GE-SX-GL1-Tech - qtronic

INSTALLATION AND OPERATION
SX TRANSISTOR CONTROL Page 1
SEPARATELY EXCITED (SX) TRANSISTORIZED MOTOR CONTROLLERS

FOR NEIGHBORHOOD ELECTRIC VEHICLE APPLICATION
INSTALLATION AND OPERATION MANUAL

(GE MODEL IC3645SH7R353T1)
Note: The information contained herein is intended to assist OEM's, Dealers and Users of electric vehicles in the application,
installation and service of GE solid-state controllers. This manual does not purport to cover all variations in OEM vehicle types.
Nor does it provide for every possible contingency to be met involving vehicle installation, operation or maintenance. For
additional information and/or problem resolution, please refer the matter to the OEM vehicle manufacturer through his normal
field service channels. Do not contact GE directly for this assistance.
General Electric Company August 2001
Table of Contents
Section 1.0 INTRODUCTION ........................................................................................................................................................ 3
1.1 Motor Characteristics .............................................................................................................. 3

1.2 Solid-State Reversing ............................................................................................................... 4
1.3 Flexible System Application..................................................................................................... 4
1.4 More Features with Fewer Components ................................................................................ 4
Section 2.0 FEATURES OF SX FAMILY OF MOTOR CONTROLLERS .................................................................................... 5
2.1 Performance.............................................................................................................................. 5
2.1.1 Oscillator Card Features .................................................................................................. 5
2.1.1.a Standard Operation................................................................................................... 5
2.1.1.b Control Acceleration ................................................................................................ 5
2.1.2 Current Limit ...................................................................................................................... 5
2.1.3 Plug Braking ...................................................................................................................... 5
2.1.4 Auxiliary Speed Control.................................................................................................... 5
2.1.4.a Field Weakening........................................................................................................ 5
2.1.4.b Speed Limits .............................................................................................................. 5
2.1.4.c Top Speed Regulation ...............................................................................................5
2.1.5 Ramp Start ......................................................................................................................... 6
2.1.6 On-Board Coil Drivers and Internal Coil Suppression ................................................. 6
2.2 System Protective Override ..................................................................................................... 6
2.2.1 Static Return to Off (SRO) ............................................................................................... 6
2.2.2 Accelerator Volts Hold Off............................................................................................... 6
2.2.3 Pulse Monitor Trip (PMT)................................................................................................. 6
2.2.4 Thermal Protector (TP)..................................................................................................... 6
August 2001
INSTALLATION AND OPERATION
Table of Contents ( Continued )

2.2.5 Low Voltage .................................... .................................................................................. 6
2.3 Diagnostics................................................................................................................................ 6
2.3.1 Status Codes...................................................................................................................... 6
2.3.1.a Standard Status Codes............................................................................................. 6
2.3.1.b Stored Status Codes ......................................... ....................................................... 7
2.3.2 Hourmeter Readings ...................................... .................................................................. 7
2.3.3 Battery Discharge Indication (BDI)....................... ......................................................... 7
2.3.4 Internal Resistance Compensation ..................... ................................................... 7
2.3.5 Handset ................................................. ............................................................................ 7
2.3.6 RS-232 Communication Port ........................................................................................... 7
2.3.7 Circuit Board Coil Driver Modules........................ .......................................................... 7
Section 3.0 ORDERING INFORMATION, ELEMENTARY AND OUTLINE DRAWINGS...................................................... 8
3.1 Ordering Information for Separately Excited Controls......................................................... 8

3.2 Outline: SX-2 Package Size...................................................................................................... 9
3.3 Standard Elementary for Neighborhood Electric Vehicle Application.............................. 10
3.4 Standard Neighborhood Electric Vehicle Application Input/Output List ........................... 11
Section 4.0 TROUBLESHOOTING AND DIAGNOSTIC STATUS CODES.............................................................................. 12
4.1 General Maintenance Instructions................................................................................................. 12

4.2 Cable Routing and Separation ............................................................................................... 12
4.2.1 Application Responsibility ............................................................................................... 12
4.2.2 Signal/Power Level Definitions ............................................................................................... 12
4.2.2.a Low Level Signals (Level L) .............................................................................................. 12
4.2.2.b High Level Signals (Level H)............................................................................................. 13
4.2.2.c Medium-Power Signals (Level MP) ................................................................................ 13
4.2.2.d High-Power Signals (Level HP) ....................................................................................... 13
4.2.3 Cable Spacing Guidelines ........................................................................................................ 13
4.2.3.a General Cable Spacing..................................................................................................... 13
4.2.4 Cabling for Vehicle Retrofits.................................................................................................... 13
4.2.5 RF Interference.......................................................................................................................... 13
4.2.6 Suppression............................................................................................................................... 13
4.3 Recommended Lubrication of Pins and Sockets Prior to Installation........................................ 14
4.4 General Troubleshooting Instructions ........................................................................................... 15
4.5 Traction Controller Status Codes ................................................................................................... 16-27
Section 5.0 SX FAMILY - GE HANDSET INSTRUCTIONS ...................................................................................................... 28
6.1 General Features ...................................................................................................................... 28

6.2 Purpose/Setup Functions ........................................................................................................ 28
6.3 Setup Function Procedures ................................ .................................................................... 29
6.3.1 Setup Mode ............................................ .......................................................................... 29
6.3.2 Status Code Scrolling....................................................................................................... 29
6.3.3 SX Handset Plug Connections and Outline Drawing..................................................... 30
6.4 Setup Functions for Traction Controller ................................................................................ 30 - 35
6.5 Summary of Current Limit Adjustments.................................................................................. 36
Section 6.0 DISPLAYS................................................. .................................................................................................................. 37
7.1 Application ............................................. ............................................................................................. 37

7.2 Standard Dash Displays .................................. .................................................................................. 37
7.3 Start-up Display Sequence ................................................................................................................ 37
7.4 Outline Drawings ........................................ ........................................................................................ 38
Section 7.0 MEMORY MAP................................................. ......................................................................................................... 39-41
August 2001
BASIC OPERATION AND FEATURES
Section 1. INTRODUCTION current to increase, providing the greater torque needed to

drive the increased mechanical load. If the mechanical
Section 1.1 Motor Characteristics load is decreased, the process reverses. The motor speed
and the back EMF increase, while the armature current and
The level of sophistication in the controllability of traction the torque developed decrease. Thus, whenever the load
motors has changed greatly over the past several years. changes, the speed changes also, until the motor is again
Vehicle manufacturers and users are continuing to expect in electrical balance.
more value and flexibility in electric vehicle motor and
control systems as they are applied today. In order to In a shunt motor, the variation of speed from no load to
respond to these market demands, traction system normal full load on level ground is less than 10%. For this
designers have been forced to develop new approaches to reason, shunt motors are considered to be constant speed
reduce cost and improve functions and features of the motors (Figure 2).
overall system. Development is being done in a multi-
generational format that allows the market to take
advantage of today’s technology, while looking forward to SPEED
new advances on the horizon. GE has introduced a second
generation system using separately excited DC shunt
wound motors. The separately excited DC motor system
offers many of the features that are generally found on the
LOAD CURRENT
STARTING
CURRENT
FULL
NO LOAD CURRENT
advanced AC systems. Historically, most electric vehicles
have relied on series motor designs because of their ability
to produce very high levels of torque at low speeds. But, as TORQUE
the demand for high efficiency systems increases, i.e.,
systems that are more closely applied to customers’
specific torque requirements, shunt motors are now often
being considered over series motors. In most applications, ARMATURE CURRENT
by independently controlling the field and armature Figure 2
currents in the separately excited motor, the best attributes
of both the series and the shunt wound motors can be In the separately excited motor, the motor is operated as a
combined. fixed field shunt motor in the normal running range.
However, when additional torque is required, for example,
to climb non-level terrain, such as ramps and the like, the
field current is increased to provide the higher level of
torque. In most cases, the armature to field ampere turn
ratio can be very similar to that of a comparable size series
SPEED
motor (Figure 3.)
NO LOAD CURRENT
LOAD CURRENT
STARTING
CURRENT
FULL
SPEED
TORQUE
ARMATURE CURRENT
Figure 1
LOAD CURRENT
FULL
NO LOAD CURRENT
As shown in the typical performance curves of Figure 1, the

STARTING
CURRENT
high torque at low speed characteristic of the series motor

is evident. TORQUE
In a shunt motor, the field is connected directly across the ARMATURE CURRENT
voltage source and is therefore independent of variations in Figure 3
load and armature current. If field strength is held
constant, the torque developed will vary directly with the
armature current. If the mechanical load on the motor Aside from the constant horsepower characteristics
increases, the motor slows down, reducing the back EMF described above, there are many other features that
(which depends on the speed, as well as the constant field provide increased performance and lower cost. The
strength). The reduced back EMF allows the armature following description provides a brief introduction to some
of these features.
August 2001
Section 1. 2 Solid-State Reversing Section 1. 4 More Features with Fewer Components
The direction of armature rotation on a shunt motor is Field weakening with a series wound motor is
determined by the direction in which current flows through accomplished by placing a resistor in parallel with the field
the field windings. Because of the shunt motor field, winding of the motor. Bypassing some of the current
typically only requires about 10% of the armature current at flowing in the field into the resistor causes the field current
full torque, it is normally cost effective to replace the to be less, or weakened. With the field weakened, the motor
double-pole, double-throw reversing contactor with a low speed will increase, giving the effect of “overdrive”. To
power transistor H-Bridge circuit (Figure 4). change the “overdrive speed”, it is necessary to change
the resistor value. In a separately excited motor,
independent control of the field current provides for
LINE POS
infinite adjustments of “overdrive” levels, between the
FUSE
A1
motor base speed and maximum weak field. The
desirability of this feature is enhanced by the
elimination of the contactor and resistor required for
Q2 Q3
field weakening with a series motor.

3/4 ARM F1 F2
CAP REC
With a separately excited motor, overhauling speed
A2
Q4 Q5 limit, or downhill speed, will also be more constant. By
Q1 its nature, the shunt motor will try to maintain a
constant speed downhill. This characteristic can be
enhanced by increasing the field strength with the
control. Overhauling load control works in just the
opposite way of field weakening, as armature rotation
NEG slows with the increase of current in the field. An
Figure 4 extension of this feature is a zero-speed detect feature
which prevents the vehicle from free-wheeling down an
incline, should the operator neglect to set the brake.
By energizing the transistors in pairs, current can be made Regenerative braking (braking energy returned to the
to flow in either direction in the field. The field and battery) may be accomplished completely with solid-state
armature control circuits typically operate at 12KHZ to technology. The main advantage of regenerative braking is
15KHZ, a frequency range normally above human hearing. increased motor life. Motor current is reduced by 50% or
This high frequency, coupled with the elimination of better during braking while maintaining the same braking
directional contactors, provides for very quiet vehicle torque as electrical braking with a diode clamp around the
operation. armature. The lower current translates into longer brush
life and reduced motor heating. Solid state regenerative
The line contactor is normally the only contactor required braking also eliminates a power diode, current sensor and
for the shunt motor traction circuit. This contactor is used contactor from the circuit.
for both pre-charge of the line capacitors and for
emergency shut down of the motor circuit, in case of For GE, the future is now, as we make available a new
problems that would cause a full motor torque condition. generation of electric traction motor systems for electric
The line can be energized and de-energized by the various vehicles having separately excited DC shunt motors and
logic combinations of the vehicle, i.e. activate on key, seat controls. Features that were once thought to be only
or start switch closure, and de-energize on time out of idle available on future AC or brushless DC technology vehicles
vehicle. Again, these options add to the quiet operation of systems are now achievable and affordable.
the vehicle.
Section 1. 3 Flexible System Application
Because the shunt motor controller has the ability to

control both the armature and field circuits independently,
the system can normally be adjusted for maximum system
efficiencies at certain operating parameters. Generally
speaking, with the ability to independently control the field
and armature, the motor performance curve can be
maximized through proper control application.
August 2001
Section 2. FEATURES OF SX FAMILY OF TRANSISTOR vehicle slows down. Once the field current reaches a
MOTOR CONTROLLERS preset value, set by Function 10, and armature plug current
can no longer be maintained, the braking function is
Section 2.1 Performance canceled, and the control reverts back to motoring.
All energy produced by the motor during plugging is
Section 2.1.1 Oscillator Card Features dumped as heat in the motor in this braking mode.
Section 2.1.1.a Standard Operation Section 2.1.4 Auxiliary Speed Control
The oscillator section of the card has two adjustable Section 2.1.4.a Field Weakening
features, creep speed and minimum field current. With the
accelerator at maximum ohms or volts, the creep speed This function allows the adjustment of the field weakening
can be adjusted by Function 2 of the Handset or a trimpot. level in order to set the top speed of the motor. The function
The field control section allows the adjustment of the field is enabled when the armature current is less than the value
weakening level in order to set the top speed of the motor. set by Function 24 and the accelerator input voltage is less
This top speed function (Minimum Field Current) is enabled than 1 volt. It is important to note that this function is used
when the armature current is less than the value set by to optimize motor and control performance, and this setting
Function 24 and the accelerator input voltage is less than 1 will be determined by GE and OEM engineers at the time of
volt. Top Speed can be adjusted by Function 7 of the vehicle development. This setting must not be changed by
Handset or a trimpot. field personnel without the permission of the OEM.
The % ON-time has a range of approximately 0 to 100 Section 2.1.4.b Speed Limits
percent. The SX controllers operate at a constant
frequency and the % ON-time is controlled by the pulse This feature provides a means to control speed by limiting
width of the voltage/current applied to the motor circuits. motor volts utilizing "adjustable speed limits", initiated by
individual limit switches. The NC switches are connected
Section 2.1.1.b Control Acceleration between input points on the control card and battery
negative. The lower motor volt limit always takes priority
This feature allows for adjustment of the rate of time it when more than one switch input is open. This motor volt
takes for the control to accelerate to 100% applied battery limit regulates top speed of the transistor controller, but
voltage to the motor on hard acceleration. Armature C/A is actual truck speed will vary at any set point depending on
adjusted by Function 3 from 0.1 to 22 seconds. the loading of the vehicle.
Section 2.1.2 Current Limit Section 2.1.4.c Top Speed Regulation
This circuit monitors motor current by utilizing sensors in This feature requires a system tachometer. The standard
series with the armature and field windings. The GE system tach is built into the motor and provides four
information detected by the sensor is fed back to the card pulses per armature revolution. Once the control has been
so that current may be limited to a preset value. If heavy calibrated to the vehicle parameters (gear ratio
load currents are detected, this circuit overrides the and wheel rolling radius), using Function 1, speed can be
oscillator and limits the average current to a value set by measured with a resolution of +/- 1 mph. When traveling
Function 4 and Function 8 of the Handset. The C/L setting is down an incline, if the vehicle speed increases to the
based on the maximum thermal rating of the control. overspeed setting, the control automatically transitions to
Because of the flyback current through 3REC, the motor the regen mode. The maximum incline on which the control
current is usually greater than battery current, except at will be able to maintain regulation is determined by the
100% ON time. characteristics of the motor, the maximum regen armature
current limit setting (Function 9), and the maximum regen
Section 2.1.3 Plug Braking field current limit setting (Function 10).
Slow down is accomplished when reversing direction by When the vehicle reaches the bottom of the incline, and
providing a small amount of retarding torque for the vehicle speed decreases below the overspeed setting
deceleration. If the vehicle is moving, and the directional on the level surface, the control automatically transitions
lever is moved from one direction to the other, the plug back to the normal running mode.
signal is initiated. Once the plug signal has been initiated,
the field is reversed, and the armature current is regulated
to the plug current limit as set by Function 16. Armature
current is regulated by increasing the field current as the
August 2001
Section 2.1.5 Ramp Start armature or field FET's are defective, so as to cause
uncontrolled truck movement.
This feature provides maximum control torque to restart a
vehicle on an incline. The memory for this function is the Section 2.2.4 Thermal Protector (TP)
directional switch. When stopping on an incline, the
directional switch must be left in its original or neutral This temperature sensitive device is internal to the power
position to allow the control to initiate full power when transistor (Q1) module. If the transistor's temperature
restarted. The accelerator potentiometer input will begins to exceed the design limits, the thermal protector
modulate ramp start current. will lower the maximum current limit, and maintain the
transistors within their temperature limits. As the control
Section 2.1.6 On-Board Coil Drivers and Internal Coil cools, the thermal protector will automatically reset,
Suppression returning the control to full power.
Coil drivers for the LINE and SP or BYPASS contactors Section 2.2.5 Low Voltage
are on-board the control card. These contactors must have
coils rated for the vehicle battery volts. Batteries under load, particularly if undersized or more
than 80 percent discharged, will produce low voltages at
Section 2.2 System Protective Override the control terminals. The SX control is designed for use
down to 50 percent of a nominal battery voltage of 36-84
Section 2.2.1 Static Return to Off (SRO) volts, and 75 percent of a nominal battery voltage of 24
volts. Lower battery voltage may cause the control to
This inherent safety feature of the control is designed to operate improperly, however, the resulting PMT should
require the driver to return the directional lever to the open the Line contactor, in the event of a failure.
neutral position anytime he leaves the vehicle and returns.
Additionally, if the seat switch or key switch is opened, the Section 2.3 Diagnostics
control shuts off and cannot be restarted until the
directional lever is returned to neutral. A time delay of The control detects the system's present operating status
approximately 2 seconds is built into the seat switch input and this status can be displayed to either the Dash Display
to allow momentary opening of the seat switch, if a bump is or the Handset.
encountered.
Section 2.3.1 Status Codes
Section 2.2.2 Accelerator Volts Hold Off
Section 2.3.1a Standard Status Codes
This feature checks the voltage level at the accelerator
input whenever the key switch or seat switch is activated. The SX control has a wide variety of Status Codes that
If, at start-up, the voltage is less than 3.0 volts, the control assist the service technician and operator in trouble
will not operate. This feature assures that the control is shooting the vehicle. If mis-operation of the vehicle occurs,
calling for low speed operation at start up. a status code will be displayed on the Dash Display for
vehicles so equipped, or be available from the status code
Section 2.2.3 Pulse Monitor Trip (PMT) displayed when the Handset is plugged into the “Y” plug of
the logic card.
The PMT design contains three features which shut down,
or lock out, control operation if a fault conditions occurs With the status code number, follow the procedures
that would cause a disruption of normal vehicle operation: outlined in DIAGNOSTIC STATUS CODES to determine the
problem and appropriate corrective action.
•= Look ahead
•= Look again Note: The Status Code Instruction Sheets do not purport to
•= Automatic look again and reset cover all possible causes of a display of a "status code ".
They do provide instructions for checking the most direct
The PMT circuit will not allow the control to start under the inputs that can cause status codes to appear.
following conditions:
Section 2.3.1.b Stored Status Codes
•= The control monitors both armature and field FET's at
start-up and during running. This feature records the last 16 "Stored Status Codes" that
•= The control will not allow the line contactor to close at have caused a PMT controller shut down and/or disrupted
start-up, or will drop it out during running, if either the normal vehicle operation. (PMT type faults are reset by
cycling the key switch). These status codes, along with the
August 2001
corresponding BDI and hourmeter readings, can be initiate opening and closing the contactor coils. All driver
accessed with the Handset, or by using the RS 232 modules are equipped with reverse battery protection, such
communications port and dumping the information to a that, if the battery is connected incorrectly, the contactors
Personal Computer terminal. can not be closed electrically.
Section 2.3.2 Hourmeter Readings
This feature will display the recorded hours of use of the

traction and pump control to the Dash Display each time
the key switch is turned off.
Section 2.3.3 Battery Discharge Indication (BDI)
The latest in microprocessor technology is used to provide

accurate battery state of charge information and to supply
passive and active warning signals to the vehicle operator.
Features and functions:
•= Displays 100 to 0 percent charge.
•= Display blinks with 20% charge. Disables mow circuit
with 10% charge. Auto ranging for 36/48 volt operation.
Adjustable for use on 24 to 80 volts.
Section 2.3.4 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.
Section 2.3.5 Handset
This is a multi-functional tool used with the LX, ZX, and SX

Series GE solid state controls. The Handset consists of a
Light Emitting Diode (LED) display and a keyboard for data
entry.
Features and functions:

•= Monitor existing system status codes for both traction
and pump controls. Monitor intermittent random status
codes.
•= Monitor battery state of charge, if available.
•= Monitor hourmeter reading on traction and pump
controls. Monitor or adjust the control functions.
Section 2.3.6 RS 232 Communication Port
This serial communication port can be used with

Interactive Custom Dash Displays to allow changes to
vehicle operating parameters by the operator. Or, it can be
used by service personnel to dump control operating
information and settings into a personal computer program.
Section 2.3.7 Circuit Board Coil Driver Modules
Coil drivers are internal to the control card, and are the
power devices that operate the Line, 1A and SP contactor
coils. On command from the control card, these drivers
August 2001
OUTLINE DRAWINGS, ELEMENTARY DRAWINGS AND INPUTS/OUTPUTS
Section 3.0 ORDERING INFORMATION, ELEMENTARY AND OUTLINE DRAWINGS
Section 3.1 Ordering Information for Separately Excited Controls
Example:
Part Number: IC3645 SH 4 D 33 2 C3

Argument Number: 01 02 03 04 05 06 07
Argument 01: Basic Electric Vehicle Control Number
Argument 02: Control Type:

SH = Separately Excited Control ( Plugging )
SR = Separately Excited Control ( Regen to Zero )
Argument 03: Operating Voltage:

1 = 120 volts 5 = 36/48 volts
2 = 24 volts 6 = 24/36 volts
3 = 36 volts 7 = 72/80 volts
4 = 48 volts
Argument 04: Package Size:

D = 6.86” X 6.67”
R = 6.86” X 8.15”
U = 8.66” X 8.13”
W = 8.66” X 10.83”
Argument 05: Armature Current

( 2 characters )
22 = 220 Amps
33 = 330 Amps
40 = 400 Amps
etc.
Argument 06: Field Current

( 1 character )
2 = 20 Amps
3 = 30 Amps
4 = 40 Amps
etc.
Argument 07: Customer / Revision

A1 = Customer A / Revision 1
B1 = Customer B / Revision 1
etc.
August 2001
Section 3.2 Outline: SX-2 Package Size
August 2001
ELEMENTARY DRAWING FOR TYPICAL
MOTOR CONNECTIONS
SX TRANSISTOR CONTROL
SEPARATELY EXCITED TRACTION MOTOR

* CUSTOMER SUPPLIED CONTROLLER FOR NEV APPLICATIONS
*
FU3
CHARGER SWITCH *
KEY SWITCH *
10A
DIRECTIONAL
*
FU1
LINE * SWITCH *
400A *
L
REVERSE
FORWARD
START SWITCH *
BUZZER *
A1
TURF SPEED LIMIT SWITCH *
+
P1 P2 P3 P4 P5 P11 P10
F1 PLUG (23 PIN)
P15 P14 P16 P7 P9 P8 P13 P6
Section 3.3 Standard Elementary for Neighborhood Electric Vehicle Application
A1
POS A1 F1
- POWER CONNECTIONS
TO CONTROL
FIELD
NEG A2 F2 A2
RED
ARMATURE
GREEN
BLACK
F2
SWITCH *
ACCEL POT *
TACHOMETER *
EMERGENCY BRAKE
A2
Page 10
August 2001
Section 3.4 Neighborhood Electric Vehicle Application Input/Output List
Connections to Main Plug (23 Pin) and “Y” Plug (8 Pin)
PIN MAIN PLUG INPUT/OUTPUT DESCRIPTION

1 BATTERY VOLTS FROM BATTERY
2 BATTERY VOLTS FROM KEY
3 BATTERY VOLTS FROM ACCELERATOR START SWITCH
4 BATTERY VOLTS FROM FORWARD SWITCH
5 BATTERY VOLTS FROM REVERSE SWITCH
6 BATTERY VOLTS FROMTURFSPEED LIMIT SWITCH
7 ACCELERATOR INPUT VOLTAGE SIGNAL
8 ACCELERATOR NEGATIVE
9 ACCELERATOR POT +5 VOLTS SUPPLY (3 WIRE POT)
10 BACK UP ALARM
11 LINE CONTACTOR COIL DRIVER
12 N/A
13 PARK BRAKE SWITCH INPUT
14 TACHOMETER INPUT SIGNAL
15 TACHOMETER 12 VOLT OUTPUT
16 NEGATIVE FOR TACH
17 N/A
18 N/A
19 N/A
20 N/A
21 N/A
22 SERIAL RECEIVE
23 SERIAL TRANSMIT
PIN “Y” PLUG INPUT/OUTPUT DESCRIPTION

1 CLOCK (OUT)
2 DATA (OUT)
3 ENABLE (OUT)
4 NEGATIVE
5 +5V SUPPLY
6 STORE (IN) (HANDSET)
7 FUNCTION
8 VALUE
1 2 3 4 5 6 6 8
PIN 1 PIN 4
9 10 11 12 13 14 15
PIN 5 PIN 8
16 17 18 19 20 21 22 23
WIRE END VIEW - PY PLUG WIRE END VIEW - MAIN PLUG

August 2001
DIAGNOSTIC STATUS CODES
Section 4.0 TROUBLESHOOTING AND DIAGNOSTIC STATUS CODES
Section 4.1 General Maintenance Instructions 160 hours of vehicle operation. Inspection is recommended
to verify that the contactors are not binding and that the
The transistor control, like all electrical apparatus, does tips are intact and free of contaminants.
have some thermal losses. The semiconductor junctions
have finite temperature limits, above which these devices GE does not recommend that any type of welding be
may be damaged. For these reasons, normal maintenance performed on the vehicle after the installation of the
should guard against any action which will expose the control(s) in the vehicle. GE will not honor control failures
components to excessive heat and/or those conditions during the warranty period when such failures are
which will reduce the heat dissipating ability of the control, attributed to welding while the control is installed in the
such as restricting air flow. vehicle.
The following Do’s and Don’t’s should be observed: Section 4.2 Cable Routing and Separation
Any controls that will be applied in ambient temperatures Electrical noise from cabling of various voltage levels can
over 100° F (40° C) should be brought to the attention of the interfere with a microprocessor-based control system. To
vehicle manufacturer. reduce this interference, GE recommends specific cable
separation and routing practices, consistent with industry
All external components having inductive coils must be standards.
filtered. Refer to vehicle manufacturer for specifications.
Section 4.2.1 Application Responsibility
The wiring should not be directly steam cleaned. In dusty
areas, blow low-pressure air over the control to remove The customer and customer’s representative are
dust. In oily or greasy areas, a mild solution of detergent or responsible for the mechanical and environmental
denatured alcohol can be used to wash the control, and locations of cables. They are also responsible for applying
then low-pressure air should be used to completely dry the the level rules and cabling practices defined in this section.
control. To help ensure a lower cost, noise-free installation, GE
recommends early planning of cable routing that complies
with these level separation rules.
For the control to be most effective, it must be mounted
against the frame of the vehicle. The metal vehicle frame, On new installations, sufficient space should be allowed to
acting as an additional heat sink, will give improved vehicle efficiently arrange mechanical and electrical equipment.
performance by keeping the control package cooler. Apply
On vehicle retrofits, level rules should be considered during
a thin layer of heat-transfer grease (such as Dow Corning
the planning stages to help ensure correct application and
340) between the control heat sink and the vehicle frame.
a more trouble-free installation.
Control wire plugs and other exposed transistor control Section 4.2.2. Signal/Power Level Definitions
parts should be kept free of dirt and paint that might
change the effective resistance between points. The signal/power carrying cables are categorized into four
defining levels: low, high, medium power, and high power.
Within those levels, signals can be further divided into
CAUTION: The vehicle should not be plugged when the
classes.
vehicle is jacked up and the drive wheels are in a free
wheeling position. The higher motor speeds can create Sections 4.2.2.a through 4.2.2.d define these levels and
excessive voltages that can be harmful to the control. classes, with specific examples of each. Section 4.2.3
contains recommendations for separating the levels.
Do not hipot (or megger) the control. Refer to control
manufacturer before hipotting. 4.2.2.a Low-Level Signals (Level L)
Use a lead-acid battery with the voltage and ampere hour Low-level signals are designated as level L. These consist
rating specified for the vehicle. Follow normal battery of:
maintenance procedures, recharging before 80 percent •= Analog signals 0 through ±15 V
discharged with periodic equalizing charges. •= Digital signals whose logic levels are less than 15 V DC
•= 4 – 20 mA current loops
•= DC busses less than 15 V and 250 mA
Visual inspection of GE contactors contained in the traction The following are specific examples of level L signals used
and pump systems is recommended to occur during every in drive equipment cabling:
August 2001
•= Control common tie customer must apply the general guidelines (section
•= DC buses feeding sensitive analog or digital hardware 4.2.3.a), outlined below.
•= All wiring connected to components associated with
sensitive analog hardware with less than 5V signals (for 4.2.3.a General Cable Spacing
example, potentiometers and tachometers)
•= Digital tachometers and resolvers The following general practices should be used for all
•= Dash display cabling levels of cabling:
•= RS-232 cabling
•= All cables and wires of like signal levels and power
Note: Signal inputs to analog and digital blocks should be levels must be grouped together.
run as shielded twisted-pair (for example, inputs from •= In general, different levels must run in separate wire
tachometers, potentiometers, and dash displays). bundles, as defined in the different classes, identified
above. Intermixing cannot be allowed, unless noted by
4.2.2.b High-Level Signals (Level H) exception.
•= Interconnecting wire runs should carry a level
High-level signals are designated as level H. These signals designation.
consist of: •= If wires are the same level and same type signal, group
those wires from one location to any other location
•= Analog and digital signals greater than 15 V DC and together in multiconductor cables or bind them
less than 250 mA together with twine or zip-ties.
•= When unlike signals must cross, cross them in 90°
For example, switch inputs connected to battery volts are angles at a maximum spacing. Where it is not possible
examples of level H signals used in drive equipment to maintain spacing, place a grounded steel barrier
cabling. between unlike levels at the crossover point.
4.2.2.c Medium-Power Signals (Level MP) 4.2.4 Cabling for Vehicle Retrofits
Medium power signals are designated as level MP. These Reducing electrical noise on vehicle retrofits requires
signals consist of: careful planning. Lower and higher levels should never
encircle each other or run parallel for long distances.
•= DC switching signals greater than 15 V It is practical to use existing wire runs or trays as long as
•= Signals with currents greater than 250 mA and less than the level spacing (see section 4.2.2) can be maintained for
10A the full length of the run.
Existing cables are generally of high voltage potential and
The following are specific examples of level MP signals noise producing. Therefore, route levels L and H in a path
used in drive equipment cabling: separate from existing cables, whenever possible.
•= DC busses less than 10 A For level L wiring, use barriers in existing wire runs to
•= Contactor coils less than 10 A minimize noise potential.
•= Machine fields less than 10 A Do not loop level L signal wires around level H, level MP, or
HP wires.
4.2.2.d. High Power Signals (Level HP)
4.2.5 RF Interference
Power wiring is designated as level HP. This consists of DC
buses and motor wiring with currents greater than 10 A. To prevent radio frequency (RF) interference, care should
The following are specific examples of level HP signals be taken in routing power cables in the vicinity of radio-
used in drive equipment cabling: controlled devices.
•= Motor armature loops
•= DC outputs 10 A and above Section 4.2.6 Suppression
•= Motor field loops 10 A and above
Unless specifically noted otherwise, suppression (for
4.2.3. Cable Spacing Guidelines example, a snubber) is required on all inductive devices
controlled by an output. This suppression minimizes noise
Recommended spacing (or clearance) between cables (or and prevents damage caused by electrical surges.
wires) is dependent on the level of the wiring inside them.
For correct level separation when installing cable, the
August 2001
Section 4.3 Recommended Lubrication of Pins and 2. Locate the plug that contains the socket (female)
Sockets Prior to Installation terminals. Maintenance needs only to be performed on
the plug containing the socket (female) type terminals.
Beginning in January of 1999, GE implemented the addition Reconnecting the plugs will lubricate the pin (male)
of a lubricant to all connections using pins and sockets on terminals.
EV100/EV200 and Gen II products. Any connection made by 3. Clean each terminal using Chemtronics contact
GE to the A, B, X, Y, or Z plugs, includes the lubricant NYE cleaner “Pow-R-WasH CZ “ as shown in Figure 1.
760G to prevent fretting of these connections during vehicle
operation.
Fretting occurs during microscopic movement at

the contact points of the connection. This movement n ic s
m t ro
exposes the base metal of the connector pin which, when Che ane
r
t cle
tac
oxygen is present, allows oxidation to occur. Sufficient con
Pow H Z
-R-C
build up of the oxidation can cause intermittent contact
and intermittent vehicle operation. This can occur at any
s
Wa
similar type of connection, whether at the control or in any
associated vehicle wiring, and the resultant intermittent
e
contact can provide the same fault indication as actual ciro
zan
component failure.
The addition of the NYE 760G lubricant will prevent Figure 1

the oxidation process by eliminating the access of oxygen
to the contact point. GE recommends the addition of this
lubricant to the 12 pin and 23 pin plugs of all new Gen II 4. Lubricate each terminal using Nye 760G lubricant as
controls at the time of their installation into a vehicle shown in figure 2. Apply enough lubricant to each
terminal opening to completely fill each opening to a
When servicing existing vehicles exhibiting depth of .125” minimum.
symptoms of intermittent mis-operation or shutdown by the
GE control, GE recommends the addition of this lubricant to
all 12 and 23 pin plugs, after proper cleaning of the
connectors, as a preventative measure to insure fretting is
not an issue before GE control replacement. Also, for long
N
term reliable control operation, the plug terminals must be

LU
ye
B
R
IC
A
N
maintained per these instructions with the recommended

TS
contact cleaner and lubricant which provides a high

degree of environmental and fretting protection.
New and re-manufactured control plugs are cleaned and

lubricated prior to shipment from the factory. However, in
applications where severe vibration or high temperature
cycling and excessive humidity ( such as freezers ) are
present, it is recommended that the plug terminals be
cleaned and lubricated every year, per this instructions. In Figure 2
normal applications, plug maintenance should be
performed every two years, unless intermittent problems
arise with the plugs, requiring more immediate attention. 5. Reconnect plugs.
Warning: Do not use any other cleaners or lubricants
other than the ones specified. Reference
WARNING: Before conducting maintenance on the Cleaner Chemtronics Pow-R-WasH CZ Contact

vehicle, jack up the drive wheels, disconnect the battery Cleaner
and discharge the capacitors. Consult the Operation and Lubricant Nye Lubricants NYOGEL 760G
Service Manual for your particular vehicle for details on
discharging the capacitors; this procedure differs GE Plug Lub Kit Contains both above products:
between SCR and Transistor controls. 328A1777G1
1. Disconnect plug from controller or mating plug.

August 2001
Section 4.4 General Troubleshooting Instructions
Trouble-shooting the ZX family of controls should be quick

and easy when following the instructions 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 vehicles equipped with a
Dash Display) or made available by plugging a Handset into
the 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.
Important Note: Due to the interaction of the logic card

with all vehicle functions, almost any status code or
control fault could be caused by the logic card. After all
other status code procedures have been followed and no
problem is found, the controller should then be replaced as
the last option to correct the 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 vehicle, but these numbers
may be different from the numbers referenced in this
publication.
WARNING: Before trouble-shooting, jack up the drive

wheels, disconnect the battery and discharge the
capacitors. Reconnect the battery as needed for specific
checks. Capacitors should be discharged by connecting a
200 ohm 2 watt resistor between the positive and negative
terminals on the control panel.
Check resistance on R x 1000 scale from frame to 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,

mis-aligned linkage to the accelerator switch, signs of
overheating of components, etc.
Tools and test equipment required are: clip leads, volt-ohm

meter (20,000 ohms per volt) and basic hand tools.
August 2001
Section 4.5 Traction Control Codes
TRACTION DESCRIPTION OF STATUS CAUSE OF STATUS INDICATION

STATUS CODE
Segments do not illuminate on the No input voltage to the control card or the display unit.
NONE Dash Display and/or the Handset.
MEMORY RECALL
NO CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
SYMPTOM
KEY
Display screen on Dash Display and/or CHARGER SWITCH
Circuits valid Handset is blank.
FU3 SWITCH
for
Traction POSSIBLE CAUSE
Positive or negative control voltage is not
Controller present.
•=Insure that the key switch is closed and
voltage is present between P1 & battery +
negative (Power Terminal “NEG”). Also
check for voltage between P2 and control
negative.
-
Open circuit between control card Plug Y & P1 P2
the Dash Display or Handset. NEG
•=Check for an open circuit or loose

connection going from the “Y” plug and
the Dash Display or Handset.
Defective Dash Display or Handset.

•= Replace Dash Display or Handset.

STATUS CODE
Emergency brake switch is open. This status code will be displayed when P13 is
-04 greater than 2.5 volts.
MEMORY RECALL
CORRECTIVE ACTIONS TROUBLE-SHOOTING DIAGRAM
NO
SYMPTOM
Control will not operate; buzzer will sound.
Circuits valid CHARGER KEY
SWITCH * SWITCH
DIRECTIONAL
START SWITCH *
for
*
POSSIBLE CAUSE SWITCH *
REVERSE
FORWARD
Traction Emergency brake switch input mis-adjusted or *

L
defective.
BUZZER *
Controller •= Input voltage at P13 should be less than

2.5VDC. Adjust or replace the brake switch to
insure that the voltage at P13 is less than
2.5VDC. P1 P2 P3 P4
PLUG (23 PIN)
P5 P11 P10
P15 P14 P16 P7 P9 P8 P13 P6
Open circuit between battery negative and P13

TACHOMETER *
BRAKE SWITCH
ACCEL POT *
EMERGENCY
GREEN
BLACK
RED
in the emergency brake switch input circuit.

*
•= Disconnect wire from P13. Check for open

circuit between this wire and battery negative.
Defective controller.
•= Voltage measured between P13 and
negative should be 4.5VDC. If not, replace
control.
August 2001

STATUS CODE
Start switch fails to close. This status code will be displayed when the
-05 accelerator voltage at P7 is >2.5V, with the start
switch open (P3< 50% of battery volts)
MEMORY RECALL
NO
SYMPTOM
Control will not operate.
SWITCH * SWITCH
for DIRECTIONAL
START SWITCH *

*
REVERSE
FORWARD
Traction Defective start switch circuit. *
•= Check start switch to insure closure when L
BUZZER *
Controller accelerator pedal is depressed.
•= Check for open circuit or loose
connections in start switch wiring.
P1 P2 P3 P4 P5 P11 P10
PLUG (23 PIN)
Defective accelerator switch. P15 P14 P16 P7 P9 P8 P13 P6
•= Check accelerator switch potentiometer
TACHOMETER *
BRAKE SWITCH
ACCEL POT *
EMERGENCY
GREEN
for proper operation and ohmic value
BLACK
RED
*
STATUS CODE
The accelerator pedal is depressed with This status code will be displayed when the
-06 no direction selected. accelerator voltage, at P7>2.5V, and no direction is
selected (P4 and P5 are both less than 50% of
battery volts)
MEMORY RECALL
NO
SYMPTOM
SWITCH * SWITCH
for DIRECTIONAL
START SWITCH *
*
REVERSE
FORWARD
Traction Accelerator pedal is depressed before closing *

L
forward or reverse directional switch.
BUZZER *
Controller •= Status code will disappear when

directional switch is closed or when
accelerator pedal is released.
P1 P2 P3 P4 P5 P11 P10
PLUG (23 PIN)
Defective directional switch P15 P14 P16 P7 P9 P8 P13 P6
•= Check forward or reverse switch to insure

BRAKE SWITCH
TACHOMETER *
ACCEL POT *
EMERGENCY
GREEN
BLACK
RED
closure when direction is selected.

*
Open circuit between directional switch(es)

and battery positive or between directional
switch(es) and P4 or P5.
•= Check all control wires and connections
shown in trouble shooting diagram.
August 2001

STATUS CODE
Accelerator voltage input is too high on This status code will be displayed when the
-08 power up after initial key switch accelerator input voltage at P7 >0.9V and either the
closure. battery plug or key switch is opened and closed.
MEMORY RECALL
NO
SYMPTOM
Control will not operate
SWITCH * SWITCH
for DIRECTIONAL
START SWITCH *

*
SWITCH *
REVERSE
FORWARD
*
Accelerator input is mis-adjusted or L
Controller
BUZZER *
defective.
•=Input voltage at P7 should be less than
0.9 volts. Adjust or replace accelerator
unit to insure that the voltage at P7 is
less than 0.9 volts before depressing P1 P2 P3 P4
PLUG (23 PIN)
P5 P11 P10
pedal. P15 P14 P16 P7 P9 P8 P13 P6
BRAKE SWITCH
TACHOMETER *
ACCEL POT *
EMERGENCY
GREEN
Disconnect wire from P7. Check for short
BLACK
RED
circuit from wire to P15. Resistance should
*
be greater than 3.5K ohms.
Open circuit at P8 or open potentiometer

wiper at P7 – verify continuity of wiring at
both points.

STATUS CODE
Both the forward and reverse switches are This status code will be displayed when P4 and
-09 closed at the same time. P5 are greater than 50% of battery volts.
MEMORY RECALL
NO
SYMPTOM
SWITCH * SWITCH
DIRECTIONAL
START SWITCH *

*
for POSSIBLE CAUSE
SWITCH *
REVERSE
FORWARD
*
Traction Forward or reverse directional switch welded L
BUZZER *
closed or mis-adjusted to be held closed.

Controller •=Replace or adjust directional switches to
insure that they are open when directional
switch is returned to neutral.
P1 P2 P3 P4 P5 P11 P10
PLUG (23 PIN)
P15 P14 P16 P7 P9 P8 P13 P6
Short circuit between battery positive and P4
and/or P5.
TACHOMETER *
BRAKE SWITCH
ACCEL POT *
EMERGENCY
GREEN
BLACK
RED
•= Disconnect wires from P4 and P5 and check

*
wire for short circuit to positive side of

directional switch
Defective control.
•= Disconnect wires and measure voltage at P4
and P5. Voltage should be less than 50% of
battery volts, if not, replace control.
August 2001

STATUS CODE
Start switch closed on power up after initial This status code will be displayed when P3 is
-11 key switch closure. greater than 50% of battery volts when the key
switch is closed.
MEMORY RECALL
NO
SYMPTOM
SWITCH * SWITCH
for DIRECTIONAL
START SWITCH *

POSSIBLE CAUSE *
SWITCH *
REVERSE
FORWARD
Traction Start switch is mis-adjusted or defective. *
•= Input voltage at P3 should be less than 50% L
BUZZER *
Controller of battery volts at key switch closure. Adjust
or replace accelerator unit to insure that the
voltage at P3 is less than 50% of battery
volts before closing the start switch. P1 P2 P3 P4 P5 P11 P10
PLUG (23 PIN)
P15 P14 P16 P7 P9 P8 P13 P6
Short circuit between P15 and P3 in start switch
TACHOMETER *
BRAKE SWITCH
ACCEL POT *
input circuit.
EMERGENCY
GREEN
BLACK
RED
•= Disconnect wire from P3. Check for short
*
circuit from this wire to 12V positive.
Resistance should be greater than 4.7K
ohms.
Defective control.
•= Disconnect wire from P3. Measure voltage
from P3 to negative. Voltage should be
zero. If not, replace the control.

STATUS CODE
Battery voltage is too low at initial key switch This status code will be displayed when the
-15 closure. battery volts are less than 68.3 volts at initial key
switch on.
MEMORY RECALL
NO
SYMPTOM
KEY
Control will not operate. CHARGER SWITCH
Circuits valid FU3 SWITCH
for POSSIBLE CAUSE

Traction Discharged battery
•=Check battery voltage to confirm that it is a
Controller minimum of 68.3 volts. Charge battery, if
required.
+
Defective battery
•=Check each battery cell for proper voltage
(greater than 1.95 volts at cell). Replace or -
repair battery. P1 P2
NEG
Incorrect control card adjustment.

•=Check Function 15 for proper adjustment for
battery being used. See Handset instruction
sheet for details. Adjust to proper settings.
Check “minimum” battery volts at P1 & NEG.
August 2001

STATUS CODE
Battery voltage is too high at initial key This status code will be displayed when the
-16 switch closure. battery volts are greater than 86 volts at initial
key switch on.
MEMORY RECALL
NO
SYMPTOM
KEY
Control will not operate. CHARGER SWITCH
Circuits valid FU3 SWITCH
for POSSIBLE CAUSE

Traction Discharged battery
•=Check battery voltage to confirm that it is a
Controller minimum of 68.3 volts. Charge battery, if
required.
+
Battery overcharged or incorrect battery used.

•=Check each battery cell for proper voltage
(maximum 2.4 volts per cell). If voltage is -
excessive, check battery charger for proper P1 P2
output voltage. NEG
Incorrect control card adjustment.

•=Check Function 15 for proper adjustment for
battery being used. See Handset instruction
sheet for details. Adjust to proper settings.
Check “maximum” battery volts at P1 & NEG.

STATUS CODE
Accelerator voltage is too high. This status code will be displayed when the
-21 accelerator voltage at P7 is greater than 4.5
volts.
MEMORY RECALL
NO
SYMPTOM
SWITCH * SWITCH
for DIRECTIONAL
START SWITCH *
POSSIBLE CAUSE *
SWITCH *
REVERSE
FORWARD
Traction Accelerator input is mis-adjusted or defective. *

Input voltage at P7 should be less than 4.5 L
BUZZER *
Controller volts after initial key switch closure.

Open wire exists between potentiometer
negative and P8.
Open wire exists between P7 and
P1 P2 P3 P4 P5 P11 P10
potentiometer negative. P15 P14 P16
PLUG (23 PIN)
P7 P9 P8 P13 P6
TACHOMETER *
BRAKE SWITCH
ACCEL POT *
EMERGENCY
GREEN
BLACK
RED
August 2001

STATUS CODE
Motor field current is too high when the This status code will be displayed when the current
-23 start switch is closed and the reverse draw in the motor field is too high on start up in the
direction is selected. reverse direction.
MEMORY RECALL
NO
SYMPTOM
Circuits valid
for POSSIBLE CAUSE
Traction Defective control.
•= Replace controller unit.
Controller
NO GRAPHIC FOR THIS
STATUS CODE

STATUS CODE
Motor field current is too high on when This status code will be displayed when the current
-24 the start switch is closed and the draw in the motor field is too high on start up in the
forward direction is selected. forward direction.
MEMORY RECALL
NO
SYMPTOM
Circuits valid
for POSSIBLE CAUSE
Controller
NO GRAPHIC FOR THIS
STATUS CODE
August 2001

STATUS CODE
12V buss is too low. This status code will be displayed when the voltage at
-27 P1 is less than 9.35V.
MEMORY RECALL
YES
SYMPTOM
KEY
Line contactor opens and closes and then CHARGER SWITCH
Circuits valid can only be closed by opening and closing
FU3 SWITCH
for the key switch.

Traction
POSSIBLE CAUSE
Controller Discharged battery.
•= Check battery to insure proper state of
charge. Voltage may be dropping +
below 12V under load.
Loose connection at P1.

•= Insure that the wire connection at P1 -
is tight. P1 P2
NEG
Defective control.

STATUS CODE
Open thermal protector (TP) or This status code will be displayed when the voltage at
-41 transistor over temperature. the thermal protector is too high.
MEMORY RECALL
YES
SYMPTOM
Reduced or no power to traction motor in
Circuits valid control range.
for
Control is in thermal cut back.
Controller •= Allow control to cool, status code
should disappear.
Defective control.
(Values of greater than 4 V at the thermal
protector are typically indicative of a failed
control.)
GE Sentry for Windows software can be

used to monitor control operation, and it
will display a value for the thermal
protector that is greater than 84
(corresponding to 1.65V), triggering this
status code.
August 2001

STATUS CODE
Motor armature offset voltage is too This status code will be displayed when the value of
-42 high. motor amps is greater than 138 (corresponding to 2.7
volts) with no current flowing in the motor circuit.
MEMORY RECALL
NO
SYMPTOM
Circuits valid
for POSSIBLE CAUSE
Controller
will display a value for the motor amps that
is greater than 138, (corresponding to
2.7V), triggering this status code.

STATUS CODE
Motor armature offset voltage is too This status code will be displayed when the value of
-43 low. motor amps is less than 117 (corresponding to 2.3
volts) with no current flowing in the motor circuit.
MEMORY RECALL
NO
SYMPTOM
Circuits valid
for POSSIBLE CAUSE
Controller
will display a value for the motor amps that
is less than 117 (corresponding to 2.3V),
triggering this status code.
August 2001

STATUS CODE
Armature transistor did not turn off This status code will be displayed when, during
-44 properly. control operation, the armature transistor fails to turn
off. This will result in a PMT condition
MEMORY RECALL
YES
SYMPTOM
Line contactor opens and closes, then can
Circuits valid only be closed by opening and closing the
for key switch.
Traction
POSSIBLE CAUSE
Controller
NO GRAPHIC FOR THIS
Defective control.
STATUS CODE

STATUS CODE
Armature transistor did not turn on This status code will be displayed when, during
-45 properly. control operation, the armature transistor fails to turn
on properly. This will result in a PMT condition
MEMORY RECALL
YES
SYMPTOM
Line contactor opens and closes, then can
Circuits valid only be closed by opening and closing the
for key switch.
Traction
POSSIBLE CAUSE
Controller
NO GRAPHIC FOR THIS
Defective control.
STATUS CODE
August 2001

STATUS CODE
“Look Ahead” test for A2 volts is less This status code will be displayed when the voltage at
-46 than 12.5% of battery volts. A2 is less than 12.5% of battery volts and Im is greater
than 52 amps, when the control is in the neutral state,
with no start switch or direction selected.
MEMORY RECALL
YES
SYMPTOM
Line contactor will not pickup.
Circuits valid FU3 *
for POSSIBLE CAUSE 10A
Traction Check for short circuit from the motor FU1 * LINE *
armature to the frame of the vehicle. A1

Controller 400A
F1
Defective control.
BATT
+
•= Replace controller unit. A1
ARMATURE
POS A1 F1
FIELD
POWER CONNECTIONS
- TO CONTROL
NEG A2 F2 A2
F2
A2

STATUS CODE
Motor field current is too low during the This status code will be displayed when the current
-49 run mode. draw in the motor field is less than 1.3 amps and
armature current is greater than 100 amps for more
than 1.27 seconds during the run mode.
MEMORY RECALL
YES
SYMPTOM
Circuits valid
for POSSIBLE CAUSE
Controller
NO GRAPHIC FOR THIS
STATUS CODE
August 2001

STATUS CODE
Capacitor volts are low before the line This status code will be displayed during “key on”
-51 contactor closes. when the capacitor volts is less than 85% of battery
volts at initial key switch on.
MEMORY RECALL
NO
SYMPTOM
Line contactor does not close when
Circuits valid capacitor does not pre-charge.
FU3 *
for 10A
Traction POSSIBLE CAUSE FU1 * LINE *
Defective control fuse.

Controller •= Check control fuse for open circuit
400A A1
F1
condition. Replace fuse, if necessary.
BATT
+
A1
ARMATURE
POS A1 F1
Defective control.
FIELD
POWER CONNECTIONS
•= Replace controller unit. - TO CONTROL
NEG A2 F2 A2
F2
A2

STATUS CODE
Controller “motor current sensor” input This status code will be displayed when the voltage
-57 is too low during running. input from the current sensor is too low (less than
2.0V, 166 amps) during running, greater than 25% on-
time.
MEMORY RECALL
YES
SYMPTOM
Circuits valid
for POSSIBLE CAUSE
Controller
Line contactor tips bounce or are not fully NO GRAPHIC FOR THIS
picked up.
STATUS CODE
August 2001

STATUS CODE
Capacitor (1C) voltage too high during This status code will be displayed when the voltage at
-76 regenerative braking. 1C exceeds 96 volts during the regenerative braking
cycle.
MEMORY RECALL
YES
SYMPTOM
Line contactor opens and closes, then
Circuits valid opens and can only close by opening and
FU3 *
for closing the key switch. 10A
Traction FU1 * LINE *
POSSIBLE CAUSE
Controller Defective control.
400A A1
•= Replace controller unit. F1
BATT
+
A1
ARMATURE
POS A1 F1
FIELD
POWER CONNECTIONS
- TO CONTROL
NEG A2 F2 A2
F2
A2
August 2001
ADJUSTABLE FEATURES
SX TRANSISTOR CONTROLS Page 28
Section 5. SX FAMILY GE HANDSET INSTRUCTIONS

START-UP DISPLAY SEQUENCE
Section 5.1 General Features
The GE Handset is a multi-functional tool to be used with Key Switch On

the LX, ZX, and SX Series GE solid-state controls. The
Handset consists of a Light Emitting Diode (LED) display
Verify Each LED Segment
and a keyboard for data entry. Note: A different handset
8888
cord is required for use with SX controls than that used
with LX and ZX controls.
MPH for 7 Sec Diagnostics Override
Section 5.2 Purpose / Setup Functions
BDI for 3 Sec With Fault
The purpose of the Handset is to allow authorized
personnel to perform the following functions of the SX
family of Controls:
•=Monitor existing system fault codes Run Mode
•=Monitor intermittent random fault codes
•=Monitor battery state of charge on systems with BDI
•=Monitor hourmeter reading
•=Monitor or adjust the following control functions:
•=Creep speed MPH for 7 Sec Diagnostics Override
•=Armature Controlled Acceleration and 1A Time BDI for 3 Sec With Fault
•=Regenerative Braking Current Limit and Disable
•=Armature and Field Current Limit Key Switch
•=Plugging Distance (Current) Off
•=Pedal Position Plug Range or Disable
•=1A Drop Out Current or Disable
•=Speed Limit Points Display Odometer
Thousands,Hundreds, Tens, Units
•=Truck Management Fault Speed Limit
For Four Seconds
•=Internal Resistance Compensation for Battery
State of Charge Indication
•=Battery Voltage (36/48 volts is auto ranging) Display Odometer
•=Selection of Card Operation Type. Hundred Thousands,Ten Thousands
For Four Seconds
At the transistor control traction card, unplug the "Y plug" if

Warning: Before making any adjustments to the control,
Warning: Before connecting or disconnecting the Handset you must consult the operating and maintenance
tool, turn off the key switch, unplug the battery and jack instructions supplied by the vehicle manufacturer. Failure
up the drive wheels of the vehicle. to follow proper set up instructions could result in mis-
the dash display is in use, and plug in the Handset to the operation or damage to the control system.
plug location "Y" on the control card. After installing the
Handset tool, plug the battery in and turn the key switch on.
Note: The dash display must be disconnected

when the Handset is plugged in, or the control
power supply will be overloaded.
The chart at the right details the start-up display sequence

that will occur.
August 2001
ADJUSTABLE FEATURES
Section 5.3 Setup Function Procedures reading at the time the fault occurred. The first of the 16
status codes will be overwritten each time a new status
With the Handset connected, hold down the CONT key and code occurs. This stored status code register can be
turn on the key switch. This will place you in the setup cleared from memory by using the Handset.
mode, ready to monitor or adjust control function settings.
ACCESSING STORED STATUS CODES
NOTE: The term “Push” means to depress key for
WITH GE HANDSET
approximately one second.
Section 5.3.1 Setup Mode Key Switch Off
Push ESC and CONT

SET-UP MODE At The Same Time
DISPLAY
ACTION SHOWS
REMARKS Release ESC and CONT
Key
Hold Down CONT Segment Check
And Turn On Key 8888 Displayed
Status Code Displayed
Selected Function No.

Push Function Number U005 Is Displayed
Push CONT Key
After One Second Stored Value For The

Time Delay 085 Function Is Displayed Displays Battery
State-Of-Charge When
Fault Occurred
Display Value
Push CONT 085 Will Blink
Push CONT Key
Change Value with Value Changes

Adjustment Knob 125 While Blinking Display Hourmeter Reading
Push CONT Key
When Fault Occurred
New Value Stored And

Push STORE 125 Blinking Stops Push CONT Key
Segment Check
Push ESC 8888 Displayed
Section 5.3.3 SX Family Handset, Plug

At this point, another function can be monitored/changed Connections and Outline Drawing
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, 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.
Section 5.3.2 Status Code Scrolling “Y“ Plug
The SX family of controllers furnishes a function register Handset Cable Part Number - 325B1002G2 (8 pin plug)
that contains the last 16 “stored status codes” that shut Handset Part Number - IC3645LXHS1EC4 (8 pin plug)
down vehicle operation (a PMT type fault that is reset by (includes handset, cable and case)
cycling the key switch) and the battery state of charge
August 2001
ADJUSTABLE FEATURES
Setting = 3600 X 2 X 3.14159265 X 9 X 1
LX g
HANDSET 5280 X 12 X 8.91 X 4 X .005 X 1
EVC
Setting = 203575
11290
Setting = 18
FUNCTION 2 CREEP SPEED

( Push 2 )
CONT STORE
This function allows for the adjustment of the creep speed
of the vehicle when the accelerator potentiometer is at its
minimum value and the start switch is closed.
1 2 3 4
+ + Range 2% to 15% on time
Set 0 to 255
5 6 7 8 Resolution 0.047% per set unit
Example Setting of 205=(205x0.047)+2
= 11% on time
9 10 11 12
Important Note: The function is used to optimize motor and
13 14 15 ESC control performance and this setting will be determined by
GE and OEM engineers at the time of vehicle development.
This setting must not be changed by field personnel without
the permission of the OEM.
Section 5.4 Setup Functions for Traction Controller FUNCTION 3 ARMATURE ACCELERATION RATE
FORWARD
FUNCTION 1 MPH SCALING (Push 3)
( Push 1 )
This function allows for the adjustment of the rate of time it
This function allows for the pulses from the tachometer to takes for the control to accelerate to 100% applied battery
be scaled to miles per hour, based on the number of pulses voltage to the motor on hard acceleration in the forward
received by the control in a given time. For example, if you direction.
were scaling to 8 MPH, it would correspond to the length of
time that it took to capture 8 tachometer pulses when the Range 0.1 to 25.5 seconds
vehicle is traveling at 8 MPH. Set 1 to 255
Resolution 0.086 seconds per set unit
Range 0 to 1.28 seconds Example: Setting of 20 = 20 x 0.086=1.72 seconds
Set 0 to 255
Example Setting of 18 = 0.09 seconds
FUNCTION 4 MAX ARMATURE CURRENT LIMIT
(Push 4)
Example to determine sitting:
This function allows for the adjustment of the armature
RR = Rolling Radius (Inches)
current limit of the control during motoring.
Pi = 3.14159265
GR = Gear Ratio
Range 150 to 357 amps
PPR = Pulses per rotation of motor
Set 0 to 255
MPH = Miles per Hour
Resolution 0.8125 amps per unit
Example: Setting of 255 =(255x0.8125)+150
Setting = 3600 X 2 X Pi X RR X Pulses per MPH
= 357 amps
5280 X 12 X GR X PPR X .005 X MPH
August 2001
ADJUSTABLE FEATURES
FUNCTION 5 PLUG CURRENT LIMIT Resolution 0.147 amps per set unit
(Push 5) Example Setting of 251=(251–51)x0.147
=29.4 amps
This function allows for the adjustment of the maximum
current allowed during plug braking. CAUTION: Do not set this function to a value less than 51.
Range 26 to 225 amps Important Note: The function is used to optimize motor and
Set 0 to 255 control performance and this setting will be determined by
Resolution 0.8125 amps per unit GE and OEM engineers at the time of vehicle development.
Example Setting of 20 = 26 + (20 X .8125) = This setting must not be changed by field personnel without
42 Amps the permission of the OEM.
FUNCTION 6 ARMATURE ACCELERATION RATE FUNCTION 9 REGEN ARMATURE CURRENT LIMIT

REVERSE (Push 9)
(Push 6)
This function allows for the adjustment of the maximum
This function allows for the adjustment of the rate of time it armature current limit during regenerative braking.
takes for the control to accelerate to 100% applied battery
voltage to the motor on hard acceleration in the reverse Range 32 to 240 amps
direction. Set 1 to 255
Resolution 0.8157 amps per set unit
Range 0.1 to 25.5 seconds Example Setting of 221 = (221x0.8157) +32
Set 1 to 255 = 212 amps
Example: Setting of 29 = 29 x 0.086 = 2.5 seconds
FUNCTION 10 REGEN FIELD CURRENT LIMIT
( Push 10 )
FUNCTION 7 MIN. FIELD CURRENT
( Push 7 ) This function allows for the adjustment of the maximum
field current limit during regenerative braking.
This function allows the adjustment of the field weakening
level in order to set the top speed of the motor. Range 0 to 30 amps
Set 51 to 255
Range 0 to 30 amps Resolution 0.147 amps per set unit
Set 51 to 255 Example Setting of 180 = (180-51)x0.147
Resolution 0.147 amps per set unit = 19 amps
Example Setting of 73 = (82-51)x0.147 = 3.2 amps
CAUTION: Do not set this function to a value less than 51.
CAUTION: Do not set this function to a value less than 51.
Important Note: The function is used to optimize motor and
Important Note: The function is used to optimize motor and control performance and this setting will be determined by
control performance and this setting will be determined by GE and OEM engineers at the time of vehicle development.
GE and OEM engineers at the time of vehicle development. This setting must not be changed by field personnel without
This setting must not be changed by field personnel without the permission of the OEM.
FUNCTION 11 TURF SPEED LIMIT

FUNCTION 8 MAX FIELD CURRENT (Push 11)
( Push 8 )
This function allows for the adjustment of the top speed of
This function allows for the adjustment of the maximum the vehicle (maximum battery volts to the motor) when it is
field current in order to obtain the maximum torque of the in Turf Mode.
motor.
Range 100% to 0% (or creep speed)
Range 0 to 30 amps Set 51 to 170
Set 51 to 255 Resolution 0.78% per set unit
August 2001
ADJUSTABLE FEATURES
Example: Setting of 0 = no speed limit 3. Calculate voltage drop (VDrop) as follows:

Setting of 170 = maximum speed VDrop = VO - VL
reduction 4. Use the table below to determine the appropriate setting
Setting of 110 =100%-((110-51) - (creep val/8)) x 0.78 using the calculated VDrop as a reference.
=44%
INTERNAL RESISTANCE COMPENSATION
TABLE
FUNCTION 12 REVERSE SPEED LIMIT
( Push 12 ) Setting VDrop Setting VDrop
2 11.44 17 1.34
This function allows for the adjustment of the top speed of 3 7.60 18 1.27
the vehicle (maximum battery volts to the motor) when it is 4 5.72 19 1.20
being operated in the reverse direction. 5 4.57 20 1.14
6 3.81 21 1.09
Range 100% to 0% of battery volts
7 3.27 22 1.04
Set 51 to 170
8 2.86 23 0.99
Resolution 0.78% per set unit
Example: Setting of 0 = no speed limit 9 2.54 24 0.95
Setting of 170 = maximum speed 10 2.28 25 0.91
reduction 11 2.08 26 0.88
Setting of 134 =100%-((134-51) - (creep val/8)) x 0.78 12 1.90 27 0.85
= 20% 13 1.76 28 0.82
14 1.63 29 0.79
15 1.52 30 0.76
FUNCTION 13 PERCENT CHARGE SWITCH PLUG TO 16 1.43 31 0.74
REGEN
( Push 13 )
FUNCTION 15 BATTERY VOLTS
This function selects the percentage of battery state of (Push l5)
charge at which the control switches from regenerative to
plug braking on overspeed. In order for the battery discharge indication feature of this
control to operate properly, this function must be set to a
When the BDI reading is less than the setting value the value between 70 and 80.
control will regenerative brake, when the BDI is greater
than the setting value the control will plug brake.
Example: A setting of 95 will plug between 100 and 96 The following functions have function numbers larger
percent state of change and regen when the battery state than the numbers on the Handset keyboard. To access
of charge is 95 percent and below. these functions, push the CONT key and the number
shown in the instructions at the same time. THE TURF
SPEED SWITCH MUST BE OPEN.
FUNCTION 14 INTERNAL RESISTANCE
COMPENSATION FUNCTION 16 OVERSPEED PLUG CURRENT LIMIT
( Push 14 ) ( Push CONT1)
This function is used when the Battery Discharge Indicator This function allows for the adjustment of the maximum
is present. Adjustment of this function will improve the current allowed for plug braking during an overspeed
accuracy of the BDI. In order to determine this setting, the condition.
voltage drop of the battery under load must first be
calculated by the following method: Range 26 to 225 amps
1. Record open circuit voltage (Vo) by measuring the Set 0 to 255
voltage at the control positive and negative power Resolution 0.8125 amps per unit
terminals. Example Setting of 20 = 26 + (20 X .8125) =
2. Load the traction motor to 100 amps in 1A and record the 42 Amps
voltage (VL) at the control positive and negative power
terminals.
August 2001
ADJUSTABLE FEATURES
FUNCTION 17 CARD TYPE SELECTION FUNCTION 21 ARMATURE CURRENT RAMP DURING

( Push CONT 2 ) REGEN
(Push CONT 6)
This function allows for the selection of the card type for
this vehicle’s application. This function should be set This function adjusts the rate at which armature current
between: ramps .8 amps steps to full value during regenerative
braking when a direction change is made.
50 – 54 when speed is measured in MPH
55 – 60 when speed is measured in KPH Range .001 to 0.255 seconds
Setting 0 to 255
FUNCTION 18 LINE CONTACTOR DROP OUT TIME Example: Setting of 12 = 0.012 seconds
DELAY
( Push CONT 3 ) Important Note: The function is used to optimize motor and
control performance and this setting will be determined by
This function allows for the adjustment of the time GE and OEM engineers at the time of vehicle development.
allowable for the start switch to be opened before the line This setting must not be changed by field personnel without
contactor opens. the permission of the OEM.
Range 0 to 25.5 seconds

Setting 0 to 255 FUNCTION 22 ODOMETER CALIBRATION
Resolution 0.1 seconds per set unit (Push CONT 7)
Example: Setting of 255 = 25.5 seconds
This function is used to adjust the number of tachometer
pulses divided by 16 that will equal .1 MPH or .1 KPM.
FUNCTION 19 FIELD CURRENT RAMP RATE DURING
REGEN/PLUGGING Range 0 to 255 pulses
( Push CONT 4 ) Setting 0 to 255
This function adjusts the rate at which field current ramps Example to calculate setting:
to full value during regenerative or plug braking when a RR = Rolling Radius (Inches)
direction change is made. GR = Gear Ratio
PPR = Pulses per rotation of motor
Range 0 to 0.255 seconds
Setting 0 to 255 MPH Setting = 6336 XGR X PPR
Resolution 0.001 seconds per set unit 6.28 X RR X 16
Example: Setting of 12 = 0.012 seconds MPH Setting = 6336 X8.91 X 4
6.28 X 9 X 16
MPH Setting = 250
FUNCTION 20 MPH/KPH OVER SPEED LIMIT
( Push CONT 5) KPM Setting = MPH Setting/1.6
This function adjusts the value of the over speed limit of the
control. FUNCTION 23 ERROR COMPENSATION
(Push CONT 8)
Resolution 1 MPH/1KPM per set unit
Example: Setting of 28 = 28 MPH/KPH This function is used to reduce the ripple in field current
due to the interaction between motor field design and the
Important: Insure that this setting is based on the Function digital field current regulation circuit. The value for this
17 setting, e.g MPH or KPH. function should be set to 32.
Important Note: The function is used to optimize motor and Important Note: The function is used to optimize motor and
control performance and this setting will be determined by control performance and this setting will be determined by
GE and OEM engineers at the time of vehicle development. GE and OEM engineers at the time of vehicle development.
This setting must not be changed by field personnel without This setting must not be changed by field personnel without
the permission of the OEM. the permission of the OEM.
August 2001
ADJUSTABLE FEATURES
FUNCTION 24 FIELD WEAKENING START (or MOTOR FUNCTION 28 STORED STATUS CODE COUNT
KNEE POINT) POINTER
( Push CONT 9) ( Push CONT 13)
This function allows for setting the armature current at This register contains the location of the last stored status
which minimum field current will be achieved. code recorded of the 16 stored status codes. These stored
status codes have caused a PMT controller shutdown
Range 0 to 350 Amps and/or disruption of normal vehicle operation.
Setting 0 to 255
Resolution 1.625 per set unit To determine which stored status code was the last one
Example: Setting of 26 = 42 amps. recorded, read the number stored in Function 28. Using the
Memory Map for your logic card, match the "stored status
Important Note: The function is used to optimize motor and code pointer number" [the number shown in (bold italics)
control performance and this setting will be determined by in the HS (Handset) number column] on the memory map,
GE and OEM engineers at the time of vehicle development. with the number obtained from Function 28. This will be the
This setting must not be changed by field personnel without last stored status code recorded.
Note: When scrolling through the stored status code
register, the register always starts at status code 1 and
FUNCTION 25 MONITOR scrolls to status code 16. Instructions for scrolling the
( Push CONT 10) register are in section 5.3.2 of this instruction booklet.
This function allows the monitoring of certain control FUNCTION 29 HOUR METER TENS AND UNITS
functions by looking directly at the RAM of the HOURS SET
microprocessor. Because absolute memory locations need ( Push CONT 14)
to be known, this function should not be used without
detailed instructions from the GE application engineer. This function allows for the adjustment of the tens and
units hours of the hour meter.
To ensure optimum operation of the control, this function
must be left with zero stored in this register. Range 0 to 99
Set 0 to 99
FUNCTION 26 RATIO OF FIELD TO ARMATURE AMPS Example 9999 Hours
( Push CONT 11)
This function sets the ratio between armature and field

current when transitioning from minimum field to maximum FUNCTION 30 HOUR METER THOUSANDS
field current. The setting represents the quantity of field AND HUNDREDS HOURS SET
current changed for each 1 amp of armature current ( Push CONT 15)
changed.
This function allows for the adjustment of the thousands
Max Max Resolution Example and hundreds hours of the hour meter.
Fld Ref Change Set Per unit value If set at 3 Range 0 to 99
30 .24 0 to 10 0.024 amps 0.072 amps Set 0 to 99
Example 9999 Hours
FUNCTION 27 HOUR METER MINUTES
(Push CONT 12)
The following functions have function numbers larger
than the numbers on the Handset keyboard. To access
This function adjusts the number of 30 second intervals
these functions, push the CONT key and the number
registering in the hour meter. This function is typically not
shown in the instructions at the same time. THE TURF
set by an OEM, it is usually only read from the register.
SPEED SWITCH MUST BE CLOSED.
Range 0 to 60 minutes
Resolution 0.5 minutes per set unit
Setting 0 to 120
Example Setting of 60 = 60 x 0.5 = 30 minutes
August 2001
ADJUSTABLE FEATURES
FUNCTION 48 ODOMETER TENTH OF MILE OR

KILOMETER SET
( Push CONT 1)
This function allows for the adjustment of the tenth of a

mile or kilometer on the odometer.
Range 0 to 9
Set 0 to 9
Example 999999.9 Miles or Kilometers
FUNCTION 49 ODOMETER TENS AND UNITS OF MILES

OR KILOMETERS SET
( Push CONT 2)
This function allows for the adjustment of the tens and

units of miles or kilometers on the odometer.
Range 0 to 99
Set 0 to 99
FUNCTION 50 ODOMETER THOUSANDS AND

HUNREDS OF MILES OR KILOMETERS
SET
( Push CONT 3)

and hundreds of miles or kilometers on the odometer.
Range 0 to 99
Set 0 to 99
FUNCTION 51 ODOMETER HUNDRED THOUSANDS

AND TEN THOUSANDS OF MILES OR
KILOMETERS SET
( Push CONT 4)

and hundreds of miles or kilometers on the odometer.
Range 0 to 99
Set 0 to 99
August 2001
ADJUSTABLE FEATURES
Section 5.5 Summary of Current Limit Adjustments
The " maximum field current"

setting is adjusted by Function 8.
This function, along with the
"maximum armature current"
(Function 4), sets the maximum
torque of the motor.
MAXIMUM
The " ratio" setting is adjusted by Function

26. This function sets the ratio between
armature and field current when transitioning
from minimum field to maximum field current.
Setting is the value of field current changed for
each 100 amps of armature current changed.
The " error compensation " setting is adjusted by

FIELD CURRENT
Function 23. This function is used to reduce the

ripple in field current due to the interaction between
motor field design and the digital field current
regulation circuit. The value for this function will be
defined by the GE application engineer.
The " minimum field

current" setting is
adjusted by Function 7. The
function sets the top speed
of the motor.
The " field weakening start "

setting is adjusted by Function 24.
This function sets the armature
current at which minimum field
current will achieved .
ZERO
238
ARMATURE CURRENT amps
MAXIMUM
ZERO
The "full load transition point"

is calculated by the control. This
function sets the maximum field
current transition point at 238
amps.
The " maximum armature

current" setting is adjusted by
Function 4. The function along
with the "maximum field
current" (Function 8) sets the
maximum torque of the motor.
August 2001
Section 6. DASH DISPLAYS From the Dash Display, the operator may select any of four
pre-set interactive modes consisting of (4) Controlled
Section 6.1 Application Acceleration levels, (4) Auto Regen levels and (4) Speed
Limit levels.
The SX family Standard and Interactive Dash Displays
allow the operator and maintenance personnel easy These interactive modes are “pre-set” using the Handset
access to truck operation information and real-time system (Functions 48 - 63) or a personal computer (Functions 97 -
diagnostics of the controller, motor and various 112). This feature allows the operator to select the best
accessories. Hourmeter readings, battery discharge vehicle performance for changing factory (task) conditions.
information, maintenance information and system status
codes are clearly displayed during startup and running The Custom Dash Display incorporates all the features and
modes. Shielded cable connections are made to the Dash functions of the Standard Dash Display, in addition to the
Display by means of five (5) 22-gage wires to the “Y” Plug following customer options:
of the traction and hydraulic pump controls.
•= LED graphics to display Battery Discharge Indication
Section 6.2 Standard Dash Displays status.
•= Various LED indicators for Maintenance Required Status
Codes. These can include options for traction, pump and
power steer motors, hourmeter, over-temperature, seat
belt, brake and other safety sensors.
•= A push-button associated with the four segment LED that
g GE Electric Vehicle
Motors & Controls displays Status Codes can be used to scroll the last 16
“Stored Status Codes” that shut down vehicle operation
with a PMT fault.
Connections
Connections are made to the Dash Display with five (5) 22-
gage wires to Plug "Y" of each control. Shielded cable is
+ - required to eliminate signal interference.
Part Number
IC3645LXTDD T 3
The GE Standard Dash Display is a four segment Light T=Traction Only

Emitting Diode (LED) instrument that displays the GE LX, ZX, P=Traction & Pump
and SX Status Codes, Hourmeter Readings, Battery
Discharge Indication, and Maintenance Required Code. 3=Round Face with four
The four LED's above the symbols indicate the active display symbols
readout mode.
For Custom Dash Displays,
Section 6.3 Interactive Custom Dash Displays contact your vehicleOEM.
+ Reference
AMP#102241-3 Dash Display mating plug
BATTERY
EVT100ZX PUSH AMP#1-87195-8 Dash Display mating pin

44A723596-G09 Dash Display plug kit
- PUSH
AMP#175965-2 "Y" Plug
AMP#175180-1 "Y" Plug receptacle
The Interactive Custom Dash Display allows the operator to

select the best vehicle performance for changing factory
(task) conditions. There are four (4) “operator interaction
modes” that can be selected by depressing a push-button
on the dash display.
August 2001
Section 6.4 Start-Up Display Sequence Section 6.5 Outline Drawings
START-UP DISPLAY SEQUENCE

g GE Electric Vehicle
Motors & Controls
Key Switch On
+ -
Verify Each LED Segment
8888 0.43
(10.9)
MPH for 7 Sec Diagnostics Override 2.98 (75.7)

CONNECTOR OMITTED
IF NOT REQUIRED
PUMP
2.45 (62.2)
2.00 (50.8)
Run Mode
0.19 TRACTION
(4.8)
MPH for 7 Sec Diagnostics Override

PY3
Key Switch
PY4
Off
PY2
PY1
Display Odometer
PUMP
Thousands,Hundreds, Tens, Units
1 2 3 4 5
For Four Seconds
Wiring connections to "Y"
BACK VIEW OF DISPLAY plugs of Traction & Pump
Display Odometer controls.
Hundred Thousands,Ten Thousands 5 4 3 2 1
For Four Seconds TRACTION
PY3
PY4
PY2
PY1
PY5
August 2001
RS-232 MEMORY MAP TABLES
Section 7.0 MEMORY MAP
E2 Func No. HS Traction Control Access By Restrictions

No. Function
0 1 1 MPH Scaling HS or PC None
1 2 2 Creep Speed HS or PC None
2 3 3 Armature Acceleration Rate Forward HS or PC None
3 4 4 Max Armature Current Limit HS or PC None
4 5 5 Plug Current Limit HS or PC None
5 6 6 Armature Acceleration Rate Reverse HS or PC None
6 7 7 Min Field Current HS or PC None
7 8 8 Max Field Current HS or PC None
8 9 9 Regen Armature Current Limit HS or PC None
9 10 10 Regen Field Current Limit HS or PC None
10 11 11 Turf Speed Limit HS or PC None
11 12 12 Reverse Speed Limit HS or PC None
12 13 13 Percent Charge Switch Plug to Regen HS or PC None
13 14 14 IR Compensation HS or PC None
14 15 15 Battery Volts Select HS or PC None
15 16 16 Overspeed Plug Current Limit HS or PC None
16 17 17 Card Type Selection HS or PC None
17 18 18 Line Contactor Drop Out Time Delay HS or PC None
18 19 19 Field Current Ramp Rate During Regen HS or PC None
19 20 20 MPH Overspeed Limit HS or PC None
20 21 21 Armature Current Ramp During Regen HS or PC None
21 22 22 Odometer Calibration HS or PC For DD on power up
22 23 23 Error Compensation HS or PC None
23 24 24 Field Weakening Start (or Motor Knee Point) HS or PC None
24 25 25 Monitor HS or PC GE Temporary Storage
25 26 26 Ratio of Field to Armature Amps HS or PC None
26 27 27 Hour Meter Minutes HS or PC None
27 28 28 Stored Status Code Count Pointer HS or PC None
28 29 29 Hour Meter Tens and Units HS or PC None
29 30 30 Hour Meter Thousands and Hundreds HS or PC None
30 31 Aux HM (Tens/Ones) PC Only None
31 32 Aux HM (Thou/Hun) PC Only None
32 33 (18) Stored Status Code #1 PC Only Reset to Zero Only
33 34 BDI 1 PC Only Reset to Zero Only
34 35 Hours (Tens/Ones) 1 PC Only Reset to Zero Only
35 36 Hours (Thou/Hun) 1 PC Only Reset to Zero Only
August 2001

No. Function
54 55 Hours(Tens/Ones) 6 PC Only Reset to Zero Only
55 56 Hours(Thou/Hun) 6 PC Only Reset to Zero Only
73 ; 74 BDI 11 PC Only Reset to Zero Only
79 80 . Hours(Thou/Hun) 12 PC Only Reset to Zero Only
84 85 (44) Stored Status Code # 14 PC Only Reset to Zero Only
88 89 (46) Stored Status Code # 15 PC Only Reset to Zero Only
August 2001

No. Function
96 97 48 Odometer Tenth of Mile or Kilometer Set HS or PC None
97 98 49 Odometer Tens and Units of Miles or Kilometers Set HS or PC None
98 99 50 Odometer Thousands and Hundreds of Miles or KM HS or PC None
99 100 51 Odometer Hundred Thousands and Tens Thousands HS or PC None
100 101 52 Not applicable HS or PC None
112 113 Secure HM (Tens/Ones) PC Only OEM Read Only
113 114 Secure HM (Thou/Hun) PC Only OEM Read Only
114 115 Secure Aux HM (Tens/Ones) PC Only OEM Read Only
115 116 Secure Aux HM (Thou/Hun) PC Only OEM Read Only
116 117 Reserved PC Only GE Future Use
120 121 OEM Use PC Only None
Numbers in (bold italics) are Stored Status Code pointers.
August 2001

GE-SX-GL1-Tech - qtronic

Uploaded by

Copyright:

Available Formats

GE-SX-GL1-Tech - qtronic

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

GE-SX-GL1-Tech - qtronic

Uploaded by

Copyright:

Available Formats

INSTALLATION AND OPERATION

SX TRANSISTOR CONTROL Page 1

SEPARATELY EXCITED (SX) TRANSISTORIZED MOTOR CONTROLLERS

INSTALLATION AND OPERATION MANUAL

General Electric Company August 2001

Section 1.0 INTRODUCTION ........................................................................................................................................................ 3

1.1 Motor Characteristics .............................................................................................................. 3

Section 2.0 FEATURES OF SX FAMILY OF MOTOR CONTROLLERS .................................................................................... 5

Table of Contents ( Continued )

Section 3.0 ORDERING INFORMATION, ELEMENTARY AND OUTLINE DRAWINGS...................................................... 8

3.1 Ordering Information for Separately Excited Controls......................................................... 8

Section 4.0 TROUBLESHOOTING AND DIAGNOSTIC STATUS CODES.............................................................................. 12

4.1 General Maintenance Instructions................................................................................................. 12

Section 5.0 SX FAMILY - GE HANDSET INSTRUCTIONS ...................................................................................................... 28

6.1 General Features ...................................................................................................................... 28

Section 6.0 DISPLAYS................................................. .................................................................................................................. 37

7.1 Application ............................................. ............................................................................................. 37

Section 7.0 MEMORY MAP................................................. ......................................................................................................... 39-41

Section 1. INTRODUCTION current to increase, providing the greater torque needed to

As shown in the typical performance curves of Figure 1, the

high torque at low speed characteristic of the series motor

Section 1. 2 Solid-State Reversing Section 1. 4 More Features with Fewer Components

field weakening with a series motor.

Section 1. 3 Flexible System Application

Because the shunt motor controller has the ability to

Section 2.1.1.a Standard Operation Section 2.1.4 Auxiliary Speed Control

Section 2.1.2 Current Limit Section 2.1.4.c Top Speed Regulation

Section 2.3.2 Hourmeter Readings

This feature will display the recorded hours of use of the

Section 2.3.3 Battery Discharge Indication (BDI)

The latest in microprocessor technology is used to provide

Section 2.3.4 Internal Resistance Compensation

This feature is used when the Battery Discharge Indicator

Section 2.3.5 Handset

This is a multi-functional tool used with the LX, ZX, and SX

Features and functions:

Section 2.3.6 RS 232 Communication Port

This serial communication port can be used with

Section 2.3.7 Circuit Board Coil Driver Modules

Section 3.0 ORDERING INFORMATION, ELEMENTARY AND OUTLINE DRAWINGS

Section 3.1 Ordering Information for Separately Excited Controls

Part Number: IC3645 SH 4 D 33 2 C3

Argument 01: Basic Electric Vehicle Control Number

Argument 02: Control Type:

Argument 03: Operating Voltage:

Argument 04: Package Size:

Argument 05: Armature Current

Argument 06: Field Current

Argument 07: Customer / Revision

Section 3.2 Outline: SX-2 Package Size

SEPARATELY EXCITED TRACTION MOTOR

Section 3.4 Neighborhood Electric Vehicle Application Input/Output List

Connections to Main Plug (23 Pin) and “Y” Plug (8 Pin)

PIN MAIN PLUG INPUT/OUTPUT DESCRIPTION

PIN “Y” PLUG INPUT/OUTPUT DESCRIPTION

WIRE END VIEW - PY PLUG WIRE END VIEW - MAIN PLUG

Section 4.0 TROUBLESHOOTING AND DIAGNOSTIC STATUS CODES

Fretting occurs during microscopic movement at

The addition of the NYE 760G lubricant will prevent Figure 1

term reliable control operation, the plug terminals must be