DeLonghi EV100 Specifikace

1INSTRUCTIONSEV100 LX/LXT SCR CONTROLSGEH-5714The information contained herein is intended to assist truck users and dealers in the serv

10EV100LX PART NUMBER IDENTIFICATION

11TERMINAL CONNECTIONS FOR LX/LXTLOGIC CARDSTRACTION TRACTION TRACTION TRACTIONINPUT STANDARD SL/FW REGEN/FW DUAL MTR PUMPTB1 Accel Pot Input Accel Po

12Control FeaturesOn-Board DiagnosticsHourmeterStored Status CodesCard Type SelectionCreep SpeedCurrent LimitPluggingPedal Position PlugRamp StartFul

13Control FeaturesVoltage RangeAccelerator InputLow Battery OperationReverse Battery ProtectionAmbient TemperatureApproximate WeightCoil DriversF/R or

14Control FeaturesAccelerator Volts LockoutAccel volts > 2.5VBattery Volts CheckBattery Discharge Indica-tionFull Load Level RunningMtr Current at

15BASICS OF CIRCUIT OPERATIONThe control circuit is energized by closing the key switch, seat switch, and moving the for-ward or reverse lever to eith

16is called flyback current. Figure 2 shows the nature of the motor current which is composed ofboth battery current and the inductive flyback curr

17PLUGGING - Slow down is accomplished when reversing by providing a small amount of retardingtorque for deceleration. If the vehicle is moving and t

18COIL DRIVER MODULES - these drivers are internal to the control card. They are the powerdevices that operate F, R, lA, D, FW, RB, and PS contactor c

19maximum current limit and not allow lREC to exceed its temperature limits. Even at a reducedcurrent limit, the vehicle will normally be able to rea

2EV100LX SCR CONTROL ORDERING INFORMATIONEXAMPLE-------------------------- IC3645EV 100 T1 TT 1ARGUMENT NO. 01 02 03 04 05ARGUMENT NO. 01 - BASIC CATA

20DUAL MOTOR IN-BOARD WHEEL REVERSAL - This feature allows for the control of the in-board traction motor while in a sharper turning condition. The in

21TRUCK MANAGEMENT MODULE (TMM2) - is a multi-function accessory card that provides ahorn alarm circuit which blows the horn when the truck is left un

22HYDRAULIC SCR CONTROL ( EV100P ) - This hydraulic controller consist of the followingfeatures:Three speeds adjustable from 0 volts to full motor v

23The current limit circuit is adjustable and operates the same as the traction SCR current limit. Seecurrent limit curves for limits and range.The co

24 GENERAL MAINTENANCE INSTRUCTIONSThe SCR control, like all electrical apparatus, does have some thermal losses. The semiconductorjunctions have fini

25 TROUBLE-SHOOTING INSTRUCTIONSTrouble-shooting the EV100/200 LX/LXT control should be quick and easy by following the instruc-tion outlined in the f

26Reactor/ChokeDisconnect all leads to the reactor.Remove the two mounting bolts and lift out.Set new reactor on SCR base and start screws back into b

27INSTRUCTIONSSTATUS CODESGEH-5722GEH-5722GEH-5722GEH-5722GEH-5722The information contained herein is intended to assist truck users and de

28STATUS CODEBLANKDISPLAYDESCRIPTIONSegments do not illuminate on Dash Display or HandsetNoMEMORYRECALLCONTROLTYPESTATUS INDICATION CRITERIAThis in

29STATUS CODE-03DESCRIPTIONNoMEMORYRECALLCONTROLTYPESTATUS INDICATION CRITERIAThis status code will be displayed when TB6 is greaterthan 60% of bat

3EV100LX COMPONENT LOCATIONS

30STATUS CODE-05DESCRIPTIONStart switch or brake switch fails to close.NoMEMORYRECALLCONTROLTYPESTATUS INDICATION CRITERIAThis status code is w

31STATUS CODE-07DESCRIPTIONAccelerator input voltage too high.NoMEMORYRECALLCONTROLTYPESTATUS INDICATION CRITERIAThis status code is displaye

32STATUS CODE-09DESCRIPTIONBoth forward and reverse directional switches are closedat the same time.NoMEMORYRECALLCONTROLTYPESTATUS INDICATION CRIT

33STATUS CODE-16DESCRIPTIONBattery volts too high.NoMEMORYRECALLCONTROLTYPETractionSTATUS CODE-15DESCRIPTIONBattery volts too low.NoMEMORYRECALLCON

34STATUS CODE-23DESCRIPTIONForward and reverse contactor coil current low.NoMEMORYRECALLCONTROLTYPETractionSTATUS CODE-17DESCRIPTIONInvalid card typ

35STATUS CODE-25DESCRIPTION1A contactor does not drop out or drops out slowly.YesMEMORYRECALLCONTROLTYPESTATUS INDICATION CRITERIAThis status code

36STATUS CODE-26DESCRIPTIONShorted coil driver for SP or FW contactor.NoMEMORYRECALLCONTROLTYPETractionFigure 1SYMPTOMSP or FW contactor picks up im

37STATUS CODE-43DESCRIPTIONNoMEMORYRECALLCONTROLTYPETractionSTATUS CODE-42DESCRIPTIONControl motor current sensor input missing.NoMEMORYRECALLCONTRO

38STATUS CODE-45DESCRIPTION1 REC did not turn on properly.YesMEMORYRECALLCONTROLTYPETractionSTATUS CODE-44DESCRIPTION1REC did not turn off prop

39STATUS CODE-47DESCRIPTIONNoMEMORYRECALLCONTROLTYPETractionSTATUS CODE-46DESCRIPTIONLook ahead test for T2 volts. ( Greater than 85% ofbattery vol

4EV100LX OUTLINE DRAWING

40STATUS CODE-48DESCRIPTIONNoMEMORYRECALLCONTROLTYPETractionFigure 1SYMPTOMForward or reverse contactor will not pick up.POSSIBLE CAUSEDefective fo

41STATUS CODE-51DESCRIPTIONNoMEMORYRECALLCONTROLTYPETractionSTATUS CODE-50DESCRIPTIONNoMEMORYRECALLCONTROLTYPETractionFigure 1Figure 1SYMPTOMForwa

42STATUS CODE-53DESCRIPTION1 REC fails to turn off during plug cycle.YesMEMORYRECALLCONTROLTYPETractionFigure 1STATUS INDICATION CRITERIAThis

43STATUS CODE-57DESCRIPTIONCurrent sensor input voltage polarity check.NoMEMORYRECALLCONTROLTYPETractionFigure 1SYMPTOMForward or reverse contactors

44STATUS CODE-70DESCRIPTIONRegen current sensor input missing ( yellow wire ).YesMEMORYRECALLCONTROLTYPETractionFigure 1STATUS INDICATION CRIT

45STATUS CODE-72DESCRIPTIONRegen contactor does not pick up.YesMEMORYRECALLCONTROLTYPETractionFigure 1STATUS INDICATION CRITERIAThis status co

46STATUS CODE-74DESCRIPTIONRegen contactor picks up too slow.YesMEMORYRECALLCONTROLTYPETractionFigure 1STATUS INDICATION CRITERIAThis status c

47STATUS CODE-90DESCRIPTIONUser defined status code - see OEM instructions manual.NoMEMORYRECALLCONTROLTYPETMMFigure 1SYMPTOMStatus code flashes on

48STATUS CODE-92DESCRIPTIONNoMEMORYRECALLCONTROLTYPETMMSTATUS CODE-91DESCRIPTIONNoMEMORYRECALLCONTROLTYPETMMFigure 1Figure 1User defined status co

49STATUS CODE-94DESCRIPTIONNoMEMORYRECALLCONTROLTYPETMMSTATUS CODE-93DESCRIPTIONNoMEMORYRECALLCONTROLTYPETMMFigure 1Figure 1SYMPTOMStatus code fla

5EV100LX WITH SPEED LIMIT AND FW9

50STATUS CODE-95DESCRIPTIONNoMEMORYRECALLCONTROLTYPETMMFigure 1User defined status code - see OEM instructions manual.STATUS INDICATION CRITERIATh

51STATUS CODE-123DESCRIPTIONForward and reverse contactor coil current low.NoMEMORYRECALLCONTROLTYPEPumpSTATUS CODE-117DESCRIPTIONInvalid card type

52STATUS CODE-125DESCRIPTION1A contactor does not drop out or drops out slowly.NoMEMORYRECALLCONTROLTYPESTATUS INDICATION CRITERIAThis status code

53STATUS CODE-141DESCRIPTIONNoMEMORYRECALLCONTROLTYPEPumpFigure 1STATUS INDICATION CRITERIAThis status code is displayed when the voltagebetwe

54STATUS CODE-143DESCRIPTIONNoMEMORYRECALLCONTROLTYPETractionFigure 1Control motor current sensor input missing.STATUS INDICATION CRITERIAThis

55STATUS CODE-145DESCRIPTION1 REC did not turn on properly.YesMEMORYRECALLCONTROLTYPEPumpFigure 1SYMPTOMForward or reverse contactor will open and c

56STATUS CODE-147DESCRIPTIONNoMEMORYRECALLCONTROLTYPEPumpFigure 1SYMPTOMPump contactor will open and close, then open and thencan only be closed by

57STATUS CODE-149DESCRIPTIONNoMEMORYRECALLCONTROLTYPEPumpFigure 1SYMPTOMPump contactor will open and close, then open and thencan only be closed by

58STATUS CODE-151DESCRIPTIONNoMEMORYRECALLCONTROLTYPEPumpFigure 1STATUS INDICATION CRITERIAThis status code is displayed when capacitor voltse

59DESCRIPTIONShorted F, R or 1A contactor coil driver.NoMEMORYRECALLCONTROLTYPEPumpFigure 1STATUS CODE-154SYMPTOMControl will not operate.POSSIBL

6EV100LX WITH REGEN AND FW9

60

61 TABLE 4 CHECKING COMPONENTSMain Logic CardAll trouble-shooting is written to check all outside devices and eliminate them as the source of thes

62Capacitor 1CDisconnect the battery and discharge the capacitor. Measure ohms through the capacitor using the R x10,000 scale. Meter should read zero

63(1). The lamp should not light. If the lamp does light, the SCR is shorted and must bereplaced.(2). If check (1) was satisfactory, test the SCR for

64Filter Block(23FIL,etc.)To check, disconnect all wires from the filter block on remove from panel. With VOM onthe R x 10,000, touch the leads to th

65REPLACEMENT OF EV-100 COMPONENTSWhen replacing stud semiconductors such as 3REC and 4REC it is not necessary to torque thesedevices to a specific

66Reactor/ChokeDisconnect all leads to the reactor.Remove the two mounting bolts and lift out.Set new reactor on SCR base and start screws back into b

location " Y " on the control card. After installing the handsettool, plug in the battery and turn on the key switch. Thefollowing is th

68DESCRIPTION AND LOCATIONZ PLUGY PLUGB PLUG A PLUGEV100 LX/LXTFUNCTION SET-UP PROCEDURES:Warning: Before making any adjustments to the controlyou m

69Example: 0 = min. current, 255 = max. currentFUNCTION 5 PLUGGING DISTANCE (CURRENT)( Push 5 )This function allows for the adjustment of the

7EV100LX DUAL MOTOR CONTROL9

70FUNCTION 8 FIELD WEAKENING DROP OUT( Push 8 )This function allows for the adjustment of the field weaken-ing contactor drop out current. This settin

71as shown in the table must be entered .Battery volts Set units24 volts Between 0 and 3136 volts Between 32 and 4448 volts Between 45 and 6972 volts

72Example: 0 = min. current, 255 = max. currentFUNCTION 5 PLUGGING DISTANCE (CURRENT)( Push 5 )This function allows for the adjustment of the

73FUNCTION 11 SPEED LIMIT 1 (PA5 OR PA6)( Push 11 )This function allows for the adjustment of the speed limit (maximum battery volts to the motor ) w

74Example: If plug distance current Function 5 is set at 500amps, then set pedal plug current at 500 amps. With thissetting pedal position will ha

75DESCRIPTION OF FUNCTION NUMBERS FOR:Control Card IC3645EVLXCD1PXFUNCTION 1 STORED FAULT CODE( Push 1)This function register contains the last status

76Setting Voltage Drop Setting Voltage Drop13 01.76 28 00.8214 01.63 29 00.7915 01.52 30 00.7616 01.43 31 00.74FUNCTION 17 CARD TYPE SELECTION( Push C

g GE Industrial Systems EV200LX SUPPLEMENT Page 1 of 5 REV 11/2002 General: The EV100LX instructions and operating information is applicab

g GE Industrial Systems EV200LX SUPPLEMENT Page 2 of 5 REV 11/2002 Component Locations: ITEM# PART NUMBER DESCRIPTION QTY/EACH5 15

g GE Industrial Systems EV200LX SUPPLEMENT Page 3 of 5 REV 11/2002 ITEM# PART NUMBER DESCRIPTION QTY/EACH30 44A717068-001 RECTIF

8EV100LX PUMP CONTROL9

g GE Industrial Systems EV200LX SUPPLEMENT Page 4 of 5 REV 11/2002 Wiring Diagram:

g GE Industrial Systems EV200LX SUPPLEMENT Page 5 of 5 REV 11/2002 Current Limit Adjustments: 01005020 30 4010 70 80 90600150300450600750

9NO. PART-NUMBER DESCRIPTION QUANTITY 4 158C3100EEP1 BASE DETAIL ...............01 11 171B3939G1 1REC ASS