General Electric EV100Lx, EV100LXT Instruction Manual

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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

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EV100LX SCR CONTROL ORDERING INFORMATION

EXAMPLE-------------------------- IC3645EV 100 T1 TT 1 ARGUMENT NO. 01 02 03 04 05

ARGUMENT NO. 01 - BASIC CATALOG NUMBER

ARGUMENT NO. 02 - POWER BASE RATING

100 - EV100 POWER BASE ( APPLICATIONS LESS THAN 150 FLLR ) 200 - EV200 POWER BASE ( APPLICATIONS LESS THAN 200 FLLR )

ARGUMENT NO. 03 - APPLICATION AND 1 REC OPTIONS

T1 - STANDARD CURRENT LIMIT TRACTION T2 - HIGH PERFORMANCE CURRENT LIMIT TRACTION P1 - STANDARD CURRENT LIMIT PUMP P2 - 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 - ACTIVE

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EV100LX COMPONENT LOCATIONS

Page 4

EV100LX OUTLINE DRAWING

Page 5

EV100LX WITH SPEED LIMIT AND FW

Page 6

EV100LX WITH REGEN AND FW

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EV100LX DUAL MOTOR CONTROL

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EV100LX PUMP CONTROL

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EV100LX PART NUMBER IDENTIFICATION

NO. PART-NUMBER DESCRIPTION QUANTITY

4 158C3100EEP1 BASE DETAIL ...........................................................01

11 171B3939G1 1REC ASSEMBLY LOW POWER ...........................01

11 171B3939G2 1REC ASSEMBLY HIGH POWER ..........................01

12 273A2523P9 THRM COND INSULATION ...................................01

14 171B3949G1 3 AND 4 REC. ASM. .................................................01

15 259A3290P1 INSULATING BUSHING .......................................... 03

16 273A2523P8 THRM COND INSULATION ...................................01

18 44A717068-001 SCR, 2REC .................................................................01

19 44A717067-001 SCR, 5REC .................................................................01

20 44A723544-001 CAP. WARNING LABEL ......................................01

21 44A723543-001 EV-100 LOGO LABEL ..............................................01

22 158C3234G1 REACTOR ASSEMBLY............................................01

24 259A9053P2 CAP MT FILM 150MF 25 .........................................01

26 IC3645LXCD1TX TRACTION WITHOUT BDI .....................................01

26 IC3645LXCD1TT TRACTION WITH BDI .............................................01

26 IC3645LXCD1MX DUAL MTR TRACTION WITHOUT BDI ...............01

26 IC3645LXCD1MT DUAL MTR TRACTION WITH BDI ....................... 01

26 IC3645LXCD1PX PUMP CONTROL ......................................................01

28 171B3933G1 SPIDER AND WIRE ASM. .......................................01

29 44A727009-G01 THERMISTOR ASM .................................................01

30 171B3940G1 SNUBBER ASM.........................................................04

34 44A718897-001 CAPACITOR MTG. STRAP ..................................... 02

37 148B5620DPP1 BUS BAR.................................................................... 01

38 148B5620DPP2 BUS BAR.................................................................... 01

39 148B5620DPP4 BUS BAR.................................................................... 01

40 148B5620DPP3 BUS BAR.................................................................... 01

43 WH7138R36G1 WIRE HARNESS .......................................................01

48 L201P17B33 NUT, M8X1.25MM....................................................02

49 L400P10B33 M8 FLAT WASHER ..................................................05

50 L401P27B33 M8 LOCK WASHER .................................................05

52 44A723274-001 M5X50MM T/R SCREW ........................................... 04

53 44A723274-002 M5X26MM T/R SCREW ........................................... 07

54 L14P17020B33 M8X1.25X20MM SCREW ........................................03

55 L10P14010B33 M5X0.8X10MM SCREW ..........................................05

56 L400P7B33 M5 NAR. FLAT WASHER ........................................05

57 L401P25B33 M5 SPRING LOCKWASHER ...................................05

58 44A723274-401 M3.5X12MM T/R SCREW ........................................ 04

59 L10P11044B33 M3.5X0.6X44MM SCREW .......................................01

60 44A723274-204 M3.5X23MM T/R SCREW ........................................ 08

61 L400P5B33 M3.5 NAR FLAT WASHER ......................................06

62 L401P23B33 M3.5 LOCK WASHER ..............................................06

63 L10P11008B33 M3.5X0.6X8MM SCREW .........................................06

64 L10P11016B33 METRIC PAN HD SCREW.......................................02

67 L14P15016B33 M6X1.0X16MM SCREW ..........................................01

69 L400P8B33 M6 FLAT WASHER ..................................................01

70 171B3954G1 SHUNT-WIRE ASM ..................................................01

73 N402P39B6 WASHER FLAT ST ...................................................03

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EV100LX PART NUMBER IDENTIFICATION

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LOGIC CARDS

TERMINAL CONNECTIONS FOR LX/LXT

TRACTION TRACTION TRACTION TRACTION

INPUT STANDARD SL/FW REGEN/FW DUAL MTR PUMP

TB1 Accel Pot Input Accel Pot Input Accel Pot Input Accel Pot Input Accel Pot Input

TB2 Start Switch Input Start Switch Input Start Switch Input Start Switch Input SL1

TB3 Seat Switch Input Seat Switch Input Seat Switch Input Seat Switch Input SL2

TB4 Key Switch Input Key Switch Input Key Switch Input Key Switch Input Key Switch Input

TB5 Forward Switch Input Forward Switch Input Forward Switch Input Forward Switch Input SL3

TB6 Reverse Switch Input Reverse Switch Input Reverse Switch Input Reverse Switch Input SL4

PA1 Plug Signal Plug Signal Plug Signal PS Coil Driver Status Code 93 Input

PA2 BDI Interrupt BDI Interrupt BDI Interrupt BDI Interrupt Status Code 93 Input

PA3 Aux Hourmeter Input Aux Hourmeter Input Aux Hourmeter Input Aux Hourmeter Input Status Code 90 Input

PA4 Not Used SL2 Sensor 2 Yellow Wire In-Board Mtr Rev Sw Status Code 94 Input

PA5 Not Used SL3 Sensor 2 Green wire Right Mtr Dropout Sw Status Code 94 Input

PA6 Not Used SL1 Mtr A2 Input Left Mtr Dropout Sw Status Code 91 Input

PB1 FW Coil Driver FW Coil Driver FW Coil Driver F Rht Mtr Coil Driver Status Code 95 Input

PB2 Not Used Not Used Regen Coil Driver F Lft Mtr Coil Driver Status Code 95 Input

PB3 SP Coil Driver SP Coil Driver SP Coil Driver R Rht Mtr Coil Driver BDI Enable Signal Input

PB4 F Coil Driver F Coil Driver F Coil Driver R Lft Mtr Coil Driver Pump (PMT) Coil Driver

PB5 R Coil Driver R Coil Driver R Coil Driver 1A coil Driver 1A Coil Driver

PB6 1A Coil Driver 1A Coil Driver 1A Coil Driver D Coil Driver Status Code 92 Input

PY1 Dash Display 4 Input Dash Display 4 Input Dash Display 4 Input Dash Display 4 Input Dash Display 4 Input

PY2 Dash Display 3 Input Dash Display 3 Input Dash Display 3 Input Dash Display 3 Input Dash Display 3 Input

PY3 Dash Display 1 Input Dash Display 1 Input Dash Display 1 Input Dash Display 1 Input Dash Display 1 Input

PY4 Dash Display 2 Input Dash Display 2 Input Dash Display 2 Input Dash Display 2 Input Dash Display 2 Input

PY5 Dash Display 5 Input Dash Display 5 Input Dash Display 5 Input Dash Display 5 Input Not Used

PY6 Not Used Not Used Not Used Not Used Not Used

PY7 Im Im Im Not Used Not Used

PY8 TMMA-9 / Pump-PY12 TMMA-9 / Pump-PY12 TMMA-9 / Pump-PY12 TMMA-9 / Pump-PY12 Not Used

PY9 TMMA-7 / Pump-PY11 TMMA-7 / Pump-PY11 TMMA-7 / Pump-PY11 TMMA-7 / Pump-PY11 Not Used

PY10 TMMA-2 / Pump-PY10 TMMA-2 / Pump-PY10 TMMA-2 / Pump-PY10 TMMA-2 / Pump-PY10 Traction PY10

PY11 Not Used Not Used Not Used Not Used Traction PY9

PY12 Not Used Not Used Not Used Not Used Traction PY8

PY13 Not Used Not Used Not Used Not Used Not Used

PY14 Not Used Not Used Not Used Not Used Not Used

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EV100LX Logic Card Specifications

Control Features

On-Board Diagnostics

Hourmeter

Stored Status Codes

Card Type Selection

Creep Speed

Current Limit

Plugging

Pedal Position Plug

IC3645LXCD1T

Standard Displayed to

Handset or Dash Display

Standard Displayed to

Handset or Dash Display

Standard

Standard Enable/Disable

Features

Adjustable

2% to 15% On Time

Adjustable

See C/L Curves

Standard/High

Performance

Adjustable

200 to 930 Amps

Adjustable 100 to 930 amps Can be Disabled

IC3645LXCD1M

Standard Displayed to

Handset or Dash Display

Standard Displayed to

Handset or Dash Display

Standard

Standard Enable/Disable

Features

Adjustable

2% to 15% On Time

Adjustable

See C/L Curves

Standard/High

Performance

Adjustable

200 to 930 Amps

Adjustable 100 to 930 amps Can be Disabled

IC3645LXCD1P

Standard Displayed to

Handset or Dash Display

Standard Displayed to

Handset or Dash Display

Standard

Standard Enable/Disable

Features

Not Applicable

Adjustable

See C/L Curves

Standard/High

Performance

Not Applicable

Ramp Start

Full Power Transition

Controlled Acceleration

1A Timed Pick-Up

1A Thermal Hold-Off

1A Plugging Hold-Off

Delay to First Pulse

PMT (Fault Shut Down)

Thermal Protection

Standard

Standard with 1A Ctr

Adjustable

.1 to 22 seconds

Follows CA by .2 seconds with Accel Volts is < .5V

or Accel Ohms is < 200

Standard at 90

cutback at 20% T

Standard

Look Ahead and Reset two

count

Standard

90oC Cutback

Standard

Standard with 1A Ctr

Adjustable

.1 to 22 seconds

Follows CA by .2 seconds with Accel Volts is < .5V

or Accel Ohms is < 200

Standard at 90oC

cutback at 20% T

Standard

Look Ahead and Reset two

count

Standard

90oC Cutback

Not Applicable

Standard with 1A Ctr

Adjustable

.1 to 5.5 seconds

Follows CA by .2 seconds

with Accel Volts is < .5V

or Accel Ohms is < 200

Standard at 90oC

cutback at 20% T

Not Applicable

Standard

Look Ahead and Reset two

count

Standard

90oC Cutback

Static Return to Off

Standard

2 Second Delay

Standard

2 Second Delay

Not Applicable

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Control Features

IC3645LXCD1T IC3645LXCD1M IC3645LXCD1P

Voltage Range

Accelerator Input

Low Battery Operation

Reverse Battery Protection

Ambient Temperature

Approximate Weight

Coil Drivers F/R or Line 1A FW Regen D PS

Shorted Driver Protection

24-80 VDC

5000-0 Ohms

3.5-0 VDC

Standard

50% at 36-80 VDC

75% at 24 VDC

Standard

-30 to +50

5.5 Kg

On-Board On-Board On-Board On-Board

Not Applicable

On-Board

Standard

24-80 VDC

5000-0 Ohms

3.5-0 VDC

Standard

50% at 36-80 VDC

75% at 24 VDC

Standard

-30 to +50oC

5.5 Kg

On-Board

On-Board Not Applicable Not Applicable

On-Board

Standard

24-80 VDC

5000-0 Ohms

3.5-0 VDC

Standard

50% at 36-80 VDC

75% at 24 VDC

Standard

-30 to +50oC

5.5 Kg

On-Board

On-Board Not Applicable Not Applicable Not Applicable Not Applicable

Standard

Shorted 3 REC Protection

F/R and Speed Input Switch Loading

1A switch

1A Current dropout

Dual Mtr Steering Logic

Dual Mtr Inside Wheel Reversal

Regenerative Braking

Field Weakening

Speed Limit Three Ranges Creep to Full Speed

Standard

Logic Current

Not Required

Adjustable

450 to 1260 Amps

Not Available

Adjustable

Regen C/L - 75A to 630A

Regen Start - 15% to 96%

Adjustable

Pick-up - 52A - 466A

Drop-out - 65A to 895A

Standard

Adjustable

Input by Limit Switch

Standard

Logic Current

Not Required

Adjustable

450 to 1260 Amps

Standard

Not Applicable

Standard

Adjustable

Two Speed Limits

Standard

Logic Current

Not Required

Not Applicable

Not Available

Not Applicable

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

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Control Features

IC3645LXCD1T

IC3645LXCD1M

IC3645LXCD1P

Accelerator Volts Lockout Accel volts > 2.5V

Battery Volts Check

Battery Discharge Indication

Full Load Level Running Mtr Current at 50% 1A duty

Continuous Duty Mtr Current with 0.3

C/Watt

Heatsink at 40oC Ambient

Plug Current Limit Min-Max @ 1 Sec Min-Max @ 3 Sec

Average Motor C/L with Typical Mtr Inductance

Min-Max @ 30% T

Standard

Optional

150 Amps Plus

103 Amps Plus

330/950 Amps 330/650 Amps

405/640 Amps (STD)

Standard

Optional

150 Amps Plus

103 Amps Plus

330/950 Amps 330/650 Amps

405/640 Amps (STD)

Standard

Optional

150 Amps Plus

103 Amps Plus

Not Applicable

405/640 Amps (STD)

Min-Max @ 50% T

Min-Max @ 70% T

Min-Max @ 30% T

Min-Max @ 50% T

Min-Max @ 70% T

EV100LX Traction and Pump H/P Curve

320/565 Amps (STD)

230/495 Amps (STD)

475/690 Amps (H/P)

455/685 Amps (H/P)

435/680 Amps (H/P)

320/565 Amps (STD)

230/495 Amps (STD)

475/690 Amps (H/P)

455/685 Amps (H/P)

435/680 Amps (H/P)

320/565 Amps (STD)

230/495 Amps (STD)

475/690 Amps (H/P)

455/685 Amps (H/P)

435/680 Amps (H/P)

EV100LX Traction and Pump STD Curve

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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

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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

Figure 3

oscillator produces the optimum frequencies 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.

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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.

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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

Page 19

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.

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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 - motor energized.

- L1 closed and L2 open - motor disabled.

- L1 and L2 closed - motor reversed from normal direction.

RIGHT TURN - R1 and R2 open - motor energized.

- R1 closed and R2 open - motor disabled.

- R1 and R2 closed - 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.

Page 21

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.

Page 22

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.

Page 23

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 - Accelerator Input TB2 - SL1 Input TB3 - SL2 Input TB4 - Key Switch Input TB5 - SL3 Input TB6 - SL4 Input

PA1 - 93 Status Code Input PA2 - 93 Status Code Input PA3 - 90 Status Code Input PA4 - 94 Status Code Input PA5 - 94 Status Code Input PA6 - 91 Status Code Input

PB1 - 95 Status Code Input PB2 - 95 Status Code Input PB3 - BDI Enable Signal PB4 - PMT Driver PB5 - 1A Driver PB6 - 92 Status Code Input

PY10 - Input to Traction PY10 PY11 - Input to Traction PY9 PY12 - Input to Traction PY8

Page 24

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.

Page 25

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.

Page 26

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.

Page 27

GEH-5722GEH-5722

GEH-5722

GEH-5722GEH-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

Page 28

STATUS CODE

BLANK

Segments do not illuminate on Dash Display or Handset

DESCRIPTION

DISPLAY

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.

MEMORY

RECALL

CONTROL

TYPE

Traction

and Pump

Defective Dash Display or Handset

 Replace Dash Display or Handset.

STATUS CODE

No seat/deadman switch input.

-01

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.

This indicates a lack of input voltage to the logic card and/or display unit.

DESCRIPTION

Figure 1

STATUS INDICATION CRITERIA

MEMORY

RECALL

CONTROL

TYPE

Traction

 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.

Page 29

STATUS CODE

Forward directional switch is closed on initial power up.

DESCRIPTION

-02

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.

MEMORY

RECALL

CONTROL

TYPE

Figure 1

STATUS INDICATION CRITERIA

This status code will be displayed when TB5 is greater than 60% of battery volts on initial start up.

Traction

Defective logic card.

 Disconnect wire at TB5; Measure voltage at TB5,

should be less than 60% of battery volts.

STATUS CODE

Reverse directional switch is closed on initial power up.

DESCRIPTION

-03

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.

MEMORY

RECALL

CONTROL

TYPE

Figure 1

STATUS INDICATION CRITERIA

This status code will be displayed when TB6 is greater than 60% of battery volts on initial start up.

Traction

Defective logic card.

 Disconnect wire at TB6; Measure voltage at TB6,

should be less than 60% of battery volts.

Page 30

STATUS CODE

Start switch input low after initial start up

DESCRIPTION

-04

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.

MEMORY

RECALL

CONTROL

TYPE

Figure 1

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).

Traction

STATUS CODE

Start switch or brake switch fails to close.

DESCRIPTION

-05

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.

MEMORY

RECALL

CONTROL

TYPE

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.

Traction

Page 31

STATUS CODE

Accelerator depressed with no direction selected.

DESCRIPTION

-06

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.

MEMORY

RECALL

CONTROL

TYPE

Figure 1

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.

Traction

STATUS CODE

Accelerator input voltage too high.

DESCRIPTION

-07

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. Ad-

just 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.

 Disconnect wire from TB1 and measure voltage at wire to

negative. Should be zero volts for potentiometer type and less than 3.7 volts for solid state type accelerator input.

MEMORY

RECALL

CONTROL

TYPE

Figure 1

STATUS INDICATION CRITERIA

Traction

This status code is displayed when the accelerator input voltage at TB1 is higher than 3.7 volts, and a directional contactor is picked up.

Page 32

STATUS CODE

Accelerator input voltage too low on power up after

-08

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 accelera-

tor input circuit.

 Disconnect wire from TB1. Check for short circuit

from wire to battery negative. Resistance should be greater than 4.7K ohms.

Defective Card

 Disconnect wire from TB1. Measure voltage from

TB1 to negative. Voltage should be greater than 4.5 volts, if not, replace card.

initial key switch closure.

SYMPTOM

DESCRIPTION

MEMORY

RECALL

CONTROL

TYPE

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 the following connections are opened and closed, battery plug or seat switch or key switch.

Traction

STATUS CODE

Both forward and reverse directional switches are closed

-09

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.

at the same time.

SYMPTOM

DESCRIPTION

MEMORY

RECALL

CONTROL

TYPE

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.

Traction

Page 33

STATUS CODE

Battery volts too low.

DESCRIPTION

-15

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.

MEMORY

RECALL

CONTROL

TYPE

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).

Traction

STATUS CODE

Battery volts too high.

DESCRIPTION

-16

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.

MEMORY

RECALL

CONTROL

TYPE

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.)

Traction

Page 34

STATUS CODE

Invalid card type selection.

-17

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.

DESCRIPTION

This status code is displayed when the card type selection value is set to an invalid number.

MEMORY

RECALL

CONTROL

TYPE

Figure 1

STATUS INDICATION CRITERIA

Traction

STATUS CODE

Forward and reverse contactor coil current low.

DESCRIPTION

-23

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.

MEMORY

RECALL

CONTROL

TYPE

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.

Traction

Page 35

STATUS CODE

T2 voltage low. (Less than 12% battery volts.)

DESCRIPTION

-24

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.

Figure 1

MEMORY

RECALL

CONTROL

TYPE

Traction

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.

Defective 1A,RB,SP or FW contactor

 Perform checks as outlined in status 23.

STATUS CODE

1A contactor does not drop out or drops out slowly.

DESCRIPTION

-25

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.

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.

MEMORY

RECALL

CONTROL

TYPE

Yes

Traction

Figure 1

STATUS INDICATION CRITERIA

This status code is displayed when 1A contactor drop out time exceeds .060 seconds.

Page 36

STATUS CODE

Shorted coil driver for SP or FW contactor.

DESCRIPTION

-26

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.

MEMORY

RECALL

CONTROL

TYPE

Figure 1

STATUS INDICATION CRITERIA

This status code is displayed when there is a shorted RB,SP or FW coil driver.

Traction

STATUS CODE

Open thermal protector (TP) or control over temperature.

DESCRIPTION

-41

SYMPTOM

Reduced or no power to traction motor in SCR range.

POSSIBLE CAUSE

Open thermal protector circuit.

 Check for loose connection or broken wire be-

tween: 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 disap-

pear.

MEMORY

RECALL

CONTROL

TYPE

Figure 1

STATUS INDICATION CRITERIA

This status code is displayed when the voltage between PZ1 and PZ5 is greater than 1.8 volts.

Traction

Page 37

STATUS CODE

Control motor current sensor input missing.

DESCRIPTION

-42

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.

MEMORY

RECALL

CONTROL

TYPE

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.

Traction

STATUS CODE

Control motor current sensor input missing.

DESCRIPTION

-43

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.

MEMORY

RECALL

CONTROL

TYPE

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.

Traction

Page 38

STATUS CODE

1REC did not turn off properly.

DESCRIPTION

-44

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).

MEMORY

RECALL

CONTROL

TYPE

Yes

Traction

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 CODE

1 REC did not turn on properly.

DESCRIPTION

-45

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).

Figure 1

STATUS INDICATION CRITERIA

This status code is displayed when, during SCR operation, 1 REC fails to turn off.

MEMORY

RECALL

CONTROL

TYPE

Traction

Yes

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.

Figure 1

STATUS INDICATION CRITERIA

This status code is displayed when 1 REC fails to gate on.

Page 39

STATUS CODE

Look ahead test for T2 volts. ( Greater than 85% of

-46

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.

battery volts)

DESCRIPTION

This status code is displayed when the voltage at T2 is greater than 85% of battery volts.

MEMORY

RECALL

CONTROL

TYPE

Figure 1

STATUS INDICATION CRITERIA

Traction

STATUS CODE

2REC does not turn properly

DESCRIPTION

-47

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).

MEMORY

RECALL

CONTROL

TYPE

Figure 1

STATUS INDICATION CRITERIA

This status code is displayed when the 2 REC fails to turn on.

Traction

Page 40

STATUS CODE

Look ahead test for T2 volts. (Less than 12% of battery

-48

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.

 Check for shorted 3 REC snubber (23 REC).

volts)

DESCRIPTION

This status code is displayed when the voltage at T2 is less than 12% of battery volts.

MEMORY

RECALL

CONTROL

TYPE

Figure 1

STATUS INDICATION CRITERIA

Traction

STATUS CODE

5 REC does not turn on properly

DESCRIPTION

-49

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.

MEMORY

RECALL

CONTROL

TYPE

Figure 1

STATUS INDICATION CRITERIA

This status code is displayed when the 5 REC circuit fails to turn on.

Traction

Defective capacitor circuit.

 Check for open capacitor.

 Check for loose connections at capacitor terminals.

Page 41

STATUS CODE

Capacitor volts low .

DESCRIPTION

-50

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.

MEMORY

RECALL

CONTROL

TYPE

Figure 1

STATUS INDICATION CRITERIA

This status code is displayed when 2 REC circuit fails to turn on at initial start up.

Traction

STATUS CODE

Excessive capacitor voltage when motor current is high.

DESCRIPTION

-51

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.

MEMORY

RECALL

CONTROL

TYPE

Figure 1

STATUS INDICATION CRITERIA

This status code is displayed when capacitor volts exceed 225 volts and motor current is greater than 300 amps.

Traction

Page 42

STATUS CODE

Excessive capacitor voltage when motor current is low.

DESCRIPTION

-52

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

R E C circuit.

Figure 1

MEMORY

RECALL

CONTROL

TYPE

Yes

Traction

Defective 3 REC circuit.

 Check for open circuit or loose connection in 3

R E C circuit.

STATUS CODE

1 REC fails to turn off during plug cycle.

DESCRIPTION

-53

Forward or reverse contactor opens and closes, then opens and can only close by opening and closing the key switch.

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 cable/

bus connections.

SYMPTOM

POSSIBLE CAUSE

STATUS INDICATION CRITERIA

This status code is displayed when capacitor volts exceed 225 volts and motor current is less than 200 amps.

MEMORY

RECALL

CONTROL

TYPE

Yes

Traction

 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).

Figure 1

STATUS INDICATION CRITERIA

This status code is displayed when any failure of 1 REC to turn off during plug cycle.

Page 43

STATUS CODE

-54

Control will not operate.

POSSIBLE CAUSE

Defective logic card.

 Replace logic card.

Shorted F, R or 1A contactor coil driver.

SYMPTOM

DESCRIPTION

This status code is displayed when either the forward, reverse or 1A contactor coil driver is shorted internal to the logic card.

MEMORY

RECALL

CONTROL

TYPE

Figure 1

STATUS INDICATION CRITERIA

Traction

STATUS CODE

Current sensor input voltage polarity check.

DESCRIPTION

-57

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.

MEMORY

RECALL

CONTROL

TYPE

Figure 1

STATUS INDICATION CRITERIA

This status code is displayed when the voltage input to PZ4 and PZ3 is the wrong polarity.

Traction

Page 44

STATUS CODE

Regen current sensor input missing ( yellow wire ).

-70

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.

DESCRIPTION

This status code is displayed when input signal at PA4 is missing.

MEMORY

RECALL

CONTROL

TYPE

Figure 1

STATUS INDICATION CRITERIA

Yes

Traction

STATUS CODE

Regen current sensor input missing ( green wire ).

-71

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.

DESCRIPTION

This status code is displayed when input signal at PA5 is missing.

MEMORY

RECALL

CONTROL

TYPE

Figure 1

STATUS INDICATION CRITERIA

Yes

Traction

Page 45

STATUS CODE

Regen contactor does not pick up.

-72

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.

DESCRIPTION

This status code is displayed when logic card is in run mode and 2.5 volts or greater is present at PA6.

MEMORY

RECALL

CONTROL

TYPE

Figure 1

STATUS INDICATION CRITERIA

Yes

Traction

STATUS CODE

Regen contactor does not drop out or drops out slowly.

DESCRIPTION

-73

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.

MEMORY

RECALL

CONTROL

TYPE

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.

Yes

Traction

Page 46

STATUS CODE

Regen contactor picks up too slow.

DESCRIPTION

-74

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.

Figure 1

MEMORY

RECALL

CONTROL

TYPE

Yes

Traction

 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

1 REC fails to turn off during Regen.

DESCRIPTION

-75

Forward or reverse contactor opens and closes, then opens and can only close by opening and closing the key switch.

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).

SYMPTOM

POSSIBLE CAUSE

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.

MEMORY

RECALL

CONTROL

TYPE

Figure 1

STATUS INDICATION CRITERIA

This status code is displayed when any failure of 1 REC to turn off during regen cycle.

Yes

Traction

Page 47

STATUS CODE

Capacitor overvoltage during Regen.

DESCRIPTION

-76

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.

 Check for long battery cables.

MEMORY

RECALL

CONTROL

TYPE

Figure 1

STATUS INDICATION CRITERIA

This status code is displayed when capacitor voltage is greater than 225 volts during the regen cycle.

Yes

Traction

STATUS CODE

User defined status code - see OEM instructions manual.

DESCRIPTION

-90

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.

MEMORY

RECALL

CONTROL

TYPE

Figure 1

STATUS INDICATION CRITERIA

This status code is displayed when the voltage at terminal 1 of TMM is at zero volts.

TMM

Page 48

STATUS CODE

User defined status code - see OEM instructions manual.

DESCRIPTION

-91

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.

MEMORY

RECALL

CONTROL

TYPE

Figure 1

STATUS INDICATION CRITERIA

This status code is displayed when the voltage at terminal 3 of TMM is at zero volts.

TMM

STATUS CODE

User defined status code - see OEM instructions manual.

DESCRIPTION

-92

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.

MEMORY

RECALL

CONTROL

TYPE

Figure 1

STATUS INDICATION CRITERIA

This status code is displayed when the voltage at terminal 4 of TMM is at zero volts.

TMM

Page 49

STATUS CODE

User defined status code - see OEM instructions manual.

DESCRIPTION

-93

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).

MEMORY

RECALL

CONTROL

TYPE

TMM

 Defective TMM card.

NOTE: When SCR pump control is used with internal TMM function, input terminal is PA1 and PA2 on pump logic card.

STATUS CODE

User defined status code - see OEM instructions manual.

DESCRIPTION

-94

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.

Figure 1

STATUS INDICATION CRITERIA

This status code is displayed when the voltage at terminal 5 and 6 of TMM is at zero volts.

MEMORY

RECALL

CONTROL

TYPE

TMM

Other Causes:

 Terminal 8 and 10 shorted to negative.

 Defective input switch (shorted).

 Defective TMM1 card.

NOTE: When SCR pump control is used with internal TMM function, input terminal is PA4 and PA5 on pump logic card.

Figure 1

STATUS INDICATION CRITERIA

This status code is displayed when the voltage at terminal 8 and 10 of TMM is at zero volts.

Page 50

STATUS CODE

User defined status code - see OEM instructions manual.

DESCRIPTION

-95

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).

MEMORY

RECALL

CONTROL

TYPE

TMM

 Defective TMM card.

NOTE: When SCR pump control is used with internal TMM function, input terminal is PB1 and PB2 on pump logic card.

Figure 1

STATUS INDICATION CRITERIA

This status code is displayed when the voltage at terminal 11 and 12 of TMM is at zero volts.

Page 51

STATUS CODE

Invalid card type selection.

-117

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.

DESCRIPTION

This status code is displayed when the card type selection value is set to an invalid number.

MEMORY

RECALL

CONTROL

TYPE

Figure 1

STATUS INDICATION CRITERIA

Pump

STATUS CODE

Forward and reverse contactor coil current low.

DESCRIPTION

-123

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.

MEMORY

RECALL

CONTROL

TYPE

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.

Pump

Page 52

STATUS CODE

T2 voltage low. (Greater than 12% battery volts.)

DESCRIPTION

-124

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.

MEMORY

RECALL

CONTROL

TYPE

Figure 1

STATUS INDICATION CRITERIA

This status code is displayed when T2 volts is greater than 12% of battery volts and the pump driver is energized.

Pump

STATUS CODE

1A contactor does not drop out or drops out slowly.

DESCRIPTION

-125

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.

MEMORY

RECALL

CONTROL

TYPE

Figure 1

STATUS INDICATION CRITERIA

This status code is displayed when 1A contactor drop out time exceeds .060 seconds.

Pump

Page 53

STATUS CODE

Open thermal protector (TP) or control over temperature.

DESCRIPTION

-141

SYMPTOM

Reduced or no power to pump motor in SCR range.

POSSIBLE CAUSE

Open thermal protector circuit.

 Check for loose connection or broken wire be-

tween: 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 disap-

pear.

MEMORY

RECALL

CONTROL

TYPE

Figure 1

STATUS INDICATION CRITERIA

This status code is displayed when the voltage between PZ1 and PZ5 is greater than 1.8 volts.

Pump

STATUS CODE

Control motor current sensor input missing.

DESCRIPTION

-142

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.

MEMORY

RECALL

CONTROL

TYPE

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.

Pump

Page 54

STATUS CODE

Control motor current sensor input missing.

DESCRIPTION

-143

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.

MEMORY

RECALL

CONTROL

TYPE

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.

Traction

STATUS CODE

1REC did not turn off properly.

DESCRIPTION

-144

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.

MEMORY

RECALL

CONTROL

TYPE

Figure 1

STATUS INDICATION CRITERIA

This status code is displayed when, during SCR operation, 1 REC fails to turn off.

Pump

Yes

Page 55

STATUS CODE

1 REC did not turn on properly.

DESCRIPTION

-145

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)

MEMORY

RECALL

CONTROL

TYPE

Yes

Pump

 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 CODE

Look ahead test for T2 volts. ( Greater than 85% of

-146

SYMPTOM

Pump contactor will not pick up.

POSSIBLE CAUSE

Defective 1 REC.

 Check for shorted 1 REC.

battery volts)

This status code is displayed when 1 REC fails to gate on.

DESCRIPTION

Figure 1

STATUS INDICATION CRITERIA

MEMORY

RECALL

CONTROL

TYPE

Pump

 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.

Page 56

STATUS CODE

2REC does not turn properly

DESCRIPTION

-147

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)

MEMORY

RECALL

CONTROL

TYPE

Pump

 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 CODE

Look ahead test for T2 volts. (Less than 12% of battery

-148

SYMPTOM

Pump contactor will not pick up.

POSSIBLE CAUSE

Defective forward or reverse contactor.

 Check for welded forward or reverse contactor

power tips.

volts)

This status code is displayed when the 2 REC fails to turn on.

DESCRIPTION

Figure 1

STATUS INDICATION CRITERIA

MEMORY

RECALL

CONTROL

TYPE

Pump

 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).

Figure 1

STATUS INDICATION CRITERIA

This status code is displayed when the voltage at T2 is less than 12% of battery volts.

Page 57

STATUS CODE

5 REC does not turn on properly

DESCRIPTION

-149

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.

MEMORY

RECALL

CONTROL

TYPE

Figure 1

STATUS INDICATION CRITERIA

This status code is displayed when the 5 REC circuit fails to turn on.

Pump

Defective capacitor circuit.

 Check for open capacitor.

 Check for loose connections at capacitor terminals.

STATUS CODE

Capacitor volts low .

DESCRIPTION

-150

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.

MEMORY

RECALL

CONTROL

TYPE

Figure 1

STATUS INDICATION CRITERIA

This status code is displayed when 2 REC circuit fails to turn on at initial start up.

Pump

Page 58

STATUS CODE

Excessive capacitor voltage when motor current is high.

DESCRIPTION

-151

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.

MEMORY

RECALL

CONTROL

TYPE

Figure 1

STATUS INDICATION CRITERIA

This status code is displayed when capacitor volts exceed 225 volts and motor current is greater than 300 amps.

Pump

STATUS CODE

Excessive capacitor voltage when motor current is low.

DESCRIPTION

-152

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

R E C circuit.

Defective 3 REC circuit.

 Check for open circuit or loose connection in 3

R E C circuit.

MEMORY

RECALL

CONTROL

TYPE

Figure 1

STATUS INDICATION CRITERIA

This status code is displayed when capacitor volts exceed 225 volts and motor current is less than 200 amps.

Yes

Pump

Page 59

STATUS CODE

-154

Control will not operate.

POSSIBLE CAUSE

Defective logic card.

 Replace logic card.

Shorted F, R or 1A contactor coil driver.

SYMPTOM

DESCRIPTION

This status code is displayed when either the forward, reverse or 1A contactor coil driver is shorted internal to the logic card.

MEMORY

RECALL

CONTROL

TYPE

Figure 1

STATUS INDICATION CRITERIA

Pump

STATUS CODE

Current sensor input voltage polarity check.

DESCRIPTION

-157

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.

MEMORY

RECALL

CONTROL

TYPE

Figure 1

STATUS INDICATION CRITERIA

This status code is displayed when the voltage input to PZ4 and PZ3 is the wrong polarity.

Pump

Page 60

Page 61

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 A and B Plugs Terminals 1 - 6 Y Plug Z Plug Screw

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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.

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(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.

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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.

Page 65

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.

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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.

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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.

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 Weaken-

ing

 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

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

Key Switch on

Verify Display Segments for

one second

8888

BDI Display Diagnostics

or override

Blank Display with fault

( No BDI used )

Run Mode

BDI Display Diagnostics

or override

Blank Display with fault

( No BDI used )

Key Switch Off

Display traction

hourmeter for

four seconds

Display pump hourmeter for

four seconds

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.

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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.

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 Display shows Remarks

Hold down CONT, 8888 Segment check turn on key displayed

Push function U 005 Selected number function number

is displayed

After one second 085 Stored value for time delay the function is

displayed

23456789

Push CONT 085 Displayed value

23456789

will blink

23456789

Change value with 125 Value changes

23456789

adjustment knob while blinking

DESCRIPTION AND LOCATION

Z PLUG

Y PLUG

B PLUG

A PLUG

EV100 LX/LXT

Push STORE 125 New value

stored and blinking stops

Push ESC 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.

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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 )

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 200 to 1000 amps (EV100)

300 to 1500 amps (EV200) Set 0 to 255 Resolution 3.14 amps per set unit (EV100)

4.7 amps per set unit (EV200)

Example: Setting of 20 = 263 amps (EV100)

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 2% to 15% on time Set 0 to 255 Resolution .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 .1 to 22.0 seconds Set 0 to 255 Resolution .084 seconds per set unit

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 450 to 1260 amps (EV100)

675 to 1890 amps (EV200) Set 0 to 250 Resolution 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 )

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 See control C/L curves Set 0 to 255

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 52 to 466 amps (EV100)

78 to 699 amps (EV200) Set 0 to 255 Resolution 1.6 amps per set unit

2.4 amps per set unit

Example Setting of 20 = 84 amps

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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.

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 )

Range 65 to 895 amps (EV100)

98 to 1343 amps (EV200) Set 0 to 255 Resolution 3.25 amps per set unit (EV100)

4.88 amps per set unit (EV200)

Example Setting of 20 = 130 amps

FUNCTION 9 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 75 to 630 amps Set 0 to 255 Resolution 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 0 to 95% on time Set 0 to 255 Resolution .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 96% to 0% battery volts Set 0 to 180

Setting of 0 set units will disable speed limit function and

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.

EV100 EV200 EV100 EV200

Setting VD VD Setting VD VD

2 11.44 07.63 17 01.34 00.89 3 07.60 05.07 18 01.27 00.85 4 05.72 03.81 19 01.20 00.80 5 04.57 03.05 20 01.14 00.76 6 03.81 02.54 21 01.09 00.73 7 03.27 02.18 22 01.04 00.69 8 02.86 01.91 23 00.99 00.66

9 02.54 01.69 24 00.95 00.63

10 02.28 01.52 25 00.91 00.61 11 02.08 01.39 26 00.88 00.59 12 01.90 01.27 27 00.85 00.57

13 01.76 01.17 28 00.82 00.55 14 01.63 01.08 29 00.79 00.53 15 01.52 01.01 30 00.76 00.51

16 01.43 00.95 31 00.74 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

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as shown in the table must be entered .

Battery volts Set units

24 volts Between 0 and 31 36 volts Between 32 and 44 48 volts Between 45 and 69 72 volts Between 70 and 80 80 volts Between 81 and 183 36/48 volts Between 184 and 250 No BDI 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 100 to 930 amps (EV100)

150 to 1425 amps (EV200) Set 0 to 255 Resolution 3.2 amps per set unit (EV100)

5.0 amps per set unit (EV200)

Example 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.

(Auto plug) 15 to 19 35 to 39 55 to 59

EV200 Standard Speed Function with FW Limit Regen/FW

STD C/L 64 to 68 84 to 88 104 to 108 STD C/L (Auto plug) 74 to 78 94 to 98 114 to 118

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 1.5 to 65 seconds Setting Between 0 and 128 Resolution .5 seconds per set unit

Example: Setting of 20 = 10.5 seconds

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 Standard Speed Function with FW Limit Regen/FW

STD C/L 0 to 4 20 to 24 40 to 44 High C/L 5 to 9 25 to 29 45 to 49 STD C/L (Auto plug) 10 to 14 30 to 34 50 to 54 High C/L

Pick up on directional switch closure and drop out time delay on directional switch opening.

Range .5 to 63 seconds Setting 129 to 255 Resolution .5 seconds per set unit

Example: Setting of 149 = 10.5 seconds

Drop out will be 1.5 seconds after the seat switch opens.

Page 72

DESCRIPTION OF FUNCTION NUMBERS FOR:

Control Cards IC3645EVLXCD1MT AND

IC3645EVLXCD1MX

FUNCTION 1 STORED FAULT CODE

( Push 1)

FUNCTION 2 CREEP SPEED

( Push 2 )

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 200 to 1000 amps (EV100)

300 to 1500 amps (EV200) Set 0 to 255 Resolution 3.14 amps per set unit (EV100)

4.7 amps per set unit (EV200)

Example: Setting of 20 = 263 amps (EV100)

Range 2% to 15% on time Set 0 to 255 Resolution .03% per set unit

Example: Setting of 20 = 2.6% on time

FUNCTION 3 CONTROLLED ACCELERATION

AND 1A TIME ( Push 3 )

Range .1 to 22.0 seconds Set 0 to 255 Resolution .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 )

Range See control C/L curves Set 0 to 255

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 )

Range 450 to 1260 amps (EV100)

675 to 1890 amps (EV200) Set 0 to 250 Resolution 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.

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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 96% to 0% battery volts Set 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.

Setting VD VD Setting VD VD

EV100 EV200 EV100 EV200

9 02.54 01.69 24 00.95 00.63

10 02.28 01.52 25 00.91 00.61 11 02.08 01.39 26 00.88 00.59 12 01.90 01.27 27 00.85 00.57

13 01.76 01.17 28 00.82 00.55 14 01.63 01.08 29 00.79 00.53 15 01.52 01.01 30 00.76 00.51

16 01.43 00.95 31 00.74 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 .

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 )

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.

Battery volts Set units

24 volts Between 0 and 31 36 volts Between 32 and 44 48 volts Between 45 and 69 72 volts Between 70 and 80 80 volts Between 81 and 183 36/48 volts Between 184 and 250 No BDI Between 251 and 255

FUNCTION 16 PEDAL POSITION PLUG

( Push CONT and 1 )

Range 100 to 930 amps (EV100)

150 to 1425 amps (EV200) Set 0 to 255 Resolution 3.2 amps per set unit (EV100)

5.0 amps per set unit (EV200)

Example 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.

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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.

Resolution .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.

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 Standard Function with FW

STD C/L 0 to 4 High C/L 5 to 9 STD C/L (Auto plug) 10 to 14

High C/L (Auto plug) 15 to 19

EV200 Standard Function with FW

STD C/L 20 to 24 STD C/L (Auto plug) 30 to 34

Range .5 to 63 seconds Setting 129 to 255 Resolution .5 seconds per set unit

Example: Setting of 149 = 10.5 seconds

Drop out will be 1.5 seconds after the seat switch opens.

Settings for these function should be made in between the values shown.

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 1.5 to 65 seconds Setting Between 0 and 128

Page 75

DESCRIPTION OF FUNCTION NUMBERS FOR:

Control Card IC3645EVLXCD1PX

FUNCTION 11 SPEED LIMIT 1 (SL1)

( Push 11 )

FUNCTION 1 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 0 to 1325 amps Set 52 to 255 Resolution 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 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.

Range 0% to 100% battery volts Set 0 to 255 Resolution .375 volts per set unit Example 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.

Range .1 to 5.5 seconds Set 0 to 255 Resolution .021 seconds per set unit

Example: Setting of 20 = .52 seconds C/A

and .72 seconds 1A time.

FUNCTION 4 CURRENT LIMIT

( Push 4 )

Range See control C/L curves Set 0 to 255

Example: 0 = min. current, 255 = max. current

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 Voltage Drop Setting Voltage Drop

2 11.44 17 01.34 3 07.60 18 01.27 4 05.72 19 01.20 5 04.57 20 01.14 6 03.81 21 01.09 7 03.27 22 01.04 8 02.86 23 00.99 9 02.54 24 00.95 10 02.28 25 00.91 11 02.08 26 00.88 12 01.90 27 00.85

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Setting Voltage Drop Setting Voltage Drop

13 01.76 28 00.82 14 01.63 29 00.79 15 01.52 30 00.76 16 01.43 31 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.

With Pump Without Pump

Function Ctr/PMT Ctr/PMT

STD C/L 0 to 8 36 to 44 High C/L 9 to 17 45 to 53 STD C/L BDI (Lockout) 18 to 26 54 to 62 High C/L BDI (Lockout) 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.

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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:

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Component Locations:

EV200LX SUPPLEMENT

ITEM# PART NUMBER DESCRIPTION QTY/EACH

5 158C3100BYP1 BASE 1 7 918D620G1 TRANSFORMER 1 8 157C8160G13 1REC ASM 1

9 171B3939G4 3REC ASM 1 10 44A727038-G01 2REC 1 11 171B3967P1L HEAT SINK 1 12 273A2523P11 THERMAL CONDUCTIVE 1 13 116C6961P1L HEAT SINK 1 14 273A2523P12 THERMAL CONDUCTIVE 1 15 259A9208PXCR RECTIFIER 1 16 171B3940G1 SNUBBER ASM 1 17 195B4039G1 SNUBBER MOUNT 1 19 116C6975G1 SPIDER ASM 1 20 273A2523P6 THERMAL CONDUCTIVE 1 21 273A2523P9 THERMAL CONDUCTIVE 1 22 171B3912G1 TERMINAL POST 2 23 259A9053P2 CAPACITOR 2 24 259A8733P1 CAPACITOR MOUNTING BRACKET 2 26 IC3645LXCD1** EV100LX CARDBOX ASM 1 28 171B3980G1 SHUNT ASM 1

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EV200LX SUPPLEMENT

ITEM#

30 44A717068-001 RECTIFIER 1 31 44A727009-G06 THERMISTOR ASM 1 35 195B6250P2 FLEX BUS 4 36 195B6250P11 FLEX BUS 4 37 202B1621P3 CAPACITOR STRAPS 8 38 148B5620EPP3 BUS BAR 1 39 148B5620EPP1 BUS BAR 1 40 148B5620EPP2 BUS BAR 1 41 259A3290P1 INSULATING BUSHING 4

PART NUMBER

DESCRIPTION

QTY/EACH

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Wiring Diagram:

EV200LX SUPPLEMENT

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Current Limit Adjustments:

1500

1350

1200

1050

EV200LX SUPPLEMENT

Motor Amperes

900

750

600

450

300

150

01005020 30 4010 70 80 9060

Percent On Time

Peak Motor C/L @ Typical Motor Inductance

Min-Max @30% ON Min-Max @50% ON Min-Max @70% ON

Average Motor C/L @ Typical Motor Inductance

Min-Max @30% ON Min-Max @50% ON Min-Max @70% ON

TIME

735/1170 Amps 560/990 Amps 390/810 Amps

615/960 Amps 480/870 Amps 347/750 Amps

Page 5 of 5 REV 11/2002

General Electric EV100Lx, EV100LXT Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual