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.
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.
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.
EV100LX PART NUMBER IDENTIFICATION 10
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
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
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.
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.
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.
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.
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.
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.
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.
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.
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).
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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 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.
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.
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 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.
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.
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 -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 -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.
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.
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 ).
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.
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.
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.
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.
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.
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.
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 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.
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.
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 .
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.
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.
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.
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.
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.
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.
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.
(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 SCRs will operate correctly even if the lamp does not remain on, particularly with a weak battery. (3).
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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 vehicles application. The table below shows the setting to select card application type depending on which control card is used.
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.
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 SNU
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
