3.14 amps per set unit (EV100)
4.7 amps per set unit (EV200)
Setting of 20 = 263 amps (EV100)
Warning: Plug settings must be in accordance with
control operating instructions. An excessively high setting could cause damage to control system or traction
motor.
FUNCTION 6
1A DROP OUT CURRENT
( Push 6 )
This function allows for the adjustment of the 1A contactor
drop out current. The 1A contactor will be dropped out and
the vehicle motor torque will be limited to SCR current limit
when the set drop out current is reached.
Range
Set
Resolution
450 to 1260 amps (EV100)
675 to 1890 amps (EV200)
0 to 250
3.24 amps per set unit (EV100)
4.86 amps per set unit (EV200)
Settings above 250 set units will disable 1A drop out function
( 1A will not drop out).
Example
Setting of 20 = 515 amps (EV100)
FUNCTION 7
PA4 INPUT SWITCH FUNCTION
SELECTION
(PUSH 7)
This function allows for the selection of PA4 input function.
The PA4 input can be adjusted to operate in either of the
following modes:
1) To activate a speed limit if a normally closed switch
is opened between PA4 and negative.
2) To reverse the direction of the in-board motor and
activate a speed limit if a normally open switch is
closed between PA4 and negative.
Set 128 or greater to select option 1 above.
Set 0-127 to select option 2 above.
FUNCTION 11 SPEED LIMIT 1 (PA5 OR PA6)
( Push 11 )
This function allows for the adjustment of the speed limit (
maximum battery volts to the motor ) when the L1 or R1
limit switch input signal is received by the control card. L1
or R1 limit switch is a normally open switch connected to
battery negative, the switch closing enables speed limit.
Range
Set
96% to 0% battery volts
0 to 180
Setting of 0 set units will disable speed limit function and
allow top speed with no limit switch connected.
FUNCTION 12 SPEED LIMIT 2 (PA4)
( Push 12 )
Same as Function 11 except using L2 or R2 limit switch for
input. See function 7 for switch operation.
FUNCTION 13 SPEED LIMIT 3
( Push 13 )
This speed limit is activated by the Truck Management
Module fault codes 90 and 93. See instructions for
IC3645TMM1A Truck Management Module for 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. In order to made this setting the voltage
drop of the battery under load must first be determined by
following the steps listed below.
1. Load the traction motor to 100 amps in 1A and
record the voltage (VO) at the SCR positive and
negative power terminal.
2. Load the traction motor to 200 amps in 1A and
record the voltage (VL) at the SCR positive and
negative power terminal.
3. Calculate voltage drop (VD) as follows:
VD = VO - VL
4. Use the table below to determine the setting using
the calculated VD as a reference.
Setting
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
EV100
VD
11.44
07.60
05.72
04.57
03.81
03.27
02.86
02.54
02.28
02.08
01.90
01.76
01.63
01.52
01.43
EV200
VD
07.63
05.07
03.81
03.05
02.54
02.18
01.91
01.69
01.52
01.39
01.27
01.17
01.08
01.01
00.95
Setting
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
EV100
VD
01.34
01.27
01.20
01.14
01.09
01.04
00.99
00.95
00.91
00.88
00.85
00.82
00.79
00.76
00.74
EV200
VD
00.89
00.85
00.80
00.76
00.73
00.69
00.66
00.63
00.61
00.59
00.57
00.55
00.53
00.51
00.49
FUNCTION 15 BATTERY VOLTS
( Push 15 )
This function allows for the adjustment of voltage range for
controls equipped with the Battery Discharge Indication
function. In order for the BDI to operate properly, the setting
as shown in the table must be entered .
Battery volts
Set units
24 volts
36 volts
48 volts
72 volts
80 volts
36/48 volts
No BDI
Between 0 and 31
Between 32 and 44
Between 45 and 69
Between 70 and 80
Between 81 and 183
Between 184 and 250
Between 251 and 255
The following functions have function numbers larger
than the numbers on the Handset keyboard. To access
these functions, push the CONT key and the number shown
in the following instructions at the same time.
FUNCTION 16 PEDAL POSITION PLUG
( Push CONT and 1 )
This function will allow the adjustment of the pedal position
plug range. Pedal position will reduce the plugging current
to the current value set by this function as the accelerator is
returned to the creep speed position. Maximum plug current
is obtained with the accelerator in the top speed position.
Range
Set
Resolution
Example
100 to 930 amps (EV100)
150 to 1425 amps (EV200)
0 to 255
3.2 amps per set unit (EV100)
5.0 amps per set unit (EV200)
Setting of 20 = 164 amps
To disable the pedal position plug function, adjust the
current value to the same current value as the plug distance
current.
73
Example: If plug distance current Function 5 is set at 500
amps, then set pedal plug current at 500 amps. With this
setting pedal position will have no effect on plugging
distance.
FUNCTION 17 CARD TYPE SELECTION
( Push CONT and 2 )
This function allows for the selection of the card type used for
your vehicle's application. The table below shows the setting
to select card application type depending on which control
card is used.
EV100
Function
Standard
with FW
STD C/L
High C/L
STD C/L
(Auto plug)
0 to 4
5 to 9
10 to 14
High C/L
(Auto plug)
15 to 19
EV200
Function
Standard
with FW
STD C/L
STD C/L
(Auto plug)
20 to 24
30 to 34
Settings for these function should be made in between the
values shown.
Warning: These settings must be changed by authorized
personnel only, following instructions supplied by the
manufacturer. Card type selection must be made within
the capabilities of the SCR control panel used and the
supporting electro-mechanical devices. Failure to comply with proper application standards could result in
misoperation or damage to the control and/or motors.
FUNCTION 18 STEER PUMP TIME DELAY
( Push CONT and 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 on seat switch closure and time delay drop out on
seat switch opening.
Range
Setting
74
1.5 to 65 seconds
Between 0 and 128
Resolution
Example:
.5 seconds per set unit
Setting of 20 = 10.5 seconds
Pick up on directional switch closure and drop out time
delay on directional switch opening.
Range
Setting
Resolution
.5 to 63 seconds
129 to 255
.5 seconds per set unit
Example:
Setting of 149 = 10.5 seconds
Drop out will be 1.5 seconds after the seat switch opens.
DESCRIPTION OF FUNCTION NUMBERS FOR:
Control Card
IC3645EVLXCD1PX
FUNCTION 11 SPEED LIMIT 1 (SL1)
( Push 11 )
FUNCTION 1
This function allows for the adjustment of the speed limit (
maximum battery volts to the motor ) when the SL1 limit
switch input signal is received by the control card. SL1 limit
switch is a normally open switch connected to battery
negative, the switch closing enables speed limit.
STORED FAULT CODE
( Push 1)
This function register contains the last status code that shut
down vehicle operation ( PMT type fault that is reset by
cycling the key switch ) . This status code will be over written
each time a new fault occurs and can be cleared from memory
by adjusting the value to zero.
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
Set
Resolution
0 to 1325 amps
52 to 255
6.5 amps per set unit
Example:
Setting of 72 = 130 amps
FUNCTION 3
CONTROLLED ACCELERATION
AND 1A TIME
( Push 3 )
This function allows for the adjustment of the rate of time it
takes for the control to accelerate to 96% applied battery
voltage to the motor on hard acceleration. The 1A contactor
will automatically close .2 seconds after the controlled
acceleration stops and the accelerator input is less than .5
volts or less than 50 ohms.
Range
Set
Resolution
.1 to 5.5 seconds
0 to 255
.021 seconds per set unit
Example:
Setting of 20 = .52 seconds C/A
and .72 seconds 1A time.
FUNCTION 4
CURRENT LIMIT
( Push 4 )
This function allows for the adjustment of the current limit
of the control. The rating of the control will determine the
range of adjustment for this function. Please refer to the
operating instructions for the control used in your vehicle.
Range
Set
See control C/L curves
0 to 255
Example:
0 = min. current, 255 = max. current
Range
Set
Resolution
Example
0% to 100% battery volts
0 to 255
.375 volts per set unit
Setting of 50=18.75 volts
FUNCTION 12 SPEED LIMIT 2 (SL2)
( Push 12 )
Same as Function 11 except using SL2 limit switch for input.
FUNCTION 13 SPEED LIMIT 3 (SL3)
( Push 13 )
Same as Function 11 except using SL3 limit switch for input.
FUNCTION 14 SPEED LIMIT 4 (SL4)
( Push 14 )
Same as Function 11 except using SL4 limit switch for input.
The following functions have function numbers larger
than the numbers on the handset keyboard. To access these
functions, push the CONT key and the number shown in
the following instructions at the same time.
FUNCTION 16 SPEED / TORQUE
COMPENSATION
( Push CONT and 1 )
This function is used to stabilize pump speed at heavy loads.
This function is set using information obtained from the
speed torque curve of the motor used. See OEM service
manual for your vehicle for this setting.
SPEED / TORQUE COMPENSATION
TABLE
Setting
2
3
4
5
6
7
8
9
10
11
12
Voltage Drop
11.44
07.60
05.72
04.57
03.81
03.27
02.86
02.54
02.28
02.08
01.90
Setting
17
18
19
20
21
22
23
24
25
26
27
Voltage Drop
01.34
01.27
01.20
01.14
01.09
01.04
00.99
00.95
00.91
00.88
00.85
75
Setting Voltage Drop
13
01.76
14
01.63
15
01.52
16
01.43
Setting
28
29
30
31
Voltage Drop
00.82
00.79
00.76
00.74
FUNCTION 17 CARD TYPE SELECTION
( Push CONT and 2 )
This function allows for the selection of the card type used for
your vehicle’s application. The table below shows the setting
to select card application type depending on which control
card is used.
Function
STD C/L
High C/L
STD C/L
BDI (Lockout)
High C/L
BDI (Lockout)
With Pump
Ctr/PMT
Without Pump
Ctr/PMT
0 to 8
9 to 17
36 to 44
45 to 53
18 to 26
54 to 62
27 to 35
63 to 71
BDI Lockout means that the BDI signal from the traction
control must be present in order for the pump control to
operate. This control will stop operation when the battery
state of charge reaches 10%.
Settings for these functions should be made in between the
values shown.
Warning: These setting must be changed by authorized
personnel only, following instructions supplied by the
manufacturer. Card type selection must be made within
the capabilities of the SCR control panel used and the
supporting electro-mechanical devices. Failure to comply with proper application standards could result in
misoperation or damage to the control and/or motors.
76
g
GE Industrial Systems
EV200LX SUPPLEMENT
General:
The EV100LX instructions and operating information is applicable to the EV200LX. The only
difference in the two control types is that the EV200 has a high current rating than the EV100LX,
a larger mounting foot print and different component parts.
Standard Outline Drawing:
Page 1 of 5
REV 11/2002
g
GE Industrial Systems
EV200LX SUPPLEMENT
Component Locations:
ITEM#
5
7
8
9
10
11
12
13
14
15
16
17
19
20
21
22
23
24
26
28
PART NUMBER
158C3100BYP1
918D620G1
157C8160G13
171B3939G4
44A727038-G01
171B3967P1L
273A2523P11
116C6961P1L
273A2523P12
259A9208PXCR
171B3940G1
195B4039G1
116C6975G1
273A2523P6
273A2523P9
171B3912G1
259A9053P2
259A8733P1
IC3645LXCD1**
171B3980G1
DESCRIPTION
BASE
TRANSFORMER
1REC ASM
3REC ASM
2REC
HEAT SINK
THERMAL CONDUCTIVE
HEAT SINK
THERMAL CONDUCTIVE
RECTIFIER
SNUBBER ASM
SNUBBER MOUNT
SPIDER ASM
THERMAL CONDUCTIVE
THERMAL CONDUCTIVE
TERMINAL POST
CAPACITOR
CAPACITOR MOUNTING BRACKET
EV100LX CARDBOX ASM
SHUNT ASM
Page 2 of 5
QTY/EACH
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
2
2
1
1
REV 11/2002
g
GE Industrial Systems
EV200LX SUPPLEMENT
ITEM#
30
31
35
36
37
38
39
40
41
PART NUMBER
44A717068-001
44A727009-G06
195B6250P2
195B6250P11
202B1621P3
148B5620EPP3
148B5620EPP1
148B5620EPP2
259A3290P1
DESCRIPTION
RECTIFIER
THERMISTOR ASM
FLEX BUS
FLEX BUS
CAPACITOR STRAPS
BUS BAR
BUS BAR
BUS BAR
INSULATING BUSHING
Page 3 of 5
QTY/EACH
1
1
4
4
8
1
1
1
4
REV 11/2002
g
GE Industrial Systems
EV200LX SUPPLEMENT
Wiring Diagram:
Page 4 of 5
REV 11/2002
g
GE Industrial Systems
EV200LX SUPPLEMENT
Current Limit Adjustments:
1500
Pe
ak
I
1350
M
1200
Ma
xim
um
Motor Amperes
1050
Pe
ak
I
900
M
750
Mi
ni
Ave
rag
e
mu
m
IM M
axim
um
600
Ave
rag
e
450
300
IM M
inim
um
150
0
0
10
20
30
40
50
60
70
80
90
100
Percent On Time
Peak Motor C/L
@ Typical Motor Inductance
Min-Max @30% ONTIME
Min-Max @50% ONTIME
Min-Max @70% ONTIME
735/1170 Amps
560/990 Amps
390/810 Amps
Average Motor C/L
@ Typical Motor Inductance
Min-Max @30% ONTIME
Min-Max @50% ONTIME
Min-Max @70% ONTIME
Page 5 of 5
615/960 Amps
480/870 Amps
347/750 Amps
REV 11/2002
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